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tm 10-3950-263-14&p-1 technical manual for crane, mobile

1. AUXILIARY GENERATOR ENGINE AND CONTROL Generator and Engine Assembly Inspect Service Replace Overhaul Crankcase Cylinder Block Service Replace Repair NIN ovo Cylinder Head Assembly Replace Repair oto N Crankshaft Replace Repair NN Oo sch sch sch S TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT Bearings Replace Flywheel Assembly Replace _ X to Piston and Connecting Rod Replace Repair NN Ow SE c Piston Pin Bearings and Rod Replace Valves Inspect Adjust Replace Repair NNO Oko to S MI Camshaft Assembly Replace Timing Gear Replace Rocker Arm Assembly Replace Repair Co oe ce oreo Rocker Cover Replace Gear Cover Replace Oil Pump SE epair 7 7 7 7 7 7 7 7 By Pass Valve Pressure Relief Replace N co Oil Filter Replace Crankcase Breather Breather Valve Service Replace Oil Pan Replace Lines and Fittings Replace Oil Gage Switches Replace A 20 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CR
2. 1 90 Procedure For Shutting Down Crane Load Lowering With A Crane Equipped With Torque Converter 1 92 Boom Foot Pin Removal System Removing Boom Foot Pins 1 31 Replacing Boom Foot Pins 1 95 Live Mast Controls 1 32 1 96 Extending The Live Mast 1 32 Retracting The Live Mast General Information Lifting Sling 1 32 1 99 Lifting Sling Assembly 1 100 Inspection 1 101 Lifting Sling Installation 1 32 1 102 Machine Tie Down 1 34 1 1 TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions Live Mast Bridle Assembly Boom Hoist Rope Cable Pendants Main Hoist Rope Cable Boom Backstops Operators Cab Upper Counterweight Carrier Cab Hook Block Boom Upper Section gee m T MA h Rear Outrigger Beam zi ANE r WAT Outrigger ZOO Nr EN t Jack NS AMI SCAN Float Or Bumper Counterweight Pontoon Front Bumper Tri Float System Outrigger Rear Wheels and Axles Front Wheels And Axles Front Outrigger Jack Outrigger Box Fig 1 1 140 ton FMC Link Belt R Crane Operator s Manual 1 1 1 2 General Information This manual contains operating and maintenance instructions for an FMC Link Belt HC238A 140 ton capacity crane The machine is manufactured by FMC Corporation in Bowling Green Kentucky The HC238A is a truck mounted crane It is designed to lift handle and place loads of up to 14
3. Final Adjustment L 4 3 4 12 Planetary Brake Adjustment 4 13 Front And Rear Drum Brake Adjustment 4 4 Boom Hoist Brake 4 5 4 15 Boom Hoist Brake Adjustment 4 5 4 16 Clutch Adiustment 4 17 Air Box Drains eese 4 18 Control Lever Adjustment 4 19 Chain Case With Chain Adjuster 4 20 Chain Adjustment a 4 7 HC238A TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Upper Adjustments TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Upper Adjustments 4 1 Engine and Power Takeoff Information on lubrication and protective maintenance of the engine and torque convertor are found inj section 23 of this manual Information on engine tune up is found in area 6 of the shop manual 4 2 Adjusting Master Clutch It will be necessary to adjust the master clutch occasionally to compensate for normal wear This check should be made every 500 hours of operation or more frequently depending on frequency of operation and operating conditions When properly adjusted 55 75 ft lbs of torque are required Fig 4 1 to drop the clutch into engagement 1 Hub Plate MORE d au Gen One way to check this torque is to weld a large nut on the 2 Clutch Disc 12 Shift Collar end of the clutch shaft Attach a torque wrench to this nut 3 Back Plate 13 Bal
4. Application Of Lubricant Unreeling Wire Cutting Wire Rope Socket And Wedge Connections Wire Rope Clip Installation Use Of Wire Rope Clips With Sockets Boom Angle Indcator Boom Angle Indicator Adjustment Boom Hoist Limtter ee Override Control Boom Hoist Limiter Adjustment TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Crane Attachment Notes Operator s Manual TM 10 3950 263 14 amp P 1 Section 5 Crane Attachment R1282 NA250 A Machine With Basic 50 Foot 15 24m Boom 4 Boom Lower Section 5 Live Mast Booms 1 Headshaft 2 Basic Pendant 3 Boom Upper Section 5 1 Tubular Boom The basic tubular boom is 50 feet 15 24m in length and consists of a 25 foot 7 62m lower section and a 25 foot 7 62m upper section The sections are connected by four pins which are in line with the boom chords Straight boom extensions are available in 10 20 30 3 05m 6 1m 9 14m foot lengths and may be combined with the basic boom to form an Overall Boom Length of 130 feet 39 6m 5 2 Lifting Capacity The lifting capacity of a machine is based upon several factors a Boom length used b Load radius c Number of parts of line used to lift load d Diameter an
5. lower pins removed WRONG boom can fall endants reconnected ehind pins being removed boom peak not b on the ground upper pins removed WRONG boom will fall Fig 32 Pin connected booms 32 When disassembling bolted boom block 33 34 securely under each end of each section when unbolting them Otherwise boom may fall and kill or injure someone Never get under a boom especially when assembling or disassembling it Disassembly of any pin connected boom can be hazardous Removing the boom pins without reconnecting pendants behind the pins being removed can cause the boom to fall to the ground If you are under the boom when it falls you may be killed Never remove boom pins unless boom peak is resting on the ground and pendants are reconnected as shown in Fig 32 If there is any doubt in your mind about the boom disassembly procedure block tightly under the boom before removing the pins When operating a machine equipped with any form of load indicating mechanism overload warning system or any automatic safety device remember that such devices cannot replace the skill and judgment of a good operator For instance such devices cannot tell when a machine is located on a supporting surface that will give way or that too few parts of line are being used to hoist a load or correct for the effects of wind or warn that the device may be improperly adjusted or correct for side pulls on the bo
6. Fig 2 10 Air Box Drain Tank 3 Drain Cock 4 Drain Hose works well Elements cleaned with air can be put back in service immediately Washed elements must be dried before use Some elements are partially covered by plastic Sleeve and fins The covered portion of the filter can be cleaned with air or water without removing the sleeve Use a stiff fiber not wire brush to remove oil and grease deposits from the fins Do not remove the plastic sleeve and fins from the element 1 Cleaning with compressed air Direct a jet of clean dry air from the inside of the element perpendicular to the pleats Pressure at air nozzle must not exceed 30 PSI 206 kPa Operator s Manual HC238A c TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Fig 2 11 Cleaning With Compressed Air Move the air Jet up and down along the pleats slowly rotating the element until no more dust is being removed Be careful not to rupture the element with the nozzle of the air Jet 2 Cleaning with water Filter elements can be cleaned by washing with water and a good non sudsing detergent If compressed air is available first direct a jet of clean dry air from the inside of the filter element When the loose dust and Soot is removed the element is ready to be washed Use 2 ounces 55g of detergent per gallon of water for washing elements Dissolve the detergent in a small amount of cool wa
7. L H HOOK BLOCK DRUM SOCKET Fig 5 27 Main Hoist Reeving L H Drum Socket HOOK BLOCK Operator s Manual TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment Fig 5 28 Wire Rope A Right Regular Lay B Right Lang Lay 5 35 Measuring Wire Rope Diameter As the illustration in indicates there is a right and wrong way to measure wire rope diameter Wire rope is always measured across the largest diameter that will fit inside a true circle Wire rope is always made larger not smaller than the nominal diameter The allowable tolerances on wire rope diameters are Nominal Dia Allowable Over In Inches mm Size In Inches To 3 4 19 05 20 6 to 25 6 25 6 to 38 1 13 16 to 1 1 8 1 3 16 to 1 1 2 1 9 16 to 2 1 4 29 6 to 51 2 5 16 And Larger 51 1 In standard practice the nominal diameter is the minimum diameter A rope is not considered oversized until its diameter exceeds the maximums listed above 5 36 Ordering Wire Ropes When ordering wire ropes the following information must be furnished to be sure of receiving the correct wire rope This is especially true when ordering wire rope from other sources than FMC Corporation a Length required b Diameter c Construction type and number of strands and wires per strand Type of core hemp or wire center Grade of steel f Direction of lay right or left lay Regular lay or lang lay Class of serv
8. Item 1 Lubricating Oil Item 2 Fuel Tank Diesel Fuel Contamination Item Fuel Lines Item 4 Cooling System Item 5 Turbocharger Item 6 Battery i Item 7 Tachometer Item 8 Air u Item 9 Drive Belts Item 10 Air Compressor Item 11 Throttle And Clutch Control Item 12 Lubricating Oil Filter 2 Item 13 Fuel Strainer And Filter Item 14 Coolant Elter TM 10 3950 263 14 amp P 1 Section 2 Preventive Maintenance And Lubrication Item 15 Starting Item 16 Air System Item 17 Exhaust System Item 18 Air Box Drain Tube Item 19 Emergency Shutdown Item 21 Radiator L Item 23 Oil Dreseure Item 24 Overspeed Govemor Item 26 Throttle Item 27 Battery Charging Alternator Item 28 Engine amp Transmission Mounts Item 29 Crankcase Pressure Item 30 Air Box Check Valves Item 31 Fan Hub Item 32 Thermostats And Seals H M o Item 33 Blower Screen 2 26 Item 34
9. Non Chromates Inhibitor Systems Coolant Filter Elements Bulk Inhibitor Additives Anti Freeze Sealer Additives General Recommendations Torque Converter Oil Level Checks General ER Cold Check uu pertes Seege Ae ele Ge Oil Specifications Oil amp Filter Check Operator s Manual Subject 12 125 12 1271 Water In OH Metal Particles Ethylene Glycol Draining Converter General Torque Converter Oil Chance Filling The Oil System 2 130 Overcenter Disconnect 2 38 Lubrication esses 2 38 Section 2 Preventive Maintenance And Lubrication TM 10 3950 263 14 amp P 1 Operator s Manual TM 10 3950 263 14 amp P 1 Section 2 Preventive Maintenance And Lubrication 2 1 General Lubrication Information Regularly and systematically lubricate the machine as shown on the lubrication charts later in this section of the manual A copy of these charts are mounted in the upper cab of the machine The time interval shown on the chart is a guide only Under unusual working conditions with the carrier in mud water etc more frequent lubrication may be necessary In these cases good judgment must be used in working out a suitable schedule The following points are important Follow them when lubricating the machine a b c Wipe the grease gun nozzle
10. RR co ter General Dimensions Overall length with basic boom in travel position over rear of carrier with bumper counterweight open throat boom 81 8 1 8 12 ae 3 69 m Overall length with basic boom in travel position over front of carrier open throat boom Height over boom live mast with basic boom in travel position over rear of carrier open throat boom 12 3 1 4 Height over boom live mast with basic boom in travel position over front of carrier open throat boom 14 9 1 2 E Height of boom hinge pin Overall width outriggers extended over floats 24 6 Overall width outriggers extended center line of jacks 22 0 Overall width outriggers retracted floats removed 11 10 Minimum ground clearance 9 9 16 Ground clearance under upper counterweight with machine on tires 4 11 1 16 Counterweight tailswing across corners 15 8 7 8 Overall upper cab width 11 0 Basic boom length open throat 50 0 HC238A 9 5 9 6 blank Operator s Manual Index Section 10 Subject SET ololo Wel HC238A Page Overload Warning System 10 1 Components and Location Component Description And Operation General System Operation 10 3 Operating Instructions 10 3 Adjustments Trouble Shooting 10 5 Section 10 Overload Warning System R783 TM 10 3950 263 14 amp P 1 10 A TM 10 3950 263 14 amp P 1 Operator s Manual Section 10
11. WRONG BOOM WILL FALL Fig 5 19 Inline Pin Boom Disassembly Incorrect Disassembly Of A Pin Connected Boom May Result In Machine_Damage Personal Injury Or Even ens tl 9 19 And The Disassembly Pro Before Disassembling Boom Read And Be Sure You Understand As An Alternate Disassembly Procedure Block Tightly Under The Pin Death Never Stand Under A Boom When Removing Pins cedure On The Preceeding Paaes Connection Before Removing Pins TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment R982 Fig 5 20 Carrying Link Assembly Pin And Cotter Pin 4 Lug 1 E Carrying Link 5 Boom Lower Section Pin And Cotter Pin 6 Live Mast 25 6 7 8m Position lower section 5 Boom up until center line of boom is straight and pendants are tight Boom Peak Must Be Resting On Ground 6 Remove the lower pins only at end of boom lower section 7 Boom down until the boom sections ahead of F are flat on the ground 8 Disassemble the boom sections ahead of point F e The boom lower section may be removed by using the live mast reeved as a short boom as explained earlier in this section 5 21 Carrying Link Assembly The boom lower section only may be transported at a reduced overall height by attaching it to the boom live mast with the carrying links as follows 5 22 Chart B Maximum Travel Speed With Base Section Over The Front Of The Carrier W A Upper Ctwt W A
12. Keep the load lines as short as possible to prevent excessive swinging Always use the shortest boom length which will do the job Remember the shorter the boom the stronger it is Watch out for centrifugal force when swinging a load Swing gently Cen TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T la Radius at 1 rest E Increases to this l from centrifugal i force Fig 20 Watch out for centrifugal force trifugal force tends to increase load radius This increase in radius could overload the machine and cause machine damage and tipping When stopping the swing overswing of the load can side load the boom The use of a tagline is recommended to control this force Angle A Angle B Center of Gravity Load Radius 8 10 11 12 Know the load radius Don t guess it Determine radius by using the boom angle indicator the boom length and the capacity chart or measure It with a steel tape Remember radius Is the horizontal distance from the centerline of rotation of the upper to the center of gravity of the load when the load is hanging free Know the boom length Don t guess Use of an incorrect boom length can cause an accident Use at least the number of parts of hoist line specified in the wire rope capacity plate to handle the load In case your machine Is not so equipped one is included on Local codes may require more
13. a Run set until thoroughly warm generator under at least 50 percent load 6 3 TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembl ADJUST VALVE CLEARANCE HERE SPEED ADJUSTING NUT VALVE SPRING RETAINER ROCKER ARM 7 TURN TO INCREASE RPM HOLD SPRING STUD IN POSITION TURN FOR MINIMUM SPEED DROP THEN ADJUST SPEED HUT VALVE SPRING OIL SEAL INTAKE VALVE ONLY GOVERNOR SPRING STUD SENSITIVITY ADJUSTMENT GOVERNOR GOVERNOR ARM SPRING GOVERNOR STUD SENSITIVITY A ADJUSTING RATCHET DECREASE DECREASE SPEED INCREASE SPEED SENSITIVITY b SPEED INCREASE ADJUSTING SENSITIVITY NUT Shut down engine and drain oil base while still warm Refill and attach a warning tag indicating viscosity of oil used Remove glow plug Pour 1 ounce of rust inhibitor or SAE 10 oil into each cylinder Crank engine over several times Install glow plug Service air cleaner Clean throttle and governor linkage and protect by wrapping with a clean cloth Plug exhaust outlets to prevent entrance of moisture bugs dirt etc Clean and wipe entire unit Coat parts susceptible to rust with a light coat of grease or oil Disconnect battery and follow standard battery storage procedure Provide a suitable cover for the entire unit 6 23 Returning A Unit To Service a b c Remove cover and all protective wrapping Remove plug from exhau
14. 15 24m Boom Over Front With Gooseneck Links 16 Part Boom Hoist Reeving Wrapping Hammer and Block Main Hoist Reeving L H Drum Socket Operator s Manual TITLE 5 35 2 6 6 16 7 6 8 6 9 o N 6 amp 10 2 2 of 2 Main Hoist Reeving L H Drum Socket Wire Rope Lay Measuring Wire Rope Diameter Wire Rope Inspection Report Wire Rope Failure Chart Uncoiling Wire Rope Wedge Type Connections Wire Rope Clip Installation Securing Dead End Of Rope With A Wire Rope Clip Boom Angle Indicator Boom Hoist Limiter Auxiliary Generator Assembly Bleeding the Fuel System Standard Control Panel Setting Gap Governor Adjustment Setting Valve Clearance Checking Valve Clearance Decompression Mechanism Air Cleaner and Fuel Filter Maintenance Oil Level Valves And Crankcase Breather Maintenance Hydraulic Power Supply S o M System Filter Relief Valve Assembly Overload Warning System Nomenclature System Cabling And Interconnect Main Electronics Adjustments List Of Illustrations PAGE RE 05 ei imp Ie EA m DN R783 TM 10 3950 263 14 amp P 1 TM 10 3950 263 14 amp P 1 Warranty Standard Warranty Cable Cranes FMC CORPORATION CABLE CRANE amp EXCAVATOR DIVISION is hereinafter called the COMPANY The products manufactured by the COMPANY exclusive of used or re built machinery or equipment are subject to the following wa
15. 5 8 Boom Live Mast The telescoping boom live mast Must Be Used with all boom lengths The mast has two positions a fully retracted 25 6 7 7m position and a fully extended 30 0 9 14m position The mast is hydraulically extended and pins in position The two positions are used as follows a The 20 0 9 14m extended position is used for assembling or disassembling the boom or raising lowering or normal crane boom operation It is also used when using live mast as a short boom b The 25 6 7 7m position is used when transporting 50 thru 130 feet 15 2 39 6m of boom horizontally over the rear of the carrier but not for normal crane boom operation Note See page 1 32 Operating Instructions for live mast extend and retract instructions Change 1 5 1 Operator s Manual ssl val Eer N amp Front Ken rit Carrier on Outriggers Note These lines determine the limiting position of of any load for operation within working areas indicated Rotetion S Reor Bope i K lt Front Ark Bogie Over Side Carrier on Tires i Mete Lanter ot L N 2629 Fig 5 2 Working Area Definition Label 5 4 Using Live Mast As A Short Boom The live mast may be used as a short boom to remove or replace the main boom the upper counterweight or the outrigger boxes The procedure is as follows a Fully extend the mast to the 30 0 9 14m position as explain
16. ER ico ie polo ER ER EN EP co Oy o co LA 1 at 1 38 Extending Or Retracting Live Mast Lifting Sling Assembly Lifting Arm Assembly Lifting Assembly Machine Tie Down 2 1 Carrier Lubrication Chart Upper Lubrication Chart Attachment Lubrication Chart Planetary Wheel Hub Chain Case 2 6 Outrigger Sump Tank Planetary Speed Reducer Swing Bevel Gear Case Reduction Shaft Bevel Gear Case Air Box Drain Tank Cleaning With Compressed Air Cleaning Element with Water Inspecting the Element Oil Check and Fill Item 1 2 47 Cooling System Item 14 2 51 Turbocharger Item 5 2 52 Tachometer Drive Item 7 2 54 Air Cleaners Item 8 2 55 Drive Belts Item 9 2 56 Air Compressor Item 10 2 57 Fuel Strainer and Filter Item 13 2 60 Starting Motor Item 15 2 62 Air Box Drains Item 18 2 65 Radiator Item 21 2 67 Alternator Item 27 2 71 v o oo HC238A List Of Illustrations PAGE ALK LLL ule 1 1 ER ERU S gt colo EP ABI Io no no 2 CET NIN ESESSES CEET 1 GALA Rn Si ER EN ER co co 1 34 ig MBIA 2 33 UN 1 o 5 2 24 5 26 E TM 10 3950 263 14 amp P 1 R783 Fan Hub Item 31 2 75 Blower Screen Item 33 2 77 Cra
17. RMP at full load speed H P at F L S Peak torque Electrical system Crankcase capacity Cool system capacity 9 2 Carrier Engine Type Bore and stroke Displacement Governed load speed Brake H P at governed load speed Peak torque Electric system Crankcase capacity Cool system capacity 9 3 Fuel Tanks Upper one Carrier two 9 4 Transmission Upper Make Type Torque Converter Make Model Type 9 5 Transmission amp Clutch Carrier Main Transmission Make Model Type Auxiliary Make Model Type Clutch Make Type 9 6 Outriggers Make Type Pump Make Model type HC238A Section 9 Specification and General Information GM 6 71N with single stage torque converter 4 1 4 x 5 6 425 6 cubic inches 2040 RPM 1900 RPM 171 1400 ft lbs 12 volt 7 25 gal 8 75 gal GM 6V 92TA 4 84 x 5 552 cubic inches 2100 RPM 318 900 ft lbs at 1400 RPM 12 volt 6 25 gal 75 gal cap 45 gal cap each FMC Quadruple roller chain Allison TCDOA 475 Single stage Eaton RTO 915 13 speed road ranger Eaton AT 1202 Two speed Lipe Rollway 14 Two plate dry disc FMC Electric hydraulic Vickers V20P series Vane w flow divider and relief valve Power takeoff Make Model Type Sump tank Make Capacity Control valves Make Model Type Mechanical Make Type Cylinders Make Type 9 7 Power Steering Type Power Steering gear Make Model Turning circle dia
18. Speed O Matic Pressure Fig 1 17 Front Instrument Panel NA212 A NA209 B Operator s Manual 1 65 1 66 ee RP sSI 1200 RPM Converter Temperature This gauge indicates the operating temperature in the torque converter The oil temperature should never exceed 250 F 121 C when the machine is operating If the temperature is too high shut the machine down and determine the cause See page 2 27 for more information Operation at temperatures exceeding 250 F 121 C can result in damage explosion and or fire Engine Oil Pressure This gauge registers the pressure of the lubricating oil in the engine As soon as the engine starts the gauge should begin to register If the gauge does not register at least the minimum pressure listed in the chart below stop the engine and determine why 1 67 Engine Temperature TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Correct the problem before running the engine again The engine coolant temperature is registered on this gauge Normal running temperatures are 150 to 185 F 65 5 to 85 C 1 68 Engine Voltmeter The engine voltmeter measures the voltage produced by the alternator and indicates the condition of the battery Refer to Fig 1 18 for voltmeter readings 1 69 Ignition On This light is on whenever the ignition switch is on The ignition switch must be turned off light out and key removed when the operator lea
19. WARNING Use Fuel Oil Or Cleaning Solvent In A Well Ventilated Area Away From Flames e Remove the strainer from the tank Thoroughly clean the strainer with approved low toxicity solvent f Remove the magnetic drain plug in the bottom of the tank Thoroughly clean the plug and magnets g Remove the breather Clean the breather in approved low toxicity solvent h Thoroughly clean the inside of the sump tank with approved low toxicity solvent i Replace the drain plug Replace the suction strainer Replace the inspection plate Replace the filter element and cover plate as explained earlier in this section i Fill the tank with oil See capacity chart on page for the proper oil k Install the breather Jack the carrier up on solid blocking so an outrigger jack can be fully extended without raising the carrier m Disconnect the hose leading to the lower port on an outrigger jack cylinder at the quick disconnects near the carrier frame Remove the quick disconnects from the end of this hose Hold the hose in a can and completely extend the jack cylinder see operation instructions pane 1 12 to force as much oil as possible from the jack cylinder n Replace the quick disconnect on the hose Connect it to the other half of the quick disconnect 0 Disconnect the hose leading to the upper port on the same jack cylinder at the quick disconnects Remove the disconnect from the hose Hold the end of the hose
20. e Engage swing lock to prevent inadvertent swinging of the machine f If machine is wheel mounted set parking brakes and place chocks on wheels to prevent movement or if on outriggers outriggers must be fully extended or securely blocked up so that machine is level g Disengage master clutch shut down engine turn off starting key switch and remove keys h By operating the swing lever run Speed o Matic system hydraulic pressure to zero to prevent inadvertent release of boom hoist brake i All doors windows and hatches should be closed and locked Remove all keys to reduce danger of vandalism or Injury j If the machine is located where it may pose a traffic hazard necessary warning lights flags and or barricades should be placed in the proper locations For longer periods of shut down more complete storage procedures are recommended which may include lowering of boom on blocking or removal of boom winding of wire ropes fully on drums and coating them with preservatives boarding over or covering of windows and similar procedures to insure against unnecessary deterioration or damage Load Lowering With A Crane Equipped With Torque Converter And Lowering Clutches When a FMC crane is equipped with a torque converter and lowering clutches there are four different methods of lowering a load a The use of lowering clutches is very good for both light and heavy loads A lowering clutch is mounted on the end of the
21. 1 46 Outrigger Pin Removal System 1 13 1 47 Outrigger Box Removal 1 13 1 48 Replacing Outrigger Boxes 1 14 Operators Cab 1 15 1 50 Starting The Upper Engine 1 15 1 51 Stopping The Upper Engine 1 15 Fluid Starting Aid During Operation 1 54 Upper Control Panel 1 16 1 55 Ignition Switch 1 16 Starter Button 1 57 Engine Shutdown 1 17 1 58 Emergency Shutdown 1 17 1 59 Windshield Wiper 1 17 238 10 3950 263 14 amp P 1 Section 1 Operating Instructions Subject Page 1 60 Blower SS Drum Rotation 1 62 Dome Light 1 17 1 63 Live Mast Control 1 17 S o M Pressure Gauge 1 65 Converter Temperature 1 66 Engine Oil Pressure 1 18 1 67 Engine Temperature 1 18 1 68 Engine Voltmeter Ignition On 1 70 Master Clutch Control 1 21 11 71 Swing Lock Control 1 21 1 72 Swing Brake Control 1 21 Swing Clutch Control Front amp Rear Drum Control Lever And Brake 1 22 Brake Pedal Locks 1 2 Drum Rotation Indicators 1 77 Boom Hoist Control 1 78 B H Limit Device Override 1 24 Engine Throttle Control Foot Throttle 1 81 Crane Operation 1 82 Hand Signal Chart Counterweight Removal Controls 1 28 Removing The Counterweight 1 85 Replacing The Counterweight 1 86 Counterweight Assemblies 1 28 1 87 Ctwt Useage AB Upper Counterweight Ass y 1 28 1 CO Ko A Bumper Counterweight Ass y 1 2d
22. 3 Check pump belt tension S o M pump 4 Check for proper oil level in all sump tanks Torque Converter Sump Upper 1 Check for leaks or damage 2 Checkfor proper oil level Electrical Systems 1 Check headlights clearance lights turn signals parking lights windshield wipers horn etc 2 Check all instrument panel gauges 3 Check battery water level Fill as required Master Clutch Upper only 1 Before engaging the master clutch read this manual in its entirety Inspect the machine for anything that interferes with moving parts before engaging the master clutch Lubrication 1 Fully lubricate the machine as explained in of this manual 792861 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions 1 6 Break In Period Operate a new machine at half throttle for the first 16 hours two shifts of operation A break in period under moderate loads will assist in providing long trouble free performance 1 7 Before Starting Operations Before starting daily operations make the following checks a b i j Engine Upper and Carrier 1 Check the fuel oil and water levels 2 Fill as required Hydraulic System S o M and Outrigger 1 Check all hoses for chafing bulging or other damage Replace if necessary before operating 2 Check for external leaks Repair them before operating 3 Check oil level Add oil if necessary Gear Cases
23. A brakes and actuating 35 FD Brake Pivot 1 A mechanisms as explained 36 LH RD Shaft Bearings 1 A in lubrication timetable 37 Gear Train 1 A 38 Red Shaft Bearing 1 A 39 BH Shaft Brg W Planetary 1 A 40 Red Shaft Brg 1 A 41 LH FD Drum Shaft W O Clutch 1 A 42 BH Brake Bell Crank 1 A 43 FD Brake Bell Crank 1 A 44 Turntable Bearing 1 A 45 Turntable Bearing 1 A 46 LH Lower Red Shaft Brg 1 A 47 Swing Lock A 48 Turntable Gear Teeth 49 Lower Swing Shaft Bearing A 50 Clutch Arms 2 Per Clutch A 51 Clutch Pivot Points A11 M 52 Front Drum Brake A11 Insp Insp 1 53 Rear Drum Brake A11 Insp Insp 1 54 B H Brake A11 Insp Insp 1 Key Check and fill if required CH Change Insp Inspect See lubrication specifications later in this section HC238A TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 17 Upper Capacity Chart Chain Case 1 5 Gal 5 6L C Reverse Bevel Gear Compartments 40 Pins 18 9L J Planetary Gear Case 2 5 Qts 2 36L E above 32 F J below 32 F 0 C S o M Sump Tank 11 9 Qt 11 2L S o M Red Shaft Pinion Housing 1 5 Qt 1 41L M Open Gears As Required H Zerk Fittings As Required A Pivot Points As Required M Fig 2 3 Attachment Lubrication Chart TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 18 Attachment Lubrication Chart Ref No 10 5
24. Adjust 4 2 3 Disassemble and repair Lubricate see Shop Manual 1 Engage master clutch see Check adjustment of clutch and controls see p 4 1 Repair or replace master clutch 2 Determine where failure is Repair or replace parts as required see Shop Manual 1 Refer to lubrication chart Lubricate gear train 2 Check backlash between gear teeth Replace worn gears see Shop Manual 3 Isolate the bad bearing Re place see Shop Manual Operator s Manual Index Section 9 CH I HS 9 6 9 9 Alba Upper Engine Carrier Engine Fuel Tanks Transmission Upper 9 1 Transmission and Clutch Carrier 9 1 Outriggers 9 1 Power Steering 9 1 Brakes 9 1 Electric System Carrier Lail Bumper Counterweight 9 2 Carrier Speeds Transmission Gear Ratios 9 2 Cab Upper Machinery Gear Train Clutches Swing System 9 21 Load Hoist Lower System Boom Hoist Lower System Control System Speed o Matic 9 3 Counterweight Upper 9 3 Attachment Component Weights Dimensions 9 5 Section 9 Specification and General Information Subject TM 10 3950 263 14 amp P 1 Page TM 10 3950 263 14 amp P 1 Operator s Manual Section 9 Specification and General Information Operator s Manual 9 1 Upper Engine Type Bore and stroke Number of cylinders Displacement High idle speed
25. And Sockets Shipped From FMC Corporation Are Stamped With Size And Type Identification A Lagging Or Socket May Be Stamped For Two Or More Sizes Of Rope And A Wedge Must Correspond To The Rope Size Used 5 43 Wire Rope Clip Installation The correct method of installing wire rope clips is as shown in Fig 5 34 The U bolt must always be over the short end of the wire rope and the base must always contact the long end Clips should not be staggered that is U bolt of one clip over short end U bolt of next clip over long end etc This practice will not only distort the wire rope excessively but will prevent maximum strength of this type fastening Placing all clips with the U bolt over the long end of the wire rope will damage strands and result in an unsafe condition The distance between clips should not be less than six times the wire rope diameter In relation to size of wire rope the minimum number of clips recommended for a safe connection is as follows TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment Wrong The clip will transfer the load to the dead end of the rope Fig 5 35 Securing Dead End Of Rope With A Wire Clip As noted before use of wire rope clips with a wedge socket connection can weaken socket connection Do not attach the dead end of the rope to the live side with the clip as this will seriously weaken the connection The clip will ultimately take the loa
26. CAUTION Use The Override With Extreme Caution As The Limiting Device Is Ineffective When The Override Is In Use The Boom Can Be Hoisted Against The Backstops With Enough Force To Cause Damage To The Boom Or The Backstops This May Result In Accident TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions 1 79 Engine Throttle Controls The standard engine throttle is mounted to the R H cab wall To increase engine speed pull up on the control To decrease engine speed push down on the control A small brake is included in the throttle control to hold the throttle at any desired setting 1 80 Foot Throttle A foot throttle is mounted in the cab floor on either side of drum brake pedals To increase engine speed push down on the throttle To decrease engine speed let up on the throttle Removing the foot completely will let the engine run at idle 1 81 Crane Operation The crane attachment is used primarily for hoisting lowering and positioning loads In order to do this with a maximum amount of safety certain procedures must be followed The following is a suggested procedure for making a typical lift a Determine the weight to be lifted Be sure to include the hook block slings grapples chains or other rigging b Consult the capacity chart located in the upper cab and find the shortest boom length and load radius that will accomplish the job If machine already has a b
27. Crankcase Breather 2 26 Item 36 Engine Tune Up n Item 39 Power Takeoff l 2 26 Item 40 Torque Converter i Engine Oil And Filter Fuel Strainer And Filter Replacement Fuel Tante Engine Cooling System Maintenance Engine Cooling System Capacity E Fill Cooling System aus naqa Drain Cooling System a a Flush Cooling System Cooling System Cleaners Reverse Flushing ES Fuel Oils For Detroit Diesel Engines Diesel Fuel Oils General Consideration Federal Specification amp ASTM Diesel Fuel Properties 2 31 Detroit Diesel Fuel Oil Specifications 2 31 Fuel Oil Selection Chart 2 32 Lubricating Oils For Detroit Diesel Engines Diesel Lubricating Oils General Considerations Detroit Diesel Lubricating Oil Specifications Used Lube Oil Analysis Warning Values Statement Of Policy On Fuel And Lubricants Additive Engine Coolarit iiic iicet Seege Coolant Requirements UE NERONE EROR Corrosion Inhibitors eene Chromates Soluble Oil
28. DATE 16 Apr82 16 DATE 16 Apr82 82 QTY OF PARTS REQ D FOR NO OF FND ITEMS UM ASL 1 5 15 620 2150 PART DESCRIPTION PAOZZ 5330 01 118 4972 22A2535 36422 Gasket Hydr Res Access Cover 4 00 PAOZZ 990717 404 36422 Wire Rope 7 8 x 675 Boom 1011 00 EA Hoist PAOZZ 4730 01 124 6535 1X5165 36422 Plug Magnetic Hydr Reservoir 5 00 EA PAOFF 1921180 36422 Lock Valve Outriggers 800 00 EA PAOZZ 5310 01 119 7198 22A2580 36422 Packing Preformed Mag Plug 1 00 EA Gasket PAOZZ 2910 01 072 1783 820 0327 06991 Fuel Eng Primer Bottle Ether 10 00 EA PAOZZ 6240 00 014 2454 MS35478 93 96906 Lamp Light Dome 1 00 EA PAOZZ 6240 00 577 8175 4001 08108 Lamp LH Headlight 10 00 EA PAOZZ 2940 00 926 4117 B298 12658 Filter Element Gen Aux 8 00 EA PAOZZ 6240 00 270 4693 500R3FL120V 08108 Lamp Cab and Boom Floodlights 20 00 EA PAOZZ 1730 01 095 0126 AB 1010 6 55524 Breather Assy Hydr Reservoir 22 00 EA PAOFH 2920 01 124 9312 1117641 16764 Alternator Eng Upper Eng 520 00 EA PAOZZ 2940 00 832 8728 P11 7331 18265 Element Filter Air Upper Eng 40 00 EA PAOZZ 6240 00 012 5588 MS15572 1 96906 Lamp Cab Gauges 1 00 EA PAFZZ 5930 00 111 8619 1996097 16764 Switch Push Outrigger Eng 10 50 EA Throttle PAFZZ 5950 00 551 0574 493419 77521 Coil Electrical Valve Stack 46 35 EA A 71 TM 10 3950 263 14 amp P 1 PRESCRIBED LOAD LIST PLL AND AUTHORIZED STOCKAGE
29. Fig 5 37 Boom Hoist Limiter NA326 B Boom Lower Section angle of the crane boom The indicator is not installed on booms shipped from the factory as it could be damaged during shipment It must be mounted in the field after the boom is assembled on the machine 5 46 Boom Angle Indicator Adjustment When mounting the angle indicator assembly make sure the pendulum pointer is at zero when the boom is horizontal The boom position may be checked by placing a level on a straight boom extension near boom mid point Set the indicator to zero by adjusting the pendulum After installation boom up slowly and observe the motion of the pendulum in various boom position If the indicator sticks or drags repair it before use An inoperative or damaged boom angle indicator must never be used to determine boom angle Recheck the indicator once a month any other time when freedom of pendulum action or position of zero is questioned or when boom has been removed from machine and then reinstalled Note Boom angle indicator is approximate only When making a lift that is close to rated loads load radius should be determined by actually measuring from center line of rotation to center of gravity of the load 5 26 1 4 Rotary Valve 2 Capscrew Lockwasher 5 Bell Crank 3 Striker 6 Override Valve 7 Lever 8 Control Cable 9 Override Control 5 47 Boom Hoist Limiter A hydraulic boom hoist limiter is used on the machin
30. Fuel Strainer Replace Fuel Filter Replace Ether Starting Aid Replace Brackets and Tubes Replace Throttle Assemblies Adjust Replace EXHAUST SYSTEM Muffler and Pipes Inspect Replace Repair A 10 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS BEE PENES EE XH MAINTENANCE CATEGORY EQUIPMENT COOLING SYSTEM Radiator Assembly Inspect Service Replace Repair Radiator Cap Pressure Type Replace Radiator Housing Replace Repair Cables Control Replace Repair Shroud Radiator Replace Water Manifold Replace Thermostats Test Replace Hose Lines and Fittings Inspect Replace Water Pump Replace Repair Fan Assembly Replace Repair Belt Drive Inspect Adjust Replace ELECTRICAL Alternator Replace Repair Belt Drive Inspect Adjust Replace TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT Starting Motor Replace Repair Solenoid Replace Repair Engine Safety Control and Interlocks Replace Instrument Control Panels Inspect Repair Instruments Inspect Repla
31. Headshaft link must be connected in 2 6 76 2cm position 5 20 Inline Pin Tubular Boom Disassembly b c d Boom down until the boom peak is resting on ground and main pendants are slack Install assembly links at 85 25 9m point They must be used to disassemble 120 to 130 36 58 39 6m foot long booms Booms 120 to 130 feet 36 58 39 6m in length 1 Remove all but 59 8 18 1m of main pendants Leave the 59 8 18 1m lengths of main pendants connected to the bridle spreader bar 2 Connect the other end of these pendants to the assembly links A in 3 up until center line of boom is straight and pendants are tight Boom Peak Must Be Resting On Ground 4 Remove the bottom pins only at or ahead of point E Removing pins behind E behind point of suspension will cause boom to fall 5 Boom down until the boom sections ahead of point E are flat on the ground 6 Disassemble the boom sections ahead of point E 7 To remove boom sections ahead of point E follow the procedure below Booms 110 feet 33 5m in length or less 1 Boom down until the boom peak or end boom section is resting on the ground and the main pendants are slack 2 Disconnect the main pendants 3 Remove all main pendants except the 19 8 5 99m basic pendant pair This pendant pair must be connected to the bridle spreader bar 4 Connect the other ends of the 19 8 5 99m basic pendant pair to
32. POWER TAKEOFF a Lubricate clutch levers and links with engine oil ref Operator s Manual b Check the clutch facing for wear ref Operator s Manual AIR SYSTEM Check all connections and hoses for damage or leaks AIR BOX DRAIN TUBES With engine running check for flow of air from the air box drain tubes If tubes are clogged remove clean and reinstall GOVERNOR Replace governor oil filter A 59 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Carrier M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in well ventilated area Avoid contact with skin eyes and clothes and don t 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 contact with skin or clothing is made flush with water If contact with eyes is made wash your eyes with water and get medical aid immedi ately Air Compressed air used for cleaning purposes will not exceed 30 psi Use only with effective chip guard ing and personnel protective equipment goggles shield gloves etc BLOWER SCREEN a Inspect screen and gasket ref Operator s Manual b Clean screen in solvent and dry with compressed ai
33. PRESCRIBED LOAD LIST PLL AND AUTHORIZED STOCKAGE LIST ASL END ITEM Crane Mobile 140 Ton Capacity Container MAKE FMC MODEL HC 238A Handler NSN 3950 01 110 9224 DATE 16 Apr 82 QTY OF PARTS REQ D FOR NO OF FND ITEMS PRIME P N PART DESCRIPTION 2540 00 477 9630 BD721011 18 Blade Wiper Upper Lower Window 6240 00 924 7526 1156 Lamp Back up Lights 6240 00 889 1799 1157 Lamp Tail Light 6240 00 763 3450 1893 Lamp RH LH Outer Headlights 6240 00 944 1264 194 Lamp I D Lights 6240 00 691 0369 4478 Lamp Battery Lighting Sys 6240 00 214 9073 4000 Lamp RH Headlight 5330 01 043 5565 1P3703 Packing Preformed Lock Valve 4130 01 098 7901 P12 9396 Filter Element Carrier Eng Air 6685 01 099 6261 RAX00 2351 Indicator Pressure Carrier Eng Air 5330 00 556 8630 3 6 Packing Preformed Bleed Plug Gasket Hydr Res 3810 01 100 4952 PX316 Filter Element Hydr Reservior 4720 01 116 7813 18A4308 Hose Carrier Eng Rad Top 4720 01 116 7815 18A4309 Hose Carrier Eng Rad Lower 2910 00 125 5600 122 0325 Filter Prim Fuel Gen Aux A 68 TM 10 3950 263 14 amp P 1 PRESCRIBED LOAD LIST PLL AND AUTHORIZED STOCKAGE LIST ASL END ITEM Crane Mobile 140 Ton Capacity Container MAKE FMC MODEL HC 238A Ee NSN 3950 01 110 9224 3950 01 110 9224 DATE 16 Apr82 16 DATE 16 Apr82 82 QTY OF PARTS REQ D FOR NO OF FND ITEMS PART DESCRIPTION U M LE PAOZZ 6240 01 115 3069 7400
34. Permissable loads per the machine capacity chart will vary from lifting quadrant to lifting quadrant The operator must make sure capacity ratings are not OVER SIDE exceeded no matter what quadrant he is operating In or when swinging from one quadrant to another NOTE THESE LINES OETERMINE THE LIMITING POSITION OF ANY LOAD FOR OPERATION WITHIN WORKING AREAS INDICATED Fig 34 s a copy of plates found in upper cab 0 20 38 39 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T WORKING AREAS Se ES 2 CENTER OF ROTATION FRONT REAR Su AIGGERS OUTRIGGER OUTRIGGER ip SIDE NOTE TEE LINES OF TERMINE RES EMG ANY LOAD FOR OPERATION WITHIN WORKING AREAS INDICATED FRONT REAR WHEEL TRACK WHEEL TRACK Fig 34 Working area charts After slack rope operation make sure rope is properly seated in sheaves and on drums before continuing to operate Use a stick or mallet to seat the rope not your hands Never lower the boom or load beyond the point where two full wraps of rope are left on the drum This condition could occur when lowering a load below ground level If all the rope runs off the drum the load will jerk which could break the rope and drop the load 40 41 42 43 On some machines equipped with live mast it is permissable to connect live mast to boom lower section with links for transportation purposes and in
35. The weight of the certified scale or load cell used to determine the weight of the load i The weight of the hook block s iii The weight of the slings chains rigging etc used to support the load or scale on the hook block s iv The total weight of all the main hoist wire rope between the boom point and hook block s Type 1 25 4mm diameter wire rope weighs 1 76 lbs 798336 kg per foot Measure the horizontal distance between the upper center of rotation to the hook block If the Reach meter does not read this distance adjust the Load Sensor as follows aa Loosen Load Sensor mounting capscrews bb Adjust the position of the Load Sensor assembly on the mounting bracket of the boom until the correct distance is indicated on the Reach meter cc Retighten mounting capscrews Recheck Reach meter reading Install cover on main electronics and secure with the retaining screws b Verify the system as follows HC238A 1 2 4 8 Visually verify the components and the cables are connected Position the power switch to On 3 Set the Reeve Select switch on the main electronics assembly to the parts of line reeved on the main hoist hook block For example 3 for 3 parts of line Set the Boom Select switch on the main electronics assembly to the length of boom on the machine For example 100 for 100 feet of boom Set Hook Selector switch to either L left or R right Hoist
36. Upper and Carrier 1 Visually inspect all gear cases for leak age or damage If any repair before operating 2 If leakage is evident fill the case to proper level before operating Controls Upper and Carrier 1 Check all controls for proper operation 2 Adjust or repair if necessary before operating Tires and Wheels Carrier only 1 Test for proper tire inflation for operating conditions Consult tire inflation chart in carrier cab or section 3 of this manual 2 Check wheel nuts Tighten evenly as necessary Brakes Carrier only 1 Check air pressure 115 125 psi 792 861 kPa maximum 2 Check low air pressure warning device for operation at 60 psi 413 kPa 3 Check foot brake operation 4 Check emergency brake operation Electrical System Carrier and Upper 1 Check headlights clearance lights turn signals parking lights tail and stop lights windshield wipers horn etc 2 Check all instrument panel gauges General 1 Visually inspect the entire machine for loose or missing bolts or cotter pins cracked welds frayed worn or damaged ropes dented or damaged boom chords or lattice etc Repair or replace any damaged worn or missing components before operating the machine 2 Visually inspect all clutch and brake linings for evidence of wear or grease and oil on the linings If any replace before operating Torque Converter Sump Upper only 1 Checkthe oil level Add oil if n
37. applications requiring frequent starts check battery specific gravity periodically and if necessary increase the charging rate slightly move slide tap nearer ungrounded lead until it keeps the battery charged Adjust only when engine is stopped Avoid overcharging The resistor is located in the connection box If a separate automatic demand control for starting and stopping is used adjust the charge rate for its maximum 4 5 amperes This normally keeps battery charged even if starts occur as often as 15 minutes apart 6 34 Valve Clearance Check valve clearance when the engine is at room temperature about 70 F a Turn the flywheel until the cylinder is on its compression stroke Use a socket wrench on the flywheel screw hex head Note To determine if the cylinder is in its compression stroke observe the action of the Push rods as the engine is rotated in a clockwise direction The exhaust valve push rod will be in its lowest position and the intake valve Push rod will be moving downward As the piston reaches top dead center the flywheel timing mark should be aligned with the timing pointer and the valve push rods stationary b Now turn the flywheel clockwise for an additional 10 to 45 degrees There is no timing mark for this position so it must be estimated With the piston located in this position it will be in its power stroke with both valves completely closed c Cylinder head bolt torques should be 37
38. hydraulically released by operator con trolled lever Brake drum involute splined to horizontal swing shaft brake 20 diameter 3 1 4 face width Swing lock Mechanically controlled pawl engages external teeth of turn table bearing swing ring gear Maximum swing speed 2 8 RPM Wire rope drum gear train front and rear main operating drums powered by chain transmission from engine Tandem de sign drums Front and rear drums One piece 17 1 4 44m root diameter smooth drums involute splined on shafts Drum clutches Control load hoist and power load lowering Clutches for front and rear main and optional third operating drums 23 diameter 6 face width Power load lowering clutches Standard on rear main operating drum optional on front drum Brakes Two piece external contracting band mechanically foot pedal operated Foot pedals equipped with latch to permit locking Operator s Manual 9 17 Boom Hoist Lowering System HC238A brakes in applied position Front and rear brakes 34 diameter 5 face width optional third drum brake 28 diameter 5 face width Drum rotation indicators Standard for front and rear main operating drums Solenoid operated indicator buttons recessed in drum clutch control lever handles pulsate whenever rope drums rotate in either direction Three to five pulsations represent approximately 1 rope travel on or off drum Independe
39. lift the A ctwt and place on positioning blocks on carrier frame c Lift the B ctwt and install the two connecting links Start a nut on each link to hold them in place d Set the B In place on top of the A ctwt making sure the links enter the holes in too of the A ctwt Le e s c quo kenge Fig 1 34 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions INFORMATION RIGHT CYLINDER LEFT CYLINDER RN OPEN V CLOSE VN OPEN CLOSE NV pusi ro PULL N A LOWER NEUTRAL TO RAISE Cylinder contro valve must close at ail times except during the actual ralsing or towering of the counterweight S NA263 A Counterweight Removal Controls 1 Decal 3 Control Valves 2 Function Lever 4 Lock Pin NA218 B AB Upper Counterweight 1 Connecting Link 2 Pin and Cotter 1 28 3 A Counterweight 4 Counterweight b Nut and Lockwasher Operator s Manual e Install the two ctwt locking pins through the holes in the A ctwt and in the connecting links Install a cotter pin in each of the locking pins f Tighten down the nuts on the connecting links to hold the two counterweights together g To raise the counterweight assembly into place on the upper refer to Counterweight Removal Controls earlier in this section 1 89 A Bumper Counterweight Assembly a Fully extend and set all outriggers on firm supporting surface M
40. or modifications to machines already in service 2 FMC will not be under obligation to credit the Government with the price of the new part or to reimburse the Government for the labor cost for repairing or replacing defective part unless within thirty 30 days of the date of the campaign work performed the Government submits a typewritten claim listing parts used and the FMC allotted time provided in the campaign letter or if FMC has not established the time satisfactory proof of the time reasonably expended in repairing or replacing the defective part 8 FMC will issue a minimum of 25 00 per claim 4 Claims which cover campaign work performed on more than one machine will not be accepted b The work must be completed within the time frame stated in the campaign agreement and campaign instructions If campaign work is not completed within the stated time frame FMC assumes no responsibility for any damage that might be incurred due to delay of campaign completion E Requirements for Qualification 1 The Government will utilize only qualified personnel in the performance of campaign work These personnel must have attended an authorized factory school on the particular product line within the past 18 months 2 The Government must maintain properly equipped service vehicles and shop facilities as dictated by general industry standards 3 The ove must have any specialized material equipment and tools required by general industry
41. standards 4 The Government must maintain a current and updated service library including service manuals bulletins policy handbook parts books and or microfilm 5 of 5 ix x TM 10 3950 263 14 amp P 1 VOLUME ONE OPERATION AND MAINTENANCE Service Manual Is contained In Volume Two Repair Pars is contained In Volume Three TABLE OF CONTENTS Section Page Operating Safety ENEE 0 1 00 1 qa 00 1 Operating INStrUCtiONS i dece oit tede petere peine equae Lora Ro dated Preventive Maintenance and Lubrication 2 38 Carrier Adjustments tinent etit laut qai riter sd tenti 3 1 3 7 Upper Adjustments E 4 1 Crane Attachment a 5 1 5 27 6 Auxiliary Generator Assembly a aaa 6 1 6 12 Sneed O Matic Control E 7 1 Troubleshooting Procedures n n a naa 8 1 8 6 9 Specifications and General Information 9 5 Overload Warning Gystem mee 10 1 10 6 E 1 72 Alphabetical Index iiinn aaaea iaa a 11 1 11 2 1of1 xi xii TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY General Read this every day someone s life may depend on it maybe your own When a crane or excavator is maintained and used properly it can be a safe highly useful pi
42. the cooling systems both upper and lower engines Leave all drains open Remove batteries and store them where they will not freeze Charge them periodically during storage Cover open spaces around boom hoist bail or drums with waterproof paper or plastic to keep rain and snow off machinery Cover entire upper with atarp if available Leave all control levers in neutral position Leave foot brake pedals in released position Refer to clutch engine and torque convertor manuals for information on storing these units Lock all doors on machine and cover all window glass with metal or wood covers to guard against vandalism and unauthorized entry Note Store machine so it doesn t provide a plaything for children Such a unit can be an attractive nuisance for children to play on If they fall off or get entangled serious injury may result 2 9 TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 9 10 11 12 13 14 15 FEET 4 m AT TTA 37 36 35 34 33 32 31 30 29 28 42 38 39 40 53 WARNING Moving Machine Do Not Service Maintain Or Lubricate Unless Master Clutch Is Disengaged And Rotation Machinery Has Stopped Or Severe Personal Injury May Result NA222 D Keep grease oil guns and containers clean Wipe all fittings before lubricating Disengage master cl
43. through retail outlets Therefore Detroit Diesel Allison does not recommend the use of any supplementary fuel or lubricant additives These include all API Letter Code products marketed as fuel conditioners smoke Service Military SAE suppressants masking agents deodorants tune up Classification Specification Grade compounds top oils break in oils graphitizers and friction reducing compounds MIL L 2104A Supplement 1 40 or 30 MIL L 2104B 40 or 30 CD SC CD SG MIL L 2104C 40 or 30 Note The manufacturers warranty applicable to Detroit Diesel engines provides in part that the provisions of such warranty shall not apply to any engine unit which has been subjected to misuse negligence or accident Accordingl MIL L 45199B Series 3 40 or 30 C SE MIL L 26152 40 or 30 40 or 30 malfunctions attributable to neglect or failure to follow the manufacturer s fuel or lubricating recommendations may not 2 102 Used Lube Oil Analysis Warning Values De Withinthe Coverage ofthe warr nty The presence of ethylene glycol in the oils is damaging to the engine Its presence and need for an oil change and for 2 104 Engine Coolant corrective maintenance action may be confirmed by glycol 1 y E Engine coolant is considered as any solution which is EE circulated through the engine to provide the means for heat Fuel dilution of the oil may result from loose fuel connections transfer from the different engine components
44. 00 186 6681 9150 00 188 9858 9150 00 189 6729 9150 00 402 4478 9150 00 402 2372 9150 00 491 7197 36422 830664001 36422 830664002 34252 Gulf AW100 80738 Exxon Nuto H100 36422 830661001 36422 830661002 15445 Conoco DN 600 A 35 TM 10 3950 263 14 amp P 1 APPENDIX H PREVENTIVE MAINTENANCE CHECKS AND SERVICES Section Operator Crew Preventive Maintenance Checks and Services MAINTENANCE FORMS AND RECORDS Every mission begins and ends with the paperwork There isn t much of it but you have to keep it up The forms and records you fill out have several uses They are a permanent record of the services repairs and modifications made on your vehicle They are reports to Organizational Maintenance and to your commander And they are a checklist for you when you want to know what is wrong with the vehicle after its last use and whether those faults have been fixed For the information you need on forms and records see TM 38 750 PREVENTIVE MAINTENANCE CHECKS AND SERVICES 1 Do your before B PREVENTIVE MAINTENANCE just before you operate the vehicle Pay attention to the CAUTIONS and WARNING During D checks and services of PREVENTIVE MAINTENANCE will be performed while the equipment and or its component systems are in operation Pay attention to the CAUTIONS and WARNINGS Do your after PREVENTIVE MAINTENANCE right after operating the vehicle Pay attention to the CAUTIONS and WARNINGS Do your wee
45. 1 Disconnected meter Engine could not run with dead or disconnected 23 When meter pointer stays below 13 3 V with the engine running fast enough to operate alternator it shows that alternator is not operating or volt age regulator is out of adjustment or that current being drawn from battery by lights heater fan or other load exceeds alternator out put 45 When engine is started pointer may stay in this area temporarily but should gradually rise above 13 3 V as alternator reaches normal output 6 This is the area in which the point er should be when alternator voltage regulator and battery are all in good condition and working properly 7 When the pointer goes above 15 2 V the voltage regulator is set too high or is jammed and continued oper ation of the engine will burn out the battery HC238A Operator s Manual TM 10 3950 263 14 amp 1 Section 1 Continued Operating Instructions Engine Shutdown Emergency Shutdown Swinq Lock Control Master Clutch ontrol Swinq Brake Control Throttle Boom Hoist Control Swing Control Rear Drum Brake Front Drum Brake Foot Throttle Boom Hoist Override The picture above shows the controls found on the upper control stand individually on the following pages 1 20 Rear Drum Control Front Drum Control i Boom Hoist z Pawl Control Live Mast Control Fig 1 19 NA233 C Upper Control Eac
46. 1 Floor Board 4 Reach Rod A 1 8 3 17mm 2 Clutch Pedal b Cross Shaft amp Lever 1 Clutch 3 Release Bearing 3 Return Spring 6 Adjusting Screw 2 Release Finger 4 Cover Plate Fig 3 4 Steering Mechanism 1 Steering Wheel 4 Drag Links 7 Equalizer Beam 2 Pitman Arm 5 Steer Cylinders A Adjust To 49 15 16 Length 127cm 3 Steering Gear 6 Idler Arm Operator s Manual Section 3 Continued Carrier Adjustmen 8 4 3 5 This practice consists of applying pressure to the clutch pedal either when there is no need to declutch or prematurely in preparation for a gear change Sustained pressure on the clutch without a declutch and gear change results in rapid wear and failure of the clutch release bearing Front Axles Two front axles are used under the carrier The axles are mounted to the carrier by bogie beams The beams attach to shafts mounted on the carrier frame The axles are attached to the bogie beams The bogie beams serve two purposes 1 They reduce the effects of bumps and road irregularities 2 They distribute loading between the two axles The front axles are also supported by four torque rods two each side As the name implies the torque rods absorb any torque caused by the tendency of the axles to turn forwards or backwards on their axis due to starting or stopping inertia or road shocks Front Wheel Alignment For maximum tire life and ease of steering front wheel al
47. 1 32 1 33 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Brake Pedal Depressing the brake pedal actuates two valves which meter air pressure to the brake actuators The farther the pedal is depressed the more air pressure is admitted to the actuators and the harder the brakes are applied Releasing the brake pedal releases the air pressure from the actuators allowing the brake shoe springs to release the brakes Clutch Pedal Fully depressing the clutch pedal disengages the carrier clutch through linkage clutch rod arrangement Raising the clutch pedal allows clutch to engage Dimmer Switch The dimmer switch located on the floor to the left of the operator controls the high and low beams When the switch is in the high beam position all four headlights are on An indicator light on the dash comes on when the headlights are on high Creeper Transmission Shift Lever A two speed creeper transmission is used in the carrier to provide both low gear ratios for slow careful machine movement around the Job site and higher ratios for normal use The low ratio is not for extra tractive effort to get out of areas requiring heavy pulls Using it for such conditions may damage the transmission or drive line For normal use the lever must be in the down position For creeper use the lever must be in the up position Note Shift the lever only when the carrier is not in motion to avoid damage to transm
48. 3 Component Description and Operation Note The system works for 50 through 130 ft 15 24 through 39 62m of main boom a Display The display assembly includes three digital and a single hook block reeved from 1 to 12 LCD meters a horn three red lights three amber parts of line or two hook blocks reeved from lights a power switch a test button and a hook 1 to 6 parts of line when using two hook select switch blocks they must be reeved with the same number of parts of line The maximum allowable loads are based on the machine s capacity chart for 50 130 ft HC238A 10 1 Operator s Manual 10 2 DISPLAY CONSOLE MAIN ELECTRONICS REEVE SELECT BOOM SELECT The top meter is the load meter It indicates the total weight of the hook block s all the wire rope between the hook block s and boom point chains slings and the load on the hook block s The middle meter is the Alert meter It indicates the crane capacity as shown on the capacity chart in the upper cab for the parts of line reeved on the main hoist hook block s at the radius shown on the Reach meter The Load and Alert meters scale read 0 to 1 999 To compute the weight multiply the meter reading by 1 000 lbs For example TM 10 3950 263 14 amp P 1 Section 10 Overload Warning System Two Blocks A LEFT LOAD SENSOR ANGLE SENSOR Fig 10 2 System Cabling and Interconnect RIGHT LOAD SENSOR A NA446 C if the meter reading is 100 then 1
49. 6 IQ Operator s Manual 1 5 On Delivery On delivery of a new machine make the following checks General Upper and Carrier 1 Check for any shortages or damages that may have occurred during transit If any notify the transportation company involved immediately 2 Clean dirt paint or any other foreign material from the machine Remove all wires wire ropes and other hold downs used during shipping 3 Check all gear compartments for the proper weight and level of lubricants If necessary change to meet local conditions Geelsecianl 2lof this manual Engine Upper and Carrier 1 Check the fuel oil water levels Start the engine and check the oil pressure water temperature ammeter etc For _more information consult pages 1 8 1 9 and Brake System Carrier only 1 Check air pressure 115 125 psi kPa maximum 2 Check low air pressure warning device for operation at 60 psi 413 kPa 3 Check foot brake operation 4 Check emergency brake operation Clutches and Brakes Upper only 1 Check adjustment of all clutches and brakes before operating the machine 2 Inspect clutches and brakes for loose or damaged cotter pins bolts nuts jam nuts misalignment damage foreign matter oil or grease on friction surfaces etc If any repair or correct before operating Hydraulic System Upper and Carrier 1 Check for leaks or damage 2 Check for correct operating pressures
50. 6 14 Bleeding Fuel System Disconnect fuel return line and operate hand priming lever on fuel transfer pump until fuel flows bubble free from fuel return line Then reconnect the fuel return line fitting Note If the camshaft s pump lobe is up crank engine one revolution to permit hand priming When finished return priming lever inward disengaged position to permit normal pump operation Batteries may be conserved by using this alternate method of bleeding the fuel system Completely loosen the lower nut on the injection pump to nozzle fuel line Loosen the delivery valve holder located below the fuel line nut until it can be turned with the fingers Crank engine until clear fuel emerges around the loosened delivery valve holder Retighten the delivery valve holder and fuel line Fuel injection should occur almost immediately when engine is cranked 6 15 Starting Sequence The starting and stopping sequence lists the manual mechanical and electrical events reguired for satisfactory start run and stop cycles rm 3 illustrates controls for starting and stopping sequence TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembly FIELD START STOP SWITCH BREAKER ANTI FLICKER BREAKER POINTS SET GAP AT 025 64mm LOCATED NEXT TO FUEL TRANSFER PUMP UNDER SMALL COVER Dc AMMETER ich PREHEAT SWITCH 6 19 Applying Load Fig 6 3 Standard Control Panel All
51. Diesel Allison does NOT approve any multigrade oils except the new generation 15W 40 lubricants previously described Although lubricants such as 10W 30 and 20W 40 are commercially available the performance of their additive Systems has not been demonstrated in Detroit Diesel engines Since properties such as sulfated ash are affected in formulating these multigrade compounds their use cannot be approved SAE 40 amp SAE 30 Single Grade Lubricants Detroit Diesel Allison continues to approve SAE 40 and SAE 30 lube oils providing they meet the 1 000 maximum sulfated ash limit the 0 07 by weight minimum zinc content and the following API Service Classifications 2 103 contamination exceed 1 00 by weight ASTM D 893 4 The total base number TBN is less than 1 0 ASTM D 664 Note The sulfur content of the diesel fuel used will influence the alkalinity of the lube oil With high sulfur fuels F the oil drain interval will have to be shortened to avoid excessive acidity in the lube oil Statement Of Policy On Fuel And Lubricant Additives In answer to request concerning the use of fuel and lubricating oil additives the following excerpt has been taken from a policy statement of General Motors Corporation It has been and continues to be General Motors policy to build motor vehicles that will operate satisfactorily on the commercial fuels and lubricants of good quality regularly provided by the petroleum industry
52. E Square Feet Square Meters PS Square Yards ae NR Square Kilometers SCH Square Miles ai 0 Square Hectometers za Acres Cubic Meters emis CUBIC Feet Cubic Meters eee Yards e Milliliters Fluid Ounces d n IEEE Liters enero QUANS u sec ep Liter allons ul Grams e OUNCES s e 5 Kilograms us a OUS as z Metric Tons Tons ES Newton Meters Pound Feet Kilopascals an Pounds per Square Inch e o Kilometers per Liter i Miles per Gallon TEENS Kilometers per Hour Miles per Hour eene 0 621 TA089991 PIN 057514 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
53. ENGINE AND OBSERVE FUEL FLOW FROM RETURN LINE 2 IF FUEL DOES NOT SPURT OUT PUMP MAY BE DEFECTIVE TM 10 3950 263 14 amp P 1 Section 6 Continued Auxiliary Generator Assembl Operator s Manual DIESEL ENGINE TROUBLESHOOTING GUIDE LIQUID OR AIR COOLED E i on Lead Defective Glow fective Control Cireult Worn or Damaged Transfer Pump Leaking Diaphragm Restricted Air intake Dirty Air Filter Poor Quality Fuel of Fuel or Shut Off Ciesed Wrong Timing Sutton in Injection Pump LOAD Time at NO e Run For Long Oi Leeks From Engine Base or Connections Light or Diluted Crankcase Ou Low Oil Supply 6 11 Operator s Manual 6 12 TM 10 3950 263 14 amp P 1 Section 6 Continued Auxiliary Generator Assembly DIESEL ENGINE TROUBLESHOOTING GUIDE LIQUID OR AIR COOLED GOVERNOR SYSTEM High Spring Sensitivity GO EE Tm COOLING SYSTEM H lz atta iia ata a EA ASA nn 202 INTERNAL ENGINE Poor Compassion Compression Loose Connecting Rod or Crankshaft Bearing Incorrect Valve Clearance Broken or Weak Valve Spring Valves Not Seating Properly Worn Cylinder Wells Pistons Rings Sticking Valves Worn or Dirty Valve Guides TM 10 3950 263 14 amp P 1 Operator s Manual Section 7 Speed o Matic Control System Index Section 7 Subject Page Subject Page S o M System Sump Tank 7 2 To Check 7 1 To Change 7 4 S o
54. Engage swing lock before roading Note Boom live mast must be fully extended and the headshaft links pinned in the 76 76 2cm position before raising boom to working position and making lifts with the boom 5 25 Carrying 50 Foot 15 24m Boom Over Front With Gooseneck Links The 50 foot 15 24m basic boom may be carried over the front of the carrier at a reduced overall height by installing gooseneck links at the top pin connections between the upper 5 15 Operator s Manual and lower boom sections To install the links proceed as follows m Chart D Break the boom down to the basic 50 foot 15 24m boom with 30 9 14m mast position Counterweight machine for travel per Chart D Remove the pin which holds the carrying links in the raised position allowing them to swing free Lower the mast until the links may be pinned to the lugs on the lower section Boom up until the boom hoist ropes are taut with the boom peak still touching the ground Remove the two upper pins only Boom up until the pin connecting holes are 3 1 4 82 5mm apart center of hole to center of hole Install the gooseneck links over the pin connecting hub on the boom lower section Install two bolt spacer and locknuts between each pair of links to hold them in place Install the boom connection pin through the links and the pin connection hole in the boom upper section Insert a keeper pin in each boom connection pin Pin the headshaft
55. Engage the swing lock b Rotate the planetary until the plug marked fill is at top dead center c Disengage master clutch Shut down engine d Clean an area around the check plug to prevent entry of foreign material Remove the check plug The unit should be full of lubricant to the level of the check plug hole Add lubricant if necessary through the fill hole See capacity chart on Gi for the right lubricant Install and tighten fill and check plug 1 Filter 4 Strainer 2 Dipstick Breather 5b Drain Plug Inspection Plate 6 Filter Cover Plate 2 36 To change a Operate the machine for a few minutes to warm up and stir up the lubricant Add lubricant if necessary thru the fill hole See capacity b ae evel around Set parking c Rotate tie can unl one of the plugs is at bottom dead center Disengage the master clutch Shut down engine 2 33 To change T a Operate the machine to warm up and stir up the d Gelle Seck See faster draining Allow the oil oil to drain thoroughly e Rotate the planetary case until the plug marked fill is at top dead center Disengage the master clutch Shut down the engine b Park machine on level ground Set the parking brake Engage swing lock Disengage the master clutch Shut off the upper engine c Remove the drain plug from th fth f Pour lubricant in the fill hole until the oil level is c case oe eod Sedan Ford even with the check plug
56. FUNCTION CATEGORY EQUIPMENT Transmission Range shift Air System Replace Repair PROPELLER SHAFT Drive Shafts Replace Repair Universal Joints Service Replace FRONT AXLES Front Axle Assembly Replace Repair REAR AXLES Rear Axle Assembly Service Replace Repair Housing Assembly Replace Repair Differential Assembly Inspect Service Replace Repair Planetary Gears Shafts Bearings Replace Walking Beam Stub Axles Replace BRAKES Service Brakes Inspect Service Replace Repair TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS Brake Shoe Assembly Replace Cam Replace Air Brake Actuator Assembly Replace Repair Air Reservoir Service Replace Repair Valve Replace Hoses Lines and Fittings Inspect Replace Air Compressor Assembly Service Replace Repair Governor Replace WHEELS Front Rear Suspension Replace Repair Torque Rod Assembly Replace Equalizer Beam Replace Bushing Replace Wheel Assembly Inspect Replace Repair Drums Replace Repair Bearings Inspect Service Replace TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS CO
57. Hub Accessory Drive Replace Repair 2 Gear Shafts and Bearings Replace TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS PURIS MEE Fe COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE FUNCTION CATEGORY EQUIPMENT c o F H D CLUTCH Clutch Assembly Inspect Service Replace Repair Yoke Pedal Linkage Service Replace FUEL SYSTEM Fuel Injector Test Replace Repair Fuel Injector Lines Replace Fuel Injector Control Tube Replace Fuel Pump Test Replace Repair Air Cleaner Inspect Service Replace Turbocharger Inspect Replace Repair Turbocharger After cooler Replace Repair Blower Assembly Inspect Service Replace Repair Blower Drive Gear Replace TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT Fuel Lines and Fittings Inspect Replace Repair Fuel Tank Inspect Service Replace Repair Fuel Manifold Replace Air Intake System Service Replace Repair Air Inlet Adapter Replace Engine Speed Governor Controls Adjust Replace Governor Service Replace Repair
58. LIST ASL END ITEM Crane Mobile 140 Ton Capacity Container MAKE FMC MODEL HC 238A Ee NSN 3950 01 110 9224 3950 01 110 9224 DATE 16 Apr82 16 DATE 16 Apr82 82 REQ D FOR NO OF SMR UNIT FND ITEMS CODE PRIME P N FSCM PART DESCRIPTION PRICE UM 15 1 5 6 20 21 50 PAFZZ 5950 00 551 0573 493482 77521 Coil Electrical Valve Stack 39 00 2 PAFZZ 5930 00 683 1633 MS24523 27 96906 Switch Toggle Outrigger Beam 15 00 EA 2 PAFZZ 5930 00p 660 3947 MS24524 27 96906 Switch Toggle Outrigger Jacks 36 00 EA 1 PAFZZ 5930 00 061 4926 MS24659 27E 96906 Switch Toggle Outrigger Jacks 54 00 EA 1 Final PAFZZ 3020 00 252 7352 RC 60 4 36422 Chain Link Upper Eng Drive 3 00 EA 4 PAFZZ 3020 01 126 1751 1H609 36422 Chain Link Connecting 4 00 EA 4 PAFZZ 3020 01 125 6120 1H610 36422 Link Offset 13 00 EA 4 PAFZZ 3020 01 126 1551 1H624 36422 Section 3 Pitch 9 00 EA 4 PAOFF 4730 01 111 4694 10673 36422 Rotating Joint Assembly 52 00 EA 1 1 A 72 TM 10 3950 263 14 amp P 1 By Order of the Secretary of the Army JOHN A WICKHAM JR General United States Army Official Chief of Staff DONALD J DELANDRO Brigadier General United States Army The Adjutant General Distribution To be distributed in accordance with SPECIAL DISTRIBUTION U S GOVERNMENT PRINTING OFFICE 1988 206 929 80102 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG
59. M System Filter 7 1 7 5 To Change 7 1 7 6 Relief Valve Assembly 7 2 HC238A TM 10 3950 263 14 amp P 1 Operator s Manual Section 7 Speed o Matic Control System Operator s Manual Place pipe plug here A when setting pres sure See Page 7 2 Fig 7 1 Hydraulic Power Supply 1 Filter 4 Drain Plug 2 Sump Tank b Dipstick and Breather 3 Strainer 7 1 S o M System Sump Tank 7 2 To check a b c Park machine on level ground Disengage the master clutch and shut down the engine Reduce the So M system to zero by working the levers back and forth If this is not done a false reading will be obtained due to the amount of oil stored in the accumulator Remove and wipe off the dipstick Insert the dipstick in the tank remove and read Add oil as necessary Use only FMC hydraulic oil in the system This oil is available in four weights and comes in either 5 gallon cans or 55 gallon drums The weights and stock numbers are as follows 1 5 Vis 5 Gal Can 18 9L 830661001 55 Gal Drum 208L 830661002 2 5 Vis 20 5 Gal Can 18 9L 830662001 55 Gal Drum 208L 830662002 3 10 Vis 20 5 Gal Can 18 9L 830663001 55 Gal Drum 208L 830663002 4 20 Vis 40 5 Gal Can 18 9L 830664001 55 Gal Drum 208L 830664002 The 5 vis oil is to be used in machines operating in temperatures of 35 F to 20 F 37 C to C The 5 vis 20 oil is to be used in temperatures of 5 F to 65 F 20 C to 18 C
60. Oil the dead end pin being careful not to get oil on the clutch shoes g Replace the shim cover and cotter pin h Tighten the locknut i Repeat the above procedure for each shoe in each clutch assembly Air Box Drains Fig 4 10 An air box drain tank is used on the upper The purpose of the drain tank is to collect water and sediment discharged from the engine air box to prevent spillage on the carrier The tank must be drained every 50 hours as follows a Open the drain cock and collect any sediment which drains from the hose under the R H deck plate b If no drainage is evident blow out the tank and drain hose with compressed air c Disconnect the hoses from the air box drain With the engine running place a finger over the drain If no air flow is felt the drains are plugged and must be cleaned Every 500 hours check and clean the system as follows a Remove the cylinder block hand hole covers and check for an accumulation of liquid or sludge on the air box floor Clean if necessary b Remove the drain tubes and blow out with compressed air c Clean out the drain tank hose and fittings Control Lever Adjustment Fig 4 11 Adjustment of the control levers should be checked occasionally to assure full operating pressure at the operating cylinders To adjust the linkage proceed as follows a With the master clutch lever disengaged toggle in the control lever b Loosen the
61. S I If not adjust control stand linage set pressure in system seen 4 872 Make sure clutch is assembled in energized position see Shop Manual 5 9 2 0 3 Adjust brake seelp 4 5 Inspect ball check valve in hydraulic line leading to B H brake cylinder Ball may be stuck 4 Converter low on oil Refill with oil see p 2 37 Torque converter defective Repair or replace see Shop Manual 5 Support boom with auxiliary Crane Unjam cable Lower boom to the ground Inspect cable for damage Replace if necessary TM 10 3950 263 14 amp P 1 Operator s Manual Section 8 Continued Troubleshooting Procedures Problem Probable Cause Solution Boom will not lower 1 Pawl not releasing 1 Release pawl with operator s control see p 1 24 Check to see if pawl is stuck If so remove clean up and lubricate Replace and adjust pawl see Shop Manual 2 Brake not releasing 2 See 3 under Cause Boom will not raise 3 Planetary brake malfunctioning 3 Adjust planetary brake see p 4 3 Check S o M pressure at planetary brake cylinder Should be 900 1050 P S I If not adjust control stand linkage Set pressure in system see 4 d 7 2 4 Cable jammed on sheave 4 See 1 under Cause Boom will not raise 5 Defective lowering planetary 5 Engage B H pawl Disassemble and repair or replace planetary see Shop Manual Boom creeps down 1 B H brake slipping 1 Adjust seelp 4
62. UU Disassemble the lifting spreader Fig 1 40 Lifting Arm Assembly Outrigger Box 5 Pins Pin amp Keeper 6 Pin Outrigger Jack 7 Lifting Arm Piston Rod 1 33 Operator s Manual 1 102 1 34 Fig 1 41 Lifting Assembly 1 Pin Sling Rear 2 Capscrew Locknut H Beam 3 Pin Corner Braces 4 Sling Front H Beam 5 H Beam Support Pendants 6 Corner Braces Trunbuckles Remove the lifting arms Store all of the parts together so none of them become lost Coat the pins and the inside of the pin holes with the preservative so they won t rust Machine Tie Down Two tiedown rings are provided at each end of the carrier When the machine is being transported by ship or rail it must be securely blocked in place and tied down Refer to Figure 1 42 After positioning the machine securely block one front wheel on each side of the machine and one rear wheel on each side of the machine Block in front and back of each wheel If blocking on a rail car secure the blocks to the wood deck with nails If blocking on a metal surface ship deck connect the two blocks together by nailing planks to the sides of the blocking After blocking shift the carrier transmission into neutral Make sure park emergency brakes are applied Two tie down hooks are installed on each end of the carrier The front two are on the frame under the bumper The back two are on the rear of the fra
63. a hammer and wooden block to tap the rope tight Refer to Fig 5 25 During this operation the rope must be kept under tension Note Grooved drums may not require this hammer and block method but the wire rope must be kept under tension Examine the spooling of the first layer to make certain that the rope is seated in the drum grooves 5 18 TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment R H BOOM DEAD END R H BOOM DEAD END 1 PART OF LINE X a PARTS OF LINE AO x R H BOOM DEAD END L H zu L H DRUM HOOK BLOCK DRUM HOOK SOCKET SOCKET 2 PARTS OF LINE Se R H BOOM DEAD END 5 PARTS OF LINE x BOOM DEAD END o9 R H HOOK BLOCK DEAD END L H L H HOOK BLOGK DRUM SOCKET Steg DRUM SOCKET 3 PARTS OF LINE R H BOOM DEAD END EE R H BOOM DEAD END o9 R H HOOK BLOCK DEAD END pun HOOK BLOCK DEAD END HOOK BLOCK DRUM SOCKET Fig 5 26 Main Hoist Reeving L H Drum Socket HC238A HUOK BLOCK DRUM 5 19 TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment 5 20 R H BOOM DEAD END 10 PARTS OF LINE HOOK BLOCK DEAD END L H DRUM SOCKET R H BOOM DEAD END L H DRUM SOCKET BOOM DEAD END HOOK BLOCK DEAD END L H RUM DRUM SOCKET SOCKET R H BOOM DEAD END BOOM DEAD END 2
64. a helper crane or live mast reeved as a short boom lift lower section and set in place Align holes in boom feet with boom foot lug holes c Push control lever toward rear of upper to push boom foot pins back into place Do Not Operate Machine As Crane With Retracted Mast Boom Boom Suspension And last May Be Damaged Mast Must Be Pinned In Extended Posi tion Or It Will Not Stay Extended And May Be Damaged Fig 1 38 Extending Or Retracting Live Mast 3 Mast Standoff 5 Pin 4 Raised Position HC238A 6 Boom Lower Section 1 31 Operator s Manual d Install lock pins on each boom foot pin Install cotter pins in lock pins Note Never remove pins unless boom is securel supported Otherwise it may fall and cause damage or injury 1 95 Live Mast Controls 1 96 Extending The Live Mast The live mast may be extended as follows a Ifthe boom is on the machine lower boom to ground v position the mast standoffs as shown in then pay out B H ropes until the standoffs contact the lugs on the boom lower section b Ifthe boom is not on the machine block under the live mast near the standoffs to hold it horizontal Note If mast goes below horizontal a helper crane must be used to raise it c Pay out on B H ropes until they are slack d With the engine running and master clutch disengaged turn mast control valve knob to extend position When the mast is fully extended rotate the knob t
65. and grease fittings before lubricating This helps keep grit from entering the bushing or bearing Keep all grease oil containers and cans clean Always replace the lid on containers when through to prevent entry of foreign material Wipe off can covers before opening Drain gear cases when hot They will drain better and grit will be more likely to be in suspension 2 2 Carrier Maintenance And Lubrication Schedule 2 3 Daily WARNING Be Careful Not To Get Burned On Hot Oil When Draining Gear Cases d Watch for signs of incorrect lubrication such as failure of fittings to take grease leakage from seals cover plates etc accumulation of grease where it shouldn t be etc Disengage the master clutch before working on machine Replace all guards before starting machine Use a clean funnel equipped with a strainer for pouring lubricants Clean an area around fill or check plugs before removing to prevent entry of foreign material Note See PP 2 14 through 2 17 later in this section of the operators manual for lubrication check and change procedures General Engine Radiator Fuel Tank Battery Tires 1 Keep the carrier clean 2 Check for loose or broken bolts nuts cotter pins and other fasteners If any tighten or replace before operating 3 Inspect all welds for cracking If any are noted consult manufacturer Do not operate until properly repaired 1 Check oil level Add oil as neces
66. as follows a Empty the dust cap at regular intervals These intervals may vary from 4 to 600 hours depending upon dust condition Do not allow the dust level in the cup to build up closer than 1 2 inch 12 7mm from the slot in the dust cup baffle Stop the engine and remove the dust cup Remove the baffle from the dust cup and empty the dust Replace the baffle in the dust cup making sure the baffle is properly seated Check the dust cup sealing edge for damage Check the dust cup gasket if so equipped Replace the dust cup to make sure it is properly positioned on the air cleaner body horizontally mounted models the proper cup position is indicated by the arrows located on the bottom of the cup Also the slot in the dust cup baffle must be at the top WARNING Warn Personnel In The Immediate Area Before Using Compressed Air For Cleaning Wear Safety Glasses Compressed Air Coming Into Contact With The Human Skin Or Causing Flying Metal Chips Can Cause Injury b Remove the main element from the air cleaner Washing in water of blowing with compressed air are two accepted methods of cleaning the element If the element regularly contains amounts of soot or oil washing in water is best If the contaminant is mostly dust either method 1 Check Plug TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Reduction Shaft Pinion Case 3 Lubricant Level 1 I I
67. b protected The use of boom point guards proximity devices insulated hooks or blocks or swing limit stops do not assure safety Even if codes or regulations require the use of such devices you must follow rules listed here If you do not follow them the result may be serious injury or death The following illustrations portray some of the limitations of the devices Power line Contact Here Insulated Link Fig 11 ven though crane equipped with insulating link and om peak guard In this situation the man is not Grounding the machine may increase the danger Popr grounding such as a pipe driven into the ground gives little or no protection In addition a grounded machine may strike an arc so heavy that a live line may be burned down This could cause the machine and the area around it to be electrified TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T This man is meaner oint Guar not protected p S Power Line The Other Man May Be Protected Insulating AY Link Fig 12 Crane equipped with both an insulating link and an insulating boom point guard These Men Are Not Protected 10 foot 3 04m vi Radius Fig 13 Crane equipped with proximity device Shaded area shows sensitivity zone with full boom length sensor used and adjusted for 10 foot 3 04m clearance Contact can be made outside this zone by the
68. be performed in the order listed B Before D During A After W Weekly M Monthly PER ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO B D AIW M FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF 13 WIRE ROPE AND FITTINGS Inspect the wire rope rope sockets and a In running ropes fittings for damage wear corrosion there are six randomly fatigue and rope lubrication distributed broken wires in one rope lay or three broken wires in one strand in one rope lay b In pendants or standing ropes there is more than one broken wire in one rope lay c loss of 1 3 the original diameter of outside wires by abra sion scrubbing or peening is found d There is rope deterioration from rust or corrosion e There is severe kinking or crushing or evidence of birdcaging f Obvious reduction in wire rope diameter exists g There is evidence of heat damage from any cause A 47 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Upper NOTE Within designated interval these checks are to be performed in the order listed B Before D During A After W Weekly M Monthly PER ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO B D AIW M FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF 14 CRANE OVERLOAD WARNING SYSTEM Test the Overload Warning System Refer to Paragraph 1
69. boom 1 25 TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions ing down or swinging load outswing from centrifugal force as these increase load radius with a resultant decrease in capacity Make sure the load being lifted remains within the lifting capacity of the machine at the boom length and load radius being used 1 82 Hand Signal Chart One workman on the job should be designated a signal man and the operators should obey signals from him only A signal to stop should be obeyed no matter who gives it See hand signal chart Fig 1 31 Note Hand signal chart recommended by USA standards committee B30 safety codes for cranes derricks hoists jacks and slings and reproduced from_the USA standard safety code for crawler locomotive and truck cranes USAS B30 5 with ermission of the publishers The American Societ Of Mechanical Engineers 1 83 Counterweight Removal Controls The counterweight remover is actuated by two hydraulic RAISE THE LOAD cylinders which receive pressure for operation from the hydraulic power supply for the S o M system The controls which operate the counterweight remover are located inside the left rear cab door in front of the engine RAISE THE BOOM AND LOWER THE BOOM AND OWEN THE LOA The function valve is a three position spring centered lever operated type This valve controls the oil flow to raise or lower the counterweight When
70. correct capacities for your machine lf the front outriggers settle throwing increased loading into the jack the horn will sound If the machine is overloaded when working over the front the horn may or may not sound If the horn sounds when you are working the machine immediately land your load Reset the outriggers as explained previously before continuing operation Continuing to work with the jack overloaded can result in machine damage or injury Outrigger Operation operated as follows The hydraulic outriggers are Apply the digging brake Shut down the engine Note Never engage or disengage the power take off with the engine running Damage to the transmission or take off will result b Pull out on the control cable under the dash to engage the power take off c Install a pontoon on the front bumper jack Install an adaptor on each of the four side outrigger jacks Install three pontoons on each adaptor Remember pontoons must rest on a smooth surface with full support No unsupported pontoon area is permissible Rough surface rocks etc under TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions pontoons will cause unequal loading may break it or cause collapse Be sure that blocking or pontoons are set on firm surface adequate to support the blocking or pontoon loading without settling slipping or collapse Blocking or matting under pontoons must form a smooth level sur
71. direction of a qualified engineer If a multiple crane lift is unavoidable observe the following rules located on firm a Cranes must be level and surfaces b Cranes should be the same size and capacity use the same boom length and be reeved similarly C Truck cranes must be completely sup TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T ported on fully extended outriggers d Cranes must be positioned so that each boom point is directly over its load attaching point Fall lines must be vertical during all phases of the lift e Rigging must be placed so each crane lifts a share of the load well within the crane s capacity f During handling be sure that more load is not transferred to any crane than it can handle g Don t attempt to travel when making multiple crane lifts h Coordinate plans with the other operator before beginning to lift i Use only one signal man j Use of an operable load and angle indicating System is desirable 26 Don t lift more than one separately rigged load at a time even if both loads combined don t exceed the crane s capacity Your full attention cannot be given to both loads creating a dangerous situation 27 Use caution when booming up to minimum radius Be prepared to stop boom travel If the boom limit device malfunctions the boom and backstops may be damaged or someone may be hurt Do not boom into boom limit device in normal ope
72. drum are splined to the shaft between the two sides of the upper frame A clutch drum spur gear assembly is mounted on each end of each shaft except the R H end of the boom hoist shaft A planetary speed reducer and gear are mounted there Z RRS O K Sy i Fig 1 3 Clutch Schematic Boom Hoist Shaft Rear Drum Shatt Reduction Shaft long Vertical Swing Shatt Swing Pinion Turntable Bearing eg ey L H Clutch R H Clutch The gear drum assemblies ride on the shaft on bearings They are not connected to the shaft All of the gears on the R H side of the frame are in mesh All of the gears on the L H side of the frame are in mesh also A clutch assembly is mounted on each end of each shaft except the R H side of the boom hoist inside the clutch drum Although we call the assembly a clutch it actually resembles an automotive brake with two shoes The clutch is connected to the shaft by splines TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions Fig 1 4 Shaft Schematic When the engine is running with the master clutch engaged all of the gears in the gear train will turn The shafts remain stationary held in place by a brake When the operator wants to rotate a shaft to raise lower a load or the boom or to swing the machine he releases the brake on that shaft and engages the control lever When he engages the cont
73. etc Avoid them with a safety margin Mark locations clearly to avoid guess work x de 212 1 5 e 2 53 Jet _ ERU UG E L 1 u T T mei EES Fig 38 Be careful where you di 6 Don t operate a dragline or clamshell with more than the recommended boom length installed on the machine Many factors are considered when setting maximum boom lengths on a machine Exceeding the maximums effect machine stability or strength and cause a failure or accident 0 24 7 Avoid slack lines when digging Slack lines cause improper spooling on drums damage the rope and shorten rope life The rope may break prematurely causing an accident Carrier Operation 1 Road the machine safely Watch for narrow bridges and low clearances When maneuvering in tight places post a signal man on the ground to guide you Check load limits height width and length restrictions in the area you are traveling Make sure your machine complies with all regulations Fig 39 Travel safely 2 When roading a carrier mounted machine note the following a Operate with lights on Use proper warning signs flags and other such devices Use an escort service if required b Lock swing lock in upper unless you are traveling with boom installed and it is necessary to swing the upper for TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T clearance or if boom i
74. facing wears this clearance will decrease If allowed to decrease excessively the release bearing may contact the release fingers and cause the clutch to slip resulting in eventual clutch failure Never wait for a clutch to start slipping before adjusting it Once the clutch starts to slip it is too late to make an adjustment Once the facings are burned by slippage they quickly wear out The clutch is adjusted as follows a Disconnect the reach rod b Place cross shaft in its most forward position c Check the overall length of the reach rod It must be adjusted so the clutch pedal is tight against the floorboard when the cross shaft lever is in its most forward position d Reconnect the reach rod and check the return Spring tension Make sure the tension is such that the clutch pedal remains tight against the floorboard e Remove the clutch cover plate from the clutch housing f Check the release bearing clearance It should be 1 8 3 17mm g To increase this clearance back off on the adjusting screw Note Excessive release bearing clearance may prevent complete clutch engagement the other hand insufficient clearance may cause slippage and shorten clutch life One of the most abusive practices which cause clutch failures is riding the clutch pedal TM 10 3950 263 14 amp P 1 Operator s Manual Section 3 Continued Carrier Adjustment Fig 3 2 NA199 C Clutch Linkage Carrier Clutch
75. for travel both on and off the highway The lower creep speed is used for slower movement around the job site but should not be used when high tractive effort is required or drive line damage may occur Power from the creeper transmission is transferred to the two rear drive axles Each axle is a double HC238A 3 2 3 3 TM 10 3950 263 14 amp P 1 Section 3 Carrier Adjustment reduction type with one gear reduction in the differential and a second in the planetary hub at each end of the axle Two steering axles are used at the front of the carrier Steering is accomplished manually with hydraulic assist Air brakes are used on all axles The rear axle brake actuators contain emergency and parking brakes Clutch Assembly The carrier clutch is a push type double dry disc Pushing on the clutch pedal pushes the release bearing against the release fingers disengaging the clutch Releasing the clutch pedal allows the release bearing to move away from the release fingers Springs in the clutch pressure plate engage the clutch Clutch Adjustment When the clutch linkage is properly adjusted there will be a small amount of free pedal travel This free pedal travel results from clearance between the clutch release bearing and the clutch release fingers This clearance is necessary to remove all loadings from the release bearing when the clutch is disengaged this clutch the clearance must be 1 8 3 17mm As the clutch
76. hole Install and tighten both plugs 2 16 Operator s Manual 1 Check Hole Planetary Speed Reducer 3 Fill Hole 2 Oil Level See capacity chart on page 2 T2 for the correct lubricant WARNING Do not service maintain or lubricate swing bevel gear case unless engine is shut down and swing lock is engaged 2 37 Swing Bevel Gear Case 2 38 To check a Park the machine on level ground Set parking brake Engage swing lock Disengage master clutch Shut down upper engine b Clean an area around check plug on rear of gear case c Remove the plug The case should be full of oil to the level of the plug hole Add lubricant if necessary See capacity chart on for proper lubricant Install pipe plug 2 39 To change a Operate the machine to warm up and stir up the oil b Park the machine on level ground Set the parking brake Engage swing lock Disengage master clutch Shut down upper engine c Remove the drain plug from the bottom of the case Allow the old oil to drain thoroughly d Install the drain plug and remove the check plug Remove the fill plug Fill the case with oil through the fill plug hole until oil is level with check plug hole Install pipe check and fill pipe plugs WARNING Do not service maintain or lubricate reduction shaft pinion case unless engine is shut down and swing lock is engaged See capacity chart on page 2 12 for the proper lubricant 2 40 Reduction Shaf
77. in operating position counterweight is held by lock up of mechanical linkage The control valves needle type are for the purpose of controlling the oil flow to the counterweight cylinders to control the rate at which the counterweight is raised or lowered and to maintain the counterweight in a level cone vac tsa nets NG condition These valves are to be closed except when operating the mechanism The instruction label shown in Fig 1 33 is located by the counterweight control valves Follow its instructions at all times 1 84 Removing The Counterweight HORN e a Fully extend and set all Outriggers on firm level supporting surface Machine must be level with all tires clear of the ground If machine is not level AB counterweight will tip into cab when lowered CAUTION Machines Equipped With AB Ctwt Can Not Be Swung Over The Side When On Rubber As The Machine Will Tip Over b Swing the upper around until the counterweight is Fig 1 31 Hand Signal Chart 2652 B lined up with the positioning blocks located on the carrier 1 26 EXTENO 800M RETRACT 00 Telesceping booms Tatescoping beers Operator s Manual 1 25 4mm Diameter Type N 29 500 13381 2 59 000 26762 4 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Note FMC Type N rope is 6x25 6X19 Class filler wire Extra Improved Plow Steel Preformed I W R C Independent Wire Rope Center R
78. jam nut Se amp Fig 4 11 c Tighten the adjusting nut until resistance to turn is felt Do not overtighten d At this point the control lever may not be returned to neutral e Back off on the adjusting nut until the lever may just be returned to the neutral position f Tighten the jam nut Note Adjustment of the linkage must always permit maximum pressure in the operating cylinder otherwise clutch slippage may result TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Continued Upper Adjustments amp D E L H Clutch S R H Clutch 4 Fig 4 9 Clutch Assembly 3 Cotter Pin 4 Shim Cover 6 Dead End Block 4 19 Chain Case With Chain Adjuster Fig 4 12 A chain case with a built in adjuster is used With this chain case it is not necessary to move the engine back and forth to adjust chain tension The chain dips into oil in the bottom of the case for lubrication 4 20 Chain Adjustment Chain tension is adjusted by lowering or raising adjusting arm and pinion 4 with adjusting screw 3 Adjust the chain as follows a Remove plug 1 from top of chain case b Loosen jam nut on adjusting screw 3 Turn in on adjusting screw until chain is taut c Measure from the lip where the plug mounts to the top strand of the chain Back off on the adjusting screw until there is 5 8 15 8mm sag in the top span of the chain lt will be necessary to push down on the top span of th
79. lay Resistant extra improved plow steel preform A improved St steel preformed Capacities shown on crane capacity plate must not be exceeded Capacities on this chart are shown in both pounds and kilograms Study operator s manual for wire rope inspection procedures and consult parts manual for wire rope size and type requirements E LC Ola 21 75 BL Rer pede e d 6 SC 6 x 19 Class Filler wire lt improved plow steel preformed fiber center 0 31 0 32 blank TM 10 3950 263 14 amp P 1 SECTION 00 INTRODUCTION 00 1 Scope This publication applies to Department of the Army units organizations and activities that use and or support the Crane Mobile Container Handling 140 ton Truck Mounted FMC Link Belt Model HC 238A 00 2 Description The crane is a truck mounted 140 ton capacity crane unit It is mounted on an 8 x 4 chassis and is diesel engine driven It has a 50 foot lattice boom which is capable of being supplemented adjusted with the use of various length boom extensions The crane is a basic commercial model with minor ancillary items added for military use 00 3 Maintenance Forms and Records Operational maintenance and historical records will be maintained as required by the current TM 38 750 00 4 Reporting of Errors For correction of errors or recommended improvements to this publication use DA Form 2028 Recommended Changes to Publications and B
80. like new condition TM 10 3950 263 14 amp P 1 2 Maintenance functions cont d k Rebuild Consists of those services actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards Rebuild is the highest degree of material maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements hours miles etc considered in classifying Army equipments components 3 Column entries Columns used in the Maintenance Allocation Chart as explained below a Column 1 Group Number Column 1 lists group numbers the purpose of which is to identify components assemblies subassemblies and modules with the next higher assembly b Column 2 Component Assembly Column 2 contains the noun names of components assemblies subassemblies and modules for which maintenance is authorized c Column 3 Maintenance Functions Column 3 lists the functions to be performed on the item listed in Column 2 d Column 4 Maintenance Category Column 4 specifies by the listing of a work time figure in the appropriate subcolumn s the lowest level of maintenance authorized to perform the function listed in Column 3 This figure represents the active time required to perform that maintenance function at the indicated category of maintenance If the number or complexity of the tasks within the listed maintenance function vary at differ
81. mission Creeper Transmission Rear End Differentials Lubrication Check and Change Planetary Speed Reducer Lubrication Check and Change Planetary Wheel Hub Lubrication Check and Change Upper Gear Case Lubrication General Information Lubrication Specifications Machinery Upper Mast Live Assembly Mast Foot Assembly Operating Theory Operation Carrier Operation During Operation Upper Operations Before Starting Outrigger Box Removal Outrigger Box Replacement Outrigger Jack Cylinder Removal Outrigger Jack Oylinder Installation Outrigger Operation Outrigger Overload Warning System Outrigger Pin Remover System Outrigger Sump Tank Change Oil Outrigger Sump Tank Check Oil Outrigger System Outrigger System Adjust Relief Valves Outrigger System Operation Outrigger System Throttle Control Overload Warning System Overload Warning System Adjustments Overload Warning System Components And Location Overload Warning System Component Description And Operation Overload Warning System General System Operation Overload Warning System Operating Instructions Pedal Accelerator Carrier Pedal Brake Carrier Pedal Clutch Carrier Pendants and Links TM 10 3950 263 14 amp P 1 Section 11 Alphabetical Index R783 Page w k iO vp IX x s DIN j wh MEN M N E mn Im ER ER ofoofo R mm o o
82. of a shell element and gasket combined into a unitized replacement assembly No separate springs or seats are required to support the filters The filter covers incorporate a threaded sleeve to accept the Spin on filter cartridges The word Primary is cast on the fuel strainer cover and the word Secondary is cast on the fuel filter cover for identification No drain cocks are provided on the spin on filters Where water is a problem it is recommended that a water separator be installed Otherwise residue may be drained by removing and inverting the filter Refill the filter with clean fuel oil before reinstalling it A 1 diameter twelve point nut on the bottom of the filter is provided to facilitate removal and installation Fig 2 33 Spin On Fuel Filter And Strainer Operator s Manual 2 84 Replace the filter as follows a Unscrew the filter or strainer and discard it b Fill a new filter replacement cartridge about two thirds full with clean fuel oil Coat the seal gasket lightly with clean fuel oil c Install the new filter assembly and tighten it to two thirds of a turn beyond gasket contact d Start the engine and check for leaks Fuel Tank Refill the fuel tank at the end of each day s operation to prevent condensation from contaminating the fuel Note A galvanized steel tank should never be used for fuel storage because the fuel oil reacts chemically with the zinc coating to form powdery fl
83. of the parts show signs of undue Front Drum Brake wear cracks or other distress replace them Reassemble and adjust the mechanism Rear Drum Brake 2 14 Every 1000 Hours or Seasonal Operation Remarks 1 000 Hours Seasonal First perform all operations listed under Every 500 Hours Reverse Bevel Gear 1 Drain clean and refill with specified lubricant Case See capacity chart Reduction Pinion Gear Case Chain Case Planetary Gear Case Bevel Gears 1 Inspect for wear or damage Repair or replace 1 Drain clean and refill with proper S o M oil See capacity chart BE rores 1 Change oil and filters Engine Drive Chains if required 2 Adjust bevel gear back lash and chain tension as necessary x S o M System x x Torque Converter Turntable Gear 1 Inspect all open gears for wear or damage i Swing Pinion Repair or replace the part if required before Gear Train further operation Operator s Manual TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication 2 15 Machine Storage Suggestions Listed below are a number of important points which should be followed when putting a machine into storage Machines stored outside must be thoroughly protected or serious deterioration will result 1 2 Lower boom to ground and slack off on boom suspension or remove boom entirely Tie down all ropes and pendants to prevent whipping in the wi
84. on the outrigger box b Connect the slings with hook block Lift outrigger box and set in place under carrier c Lift outrigger box until mounting lugs on box enter mounting lugs on carrier Set hoist brakes to secure load d Connect all outrigger hoses at quick disconnects e Operate outrigger jacks as explained on Page 1 12 to raise or lower boxes until pin holes line up Install mounting pins and keepers g Fully retract jacks before traveling machine h Remove and store lifting slings aS 1 46 Outrigger Pin Remover System An outrigger box pin remover system is available as an option A hydraulic cylinder is mounted between each pair of outrigger box mounting pins These cylinders use hydraulic oil under pressure from the hydraulic outrigger system to remove the outrigger box pins 1 47 Outrigger Box Removal a Outrigger boxes can be removed by using a helper crane or the machine s live mast used as a short boom b Fully retract all jacks and beams Remove left front jack cylinder as explained earlier in this section c Connect a chain or wire rope sling to the lifting lugs on top of the outrigger box Hoist to support the weight of the outrigger box Set the hoist brake d Unhook quick disconnects in lines leading from carrier to outrigger box Both sides of carrier Install dust caps or plugs in all quick disconnects e cylinder hose disconnects to beam quick disconnects f Attac
85. or each time the engine oil is changed whichever occurs first When the engine is equipped with a turbocharger 1 Disconnect the oil inlet supply line at the bearing center housing 2 Fill the bearing housing cavity with clean engine oil Turn the rotating assembly by hand to coat all of the internal surfaces with oil 3 Add additional engine oil to completely fill the bearing housing cavity and reinstall the oil line Clean off any spilled oil 4 Start and run the engine at idle until oil pressure and supply has reached all of the turbocharger moving parts A good indicator that all the moving parts are getting lubrication is when the oil pressure gauge registers pressure 10 psig 69 kPa at idle speed WARNING Do Not Hold The Compressor Wheel For Any Reason While The Engine Is Running This Could Result In Personal Injury If the engine is equipped with a governor oil filter change the element every 1 000 hours Check for oil leaks after starting the engine 2 23 Operator s Manual Fig 2 20 Air Compressor Item 10 2 57 2 60 2 61 2 24 Item 13 Fuel Strainer And Filter Install new elements every 300 hours or 9 000 miles or when plugging is indicated A method of determining when elements are plugged to the extent that they should be changed is based on the fuel pressure at the cylinder head fuel inlet manifold and the inlet restriction at the fuel pump In a clean system the maximum pu
86. or installed backwards 9 Gasket on main element damaged 10 Plastic sleeve and fins plugged damaged The following general rules on service and care of air filters should be followed at all times 1 The elements should be replaced after one year or six cleanings whichever occurs first 2 Store filter elements where they are protected from dust and potential damage 3 If the sealing surface of the elements open end is damaged to the extent that a good air seal cannot be guaranteed discard the element and install a new or cleaned element 4 Keep spare elements new or cleaned on hand to reduce vehicle downtime for servicing 5 When replacing filter elements be absolutely sure that the proper size and model element is used 2 19 TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 46 Preventive Maintenance And Lubrication Engines And Maintenance Schedule Explanation Torque Converter The time and mileage increments shown apply only to the The lubrication and preventive maintenance schedule is maintenance function described These functions should be intended as a guide for establishing a preventive coordinated with other regularly scheduled maintenance maintenance schedule The suggestions and recommendations for preventive maintenance should be The daily instructions pertain to routine or daily starting of an followed as closely as p
87. repair or replacement and all other costs or expenses required for Government correction of warranty defect as set forth in the paragraph Remedies above The contractor shall respond within 30 days after receipt of this notice of his intention to furnish identified replacement parts and or cost reimbursements to the Government In the event it is later determined that the contractor did not breach the warranty in paragraph Warranties above the contract price will be equitably adjusted pursuant to the terms of the Changes clause of the contract Failure to agree to such an equitable adjustment or upon any determination to be made under this clause shall be a dispute concerning a question of fact within the meaning of the Disputes clause of this contract The Contractor shall furnish with his proposal a listing of distributors dealers and franchise outlets where warranty claims may be exercised 7 4 Decalcomania A synopsis or simplified summary of the warranty coverage and its implementation will be printed on a decalcomania approximately 3 x 4 and shall be mounted in view of the operator as near as possible to the center of the instrument panel of each vehicle On those vehicles requiring concealed markings and registration numbers said decalcomania shall be placed in a readable position on the engine side of the firewall J 7 5 Rights The rights and remedies of the Government provided in this clause are in addition to and do not limit a
88. sheave 5 Connect to dead end wire rope socket on TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment WARNING The Hammer And Block Method Requires Being Near Moving Machinery Perform This Operation Slowly And Cautiously The Operator And Workers Must Be Fully Informed Of The Procedures To Avoid Pinching Tools Or Body Parts In The Machine Do Not Use Your Hands To Guide The Wire Rope At The Drum Or Sheaves Or Entanglement May Result 5 32 To Obtain Tight Successive Layers To obtain tight successive layers keep the rope under tension and take care that it is seated in the depressions Fig 5 25 Hammer And Block 2955 4 between the strands of the previous layers Note This must be done on all drums 5 29 Spooling Wire Rope Cable General 5 33 Main Hoist Reeving Proper spooling of hoist rope is becoming increasingly The main hoist rope can be reeved with one through 12 important as wire rope cost and availability become pressing parts depending upon the job at hand Figures 5 26 and 5 problems 27 illustrate the recommended way to reeve for the various P BEN parts of line that may be used on the machine The following information is intended to provide general and specific instructions the selection strength Consult the parts book page 16 4 22 0 to find the proper installation of wire rope on hoist drums p pag RISE size type and length of rope to
89. the boom has sequenced Incorrectly When this happens capacities must be considerably reduced if the machine is to be operated On machines with two lever control telescope the boom sections out equally Load charts for these machines are bases on equally extended boom sections Know the load radius This is particularly important on hydraulic cranes Any two of three variables 1 boom length 2 boom angle 3 load radius must be known to properly figure what load can be lifted On hydraulic cranes it Is difficult to figure the boom length This fact makes it Imperative that load radius and boom angle be known Measure the radius with a steel tape Find the boom angle by reading the angle Indicator Be careful when swinging a long load While this applies to all cranes it is particularly important on hydraulic yard cranes where the operator sits In a cockpit In the carrier frame If one end of the load catches on an obstruction the other end may hit the machine TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T Maximum lifting capacities based on wire rope strength 3 8 Dia 5 8 Dia 830 tg 7 8 Dia 22 22m 66996 HI ums H y regular lay nh 6 19 Class right lay z regular lay x7 Rotation Resistant xtra improved plow steel preforme D er wire extra NH plo w Stee right Jay Yang Ier 9 Class Filler wire extra s right lay regular
90. the front bumper outrigger A larger 3 4 valve stack operates the four side outriggers When the system is operating and no control switches are actuated a 10 G P M priority flow of oil from the pump is directed to the 3 8 valve stack If no solenoids are actuated the oil flows through the valve and goes to the 3 4 valve stack It joins the secondary flow of oil from the pump The secondary flow can be as little as zero or as much as 7 G P M depending on pump speed The combined flow of oil with a maximum flow of 17 G P M flows through the 3 4 valve stack if no solenoids are actuated and into a blocking valve at the end of the assembly The blocking valve directs the flow of oil to the sump tank When a beam control switch is actuated a solenoid on the 3 8 valve stack shifts a spool in the valve stack This directs a 10 G P M flow of oil into a beam or the front jack cylinder As the cylinder extends or retracts oil returning from the other side of the piston in the beam or front jack cylinder flows into a port on the solenoid valve stack and is directed to the sump tank through the 3 4 valve stack as explained previously When a jack control switch is actuated a solenoid on the 3 4 valve stack shifts a spool in the valve stack At the same time the blocking valve closes This causes oil to flow to the jack cylinder instead of to the sump As the jack HC238A Planetary Carrier Thrust Cap Snap Ring Sun Gear
91. the rear of the carrier At this time the links are pinned in the 4 0 121 9cm position Additional pendants are available in 10 20 30 foot 3 05 6 1 9 14 lengths to match the straight boom extension available Deflector Rollers The deflector rollers are 3 76 2mm diameter rollers that are mounted in pillow block bearings bolted to the top of the boom They are used to guide the hoist rope over the top of the boom The number and location of rollers required will vary with the boom length being used See Fig 5 9 TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment Fig 5 5 Boom and Mast Foot N7 D i Assemhlies 5 Cotter Pin 1 Cotter Pin 2 Pin 6 Pin 3 Boom Foot Pin 7 Mast Foot Pin 4 Arrow 8 Arrow Assemble pins with arrow pointing up Fig 5 6 Boom Backstop Assemblies 1 Live Mast Backstops 2 Main Boom Backstops 3 Struts 4 Bumpers 5 Tie Down Links 6 Backstop Supports 7 Spacers 8 Pin 9 Boom Lower Section TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment TOC Fig 5 7 Main Pendants and Links 70 Ft 21 3m Boom Shown 1 Two Position Link 2 6 3 20 Foot ru Pendant 5 30 0 9 14m Mast Position 76 2cm 4 5 Inch 63 5cm Spreader Req d All Boom 2 19 8 Basic Pendant Req d Bar Lengths 11 Booms 5 99m Note On booms 90 feet 27 43m and over a 5 foot 1 52m pendant is used in addition
92. thoroughly flush the system with the fluid to be used before refilling 2 129 2 130 2 131 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Filling The Oil System Install reservoir sump drain plug and tighten if sufficiently to prevent leakage Install or replace filters and strainers if used Check to ensure that all drain plugs oil filters and oil lines have been installed or replaced and secured sufficiently to prevent leakage Fill the converter reservoirs with 9 gallons Start the engine and bring the unit to operating temperature 180 200 F 82 93 C Check the oil level again and add or drain enough oil to bring the level to the Full mark Overcenter Disconnect Clutch Lubrication Lubricate the throw out bearing and shaft bearing with high temperature grease 300 F 150 C minimum melting point every 60 hours of operation This time interval may vary due to specific operating conditions Using a grease gun inject 1 shot into each grease fitting located on the top of the clutch housing CAUTION Over lubrication Of Either Bearing Will Cause Grease To Be Thrown Onto The Clutch Facing Causing The Clutch To Slip Or Grab Operator s Manual Section 3 Carrier Adjustment Index Section 3 Subject Page Subject Carrier General rinnen 3 1 Clutch Aesembhy nenene 3 3 Clutch Adiusiment ees 3 4 Front Axles Front Whe
93. unless engine is shut down and swing lock is engaged GEAR CASES REDUCTION PINION GEAR CASE REVERSE BEVEL GEAR CASE PLANETARY GEAR CASE a Check oil levels rel pg 2 14 para 2 20 Operator s Manual b Check for damage or leakage c Drain clean and refill with specified oil MASTER CLUTCH a Check clutch for wear or damage especially the throwout collar and the grease hose and fittings leading to it b Check adjustment ref Operator s Manual TORQUE CONVERTER a Inspect and clean exterior including oil breather b Lubricate the input clutch release bearing ball bearing and front disconnect clutch drive shaft bearing A 61 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Upper M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY c Change oil and filters refl pg 2 27 2 81 Operator s Manual NOTE For Army Oil Analysis Program Procedures refer to TB 43 0212 CONTROL VALVES SPEED O MATIC Inspect valves and linkage for rust or corrosion clean any that is found Lubricate valve spools with clean hydraulic oil CLUTCHES AND BRAKES a Check all clutches and brakes for proper adjustments and adjust as necessary ref SEC 4 Operator s Manual b Check condition of linings greasy worn deteriorated linings should be replaced Check for foreign material which may
94. use for each reeving 5 30 Wrapping Never lower the boom or a load past the point where two full wraps of rope are left on the drum Improper wrapping of the hoist rope on a drum leads to P 1 Jerky operation of hoist lines 5 34 Wire Rope Construction 2 Scuffing fraying and crushing of hoist ropes Wire ropes are made with two types of lay Lay refers to the direction in which the wires and strands are twisted to form the rope Refer to Fig 5 24 Note that on the properly wrapped example the first layer of rope is even and rope contact is maintained all the way across the lagging Succeeding layers will fall in the low spots created by the layer of rope l he directi f DE EECH Regular lay as opposed to lang lay denotes the direction o wire twist In the individual strands In regular lay rope the wires in each strand lay in the opposite direction from the CAUTION strands The First Layer Of Rope On The Drum Must Be Tight And Without Spaces To Insure In lang lay rope the wires in each strand lay in the same Succeeding Layers Will Go On Properly direction as the strands In the incorrect example the irregular first layer has led to Right or left are used to refer to the lay of the strands improper spooling of the second and third layers Right regular lay rope is the most commonly used and will 5 31 To Obtain A Tight First Layer be furnished on an order unless other lay is specified Use
95. warmed up This is especially important in cold weather i For maximum line speed and pull during operation the engine must be run at full load speed A 16 hour or two shift break in period at reduced throttle should be followed on a new machine j During long engine idling periods the engine coolant temperature may fall below the normal operating range The incomplete combustion of fuel in a cold engine will cause crankcase dilution formation of lacquer or gummy deposits on the valves pistons and rings and rapid accumulation of sludge in the engine Note When prolonged engine idling is necessary maintain at least 800 RPM HC238A OR OPERATING INSTRUCTIONS ENGINE T Fig 1 14 Pin Remover Controls NA215 A 1 Jack Controls 2 Pin Control 3 Throttle Control Piercing Shaft Capsule Fluid Starting Aid 1 51 Stopping The Upper Engine a Throttle the engine back to an idle b Disengage the master clutch c Allow the engine to idle for a few minutes to cool down d Move the fuel shutdown control switch to the off position e Pull out on shut down control with Detroit Diesel engine f Turn the key ignition switch to the off position Remove the key to prevent starting by unauthorized persons 1 52 Fluid Starting Aid The fluid starting aid injects a highly volatile fluid into the air intake system at low temperatures to assist in starting the engine The fluid is in a metal cap
96. 0 Viscosity 100 F 38 C Kinematic cs min Saybolt SUS min id en on Kinematic cs max 3 0 2 5 4 3 4 3 Saybolt SUS max 34 4 40 1 Sulfur by wt max HC238A 2 97 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Residual fuels and domestic furnace oils are not considered satisfactory for Detroit Diesel engines however some may be acceptable See Detroit Diesel Fuel Oil Specifications Note Detroit Diesel Allison does not recommend the use of drained lubricating oil as a diesel fuel oil Furthermore Detroit Diesel Allison will not be responsible for any engine detrimental effects which it determines resulted from this practice All diesel fuel oil contains a certain amount of sulfur Too high a sulfur content results in excessive cylinder wear due to acid buildup in the lubricating oil For most satisfactory engine life fuels containing less than 0 5 sulfur should be used Fuel oil should be clean and free of contamination Storage tanks should be inspected regularly for dirt water or water emulsion sludge and cleaned if contaminated Storage instability of the fuel can lead to the formation of varnish or sludge in the tank The presence of these contaminants from storage instability must be resolved with the fuel supplier Detroit Diesel Fuel Oil Specifications Detroit Diesel Allison designs develops and manufacturers commercial diesel engi
97. 0 Operator s Manual 2 47 2 48 2 49 Item 1 Lubricating Oil Check the lubricating oil level with the engine stopped If the engine has just been stopped wait approximately twenty minutes to allow the oil to drain back to the oil pan Add the proper grade oil as required to maintain the correct level on the dipstick Note Oil may be blown out through the crankcase breather if the crankcase is overfilled Make a visual check for oil leaks around the filters and external oil lines It is recommended that new engines be started with 150 hour oil change periods The oil drain intervals may be extended if supported by used oil analysis refer to Lubricating Oil Specifications Item 2 Fuel Tank Keep the fuel tank filled to reduce condensation to a minimum Select the proper grade of fuel in accordance with the Diesel Fuel Oil Specifications Open the drain at the bottom of the fuel tank every 500 hours or 15 000 miles to drain off any water or sediment Diesel Fuel Contamination The most common form of diesel fuel contamination is water Water is harmful to fuel system in itself but it also promotes the growth of microbiological organisms microbes These microbes clog fuel filters with a slime and restrict fuel flow DIPSTICK OIL PAN OIL FILTER Oil Check And Fill Item 1 2 47 HC238A 2 50 2 51 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Wate
98. 0 01 035 5396 9150 01 035 5395 9150 01 035 5396 9150 01 035 5392 9150 01 035 5393 9150 01 035 5394 9150 01 035 5392 9150 01 035 5393 9150 01 035 5394 9150 01 035 5395 9150 01 035 5396 9150 00 698 2382 9150 00 627 1503 9150 00 657 4959 9150 00 190 0904 9150 00 190 0905 9150 00 190 0907 9150 00 530 7369 6810 00 249 9354 UNIT OF DESCRIPTION CAPACITY MEASURE NSN FSCM PN A 33 TM 10 3950 263 14 amp P 1 CARRIER UNIT OF COMPONENT DESCRIPTION CAPACITY MEASURE NSN FSCM PN Various Dry Cleaning Solvent As Req d 6850 00 281 1985 Components SD 2 P D 680 Outrigger Speed o Matic Oil 35 Gal 36422 830664001 System 36422 830664002 34252 Gulf AW100 80738 Exxon NutoH100 Speed o Matic Oil 36422 830661001 Sub Zero 36422 830661002 15445 ConocoDN 600 UPPER UNIT OF COMPONENT DESCRIPTION CAPACITY MEASURE NSN FSCM PN Cooling Coolant 50 50 Ethylene 8 3 4 Gal 6850 00 181 7929 System Glycol Water 6850 00 181 7933 Fuel Tank Fuel Oil Diesel DF2 75 Gal 9140 00 286 5294 W F 800 Engine Lubricating Oil Engine 7 1 4 Gal 9150 00 186 668 1 Crankcase OE 30 MIL L 2104C 9150 00 188 9858 9150 00 189 6729 Lubricating Oil Sub Zero 7 1 4 Gal 9150 00 402 4478 MIL L 46167 9150 00 402 2372 9150 00 491 7197 Torque Lubricating Oil OE HDO 10 9150 00 189 6727 Converter MIL L 2104C 9150 00 186 6668 9150 00 191 2772 Lubricating Oil Sub Zero 9150 00 402 4478 MIL L 46167 9150 00 402 2372 9
99. 0 250 No Description pone E Hours Hours Boom Foot Pins 2 Mast Foot Pins 1 3 Live Mast Tubes 4 A 4 Telescoping Backstop Supports 2 A 5 Bridle Sheaves 9 A 6 Aux Lifting Sheaves 2 A 7 Horizontal Bail Sheave 1 A 8 Vertical Bail Sheaves 6 A 9 BH Bail Frame 2 A 10 Pendant Links 2 A 11 Boom Head Sheaves 2 5 6 A 12 Boom Backstop Struts 2 A 13 Hook Block Sheaves A11 A BH Limiting Actuator 1 A 14 Wire Rope A11 Inspect 15 Boom Backstops 2 A After 5 extend retract cycles or every 3 months whichever comes first lubricate mast tubes Auxiliary lifting sheaves every 50 hours if used regularly every 3 months otherwise 2 19 Lubrication Specifications NOTE The following manufacturer recommended lubricants are provided for reference only For actual lubrication seed Appendix G ES A Heavy Duty E P Bearing Grease NLGI Grade 2 API Gravity 27 0 Min Flash Point 425 Min This grease shall be a homogeneous combination of refined mineral oil Viscosity at 2100 F S U S 61 70 and lithium soap This grease shall not contain any fillers which Carbon Residue Includes adversely affect the lubricating qualities of the product It may have AshFrom Additives 1 8 Max additives that give a high degree of protection against corrosion of Viscosity Index 90 Min metals and oxidation of the grease It shall be free of any disagreeable odor D SAE 90 Gear Lubricant The product shall be a non c
100. 0 4 of the Commercial Operator s Manual A 48 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Upper NOTE Within designated interval these checks are to be performed in the order listed B Before D During A After W Weekly M Monthly PER ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO B D AIW M FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF 15 CAB INSTRUMENTS GAUGES a Inspect for damage or loose mountings b Check normal operating readings for Readings are outside the instruments as follows indicated range 1 Engine water temperature 150 185 F Battery voltmeter 11 8 15 2 volts Engine oil pressure 25 PSI 1200 RPM 30 PSI 2100 RPM WARNING Never operate machine when torque converter temperature is 2500F or over Fire or explosion may re sult NOTE At maximum machine load temper ature may exceed 220 F Torque converter oil temperature Temperature exceeds 180 220 F normal Maximum 250 F machine load temperature 220 250 F NOTE 1250 P S I indicates the system is working over relief pressure and should be shut down Hydraulic system pressure Pressure is 1250 P S I Speed O Matic 900 1050 PSI or above A 49 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Upper NOTE Within designated interval these checks are to be performed in the order listed B Befo
101. 0 tons Truck Carrier Assembly The truck carrier uses 8 X 4 drive A one man cab offset to the left is used All controls and instruments necessary to drive the carrier are inside the cab The carrier is powered by a Detroit Diesel 6V92TC engine The engine is a two stroke cycle design A blower is used to force air into the cylinders to expel exhaust gases and supply the cylinders with fresh air from combustion Power from the engine is delivered to a Fuller Road Ranger RTO 915 transmission A Lipe Rollway double disc clutch connects the two The transmission has a 5 speed front section and a two speed rear section which enables the driver to select 10 forward speeds evenly and progressively spaced An additional 5 ratios are obtained with a deep reduction gear The 5 deep reduction gears are evenly and progressively spaced however they overlap the low range ratios Output from the transmission is delivered to a two speed creeper transmission through a drive tube The high gear ratio in the creeper transmission is 1 to 1 and is used for all normal driving situations The second ratio is lower and is only used when driving creeping the carrier into position on a job site with the crane boom in place Output from the creeper transmission is delivered to the two rear axles by drive tubes The rear axles are double reduction Clark planetary units The primary reduction is in the differential The secondary reduction is in the plane
102. 00 multiplied by 1 000 lbs equals 100 000 Ibs The bottom meter is the Reach meter It indicates horizontal distance in feet from the upper centerline of rotation to the main hoist hook block s The meter scale reads from 0 to 199 9 The Amber lights are warning devices lt will come on when 85 of the maximum allowable load shown on the Alert meter has been reached For example if the Alert meter reads 100 100 000 Ibs the Amber light will then come on when the Load meter Operator s Manual c equals or exceeds 85 85 000 Ibs The Red lights and Horn are also warning devices They will come on when 10096 of the maximum allowable load shown on the Alert meter has been reached Note There are separate sets of warning lights for each hook arrangement L Left R Right And B Both The Hook Selector switch must be set to the hook arrangement that is being used for the system to function properly The Power PWR switch turns the system On and Off The Test button is a system test switch When pushed the Amber lights Red lights and Horn will come on and each meter will indicate predetermined numbers refer to Table 1O 1 Note The Alert reading is from the crane s capacity chart for 100 ft of main boom with 4 parts of line at 40 ft radius Main Electronics The main electronics assembly has two rotary switches They are Boom Select and Reeve Select The Boom Select switch must be set to the
103. 000 Miles 8046 7km Carrier Capacity Chart Carrier Lubrication Chart Upper Maintenance And Lubrication Schedule Every 10 Hours Every 50 Hours Every 250 Hours Every 500 Hours Every 1000 Hours Or Seasonal Machine Storage Suggestions Upper Lubrication Chart Upper Capacity Chart Attachment Lubrication Chart Lubrication Specifications 2 1 Gear Case Check And Change Procedure 2 14 Main Transmission Creeper Trans mission Steering Gear Rear End Differentials 2 14 dee 2 14 To Change Planetary Wheel Hub ES Hence HEEO T E Outrigger Sump Tank To Check To Change Filter To Change Oil Chain To Check Chain Case To Change Chain Case Planetary Speed Reducer To Check Planetary To Change Planetary Swing Bevel Gear Case To Change Reduction Shaft Pinion Case TO Check Regele EE Air Box Deag eite easet ete Draining The Tank Engine Air Cleaner Preventive Maintenance And Lubrication Engines And Torque Converter
104. 08806 Lamp Rotary Light 2 00 4 PAOZZ 990704 463 36422 Wire Rope 1 x 980 Boom Load 1285 00 EA 2 PAOZZ 5330 00 255 4669 2 329N674 7 02697 Packing Preformed Clutch Cyl 3 00 EA 8 PAOZZ 5330 00 821 7 317 1626545PC53 10001 Packing Preformed Strainer 1 00 EA 4 Hydr Res PAOZZ 5330 01 119 9372 5810 584003 329 02697 Packing Preformed Clutch Cyl 50 EA 6 PAOZZ 5920 00 424 8873 AGC 15 71400 Fuse 15 Amp 75 EA 10 PAOZZ 2910 01 100 3302 25010776 72582 Filter Pri Fuel Carrier Eng 11 50 EA 8 PAOZZ 2910 01 097 6496 25010778 72582 Filter Sec Fuel Carrier Eng 11 50 EA 8 PAOZZ 3030 00 934 8090 5133519 72582 Belt Alternator Upper Eng 8 00 EA 4 PAOZZ 3030 00 411 3741 5133762 72582 Belt V Eng Fan Carrier Eng 24 00 SET 2 PAOZZ 3030 00 689 6099 17425 73842 Belt Eng Fan Upper Eng 7 00 EA 4 PAOZZ 3030 00 298 6831 5148276 72582 Belts V Alt Carrier Eng 14 00 SET 2 PAOZZ 4720 00 785 8231 5187231 72582 Hose Rad Inlet Upper Eng 3 00 EA 2 PAOZZ 4720 01 037 1711 5199776 72582 Hose Rad Outlet Upper Eng 12 00 EA 2 PAOZZ 2940 00 580 6283 MS35802 3 76110 Filter Oil Trq Conv and Eng 6 50 EA 12 A 69 Ee NSN 3950 01 110 9224 3950 01 110 9224 SMR CODE PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ A 70 2910 00 125 5601 2940 00 829 5676 2530 00 986 7596 5330r01 118 9147 5365 01 113 3847 5330 01 1
105. 1 Oil 6 2 Recommended Fuel Bleeding Fuel System 6 15 Starting Sequence 6 2 16 16 Pre Heating And Starting 6 3 Automatic Starting And Stopping 6 3 Stopping 6 3 6 19 Applying Load 6 3 16 201 Emergency Operation If Battery Fails 6 3 Break In Procedure Out Of Service Protection 6 23 Returning A Unit To Service 6 4 High Temperatures Low Temperatures 6 26 Dust And Dirt 6 5 6 27 High Altitude 6 5 Adjustments 6 5 Anti Flicker Points 6 30 Governor 6 5 6 31 Speed Adjustment 6 5 Sensitivity Adjustment 6 33 Charge Rate Adjustment 6 5 6 34 Valve Clearance 6 5 HC238A TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Auxiliary Generator Assembly Operator s Manual 6 1 General An Onan DJA Series electric generating set consists of a one cylinder diesel engine and a 3 0 kW 2 5kW for 50 Hertz alternating current generator with standard or optional equipment as ordered 6 2 Engine The DJA engine has 30 cubic inch 491 piston displacement 19 to compression ratio and is air cooled Basic measurements and other details are listed under Specifications 6 3 Generator The generator is a revolving armature 4 pole single phase self excited model of drip proof construction The generator aligns to the engine through a rigid coupling and incorporates an engine cranking winding A commutator collector rings and associated brushes provide the electrical connec
106. 1 065 0166 Equipment Record H3986 1 EA Folder 72094 4210 00 889 2221 Extinguisher CS4210 0009CEFN EA Fire Dry 16236 Chemical A 32 COMPONENT Cooling System Fuel Tank Engine Crankcase Rear Axle Differen tial Rear Axle Planetary Hub Main Trans mission Creeper Transmis sion Steering Gear Power Steering System Wheel Bearings and Grease Fittings Battery MAINTENANCE OPERATING AND SUPPLY LIST FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY APPENDIX G TM 10 3950 263 14 amp P 1 TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 Coolant 50 50 Ethylene Glycol Water Fuel Oil Diesel DEZ W F 800 Lubricating Oil Engine OE 30 MIL L 2104C Lubricating Oil Sub Zero MIL L 46167 lubricating Oil Gear GO 85 140 MIL L 2105C Lubricating Oil Gear GO 85 140 MIL L 2105C Lubricating Oil Gear GO 80 90 MIL L 2105C Lubrication Oil Gear GO 80 90 MIL L 2105C Lubricating Oil Gear GO SS 140 MIL L 2105C Automatic Transmission Fluid Type A Dexron Bearing Grease Automotive MIL G 10924 Sulfuric Acid Electrolyte CARRIER 8 3 4 Gal 2 Tanks 45 Gal ea 6 1 4 Gal 6 1 4 Gal 35 Pts ea 8 Pts ea 2 1 2 Pts 3 Gal As Req d As Req d 6850 00 181 7929 6850 00 181 7933 9140 00 286 5294 9150 00 186 6681 9150 00 188 9858 9150 00 189 6729 9150 00 402 4478 9150 00 402 2372 9150 00 491 7197 9150 01 035 5395 915
107. 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment length Install a cotter pin in each pendant pin 5 15 Assembly Of Crane Boom 120 to 130 36 5m to 39 6m Feet In Length CHART A 5 16 Boom Assembly Step 1 Reeve the live mast as short boom See Fig 5 4 Use the short boom to install the Pendant Length Required boom lower section on the machine 19 8 5 99m Basic Reposition the live mast backstop target Eig 5 3 to the Basic 10 3 05m vertical position Unpin the backstop tie down links Fig 5 4 Basic 20 6 10m Install the backstop struts Fig 5 6 between the boom Basic 30 9 14m lower section and the backstop tubes Basic 40 12 19m 1 52m Install the assembly links over the pin connection hubs at Basic 50 15 24m 5 5 1 52m the end of the boom lower section Install the spacer Basic 60 18 29m 5 1 52m capscrew hex nut and lockwasher which holds links Basic 70 21 34m 5 Basic 80 28 38m 5 Mid point suspension required 1 52m together Connect a 19 8 5 99m basic pendant pair to these links Connect the other ends of these pendants to taam the bridle spreader bar See Figs 5 3 5 4 The following points Must Be noted before proceeding CAUTION a Whenever possible assemble boom with short sections Always Use Correct Pendant Lengths Use close to the boom foot Two short Of Inco
108. 13 1322 2520 01 124 8890 2540 01 125 9697 2940 01 131 5928 6240 00 817 9803 5920 00 879 6285 6240 00 155 8717 PRESCRIBED LOAD LIST PLL AND AUTHORIZED STOCKAGE LIST ASL END ITEM Crane Mobile 140 Ton Capacity Container 122 0326 140 0636 213984 23J83 80579 80615 1486 21 91380 26 25010971 16 3456 MS25231 316 F02A125V10AS 67 44940 44940 62983 36422 36422 36422 52304 60703 60703 70040 18265 96906 81349 08108 MAKE FMC PART DESCRIPTION Filter Sec Fuel Gen Aux Filter Element Air Gen Aux Element Pump Power Steering Gasket Hydr Res Fil Access Cover Packing Preformed Hydr Res Oil Fil Gasket Hydr Res Oil Fil Teflon Air Valve Filter Carrier Air Sys Blade Wiper Upper Upper Window Cab Blade Wiper Carrier Cab Filter Eng Oil Carrier Eng Element Filter Hydr Reservoir Lamp Warning Light Fuse 10 Amp Lamp Parking and Clearance Lights MODEL HC 238A TM 10 3950 263 14 amp P 1 DATE 16 Apr82 16 DATE 16 Apr82 82 QTY OF PARTS REQ D FOR NO OF FND ITEMS U M LE EA EA EA EA EA EA EA EA EA EA EA EA EA TM 10 3950 263 14 amp P 1 PRESCRIBED LOAD LIST PLL AND AUTHORIZED STOCKAGE LIST ASL END ITEM Crane Mobile 140 Ton Capacity Container MAKE FMC MODEL HC 238A Ee NSN 3950 01 110 9224 3950 01 110 9224
109. 150 00 491 7197 Chain Case Lubricating Oil SAE 10W30 1 1 2 Gal 9150 00 186 6699 MIL L 46152 9150 00 256 641 1 9150 00 186 6703 9150 00 451 6947 A 34 COMPONENT Reverse Bevel Gear Compart ments Planetary Gear Case Reduction Shaft Bear ing Housing Turntable Gear Teeth Grease Fittings Linkages and Pivot Points Battery Various Components Auxiliary Generator Hydraulic S o M System Lubricating Oil Gear GO 85 140 MIL L 2105C lubricating Oil Gear GO 85 140 MIL L 2105C Lubricating Oil OE 50 MIL L 2104C Grease Exposed Gear MIL L 18458 Grease Automotive MIL G 10924 Lubricating Oil OE 50 MIL L 2104C Sulfuric Acid Electrolyte Dry Cleaning Solvent SD 2 P D 680 Lubricating Oil Engine OE 30 MIL L 2104C Lubricating Oil Sub Zero MIL L 46167 Speed o Matic Oil Speed o Matic Oil Sub Zero UNIT OF DESCRIPTION CAPACITY MEASURE 2 1 2 Qts 1 5 Qts As Req d As Req d As Req d As Req d As Req d 3 Qts 11 9 Qts 11 9 Qts TM 10 3950 263 14 amp P 1 NSN FSCM PN 9150 01 035 5395 9150 01 035 5396 9150 01 035 5395 9150 01 035 5396 9150 00 188 9864 9150 00 188 9865 9150 00 188 9867 9150 00 433 5968 9150 00 530 6814 9150 00 530 6813 9150 00 190 0904 9150 00 190 0905 9150 00 190 0907 9150 00 530 7369 9150 00 188 9864 9150 00 188 9865 9150 00 188 9867 9150 00 433 5968 6810 00 249 9354 6850 00 281 1985 9150
110. 3 14 amp P 1 Organizational Preventive Maintenance Check and Services Upper M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY ENGINE Change oil replace filter and clean crankcase breather cap ref Operator s Manual NOTE For Army Oil Analysis Program Procedures refer to TB 43 0210 DRIVE BELTS Check tension of belts and adjust as necessary ref page 2 22 Operator s Manual HYDRAULIC SYSTEM SPEED O MATIC NOTE The first filter change should be at 50 hours a Change filter b Drain clean and refill the system ref Operator s Manual BRAKES BOOM HOIST FRONT AND REAR DRUMS a Check band connecting lugs actuating linkage related pins and the mounting bracket pin hole for signs of wear or damage Repair or replace as necessary b Check band for any indications of bending interference or un usual lining wear which would indicate excessive wear of brake parts Repair or replace as necessary Check condition of the band adjusting bolt and nut to make sure the locking nut will hold against rotation during operations d Remove the band and all related parts for a detailed inspection If any parts show excessive wear cracks or other damage replace them Reassemble and adjust the mechanism ref page 4 4 page 4 5 Operator s Manual A 64 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Chec
111. 44 Spin on Nalcool 2000 Liquid Perry LP 20 Liquid Sy Cool Liquid Lubercool Liquid DuBois Chemicals IWT 48 Liquid Norman Chemicals C15 Liquid Aqua Tane Liquid Corrosion Inhibitor Type Chromate Chromate Chromate Chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Non chromate Complete Inhibitor System No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Inhibitor Compatibility Ethylene Glycol Base Water Antifreeze Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Caution Do not use methoxy propanol base antifreeze in Detroit Diesel engines Fig 2 36 Coolant Inhibitor Chart Several brands of permanent antifreeze are available with sealer additives The specific type of sealer varies with the manufacturer Antifreeze with sealer additives is not recommended for use in Detroit Diesel engines due to possible plugging throughout various areas of the cooling system General Recommendations All Detroit Diesel engines incorporate pressurized cooling Systems which normally operate at temperatures higher than non pressurized systems It is essential that these systems be kept
112. 5 Lower boom to the ground Disassemble brake and inspect for contaminated or glazed linings Replace as necessary see Shop Manual Boom lowers when trying to raise 1 Engine running too slow Increase engine throttle set ting 2 Boom hoist clutch slipping Adjust clutch seelp 4 6 Check clutch shoes and drum for scoring glazing oil on surface Clean or replace parts as necessary see Shop Manual Check S o M pressure at clutch cylinder Should be 900 1050 P S I If not adjust control stand linkage Set pressure in system see f Will not boom up with load 1 Engine running too slowly 1 Increase engine throttle set ting 2 Boom hoist clutch slipping 2 See 2 under Cause Boom lowers when trying to raise 3 Overload 3 Check capacity chart Make sure load is within capacity of machine Swing System Machine will not swing either left 1 Swing lock engaged or right 2 Swing brake engaged 3 Master clutch not engaged 3 Engage sed p 1 21 Check operating controls and adjustment see p 4 1 4 Mechanical failure 4 Inspect shafting pinion bevel gears drive chain turntable bearing Repair or replace components as necessary see Shop Manual HC238A Operator s Manual Problem Machine swings one way and not the other Jerky or rough swing Swing brake will not hold Swing brake will not release Gear Train Gear train will not turn Gear train is noisy Section 8 Conti
113. 5 30 Wire Rope Inspection Report 2663 A This inspection should determine the degree of deterioration at the worst rope lay as this will determine the suitability of the rope for continued service By definition a rope lay is the axial distance along the rope in which one strand makes on complete turn around the rop questio b c 5 22 e Conditions such as the following would be reason to n rope safety Evidence of rope deterioration from corrosion should be cause for replacement More than one broken wire in any one strand should be cause for caution Breaks that occur on the worn crown of the outside wires indicate normal deterioration Breaks that occur in the valleys between strands indicate some abnormal condition possibly fatigue and breakage of other wires not readily visible One or more valley breaks should be cause for replacement Wire breaks generally occur in those portions of a wire rope which pass over sheaves wind onto drums or receive mechanical abuse Breaks that occur near attached fittings are apt to result from fatiguing stresses concentrated in these localized sections Breaks of the latter type should be cause for replacement of the rope or renewal of the attachment to eliminate the locally fatigued area Heavy wear or broken wires may occur in sections under equalizer sheaves or other sheaves where rope travel is limited or in contact with saddles Particular care should be taken to inspe
114. 5 Boom And Mast Foot Assembly When installing the boom lower section or the live mast on their mounting lugs the foot pin must be installed with the arrow on the pin head pointing up This aligns the grease hole in the pin with grease groove in the bushing so the bushing can be lubed with the boom in the air The pins are retained by a pin driven through the mounting lug and the pin This pin is retained by a cotter pin at each end 5 6 Boom Backstops Operator s Manual TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment ig 5 4 Live Mast Used As A Short Boom A Maximum Radius 27 0 8 2m B Minimum Radius 10 0 3 05m 1 3 Parts 7 8 22 2mm or 1 25 4mm Rope Two sets of boom backstops are used on the machine The main boom backstops and the live mast backstops Fig 5 6 The main boom backstops are long tubes with spring loaded bumpers at one end The other end of each tube is anchored to the gantry headshaft at the rear of the machine There are a pair of telescoping struts pinned between the boom lower section and the backstop tubes As the boom is raised these struts raise the tubes into the air As the boom nears minimum radius the spring loaded bumpers on the backstop tubes enter a pair of targets welded to the upper chords of the boom lower section When the boom is lowered the backstops come to rest in a pair of supports which are bolted to the upper revolving frame The backstop struts t
115. 518 T10138 Truck Mounted SC 4940 95 CL B04 2 Shop Equip Auto Maint 4910 00 754 0654 W32593 Org Maint Common No SC 4910 95 CL A74 3 Shop Equip Auto Maint 4910 00 754 0650 W32730 Org Maint Common No SC 4910 95 CL A72 4 Shop Equip Auto Maint 4910 00 754 0653 W32867 Org Maint Supp No 1 SC 4910 95 CL A73 5 Tool Kit General 5180 00 177 7033 W33004 Mechanics Auto x SC 5180 90 CL N26 6 Tool Kit Rigging Wire 5180 00 596 1513 W50266 Rope SC 5180 90 CL N17 7 Shop Equip Auto Maint 4910 00 754 0705 T24660 Field Maint Basic SC 4910 95 CL A31 8 Shop Equip Fuel and Elec 4910 00 754 0714 T30414 Sys Engine Field Maint Basic SC 4910 95 CL AO1 9 Tool Kit Master Mechanics 5180 00 699 5273 W45060 SC 5180 90 CL N05 10 Multiplier Torque Wrench 5120 00 482 2543 Y81747 2500 ft lbs PN PD2501 11 Shop Equip Welding 3470 00 357 7268 T16714 Field Maint SC 3470 95 CL A08 12 Shop Equip Machine Shop 3470 00 754 0708 T15644 Field Maint Basic SC 3470 95 CL A02 A 26 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS TOOL OR TEST EQUIPMENT MAINTENANCE NOMENCLATURE NATIONAL NATO TOOL REFERENCE CATEGORY STOCK NUMBER NUMBER CODE 13 F H Tool Kit Body and Fender 5180 00 754 0643 W33689 Repair SC 5180 90 CL N34
116. 62 68 N m torque Item 10 Air Compressor WARNING Use Fuel Oil Or Cleaning Solvent In A Well Ventilated Area Away From Flames To clean either the hair or polyurethane type air compressor air strainer element saturate and squeeze it in fuel oil or any other cleaning agent that would not be detrimental to the element until dirt free Then dip it in lubricating oil and squeeze it dry before placing it back in the air strainer For replacement of the air strainer element contact the nearest Bendix Westinghouse dealer replace with polyurethane element if available Item 11 Throttle And Clutch Controls Every 200 hours or 6 000 miles lubricate the limiting speed governor control shaft Remove the plug in the end of the shaft and install a temporary grease fitting Then remove the governor cover to obtain a visual indication when greasing is complete After greasing the shaft remove the fitting and install the plug and governor cover using a new cover gasket Use an all purpose grease No 2 grade at temperatures 30 F 1 C and above At temperatures below this use a No 1 grade grease TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Fig 2 19 Drive Belts Item 9 2 56 Lubricate the clutch control levers and all other control mechanisms as required with engine oil Item 12 Lubricating Oil Filter Install new oil filter elements and gaskets at a maximum of 500 hours
117. A 27 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION IV REMARKS REFERENCE A 28 CODES REMARKS Repair on the Crane Overload Warning System is limited Refer to Section 10 of this commercial operator s manual for Maintenance Instructions Limitations and Repair Procedures on the Overload Warning System Repair of the Crane Boom Assembly is very limited Refer to Appendix D Maintenance Instructions Limitations and Repair Procedures on the Boom Assembly TM 10 3950 263 14 amp P 1 APPENDIX D ADDITIONAL MAINTENANCE INSTRUCTIONS 1 Oil Analysis Sampling Valves Oil sampling valves have been installed on all 140 ton Mobile Cranes as a provision of Contract No DAAEO07 80 C 6058 as follows a Two valves one each on both engines upper lower b One valve on the upper engine torque converter Reference TB 43 0210 5 Oct 81 for specific instructions including responsibilities of user sampling techniques special precautions and INITIAL ENTRY INTO AOAP 2 Prolonged Diesel Engine Idling It is recommended that rather than idling the engine for periods longer than 5 minutes it be stopped and restarted when power is again required If prolonged idling is absolutely necessary it should be for as short a time as possible and at speeds of 1 000 RPMs or more In addition the engi
118. ANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT Intake Exhaust Manifold Replace Fuel Pump Service Replace Repair Fuel Injection Pump Replace Fuel Injection Nozzle Adjust Air Cleaner Service Replace Engine Speed Governor Adjust Replace Repair Fuel Filters Replace Engine Priming System Lines Replace Muffler and Pipes Inspect Replace Repair Engine Cowling Blower Housing Replace Repair Generator Test Adjust Replace Repair Starting Solenoid Solenoid Relay Test Replace Switches Fuses Replace A 21 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT GAGES Instruments Speed and Distance Replace Gages Pressure Quantity etc Replace Lines and Fittings Replace PRECISION INSTRUMENTS AND SYSTEMS Overload Warning System Inspect Test Adjust Replace Electrical Cables Replace Repair CRANE COMPONENTS Boom Inspect Service Replace Mast Service Replace Boom Backstops Replace Bridle Assembly Replace Hook Block Replace Crane End Ite
119. Assembly Step 3 5 7 Boom Assembly Step 4 5 7 Assembly Of Crane Boom 120 to 130 36 5m to 39 6m Feet In Length 5 8 Boom Assembly Step 1 5 8 Boom Assembly Step 2 5 9 Boom Assembly Step 3 5 10 Boom Assembly Step 4 5 10 Inline Pin Tubular Boom Disassembly 5 10 Carrying Link Assembly 5 13 Chart B Maximum Travel Speed With Base Section Over Front 5 13 Disconnecting Links 5 15 Carrying Booms Horizontally Over Rear Of 5 15 TM 10 3950 263 14 amp P 1 Section 5 Crane Attachment Subject Carrying 50 Foot 15 24m Boom Over Front With Gooseneck Links Removing Gooseneck Links 01010011 Travel On Tires Job Site Moves Only Boom Hoist Reeving Spooling Wire Rope Cable General 5 30 Wrapping OT To Obtain A Tight First Layer To Obtain Tight Successive Layers Main Hoist Beevinmg 5 34 Wire Rope Construction Measuring Wire Rope Diameter Ordering Wire Ropes Wire Rope Inspection And Replacement Lubrication Wire
120. Away From Flames P 2 171 2 18 2 251 2 26 WARNING Warn Personnel In The Immediate Area Before Using Compressed Air For Cleaning Wear Safety Glasses Compressed Air Coming Into Contact With The Human Skin Or Causing Flying Metal Chips Can 1 Cause Injury WARNING Before Lifting Crane Inspect Lifting Sling Again Make Sure Everything Is Assembled Right Make Sure All Pins Have Keepers Don t Let Anyone Near The Machine While It Is Being Lifted P 2 27 WARNING WARNING Be Careful Not To Get Burned On Hot Hot Oil Can Cause Severe Burns Be Careful When Draining The Oil WARNING Do Not Hold The Compressor Wheel For Any Reason While The Engine Is Running This Could Result In Personal Injury Oil When Draining Gear Cases HC238A 10f3 Operator s Manual P 2 36 2 of 3 WARNING Use Extreme Care When Removing A Radiator Pressure Control Cap From An Engine The Sudden Release Of Pressure From A Heated Cooling System Result In Loss Of Coolant And Possible Personal Injury Scalding From The Hot Liquid WARNING Anchor The Upper Machinery Against Rotation By Lowering The Attachment To The Ground Before Working On The Swing Lock WARNING Don t Get Under Any Part Of The Boom Especially When Boom Sections Are Being Raised Lowered Or Positioned WARNING Do Not Get Under Any Part Of Boom Especially While Boom Sections Are Being Raised Lowered Or Position
121. Belts are frayed or deterioration cracked or missing RADIATOR Check coolant level add coolant as re quired Level should be approximately one inch from the bottom of the filler neck A 44 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Upper NOTE Within designated interval these checks are to be performed in the order listed B A ITEM me NO B D AW M A After ITEM TO BE INSPECTED D During PROCEDURE CHECK FOR AND HAVE REPAIRED FILLED OR ADJUSTED AS NEEDED AIR CLEANER a Check air restriction indicator If indicator has tripped clean or replace air cleaner element and reset indicator b Empty dust caps c Inspect air cleaner element Clean or replace as necessary FUEL TANK Inspect fuel tank and visible lines and fittings for looseness damage or leaks HYDRAULIC SYSTEM SPEED O MATIC Check hydraulic S O M fluid level Add fluid as required to bring level to FULL on dipstick BOOM CHORDS AND LATTICE a Check for obvious cracks bends or damage b Check that LOAD TEST is current refer to TB 43 0142 REQUIRED LUBRICATION The following assemblies require lubrica tion IAW Lubrication Chart Pg 2 13 Opera tor s Manual 1 Boom foot pins 2 Mast foot pins W Weekly M Monthly EQUIPMENT IS NOT READY AVAILABLE IF Air restriction indi cator has tripped Air cleaner element or gasket is damaged
122. Brake out of adjustment Load too light to overhaul cable too many parts of line Cable jammed on drum or sheave Bearing failure in side frame Brake out of adjustment Brake linings glazed or contaminated TM 10 3950 263 14 amp P 1 Make sure clutches are assembled in energized position see Shop Manual 5 9 2 0 3 Load to heavy for machine as equipped see Cause 1 previously Torque converter defective Repair or replace see Shop Manual Converter low on oil Refill will oil see p 2 37 Adjust see p 4 1 Replace clutch linings see Shop Manual Adjust brake 4 4 Power load down with lowering clutch Reeve with fewer parts of line Remove load with auxiliary crane Lower boom to the ground Unjam cable Inspect cable for damage replace if necessary Remove load with auxiliary crane Remove and replace bearing see Shop Manual 1 Adjust brake see p 4 4 2 Replace brake linings see Shop Manual Boom Hoist System Boom will not raise 1 2 3 4 5 Boom too long Clutch slipping Brake not releasing Torque converter slipping Cable jammed on drum or sheave 1 Reduce boom length below max aximum listed in operator s manual 2 Adjust clutch 4 6 Check clutch shoes and drum for scoring glazing oil on surface Clean or replace parts as necessary see Shop Manual Check S o M pressure at clutch cylinder Should be 900 1050 P
123. Bumper Ctwt 5 MPH 8 04 kph W A Upper Ctwt W O A Bumper Ctwt 20 MPH 32 2 kph W O Upper Ctwt W O Bumper Ctwt 40 MPH 64 3 kph HC238A b NA241 D NA242 B 7 Raised Position Of Link 8 Pin And Cotter Pin Remove all boom but the lower section as explained under Disassembly Of Inline Pin Connected Boom earlier in this section Retract mast to 25 6 7 77m length as explained on Remove the pin which holds the carrying links in the raised position allowing them to swing free Lower the mast until the links may be pinned to the lugs on the boom lower section Boom up until the lower section will clear the boom cradle Swing the boom around over the front of the machine Engage the swing lock Do not raise boom higher than necessary to clear cradle as damage to the base section may result Counterweight machine for travel per Chart B Overall travel height is 14 9 1 2 4 5m CAUTION Do Not Allow Boom To Rest On Cradle Or It May Be Damaged Lower Section Only May Be Carried With These Links TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment R982 Live Mast Retracted 25 6 7 7m Position Headshaft Link Pinned In 48 1 21m Position A Upper Ctwt Ctwt PPS EE wd Fig 5 21 Carrying Boom Horizontal Over Rear A Overall Weight Measured Here Overall Length Measured Here Chart C W A Upp
124. Continued Overload Warning System R783 10 B TM 10 3950 263 14 amp P 1 Operator s Manual Section 10 Overload Warning System Two Blocks LOAD ASSEMBLIES LOAD SENSOR CABLES BOOM CABLE ASSEMBLES MAIN ELECTRONICS ANGLE SENSOR DISPLAY PANEL Fig 10 1 Overload Warnina Svstem Nomenclature 10 1 Overload Warning System CAUTION 15 24 39 62m of main boom using AB This System Is Designed To Function With upper and A bumper counterweights Crane Power From 10 Volts DC to 14 Volts lifting on outriggers only and over the rear DC Voltages Outside Of These Limits Will and 1 26mm diameter type N wire rope Cause Erroneous Readings Or Damage To The System 10 2 Components and Location The System Must Be Connected With Black The crane overload warning system is made up of the Wire To Positive And White Wire To following six different assemblies Negative Crane Power Supply a Display b Main Electronics Angle Sensor This crane is equipped with an overload c warning system When used properly this d Dual Head Amplifier e System will provide the operator with a precise moment by moment updating of the hook block radius in feet reports on the weight of the load and alert the operator with audible and visual The location of each assembly is shown in warning signals when the load is at or above shows the connections between each assembly the rated capacity Load Sensors f Cables 10
125. ENGINE PUSH PREHEAT SWITCH AND HOLD 30 SECONDS IF ABOVE 55 F 13 C 80 SECONDS IF BELOW 55 F 13 TO START PREHEAT START t RELEASE PREHEAT di ENGAGE START SWITCH STOP LIMIT CRANKING TO 15 TO 20 SECONDS TO CONSERVE BATTERY ALLOW 1 MINUTE BEFORE RE CRANKING IF ENGINE DOES NOT START IF ENGINE FIRED REPEAT ABOVE PROCEDURES INCLUDING PRE HEAT IF IT STILL DOES NOT START PROCEED AS FOLLOWS TEMPERATURES BELOW 32 F 0 USE NUMBER 1 DIESEL FUEL USE CORRECT VISCOSITY OIL KEEP BATTERIES FULLY CHARGED DO NOT USE ETHER STARTING AID Se OBSERVE ENGINE EXHAUST SIGNALS LITTLE OR EXHAUST SMOKE ENGINE IS NOT GETTING FUEL ee PRIME FUEL SYSTEM AS SHOWN ABOVE OBSERVE FUEL FLOW FROM RETURN LINE FUEL FLOWS STEADILY LITTLE NO FUEL FLOW 1 OBSERVE AIR HEATER THRU CHECK FUEL SOLENOID AIR INLET HOLE OR BY REMOV az SOLENOID ROD SHOULD ING AIR CLEANER PULL IN AND THROTTLE ARM CHECK FUEL SUPPLY ENGAGE PREHEAT B v FOLLOW AS SHOWN WHEN SYSTEM IF HEATER ELEMENT DOES NOT START SWITCH IS TURNED FUEL TANK EMPTY ON IF NOT CHECK FOR SHUTOFF VALVES GLOW RED WITHIN 30 CHECK FO edis SECONDS CHECK AIR HEATER I BINDING LINKAGE AND GLOW PLUG WIRING LOOSE OR BROKEN WIRES FUEL CINES INKED LOOSE CONNECTIONS CONNECTIONS TIGHT 1 SE e FREE FROM CORROSION M SOLENOID ROD CLOGGED FUEETIETERS N THROTTLE ARM IF ENGINE IS STILL NOT GETTING FUEL CHECK TRANSFER PUMP 1 CRANK
126. IN DOUBT NOTIFY YOUR SUPERVISOR Leakage Definitions For Crew Operator PMCS Class Seepage of fluid as indicated by wetness or discoloration not great enough to form drops Class Il Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked inspected Class Ill Leakage of fluid great enough to form drops that fall from the item being checked inspected A 37 TM 10 3950 263 14 amp P 1 CAUTION Equipment operation is allowable with minor leakages Class I or Il Of course consideration must be given to the fluid capacity in the item system being checked inspected When operating with Class or Il leaks continue to check fluid levels as required in your PMCS Class Ill leaks should be reported to your supervisor or Organizational Maintenance 12 This PMCS is divided into a Carrier PMCS an Upper PMCS and a Lifting Spreader Assembly PMCS A 38 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Carrier NOTE Within designated interval these checks are to be performed in the order listed B pes ITEM me NO B DA W M D During A After W Weekly M Monthly ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND HAVE REPAIRED FILLED OR ADJUSTED AS NEEDED NOTE PERFORM WEEKLY AS WELL AS BEFORE PMCSs IF a You are the assigned driver but have not operated crane carrier since the last weekly b You are operating the carrier
127. ION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT BODY CAB AND HOOD Cab Assembly Repair i 1 7 9 13 Hood Panel Assemblies Replace Repair Door Assembly Cab Replace Repair Windshield Windows Replace Floorboards Replace Repair Seat and Back Assembly Replace Repair BODY ACCESSORY ITEMS Mirrors Reflectors Replace Windshield Wipers Replace Repair Wiper Motor Replace Air Horn Replace Repair Personnel Heater Replace Repair Heater Hoses Replace Data and Inspection Plates Replace TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS GROUP COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE TOOLS NUMBER FUNCTION CATEGORY EQUIPMENT F p HYDRAULIC SYSTEM Speed O Matic Pump Replace Repair Hydraulic Valves Inspect Service Replace Repair xo Accumulator Replace Repair Hoses and Fittings Replace Repair Strainer Replace N Filter Replace Hydraulic Cylinders Replace Repair xoxo Hydraulic Reservoir Service Replace Repair 5 7 5 7 2 2 5 5 7 7 5 7 7
128. In general or from prolonged engine idling A fuel dilution exceeding water containing various materials in solution is used for this 2 596 of volume indicates an immediate need for an oil purpose Ge ee Ee The function of the coolant is basic to the design and to the by oil suppliers or independent laboratories successful operation of the engine Therefore coolant must be carefully selected and properly maintained In addition to the above considerations if any of the following occur the oil should be changed 2 105 Coolant Requirements 1 Ds 1 SE ege ae 5i A suitable coolant solution must meet the following basic 1 measured at the same temperature ASTM D 445 requirements and D 2161 1 Provide for adequate heat transfer n 2 Provide a corrosion resistant environment within the cooling system 3 Prevent formation of scale or sludge HC238A 2 33 Operator s Manual 2 106 2 107 2 108 2 34 deposits in the cooling system 4 Be compatible with the cooling system hose and seal materials 5 Provide adequate freeze protection during cold weather operation The first four requirements are satisfied by combining a suitable water with reliable inhibitors When operating conditions dictate the need for freeze protection a solution of suitable water and a permanent antifreeze containing adequate inhibitors will provide a satisfactory coolant Water Any water whether of drinking quality or not w
129. K FOR AND REPAIR FILL OR ADJUST AS NECESSARY WARNING Do not service maintain or lubricate gears drive chains or chain case unless engine is shut down and swing lock is engaged BEVEL GEARS ENGINE DRIVE CHAINS a Inspect for excessive wear or damage and repair or replace as necessary ref page 2 8 Operator s Manual b Adjust bevel gear backlash and chain tension as necessary ref Operator s Manual OPEN GEARS Inspect for excessive wear or damage and repair or replace as necessary CHAIN CASE Drain clean and refill ref 2 33 Operator s Manual GOVERNOR Replace governor oil filter BLOWER SCREEN a Inspect screen and gasket ref Operator s Manual WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in well venti lated area Avoid contact with skin eyes and clothes and don t breathe vapors Do notuse near open flame or ex cessive heat If you become dizzy while using cleaning solvent get fresh air immediately and get medical aid If contact with skin or clothing is made flush with water If contact with eyes is made wash your eyes with water and get medical aid immediately Air Compressed air used for cleaning purposes will not exceed 30 psi Use only with effective chip guarding and personnel protective equipment goggles shield gloves etc b Clean screen in solvent and dry with compressed air Reinstall and check for sign
130. Locknut Pinion Gear And Hub 1 2 3 4 5 6 7 TM 10 3950 263 14 amp P 1 Section 3 Continued Carrier Adjustment extends or retracts oil returning from the other side of the piston in the jack cylinder is returned to the sump tank through porting in the solenoid valve stack The priority flow 10 G P M and secondary flow 7 G P M combine to operate the outrigger jacks Relief Valve Adjustment There are three relief valves in the System One is in the pump one in the 3 8 valve stack and one in the 3 4 valve stack The relief valve in the pump controls pressure in the outrigger beam extend retract System It is preset and nonadjustable The one in the 3 8 valve stack controls pressure in the front bumper outrigger circuit The one in the 3 4 valve stack controls pressure in the jack raise lower circuit Adjust the relief valves as follows WARNING Fully Retract All Jacks And Beams Before Attempting To Set Pressures Never Work On A Carrier Outrigger System When It Is Elevated On Outriggers Unless You Thoroughly Block The Machine First It May Come Down And Cause Injury Or Damage a Use a 2500 psi pressure gauge to adjust the relief valves This gauge should be protected against pressure surges by an orifice or a nearly closed needle valve Refer to for examples of gauge assemblies with orifices and quick disconnects Rear Axle Assembly 8 Bearings 9 Wheel Hub 10 Brake Drum 11 B
131. Loose or corroded connections Clean and tighten connections Engine will not start 1 No fuel Fill fuel tank 2 Temperature too low Use fluid starting aid see 3 Emergency shutdown actuated 3 Pushin on emergency shutdown cable Reset emergency manual reset on engine 4 Upper engine engine shutdown 4 Push in on cable Check actuated adjustment of shutdown 5 Carrier engine defective stop Replace components as necessary Switch or solenoid see Shop Manual Engine runs hot 1 Low on coolant Check coolant level Fill as necessary sed p 2 29 2 Loose belts Tighten belts see p 2 22 3 Defective thermostat Replace thermostat see Shop Manual 4 Restricted air flow through Clean radiator cooling fins radiator Engine lacks power runs irregularly 1 Water in fuel or clogged filters Remove water from fuel and or misfires filters Replace filter elements sedp 28 2 Loss of compression sticking Engine may need a tune up or or burned valves defective major overhaul Refer to Shop injectors Manual Engine oil pressure drops suddenly 1 Loss of oil in crankcase 1 Check for leaks Repair and refill see p 2 27 2 Defective gauge sending unit 2 Replace components as necessary oil pump see Shop Manual Voltmeter reading incorrectly 1 Charging system defective 1 Check electrical system and repair see p 1 19 Braking System Insufficient braking action 1 Brakes out of
132. Loose or damaged parts or Class III leakage are evident The boom chords or lattice are cracked bent or damaged LOAD TEST not current A 45 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Upper NOTE Within designated interval these checks are to be performed in the order listed B Before ITEM INTERVAL NO B D A W M 10 11 12 A 46 A After ITEM TO BE INSPECTED D During PROCEDURE CHECK FOR AND HAVE REPAIRED FILLED OR ADJUSTED AS NEEDED IAW Lubrication Chart pg 2 11 Opera tor s Manual 1 Throwout collar 2 Clutch cross shaft CHAIN CASE Check oil level It should be to the bottom of the check plug opening Add SAE 10W30 detergent engine oil if neces sary OPEN GEARS WARNING Upper engine must be shut down and swing lock engaged while applying grease This will help avoid injury to personnel Maintain a thin film of grease on open gears at all times to include swing pinion and turntable bearing AUXILIARY GENERATOR ENGINE a Check dipstick for proper engine oil level Add oil as necessary to FULL mark ref pg 6 9 Operator s Manual b Inspect and clean air cleaner ref pg 6 8 Operator s Manual W Weekly M Monthly EQUIPMENT IS NOT READY AVAILABLE IF TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Upper NOTE Within designated interval these checks are to
133. M pressure gauge will register between 900 and 1 050 6205 7239 kPa PSI which are the values the unloading valve is set at If the unloading valve should malfunction pressure could rise well above 1 050 PSI 7239 kPa For this reason a relief valve is included in the S o M system The relief valve is set at 1250 P S I 8615 kPa The relief valve is adjusted as follows a Disengage the master clutch Shut down engine b Reduce S o M system pressure to zero by working the control levers back and forth c Remove the return line from the unloading valve at A in Place a pipe plug in the hole to force system pressure to build up to relief valve pressure d Start the engine and read the pressure off he gauge in the front instrument panel If the gauge reading is 1 300 PSI 8963 kPa or more immediately shut off the engine This would indicate too high a setting or a stuck spool in the valve e If the setting is not 1250 P S I 8615 kPa it may be changed as follows 1 Remove valve cap 2 Add or subtract shims 6 to change relief valve setting The following shims are used a JC1690 20 Ga 911mm b JC1691 28 Ga 378mm Setting the pressure is a trial and error process Add or subtract one shim at a time until correct pressure is reached TM 10 3950 263 14 amp P 1 Zi irme dd yan S Hp ugs Fig 7 3 Relief Valve Assembly O Ring Pist
134. MPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT Inspect Service Replace Repair STEERING Steering Wheel Replace Steering Gear Inspect Service Replace Repair Column Replace Repair Tie Rod amp Drag Link Replace Power Steering Pump Service Replace Repair Hoses Lines and Fittings Inspect Replace Power Steering Cylinder Replace Repair Reservoir Service Replace Replace Steering System Valves Replace Repair FRAME Frame Assembly Repair TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS f 02 3 4 4 5 6 COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT 1501 Bumper Front Replace Repair 1502 Counterweights Replace Counterweight Remover Cylinder Replace Repair Outrigger Beam Box Pontoon Assembly Replace Repair Outrigger Hydraulic Tank Service Replace Repair Outrigger Hydraulic Filter Replace Outrigger System Values Replace Repair Outrigger Cylinders Replace Repair Outrigger Hydraulic Pump Replace Repair Outrigger Hydraulic Power Take off Inspect Service Replace Repair Outrigger Hoses Lines Fittings Replace Outrigger Controls Switches Replace Repair TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCAT
135. NING Be Careful Not To Get Battery Electrolyte On Your Skin Or Clothing Or Especially In Your Eyes It Is Acid And Can Cause Injury Don t Smoke Or Use Open Flame Near A Battery Battery Gas Is Explosive 1 Inspect all parts of the attachment paying particular attention to the boom chords and lattice If damaged the boom may collapse If a lattice or diagonal bracing member is broken replace it If bent straighten it Refer to Shop Manual 9 1 2 0 for repair information If a main chord is damaged or bent even a small amount don t use it Don t try to repair it These members are so vital that it is not practical to attempt repair Replace the entire boom section 2 Ifthe live mast is damaged repair or replace before using TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 11 Every 50 Hours First perform all operations listed under Every 10 Hours Torque Converter Reduction Pinion Gear Case Reverse Bevel Gear Case Planetary Gear Case Master Clutch Side Housing Bearings All Horizontal Shafts S o M Filter Outrigger System Filter On Carrier Air Box Drains Clutch Heel Blocks Control Lever Linkage Swing Lock Linkage Swing Brake Linkage And Pins S o M Valve Spools Clutches Brakes General Upper And Attachment Turntable Bearing S o M Control Valves HC238A Inspect and clean exterior of converter Repair any oil leaks or o
136. OR LIABILITY ON THE PART OF THE COMPANY B Limitation of Liability It is expressly understood that the COMPANY s liability for its products whether due to breach of warranty negligence strict liability or otherwise is limited to the furnishing of such replacement parts and the COMPANY will not be liable for any other injury loss damage or expense whether direct or consequential including but not limited to loss of use income profit or production or increased cost of operation or spoilage of or damage to material arising in connection with the sale installation use of inability to use or the repair or replacement of the COMPANY s products The COMPANY reserves the right to make alterations or modifications in their equipment at any time which in their opinion may improve the performance and efficiency of the machine They shall not be obliged to make such alterations or modifications to machines already in service Any operation beyond rated capacity expressly prohibited in the operating instructions or safety manual furnished with the machine or any adjustment or assembly procedures not recommended or authorized in the operating or service instructions shall void such warranty Special Provisions The standard machine warranty is modified by special provisions in solicitation DAAE07 80 B 5230 J07 EQUIPMENT WARRANTY J 7 1 Definitions Acceptance The word acceptance as used herein means the execution of the Accept
137. ORM DA u 72028 2 ARE OBSOLETE RECOMMENDATION MAKE CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS REVERSE OF OA FORM 2000 2 FILL IN YOUR UNIT S ADDRESS l 1 1 l l 1 FOLO BACK E l 1 l l l l l l 1 l l DEPARTMENT OF THE ARMY POSTAGE AND FEES OEPARTMENT OF THE ARMY DOO 314 OFFICIAL BUSINESS PENALTY FOR PRIVATE USE 300 Commander US Army Tank Avutomctive Command ATTN AMSTA MB Warren Michigan 48397 5000 THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE SQUARE MEASURE 1 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 WEIGHTS CUBIC MEASURE 1 Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Cu Centimeter 1000 Cu Millimeters 0 06 Cu Inches 1 Kilogram 1000 Grams 2 2 Lb 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons LIQUID MEASURE TEMPERATURE 5 9 F 32 G 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 212 Fahrenheit is equivalent to 100 Celsius 1 Liter 1000 Milliliters 33 82 Fluid Ounces 90 Fa
138. PERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T extended If you swing over the side the machine may tip over or the boom may be damaged from side loadings because the machine is not level When working a machine with mechanical non hydraulic outriggers make sure the beams are pinned in place otherwise they can creep in while operating causing an unstable condition possibly tipping the machine over When using a boom length where retractable gantry or live mast is required be sure they are fully extended and pinned in place When operating a lifting crane on crawlers where the tracks sink into the soil any noticeable amount use matting Timbers used for matting should be at least as long as the total width of the lower and should be heavy enough to withstand loadings without damage Timbers should be close together to form a solid platform When lifting over crawler ends block under track ends so full support is provided where track leaves the ground Don t alter any part of the machine Additions to or changes in any part of the equipment can create loadings which the machine was not designed for Such changes may seriously affect the useable capacities and make the entire capacity chart invalid Such changes can dangerously overload or weaken critical parts and may cause disastrous failure Don t operate over the front of a truck Fig 24 Use matting on soft ground Fig 25 Working over th
139. R SF 368 will be limited to the reporting of equipment failure in design which pose a threat to operator safety or which detract from the operational capability and for the reporting of delays exceeding 20 days from contractor notification in completing requested warranty services or unsatisfactory workmanship resulting in user dissatisfaction with such services 4 TM 10 3950 263 14 amp P 1 APPENDIX C MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 Section INTRODUCTION 1 General This Maintenance Allocation Chart designates responsibility for performance of Maintenance functions to specific Maintenance categories 2 Maintenance functions a Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination b Test To verify serviceability and detect incipient failures by measuring the mechanical or electrical characteristics of an item and comparing those characteristics with prescribed standards Service Operations required periodically to keep an item in proper operating condition i e to clean decontaminate to preserve to drain to paint or to replenish fuel lubricants hydraulic fluids or compressed air supplies d Adjust To maintain within prescribed limits by bringing into proper or exact po
140. Rollers Delivery of a Machine Dimensions of Machine Engine Air Cleaner Engine and Power Take Off Engine Fluid Starting Aid Engine Maintenance Chart Engine Starting and Stopping Carrier Engine Starting Upper Engine Stopping Upper Gauge Converter Temperature Upper Gauge Emergency Air Pressure Carrier Gauge Engine Oil Pressure Carrier Gauge Engine Oil Pressure Upper Gauge Engine Temperature Carrier Gauge Engine Temperature Upper Gauge Fuel Carrier Gauge Service Brake Pressure Carrier Gauge S o M Pressure Upper Gauge Speedometer Carrier Gauge Supply Air Pressure Carrier Gauge Tachometer Carrier Gauge Voltmeter Carrier Gauge Voltmeter Upper Indicators Drum Rotation Information General Instruments See Gauges Lever Creeper Transmission Shift Lifting Sling Assembly Lifting Sling Inspection Lifting Sling Installation Light Ignition on Upper Live Mast Controls Live Mast Extending Live Mast Operation Live Mast Retracting Load Lowering Crane Equipped with Torque Converter amp Lowering Clutches 1 29 Operator s Manual Subject Lubrication and Maintenance Schedule Carrier Lubrication and Maintenance Schedule Upper lubrication Capacity Chart Carrier Lubrication Capacity Chart Upper Lubrication Chart Attachment Lubrication Chart Carrier Lubrication Chart Upper Lubrication Check and Change Chain Case Lubrication Check and Change Main Trans
141. S NUMBER FUNCTION CATEGORY EQUIPMENT F H D ENGINE Engine Assembly Inspect Service I 2 5 Adjust 1 7 9 Replace 1 7 9 Repair 1 7 9 12 Overhaul 1 7 9 12 Engine Mounting Inspect I 7 9 Replace 7 9 Crankcase Cylinder Block Service Replace Repair Cylinder Head Assy Replace Overhaul Oylinder Sleeves Replace Repair Air Box Drain Tube Service Replace Crankshaft Replace Repair Bearings Main Replace Pulley Damper Replace Flywheel Assembly Replace Repair Ring Gear Replace Flywheel Housing Replace Repair Pistons Replace Repair Connecting Rod Replace TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION Il ASSIGNMENT OF MAINTENANCE FUNCTIONS pin so cq DE EE s e COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE FUNCTION CATEGORY EQUIPMENT Bearings and Rings Replace Rocker Arm Assembly Adjust Replace Repair I Valve Rocker Cover Replace i Valves Replace I Repair 7 Camshaft Assy Replace Balance Shaft Replace Timing Gear Train Replace Oil Pan Replace Repair Oil Pump Replace Repair I Oil Filters Spin on Replace Oil Filter Cartridge Replace Service Oil Cooler Replace Oil Pressure Regulator Replace Repair Manifold Exhaust Inspect Replace Accessory Driving Mechanism Replace Repair
142. TM 10 3950 263 14 amp P 1 TECHNICAL MANUAL FOR CRANE MOBILE CONTAINER HANDLING TRUCK MOUNTED 140 TON CAPACITY DED FMC LINK BELT MODEL HC 238A ARMY MODEL MHE 248 NSN 3950 01 110 9224 FMC CORPORATION CABLE CRANE AND EXCAVATION DIVISION This copy is a reprint which includes current pages from Change 1 HEADQUARTERS DEPARTMENT OF THE ARMY 15 JULY 1985 TM 10 3950 263 14 amp P 1 Change HEADQUARTERS No 1 DEPARTMENT OF THE ARMY Washington D C 8 March 1987 TECHNICAL MANUAL CRANE MOBILE CONTAINER HANDLING TRUCK MOUNTED 140 TON CAPACITY DED FMC LINK BELT MODEL HC 238A ARMY MODEL MHE 248 NSN 3950 01 110 9224 TM 10 3950 263 14 amp P 1 15 July 1985 is changed as Follows 1 Remove old pages and insert new pages as indicated below 2 New or changed material is indicated by vertical bar in the margin of the page 3 Added or revised illustrations are indicated by a vertical bar adjacent to the illustration identification number REMOVE PAGES INSERT PAGES 5 1 and 5 2 5 1 and 5 2 4 File this change sheet in front of the publication for reference purposes By Order of the Secretary of the Army JOHN A WICKHAM JR General United States Army Official Chief of Staff R L DILWORTH Brigadier General United States Army The Adjutant General Distribution To be distributed in accordance with DA Form 12 25F Operator Organizational Direct Support and General Support Maintenance requirements
143. The 10 vis 20 oil is to be used in temperatures of 10 F to 90 F 12 C to 32 C The 20 vis 40 oil is to be used in temperatures of 30 F to 115 F 1 C to 46 C HC238A a b c TM 10 3950 263 14 amp P 1 Section 7 Speed o Matic Control System In machines operating in temperatures of 40 F and lower it is permissible to dilute the oil with uncracked kerosene Kerosene will evaporate especially during warm spells therefore the sump tank level should be checked more often than usual Caution should be used in diluting with kerosene in temperatures where it becomes this cold only upon occasion When ordering oil always specify the grade stock number and amount needed 7 3 To change Park the machine on level ground Decrease the operating pressure to zero by working the control levers back and forth Remove the oil by removing the magnetic drain plug from the bottom of the tank WARNING Use Fuel Oil Or Cleaning Solvent In A Well Ventilated Area Away From Flames Remove and thoroughly clean the breather cap on top of the tank Use kerosene or some similar approved solvent Remove the top cover from the sump tank Remove and thoroughly clean the sump tank strainer in kerosene or some similar solvent Thoroughly clean the inside and outside of the tank and cover with kerosene or some similar approved solvent Reassemble the sump tank strainer and cover Clean and replace the magnetic d
144. The release When reassembling the rocker cover remove the solenoid energizes when starting speed is attained to release solenoid and dip the plunger O ring in oil Reinstall the exhaust valve for operation as long as the engine runs solenoid when cover is on the engine Align solenoid so The solenoid deenergizes when the engine is shut down terminal SW is above terminal IGN allowing the release mechanism to open the exhaust valve and stop the engine by decompression Note Before adjusting the decompression mechanism the valves must be set for the correct clearance a With piston 10 degrees to 45 degrees past TDC on power stroke hold arm in decompression position tension against spring Turn set screw so it just touches exhaust rocker arm The release arm must be tight against snap ring during adjustment Then turn screw exactly one revolution clockwise Original factory setting is marked with white or yellow paint Note If screw is tightened more than one Turn piston could hit exhaust valve Hold the set screw and lock it into position with the attached nut Turn the nut hand tight plus 1 4 to 1 2 turn to lock the mechanism TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembly 6 36 General Maintenance 6 37 General Follow a regular schedule of inspection and servicing based on operating hours Table 1 Keep an accurate logbook of maintenance servicing and ope
145. Transmission 12 Pints 5 6 Liters D Steering Gear 2 5 Pints 1 3 Liters E Power Steering System 3 Gal Approx 11 3 Liters F Engine Crank Case w Filter 6 25 Gal 236 Liters Change G M C Outrigger Sump Tank 20 Gal 75 7 Liters S o M Oil Outrigger System 35 Gal Approx 132 4 Liters S o M Oil All Lubrication Fittings As Required Key A C D E F H J See lubrication specifications o HC238A 2 3 Operator s Manual Ill er A mg li MI jJ 2254 4 Section 2 Continued Preventive Maintenance And Lubrication M I BE Af i iH d aia p V L m ih WB 1 N i W ME Ik d Aj BR a h EE F 7 qu b lza DRR TM 10 3950 263 14 amp P 1 NA206 D NA220 D Shut down engine Engage park brake before working on carrier Keep grease oil guns and containers clean Wipe all fittings before lubrication Fig 2 1 Carrier Lubrication Chart TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 8 Carrier Lubrication Chart Monthly Or Semi Annual Ref No 1000 Miles Or 5000 Miles No Description Points Daily Weekly 1609 3 km 3046 7 km 1 Radiator 1 u 2 Engine A11 See Chart p 2 20 3 Battery A11 4 Wheel Bearings 4 Repack A 5 Tie Rod Ends 4 A 6 Brake Cam Shafts 4 A 7 King Pins 8 A 8 Hyd Outrigger Sump Tank 1 Change Season
146. UP A HIGH RANGE Figure 1 8 Shifting Diagram A High Range B Low Range C Deep Reduction 1 34 Upshifting There are several patterns of upshifting depending upon conditions of road and load Check gear ratios to determine the best ratio progression for your particular condition The following instructions are recommended for normal conditions a With the gear shift lever in neutral the engine started and the air system pressure normal push the range control button to the down position b Move the deep reduction valve to the in position to engage the deep reduction gears c Start the vehicle in 1st position of the deep reduction shaft pattern Once the carrier is moving and adequate momentum has been obtained the transmission can be shifted from 1st through 2nd 3rd 4th 5th while In deep reduction range TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions d When ready to upshift from 5th in deep reduction move the deep reduction valve to the out position and move the gear shift lever to the 4th speed position thus shifting out of 5th in deep reduction into 4th in low range Torque will keep the gear engaged until the shift out of deep reduction is made Remember a shift from deep reduction to low range is an upshift and the accelerator must be moved accordingly Always declutch when shifting from the deep reduction range e Shift from 4th to the 5th speed position while in low r
147. WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADORESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT Sun mailing address QUT FOLD IT AND DROP IT IN THE MAIL DATE SENT Date you filled out this form B PUBLICATION NUMBER PUBLICATION DATE PUBLICA TITLE 10 3950 263 14 amp P 1 15 July 1985 Crane 140 Ton 248 BE EXACT PIN POINT WHERE IT IS ww THIS SPACE TELL WHAT IS WRONG PAGE PARA EO EN taste AND WHAT SHOULD BE DONE ABOUT IT NO GRAPH NO NO 2 26 2 79 This paragraph states that as long as engine performance is satisfactory no tune up should be needed PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE DA FORM 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 130079 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBUCATIONS SOMETHING WRONG wan mis pusucanon THEN JOT DOWN THE FROM PRINT YOUR UNIT S COMPLETE ADORESS DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOI D IT AND DROP iT IN THE MAIL DATE SENT PURIM A TIO MEIER PUBLICATION PUBLICATION TITLE TM 10 3950 263 14 amp P 1 15 July 1985 Crane 140 248 IN THIS SPACE TELL WHAT I WRONG AND WHAT SHOULD DONE ABOUT IT PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBERS PREVIOUS EDITIONS P IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR F
148. accessory drive belts after 1 2 hour or 15 miles and again after 8 hours or 240 miles of operation Thereafter check the tension of the drive belts every 200 hours or 6 000 miles and adjust if necessary Too tight a belt is destructive to the bearings of the driven part a loose belt will slip Replace all belts in a set when one is worn Single belts of similar size should not be used as a substitute for a matched belt set premature belt wear can result because of belt length variation All belts in a matched belt set are within 0320 of their specified center distances Adjust the belt tension so that a firm push with the thumb at a point midway between the two pulleys will depress the belt 1 2 to 3 4 If belt tension gauge BT 33 73FA or equivalent is available adjust the belt tension as outlined in the chart Fan Drive Generator Drive Model 20f3 Single Two 3 8 or One 1 2 Belts Belt 1 2 Belts Belt Belt 6V 92 6 71 60 80 80 40 50 50 70 40 50 100 Note When installing or adjusting an accessory drive belt be sure the bolt at the accessory adjusting pivot oint is properly tightened as well as the bolt in the adjusting slot Tighten the 7 16 14 300M pivot bolt to 72 77 ft lbs 98 104 N m torque Tighten the 7 16 14 280M pivot bolt to 46 50 ft Ibs Operator s Manual EE 2 17 x Tachometer Drive ltem 7 2 54 2 57 2 58 Fig 2 18 Air Cleaners Item 8 2 55 HC238A Tachometer
149. achine must be level with all tires clear of ground b Lift the A bumper ctwt with either the live mast reeved as a boom or with basic boom c Set the ctwt in place on the mounting lugs on the front bumper Install the locking pin to secure the ctwt to the bumper 1 90 Procedure For Shutting Down Crane When a machine is to be shut down for overnight or similar periods the following procedure is suggested a Land any loads and secure against toppling b For boom lengths or boom plus jib lengths less than 40 of the maximum boom length permissible it is usually unnecessary to lower such booms to the ground However should high winds be possible lower boom to the ground if at all possible If not possible rest boom tip lightly against some adequate structure and securely tie off to prevent its being blown over Longer booms must be lowered to the ground or tied off to prevent wind damage c When boom is in position as indicated in b above the boom hoist lever must be placed in the neutral off position and the boom locking pawl engaged d Anchor hooks and hook blocks securely to an adequate anchorage or part of the crane itself the hoist lines drawn snug and hoist brakes set and latched in This is to reduce likelihood of wind damage Fig 1 35 Bumper Counterweight 1 Bumper Ctwt 2 Locking Pin HC238A 1 91 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions
150. ack ball may hit the boom and damage it When using a clamshell bucket on demolition work and taking a bite on a piece of unknown weight be ready to release the closing line as more weight than you can handle may break loose Be prepared to drop the load When dismantling a structure where a portion is being cut loose while suspended by a crane be sure the weight of the portion being cut loose is known and the crane pull on the load is equal to the weight The point of attachment must be directly above the center of gravity of the load The fall lines must be vertical This is an extremely hazardous operation The services of a professional engineer should be used to plan and supervise such lifts Excavator Safety Keep holding line taut when hoisting a clamshell Don t permit it to overhaul the closing line otherwise bucket will open to dribble the load Release closing line gently to avoid shock to holding line and boom when opening bucket When loading a truck load from the rear never swing over the cab Make sure the truck driver leaves the cab during loading 0 23 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T 3 When loading a truck with a hoe raise boom when extending dipper to avoid hitting the truck 4 Keep crawlers back from the edge of the hole to keep the machine from falling in 5 Know the exact location of buried lines gas water sewer telephone electric
151. adjustment 1 ay brakes sed p 3 4 3 5 2 Low air pressure in system 2 Check for leaks and or defective components see Shop Manual 3 Brake shoes and or drums worn 3 Replace components as necessary see Shop Manual 4 Brakes overheated because of 4 Allow brakes to cool Check excessive use or faulty air and repair system see Shop System Manual Brakes engage unevenly or are noisy 1 Brake shoes drums or mountings 1 Check repair or replace as Worn or damaged required see Shop Manual Transmission and Clutch Transmission shifts incorrectly 1 Fluid level low 1 Fill to correct level see p 2 14 2 Transmission defective 2 Repair or replace see Shop Manual 3 Shifter slave or linkage not 3 Lubricate See lube chart lubricated HC238A 8 1 Operator s Manual Problem Transmission shifts incorrectly cont Transmission overheats Section 8 Continued Troubleshooting Procedures Probable Cause 4 Shifter slave or linkage defective 5 Transmission air controls defective 1 Fluid level low 2 Transmission defective TM 10 3950 263 14 amp P 1 4 Repair or replace see Shop Manual 5 Repair or replace controls see Shop Manual 1 Fill to correct level see p 2 14 2 Repair or replace see Shop Manual Transmission grinds when shifting 1 Clutch not properly disengaging 1 Adjust clutch see p 3 1 Clutch slipping 1 Clutch not
152. ain Hoist Wire Rope Cable Torque Converter Pinion Drive Chains Chain Case Swing Lock Assembly Service Replace Repair Inspect Service Adjust Replace Repair Replace Repair Replace Inspect Replace Replace Repair Inspect Replace Inspect Service Replace Repair Replace Adjust Replace Repair Service Replace Repair Service Replace Repair toto woo ow xo ck sch sch M MAM sch sch sch IM NNN NNO N S Oo ow xo to 0 INA coo a ck M sch sch sch M sch sch sch TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS GROUP COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT 7420 Gearcases Inspect Service Replace Repair Housing Assembly Replace Repair 7422 Control Levers Pedals Linkage Service Replace Repair TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS TOOL OR TEST EQUIPMENT MAINTENANCE NOMENCLATURE NATIONAL NATO TOOL REFERENCE CATEGORY STOCK NUMBER NUMBER CODE 1 Shop Equip Contact Maint 4940 00 294 9
153. ain readily Supply a drain pan large enough to hold the oil without spilling over Remove the pan plug and allow the oil to drain thoroughly WARNING Hot Oil Can Cause Severe Burns Be Careful When Draining The Oil Clean the pan plug thoroughly and replace b The full flow and by pass filters should be replaced each time the engine oil is changed CONVERTER Fig 2 29 Torque Converter ltem 40 2 81 2 27 Operator s Manual twee g SES mg st E Fig 2 32 Typical By Pass Filter Mounting 2 28 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Place a drain pan under the filter housing Remove the drain plug and drain the oil c The filter shell element and stud may be detached as an assembly after removing the center stud from the adaptor Discard the gasket d Clean the filter adaptor e Discard the used element wipe out the filter shell and install a new element on the center stud f Place a new gasket in the filter adaptor position the shell and element assembly on the gasket and tighten the center stud carefully to prevent damaging the gasket or center stud g Install the drain plug refill engine with oil and after the engine is started check for oil leaks 2 83 Fuel Strainer And Filter Replacement A spin on type fuel strainer and fuel filter is used on both engines The spin on filter cartridge consists
154. akes which quickly clog the fuel strainer and filter and damage the fuel pump and injectors 2 85 Engine Out Of Fuel The problem in restarting the engine after it has run out of fuel stems from the fact that after the fuel is exhausted from the fuel tank fuel is then pumped from the primary fuel strainer and sometimes partially removed from the secondary fuel filter before the fuel supply becomes insufficient to sustain engine firing Consequently these components must be refilled with fuel and the fuel pipes rid of air in order for the system to provide adequate fuel for the injectors When an engine has run out of fuel there is a definite procedure to follow for restarting the engine a Fill the fuel tank with the recommended grade of fuel oil If only partial filling of the tank is possible add a minimum of ten gallons 38 liters of fuel b Remove the fuel strainer shell and element from the strainer cover and fill the shell with fuel oil Install the shell and element c Remove and fill the fuel filter shell and element with fuel oil as in Step b d Start the engine Check the filter and strainer for leaks Note In some instances it may be necessary to remove a valve rocker cover and loosen a fuel pipe nut in order to bleed trapped air from the fuel system Be sure the fuel pipe is retightened securely before replacing the rocker cover Primer J 5956 may be used to prime the entire fuel system Remove the fi
155. ally or Every 1000 Operating Hrs 9 Hyd Outrigger Filter 1 Change Every 250 Operating Hours 10 Outrigger Strainer 1 Clean When Sump Tank Is Drained 11 Air Reservoirs A11 Drain Water Daily 12 Tires A11 18 U Joints 6 A 14 Creeper Transmission 1 CH D 15 Fuel Tanks 2 16 Planetary Hubs 4 CH E 17 Differentials 2 T CH E 18 Rear Axle Vents 2 CL 19 Brake Cam Shaft 4 A 20 Center Bogie Beam Bushing 2 A 21 End Bogie Beam Bushing 4 A 22 Slip Joints 3 A 23 Main Transmission 1 CH D 24 Power Steer Reservoir 1 CH F 25 Clutch Release Bearing 1 A 26 Clutch Shaft Support 1 27 Clutch Cross Shaft 1 A 28 Steering Linkage 11 A 29 Trans Shifter U Joints 2 A 30 Steering Gear 1 31 Steering Column U Joints 2 A 32 Transmission Air Filter 1 CH Key A D E F See Lube Specificationd Page 2 13 Check And Fill If Necessary CH Change CL Clean HC238A Operator s Manual 2 9 Upper Maintenance And Lubrication Schedule Every 10 Hours TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication General Engine Master Clutch Torque Converter Chain Case Wire Rope Cable S o M Sump Tank Outrigger Sump Tank WARNING Do not service maintain or lubricate open gears unless upper engine is shut down and swing lock is engaged Open Gears Fuel Tank Radiator Batteries Boom Chords And Lattice 1 Keep the upper clean 2 Check for loose or broken bolts
156. alm wind c No side loads or outswing of load d Good visibility e Machine in A 1 condition and equipped as when leaving the factory Know your load When such conditions cannot be attained loads being handled must be reduced to compensate The amount loads are reduced depends upon how good or how poor the actual operating conditions are It is a matter of judgement and experience Some factors which may require reduction of loads below listed ratings are a or unpredictable supporting surfaces b Wind c Hazardous surroundings d Inexperienced personnel e Poor visibility f Fragile loads g Machine in poor condition When in doubt don t take a chance Reduce ratings more than you think you need to Avoid working a machine in high winds If you must work in a wind reduce capacities considerably below those shown on the capacity chart Wind blowing against the load and the boom produces a side load on the boom and reduces its capacity When lifting large loads such as building panels in a wind the movement of the load may pose a danger to workmen or building structures Outswing of a load will increase load radius and may overload the machine This could lead to boom failure or machine tipping Don t operate at radii and boom lengths where the capacity chart lists no capacity Don t use longer booms or jibs than listed on the chart Any of the above can tip the machine over or cause boom and or jib failure
157. am cylinders extend or retract the outrigger beams horizontally The jack cylinders raise or lower the machine vertically Upper Machinery The upper machinery is powered by a Detroit Diesel 6 71 series engine The engine is a two stroke cycle design inline 6 cylinder A blower is used to force air into the cylinders to expel exhaust gases and supply the cylinders with fresh air for combustion Power from the engine is delivered to an Allison single stage torque convertor The torque convertor supplies power to drive the upper machinery A pinion on the convertor is connected to a chain wheel on the upper machinery with a roller chain The chain is enclosed in a chain case which contains oil for lubrication of the chain and gear teeth The chain wheel is connected to a reduction shaft which has two pinions One pinion drives the R H gear train The other pinion drives a countershaft A pinion on the countershaft drives the L H gear train Four horizontal shafts are used in the upper machinery Two are used for lifting loads the front drum and rear drum shaft One is used to raise or lower the boom the boom hoist shaft The fourth is used to swing the machine the reverse shaft The upper machinery swings on a large ball bearing the turntable bearing pinion on the vertical swing shaft engages teeth on the turntable bearing to swing the machine The vertical swing shaft is powered by the reverse shaft through a pair of bevel g
158. ams and jacks b Park the machine on level ground Set the parking brake Shut off the carrier engine c Remove and wipe off the dipstick Insert the dipstick fully into the tank then remove and read oil level Add oil if necessary See capacity chart or page 2 3 for the proper oil 2 29 To Change Filter Change the filter after the first 50 hours of operation on a new machine and every 250 operating hours thereafter as follows a Thoroughly clean the filter cover plate and area of the tank around it to prevent entry of foreign material b Unbolt and remove the cover plate c Remove and discard the filter element Remove the spring and by pass valve from the filter and install in the new element d Install the new element in the filter compartment Push the element over the pipe nipple which extends into the filter compartment e Replace the filter cover and gasket and tighten down evenly 2 30 To Change Oil Change the oil in the outrigger system every 1 000 hours or seasonally as follows a Park the machine on level ground Set the parking brake Fully retract all outrigger beams and jacks Shut off the carrier engine b Remove the drain plug Allow the oil to drain thoroughly c Remove the filter element as explained earlier in this section d Remove inspection plate from the tank HC238A 2 31 2 32 10 3950 263 14 amp 1 Section 2 Continued Preventive Maintenance And Lubrication
159. ance Block and signing of a DD Form 250 by the authorized Government representative Supplies The word supplies as used herein means the end item and all parts and accessories thereof furnished by the contractor and any related services required under this contract The word does not include technical data J 7 2 Warranty Notwithstanding inspection and acceptance by the Government of the supplies furnished under the contract or any provision of this contract concerning the conclusiveness thereof the contractor hereby warrants that the supplies are free from defects in design material and workmanship and will conform with the specifications and all other requirements of this contract for a period of 15 months from date of acceptance as shown on the Material Inspection and Receiving Report DD Form 250 or 1500 hours of operation whichever occurs first Equipment designated as Production Samples shall be treated as equipment delivered 1of5 TM 10 3950 263 14 amp P 1 Warranty at the time as the production units If a Safety Recall defect occurs during equipment warranty period the contractor agrees to extend the term of the warranty by the period of time equal to the time period required to make necessary safety defect corrections Additionally to the extent of the contractor or his supplier s provide to commercial customers a greater warranty for the supplies furnished therein the contractor hereby likewise provides such greater warran
160. and fall lines can be used as a plumb bob to level a machine Pick up a compact 0 10 load 2000 3000 Ibs 907 1360 kg a few Inches above the ground If machine is level fall lines will hang directly between the boom feet as you face the boom Now swing over the side The lines should still hang directly between the boom feet Don t use this method on a windy day Right Load hangs midway Wi between boom feet Hil Grade ground level yl al or block under Un machine ail x Wrong A 3 degree side tilt can reduce capacities by over Fig 17 Level the machine 2 The hoist line must be vertical when TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T starting to lift If not load will swing in out or sideways when lifted from the ground Just a little side tilt when working over the end A what can happen i when you swing over the sidell Load radius increases when swung over the side Fig 18 Effect of side tilt When picking a heavy load machine will lean toward the boom This is caused by elasticity of the machine and the boom The lean is more noticeable when picking over the side on rubber The lean will increase operating radius so the load will swing outward when it clears the ground This outswing is dangerous to anything in the path of the load and because of the increase in load radius may overload the machine To ov
161. and on this ladder to open the cab door b Unlock the door with the door key c Twist the outside handle to the right to unlatch the door d Slide to the rear to open e Machine can be operated with the door open or closed To close the door slide it forward after entering until it latches To open from the inside a Squeeze inside handle to unlatch b Pull the door to the rear to open Note Always position upper so you can step out onto non skid surfaces on carrier fenders and deck or onto carrier ladder when you leave the cab Grab bars are provided for the operator s use when entering or leaving the cab Use them to help prevent accidents 1 50 Starting The Upper Engine a Insert key in ignition switch Turn to on position b Make sure master clutch is disengaged c On machines with Detroit Diesel engine push in on shutdown control d Open the engine throttle to just above idle e Push the throttle control forward to about 1 4 throttle Push the starter button until the engine starts Release the button and throttle back to an idle Note Don t operate the starter more than 15 seconds at a time when starting the engine f Run the engine at part throttle and no load for about 5 minutes allowing it to warm up before applying a load g With the engine running just above idle engage the master clutch h Run the engine slowly until the S o M system torque converter and gearing are
162. and should be centered with the brake drum The middle area of each band is centered with the drum by means of a centering bracket item 12 in Fig 4 7 The rest of each band is centered with the brake drum by shimming between the dead end lug and the dead end mounting bracket on the frame The following 5 Front Drum Brake C 49 15 16 1 26mm D 10 1 4 260mm 9 Dead End Pins 10 Standoff Bolts 11 Return Spring 12 Band Centering Bracket When the boom hoist control is actuated to raise or lower the boom oil under pressure is also admitted to the boom hoist brake cylinder 6 to release the brake When the control lever is returned to neutral the oil in the cylinder 6 flows directly to the S o M sump tank The spring 11 then applies the brake shims are available for use at this point 4 15 Boom Hoist Brake Adjustment Check the boom hoist brake 1 1D144 10 Ga 3 41mm adjustment upon delivery of a new machine and every 50 2 1D145 22 Ga 759mm hours thereafter as follows 3 1J218 16 Ga 1 51mm a Boom down until boom is lying on ground and d Adjust the pedal return spring to return the pedal boom hoist ropes are slack before working on B H to its extreme upward position when unlatched brake This will completely release the brakes if the band b The band must be centered with the B H brake and standoffs are in correct adjustment Adjust the stop nut on the pedal return spring bolt
163. ange f When ready for the next upshift pull the range control button up while in the 5th speed position and shift the lever to the 1st speed position of the shift pattern thus shifting from 5th in low range to 6th in high range As the shift lever passes through neutral the transmission will automatically shift from low to high range 1 35 Alternative Shift Procedures The shift from the deep reduction range to low range can be made from the 2nd 3rd or 4th speed gear positions while in deep reduction shifting from 2nd in deep reduction to 1st low range or from 3rd deep reduction to 2nd low range etc 1 36 Speed Progression Where operating conditions warrant the transmission can be shifted from 1st speed deep reduction to 1st speed in low range This is a 43 upshift step and the vehicle must have sufficient momentum to accomplish shift This is a shift usually used in on highway vehicles 1 37 Down Shifting a Shift from 10th speed through 9th 8th and 7th to the 6th speed position of high range b When ready for the next down shift push the range button to the down position and shift the lever to the 5th speed position As the shift lever passes through neutral the transmission will automatically shift from low to high range c Shift down from 5th through 4th 3rd and 2nd to the first speed position When down shifting it should not be necessary to shift into deep reduction ratios The reduction in low range
164. arrier should not be driven other than around the job site at creep speed with the tires inflated for maximum static lifts The eight rear tires and four front tires must be maintained at the same inflation pressure to eliminate roll and to assure even tire wear Wheel Torque Procedure Operator s Manual Size Rang Rating Load Ply Use Per 5 Miles 50 M P H Maximu Static Only Hour m Inflation Inflation Inflation 793 kPa 690 690 kPa kPa For maximum tire life a 30 minute rest period is recommended every 50 miles of continuous travel Fig 3 9 Tire Inflation Chart 3 9 3 10 Rear Wheel Brake Adjustment Adjust the brakes periodically to compensate for lining wear and also to provide the most efficient braking Adjust the rear wheel brakes as follows a Block the carrier wheels so the carrier cannot move b Adjust the brake slack adjuster Seel Fig 3 10 to change position of the slack adjuster with respect to the brake camshaft Turning the adjusting screw clockwise will decrease clearance between brake lining and drum c Adjust the brakes to give full brake application with 1 25 4mm of brake chamber push rod travel d Adjust all rear slack adjusters for the same amount of push rod travel Outrigger System Operation Fig_3 11 Two solenoid valve stacks are used to operate the outriggers A small 3 8 valve stack operates the beam extend retract cylinder and
165. as directed that their dealers or service representatives involved in the initial set up of the Crane establish Warranty reporting procedures with the unit Field units must recognize that not all maintenance repairs services are covered under Warranty For example minor adjustments repairs lubricants filters lights etc are not covered If there is any question or doubt as to whether a repair service is covered under Warranty please contact the FMC Corporation Government Service Representative listed below This representative must be contacted before any major Warranty repair is initiated Recommend the local EIR QDR Warranty Claim Coordinator be the point of contact for Warranty claims Mr John Claflin 2800 Lakeside Dr Bannockburn IL 60015 Telephone 312 295 5500 Ext 342 2 All warranties settled or unsettled will be reported to the National Maintenance Point NMP at TACOM on a DA Form 2407 The instructions for submitting the DA Form 2407 are outlined in paragraph 12 2 of TM 38 750 The Army Maintenance Management System For warranties settled locally the DA Form 2407 will contain a statement For Information Only in block 16A This information is required by the NMP for determining warranty utilization warranty cost avoidance to the Government and analyzing failure trends on newly fielded equipment Be certain to include the vehicle serial on the DA Form 2407 3 During the Warranty Period Quality Deficiency Report EIR QD
166. atch those in Table 10 1 the last cable assembly or component is faulty Replace that cable or component and recalibrate the system Table 10 2 Trouble Shooting Chart 10 6 TM 10 3950 263 14 amp P 1 Operator s Manual Section 10 Overload Warning System Two Blocks PROBLEM REMEDY Reach meter and Alert meter 1 Is Reeve Select switch set to the correct parts of line reeved on read correctly but the Load hook block meter does not read correctly 2 Hoist a known weight If Load meter value is incorrect after the reeving on the block has recalibrate the system been changed 3 Contact FMC Service Department Table 10 2 Continued Trouble Shooting Chart HC238A 10 7 10 8 blank Operator s Manual Major subject areas in the Operator s and Maintenance Manual are listed here alphabetically In some cases subjects are listed under more than one name for instance both cable and wire rope are listed as both names are used field situations Subject Page Air Box Drain Tank Air Cleaner See Engine Alignment Front Wheels Assembly Truck Carrier Aux Generator Adjustments Aux Generator General Information Aux Generator Maintenance Aux Generator Operation Backstops Boom Boom Angle Indicator Boom Assembly of 50 110 Ft Boom Assembly of 120 130 Ft Boom Disassembly of Boom Foot Assembly Boom Foot Pin Removal System Boom Foot Pins Removal Boom Foot Pins Replacing Boom Genera
167. ation of chemical compounds which provide corrosion protection pH control and water softening ability Corrosion protection is discussed under the heading Corrosion Inhibitors The pH control is used to maintain an acid free solution The water softening ability deters formation of mineral deposits Inhibitors systems are available in various forms such as coolant filter elements liquid and dry bulk inhibitor additives and as an integral part of permanent antifreeze Coolant Filter Elements Replaceable elements are available with various chemical inhibitor systems Compatibility of the element with other ingredients of the coolant solution cannot always be taken for granted Problems have developed from the use of the magnesium lower support plate used by some manufacturers in their coolant filters The magnesium plate will be attacked by solutions which will not be detrimental to other metals in the cooling system The dissolved magnesium will be deposited in the hottest zones of the engine where heat transfer is most critical The use of an aluminum or zinc support plate in preference to magnesium is recommended to eliminate the potential of this type of deposit High chloride coolants will have a detrimental effect on the water softening capabilities of systems using ion exchange resins Accumulations of calcium and magnesium ions removed from the coolant and held captive by the zeolite resin can be released into the coolant by a regen
168. ay on the rope c They must be able to penetrate between the wires and strands d They must have high film strength e They must resist oxidation f They must remain soft and pliable WARNING Warn Personnel In The Immediate Area Before Using Compressed Air For Cleaning Compressed Air Wear Safety Glasses Coming Into Contact With The Human Skin Or Causing Flying Metal Chips Can Cause Injury 5 39 Application Of Lubricant Wire ropes that have been in service must be cleaned before lubrication Use a wire brush and compressed air to clean the rope All possible foreign material and old lubricant must be removed from the rope before lubrication Use one of the following methods to apply the lubricant a Continuous Bath Run the rope through a container filled with lubricant A sheave mounted in the center of the container will hold the rope submerged as it passes through the container Use swabbing to remove excess lubricant as the rope leaves the container b Dripping Place a container above a sheave so that a spigot may be opened to drip oil on the wire rope as it passes through the sheave groove Swabbing and Painting Two fast methods are swabbing the lubricant on with rags or painting it on with a brush d Spraying Light lubricants may be applied with a spray gun Aerosol cans of lubricant are also available 5 23 TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachm
169. b 1 B upper counterweight 31 000 Ib 1 A bumper counterweight 13 500 Ib 1 B bumper counterweight 15 000 Ib 1 60 flat car 1 10 extension 1 378 Ib 2 20 extension 4 600 Ib 1 30 extension 3 350 Ib 1 outrigger 7 600 Ib A 30 TM 10 3950 263 14 amp 1 Rail Export continued 1 60 flat car 1 base 9 600 Ib 1 peak 1 gantry 3 600 Ib 1 parts box 2 500 Ib 3 hookblocks 6 850 Ib 3 reelof cable 5 100 Ib 1 spare tire 300 Ib Domestic amp Export Truck Domestic Export 1 flat bed 4 950 Ib 1 peak 2 200 Ib 9 800 Ib 1 base 15 200 Ib 15 200 Ib 2 outriggers 31 000 Ib 31 000 Ib 1 drop frame 5 650 Ib 6 850 Ib 1 B upper ctwt 3 900 Ib 5 100 Ib 3 hookblocks 3 reelof cable 1 392 Ib 3 350 Ib 992 Ib 2 300 Ib 1 drop frame 30 577 16 1 378 Ib 1 30 extension 2 500 Ib est 2 500 Ib est 1 20 extension 1 10 extension 15 000 Ib 15 000 Ib 1 parts box 3 600 Ib 3 600 Ib 1 drop frame 31 000 Ib 31 000 Ib 1 B bumper ctwt 992 Ib 2 300 Ib 1 gantry 13 500 Ib 13 500 Ib 1 drop frame 30 150 Ib 300 Ib 1 A upper ctwt 1 20 extension 91 720 Ib 91 720 Ib 1 drop frame 1 B bumper ctwt 1 tire 1 removable gooseneck 1 HC 238A A 31 TM 10 3950 263 14 amp P 1 APPENDIX F TROOP AUTHORIZED OR INSTALLED ITEM LIST NOTE The following items are authorized but not issued with the end item National Part Number Unit of Quantity Stock No Description FSCM Measure Authorized 7350 0
170. boom is over rear of carrier b Boom down until boom lower section just contacts ground with boom hoist ropes still taut c Remove pins which connect links to lower section lugs d Pin links in raised position as shown above e Lower mast to rest on boom base lugs and allow boom hoist ropes to slack f Extend mast and pin Assemble desired boom length on machine as explained earlier in this section 5 24 Carrying Booms Horizontally Over Rear Of Carrier Booms of 130 feet 39 62m and less may be suspended over the rear of the carrier for transportation purposes The pendants are hooked to the headshaft links in the normal manner except that the links must be pinned in the 48 1 21m position To transport the boom proceed as follows a Lower boom to the ground b Retract the live mast to the 25 6 7 8m position as explained on page 1 32 HC238A 3 Boom connection Pin 4 Capscrew Spacer Locknut B 1 25 4mm Clearance 5 Pin Connection Hub 6 Boom Lower Section c Pin the two position headshaft link in the extended 48 1 21m position d On 90 through 110 foot booms only boom down until the pendants are slack remove the 5 foot 1 52m pendant pair and rehook the main pendants to the headshaft link This reduces overall travel height Note The 5 foot 1 52m basic pendant pair must be installed in the pendant system before making any lifts e Boom up until boom is horizontal f
171. cant Film thickness and its ability to prevent metal to metal contact of moving parts is related to oil viscosity The optimums for Detroit Diesel engines are 15W 40 or SAE 40 or 30 weight High Heat Resistance Temperature is the most important factor in determining the rate at which deterioration or oxidation of the lubricating oil will occur The oil should have adequate thermal stability at elevated temperatures thereby precluding formation of harmful carbonaceous and or ash deposits Control Of Contaminants The piston and compression rings must ride on a film of oil to minimize wear and prevent cylinder seizure At normal rates of consumption oil reaches a temperature zone at the upper part of the piston where rapid oxidation and carbonization can occur In addition as oil circulates through the engine it is continuously contaminated by soot acids and water originating from combustion Until they are exhausted detergent and dispersant additives aid in keeping sludge and varnish from depositing on engine parts But such additives in excessive quantities can result in detrimental ash deposits If abnormal amounts of insoluble deposits form Winter No 2 D 675 F 0 50 Summer No 2 D 675 F 40 0 50 357 C 2 101 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication particularly on the piston in the compression ring area early engine failure may result Oil that is carried up the
172. ce Switches Fuses Inspect Replace Junction Boxes Replace Headlights Inspect Test Replace Taillights Inspect Test Replace Clearance Lights Inspect Test Replace Rotary Light Inspect Test Replace Floodlights Inspect Test Replace Sending Unit and Warning Switches Inspect Test Replace TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT Replace Horn Switch Test Replace Batteries Inspect Service Test Replace Battery Box Replace Repair Battery Cables Inspect Replace Repair Wiring Harness Test Replace Repair TRANSMISSION Transmission Assembly Main Inspect 2 5 Service 2 5 Replace 1 7 9 Repair 1 7 9 12 Overhaul 1 7 9 12 Transmission Assembly Creeper Inspect Service Replace Repair Overhaul 1 7 9 12 Transmission Shafts Replace 1 7 9 Bearings Gears Seals Gaskets Replace Transmission Top Cover Assembly Replace Repair TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS 1 ucl E COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER
173. clean and leak free that filler caps and pressure relief mechanisms be correctly installed at all times and that coolant levels be properly maintained WARNING Use Extreme Care When Removing A Radiator Pressure Control Cap From An Engine The Sudden Release Of Pressure From A Heated Cooling System Can Result In A Loss Of Coolant And Possible Personal Injury Scalding From The Hot Liquid 1 Aways use a properly inhibited coolant 2 Do not use soluble oil 3 Maintain the prescribed inhibitor strength 4 Always follow the manufacturer s recommendations on inhibitor usage and handling Operator s Manual M m C a xnmo m 6 m C gt x m m RECOMMENDED CONCENTRATION IF RANGE 30 67 RE IS REES EISE E LIL LIN I I LL N RA WISS AEN I v eee quse 73 10 20 30 40 50 60 70 80 90 100 ANTIFREEZE CONCENTRATION BY VOLUME Fig 2 37 Coolant Freezing And Boiling Temperatures vs Antifreeze Concentration Sea Level 5 If freeze protection is required always use a permanent antifreeze 6 Re inhibit antifreeze with a recommended non chromate inhibitor system 7 Do not use a chromate inhibitor with permanent antifreeze 8 Do not use methoxy propanol base antifreeze in Detroit Diesel engines 9 Do not mix ethylene glycol base antifreeze with methoxy propanol base antifreeze in the cooling system 10 Do not use an antifreeze containing sealer ad
174. ct ropes at these points h TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment Rope stretch is generally greatest during initial stages of operation when the strands are becoming adjusted and seated This is accompanied by some reduction in rope diameter but not the extent that the condition of the rope can be judged on this basis Time for rope replacement is indicated by the extent of abrasion scrubbing and peening on the outside wires broken wires evidence of pitting or severe corrosion kink damage or other mechanical abuse resulting in distortion of the rope structure Sheaves guards guides drums flanges and other surfaces contacted by wire rope during operation should be examined at the time of inspections Any condition harmful to the rope in use at the time should be corrected The same equipment and particularly sheave and drum grooves should be inspected and placed in proper condition before a new rope is installed Any of the following listed conditions should be cause for rope replacement a In running ropes six randomly distributed broken wire in one rope lay or three broken wires in one strand in one rope lay b In pendants or standing ropes evidence d more than one broken wire in one rope lay c Abrasion scrubbing or peening causing loss of more than 1 3 the original diameter of the outside wires d Evidence of rope deterioration from corrosion e Severe kinking seve
175. cylinder liner wall is normally consumed during engine operation The oil and additives leave carbonaceous and or ash deposits when subjected to the elevated temperatures of the combustion chamber The amount of deposits is influenced by the oil composition additive content engine temperature and oil consumption rate Detroit Diesel Lubricating Oil Specifications Oil Quality is the responsibility of the oil supplier The term oil supplier is applicable to refiners blenders and rebranders of petroleum products and does not include distributors of such products There are hundreds of commercial crankcase oils marketed today Obviously engine manufacturers or users cannot completely evaluate the numberous commercial oils The selection of a suitable lubricant in consultation with a reliable oil supplier observance of his oil drain recommendations based on used oil sample analysis and experience and proper filter maintenance will provide the best assurance of satisfactory oil performance Detroit Diesel Allison lubricant recommendations are based on general experience with current lubricants of various types and give consideration to the commercial lubricants presently available Recommendation Detroit Diesel engines have given optimum performance and experienced the longest service life with the following oil performance levels having the ash limits and zinc requirements shown 15W 40 Multigrade Lube Oil Detroit Diesel A
176. d as shown in Fig 5 35 and may deform or break the rope Either install the clip on the dead end of the rope or loop the dead end over and install a clip The loop thus formed must not be allowed to enter the wedge or the connection will be weakened Clip Min No Amount Of Torque Size Of Clips Rope Turnback In Ft Lbs 7 8 22 2mm 19 48cm 225 300Nem 1 25 4mm 26 66cm 225 300Nem Note If a greater number of clips are used than shown in the table above increase the turnback of rope a eS VAR 2 CAUTION Apply The Initial Load And Retighten Nut To Fig 5 36 Boom Angle Indicator The Recommended Torque Rope Will 1 Upper Section 4 Indicator Stretch And Shrink In Diameter When Loads 2 Extension 5 Boom Lower Section Are Applied Inspect Periodically And 3 Level Retighten 5 45 Boom Angle Indicator 5 44 Use Of Wire Rope Clips With Sockets The boom angle indicator when properly installed and Some codes require the use of a wire rope clip in conjunction adjusted reflects the approximate working with a wedge socket In some cases particularly in wrecking ball work there is a chance that the wedge can loosen releasing the socket from the rope This could be caused by the banging action and alternate loading and unloading of the rope that occurs during this type work HC238A 5 25 Operator s Manual TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment
177. d paint rust or gaps where parts are welded together If you find a bad weld report it to direct support d Electric wires and connectors Look for cracked or broken insulation bare wires and loose or broken connectors Tighten loose connectors and make sure the wires are in good condition e Hoses and fluid lines Look for wear damage and leaks Make sure clamps and fittings are tight Wet spots show leaks of course but a stain around a fitting or connector can mean a leak If a leak comes from a loose fitting or connector tighten it If something is broken or worn out either correct it or report it to direct support refer to MAC Chart 6 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 Leakage Definitions For Crew Operator PMCS Class Seepage of fluid as indicated by wetness or discoloration not great enough to form drops Class 11 Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked inspected Class III Leakage of fluid great enough to form drops that fall from the item being checked inspected A 55 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Carrier M Monthly S Semiannuall
178. d type of wire rope used e On or off outriggers f Over the side or rear of the carrier Sed Fig 5 2 g Machine weight and stability h Some lifts on strength of material i When lifting on tires tires must be inflated to pressure on tire charts on carrier UI Amount of counterweight on machine Maximum rated capacity is based upon a Basic boom 50 feet 15 24m b Minimum radius c On outriggers tires clear of ground d Twelve parts of specified size and type of rope on front or rear drum See parts book for wire rope size e Picking over the side or rear Sed Fig 5 2 f Machine on firm level supporting surface g Machine unaltered in first class working condition and HC238A Req d A11 Booms 6 Boom Backstops Req d 11 7 Pin Connections equipped as when originally shipped from factory h Correct counterweight installed Before making any lifts consult the capacity chart located in the upper cab Make sure the load being lifted is within the rated capacity of the machine under the existing conditions Boom length load radius etc Inspect the boom periodically to make sure it has not been damaged f a boom or jib section is damaged it must be repaired or replaced before the boom is used Damaged lattice may be replaced If a main chord is bent or damaged the boom section Must Be replaced before making any lifts See shop manual 9 1 2 0
179. des Under 40 ppm Chlorides Over 40 ppm And Or Sulfates Under 100 ppm And Sulfates Over 100 ppm 0 r Total Dissolved Solids Over 340 ppm Determine Total Distill De Mineralize Hardness Of The Mater Or De ionize The Water Total Hardness Total Hardness Water Suitable For Under 170 ppm Over 170 ppm Use In Coolant Soften Plus Inhibitors The Water Water Suitable For Use In Coolant Plus Inhibitors n Total Dissolved Solids Under 340 ppm t 4 1 4 CAST CAST JRON IRON A 1 16 MINERAL DEPOSIT 1 CAST IRON PLUS 1 16 MINERAL DEPOSIT 4 1 4 CAST IRON IN HEAR TRANSFERABILITY B Fig 2 35 Heat Transfer Operator s Manual 2 109 2 110 2 111 2 112 Soluble Oil Soluble oil has been used as a corrosion inhibitor for many years It has however required very close attention relative to the concentration level due to adverse effects on heat transfer if the concentration exceeds 1 by volume For example 1 1 4 of soluble oil in the cooling system increases fire deck temperature 6 and a 2 1 2 concentration raises fire deck temperature up to 15 Soluble oil is not recommended as a corrosion inhibitor Non Chromates Non chromate inhibitors borates nitrates nitrites etc provide corrosion protection in the cooling system with the basic advantage that they can be used with either water or a water and permanent antifreeze solution Inhibitor Systems An inhibitor system Fig 2 36 is a combin
180. distortion of the engine castings c Start the engine and operate it for 15 minutes to thoroughly circulate the water d Drain the cooling system completely e Refill the system with the solution required for the coming season Cooling System Cleaners If the engine overheats and the water level and fan belt tension are satisfactory it will be necessary to clean and 2 93 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication flush the entire cooling system Scale formation should be removed by using a quality de scaling solvent Immediately after using the solvent neutralize the system with a neutralizer It is important that the directions printed on the container of the descaling solvent be thoroughly read and followed After the solvent and neutralizer have been used drain the engine and radiator and flush it with clean water Then fill the system with the proper cooling solution Note Whenever water is added to a hot engine it must be done slowly to avoid rapid cooling which may cause distortion and possible cracking of engine castings Reverse Flushing After the engine and radiator have been thoroughly cleaned they should be reverse flushed The water pump should be removed and the radiator and engine reverse flushed separately to prevent dirt and scale deposits clogging the radiator tubes or being forced through the pump Reverse flushing is accomplished by hot water und
181. ditives 11 Do not use methyl alcohol base antifreeze 12 Use extreme care when removing the radiator pressure control cap HC238A 2 117 2 118 2 119 2 120 2 121 2 122 2 123 2 124 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Torque Converter Oil Level Checks General The correct amount of oil in the reservoir or transmission sump is important to converter operation Poor or erratic performance overheating and possible damage can occur when the oil level is not within the specific limits To ensure that the oil level is properly maintained two check procedures are recommended the cold check and hot check Although different means of checking dipstick level plugs or petcocks the procedures remain the same Cold Check Before starting the engine check the oil level in the reservoir If the level is at the Add line the engine can be started safely If it is necessary to add oil DO NOT fill above the Add line Hot Check After the oil reaches operating temperature 180 200 F 82 to 93 C idle the engine and check the oil level Add or drain oil as necessary to bring the oil level to the Full line If the converter is equipped with an input disconnect clutch engage the clutch before making the hot check Oil Specifications Only Type C 2 hydraulic transmission fluid is recommended for use in these converters When the ambient tempera
182. dn t raise b Rotate the valve to its original position and try the control again The boom should raise this time c Boom up VERY CAUTIOUSLY to see what position the limiter functions at The limiter should function when the boom backstop bumpers just contact the targets on the boom lower section If not boom down to a position which allows room to adjust the limiter Loosen capscrews 2 and move striker m 3 in or out to adjust boom angle Move out away from boom to increase boom angle Move in toward boom to decrease boom angle Tighten capscrews d Boom up VERY CAUTIOUSLY to see what position the limiter functions If necessary repeat step c until proper adjustment is reached HC238A TM 10 3950 263 14 amp P 1 5 27 5 28 blank TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Auxiliary Generator Assembl Index Section 6 Subject Page Subject Page General 6 35 Decompression Release 6 6 Engine General Maintenance 6 3 Generator 6 1 6 37 General 6 7 6 4 Controls 6 1 6 38 AC Generator 6 7 6 5 Start Stop Switch 6 1 6 39 Batteries 6 7 6 6 Battery Charge Rate DC Ammeter Le 6 40 Maintenance Schedule Pre Heat Switch 6 41 Oil Filter Change 6 7 6 8 Oil Pressure Gauge L 6 1 6 42 Onan Diesel Starting Guide 6 10 6 9 Fuse Pre Starting 6 11 Operation 6 2 16 12
183. drum shaft opposite the hoisting clutch The power shaft in the hoisting clutch connects the load and drum carrying the load to gear train The descent of the load is controlled by the speed of machinery which is controlled by engine speed A sprag in the torque converter prevents the machinery from turning faster than the engine Lowering heavy loads may cause the engine to turn faster as the load is now trying to drive the engine The speed of descent can be controlled by the drum brake To stop load brake must be applied and clutch disengaged b By gravity which is controlling the speed of descent with the brake This method is allowable for light loads high cycle or any occasional work c Lowering a load through the torque converter will work on heavy loads high line pulls only This is accomplished by leaving the hoist clutch engaged and regulating the engine Speed to either hold the load suspended or by reducing the speed and allow the load to creep down When this method is being used the engine is turning normally and the machinery is turning backward 1 29 Operator s Manual The load can be stopped by either increasing the engine speed or applying the brake To hold load suspended other than momentarily the hoist brake should be applied and the hoist clutch disengaged This method is recommended only for precise spotting of heavy loads d By gravity but connecting the side housing gears to the drum This is done by
184. e alc Subject Reeving B H Reeving Main Hoist Shutdown Emergency Engine Carrier Socket amp Wedge Connections S o M Filter Change S o M Relief Valve Adjust S o M System General S o M System Oil Change S o M System Oil Check S o M Troubleshooting Specifications Starter Button Upper Storage Suggestions Machine System Low Pressure Warning Carrier Swing Lock Adjustment Switch Blower Upper Switch Dimmer Carrier Switch Dome Light Switch Drum Rotation Indicators Switch Heater amp Defroster Control Switch Headlight Carrier Switch Ignition Upper Switch Windshield Wiper Carrier Switch Windshield Wiper Upper Theory Upper Operation Throttle Carrier Tie Down Carrier Tires And Tire Inflation Torque Convertor And Engine Maintenance Chart Transmission Alternative Shift Procedure Transmission Down Shifting Transmission Important Procedures Transmission Skip Shifting Transmission Speed Progression Transmission Upshifting Troubleshooting Brakes Troubleshooting Clutch Carrier Troubleshooting Engines Troubleshooting Gear Train Troubleshooting Load Hoist System Troubleshooting Overload Warning System Troubleshooting Outriggers Troubleshooting S o M Troubleshooting Steering Driveline Troubleshooting Swing System Troubleshooting Torque Convertor Master Clutch Troubleshooting Transmission Weights Wheels Torque Procedure Wire Rope See Cab
185. e 3 Select 4 parts of line on the main electronics assembly Reeve Select switch regardless of the hook block reeving 4 Push the Test button on the display and hold it Record the meter readings and note if the warning lights glow and the horn sounds Compare the meter readings to those in Table 10 1 Record the crane s capacity for 100 ft 30 4m of boom using AB upper and A bumper counterweight lifting on outriggers only and over the rear at a radius of 40 ft 12 1m off the metal capacity plate METER READING Load 194 206 Alert 166 182 Reach 39 41 Table 10 1 Self Test Reading If the meter readings and the Table 10 1 do not agree use the information in step 4 to help trouble shoot the system CAUTION Always Turn The Power Switch On The Display Assembly OFF Before Connecting Or Disconnecting A Cable Assembly Or Component Otherwise A Power Surge Or b Damage To The System Can Occur If problems with the overload warning system are encountered perform the self test procedure Record the results of the test procedure and use this information to trouble shoot the system Refer to trouble shooting chart sed Table 10 2 10 5 Operator s Manual TM 10 3950 263 14 amp P 1 Section 10 Overload Warning System Two Blocks PROBLEM REMEDY Load meter Alert meter and Reach meter do not exactly repeat their values when PWR Switch is flicked ON and OFF Load meter and Alert meter
186. e As the boom nears minimum radius a striker 3 on the boom lower section contacts a bell crank 5 on rotary valve 4 As the boom raises further the rotary valve 4 actuates directing oil from the B H clutch and brake back to the sumo tank This allows the clutch to disengage and the spring applied brake to engage stopping upward travel of the boom When the boom is lowered the striker pulls on the bell crank shifting the rotary valve back to its original position allowing the boom hoist system to function normally again 5 48 Override Control In some cases it is necessary to boom up slightly to release the B H ratchet pawl after the boom hoist limiter has functioned Pulling upon the override control on the cab floor will direct oil under pressure around the rotary valve so the boom hoist system will function CAUTION Boom Up With Extreme Caution When Overriding The B H Limiter The Bell Crank Striker Boom Lower Section Or Boom Backstops May Be Damaged By Booming Up Past Minimum Radius Operator s Manual Section 5 Continued Crane Attachment 5 49 Boom Hoist Limiter Adjustment The limiter should be adjusted upon delivery of a new machine any time the boom is removed from or replaced on the machine or any time the machine is to be used after sitting idle 50 hours or more Adjust as follows a Check limiter operation Trip the rotary valve by hand then actuate the boom hoist lever The boom shoul
187. e The swing brake is operated as follows a To release the swing brake push on the handle Fig 1 21 Swing Lock Control b To apply the swing brake pull on the control handle c The control may be left partially applied to allow some drag when working in tight quarters or when spotting loads where free swing is not desirable HC238A 4 94 TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions CAUTION Never Use The Swing Brake As A Swing Lock When Traveling Transporting Or Leaving The Machine For Any Reason It Is Designed As A Drag Brake Not As A Lock The Swing Lock Is Provided For Locking Use Avoid Using The Swing Brake For Making Sudden Swing Stops As Damage To The Upper Machinery May Result Or Load May Get Out Of Control 1 73 Swing Clutch Control To swing the upper disengage the swing lock see pagel 1 21 Push the control lever forward to swing right and pull the control lever to the rear to swing left Stop the swing by easing the lever in the opposite direction to that which started the swing CAUTION Attempting To Swing With The Swing Lock Engaged Can Result In Structural Damage To The Machine 1 74 Front And Rear Drum Control Lever And Brake The front and rear drum control levers actuate a variable pressure control valve which engages the front or rear drum raising or lowering clutch The front drum unit is operated as follows a Pull the le
188. e chain with a stick or bar to make sure the bottom span of the chain is tight when measuring the sag Tighten jam nut on adjusting screw Replace plug 1 Air Box Drains GMC Engines 1 Air Box Drain 2 Sediment Tank 3 Drain Cock 4 Drain Hose Ic HC238A 4 7 TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Continued Upper Adjustments Left Hand Control Stand Right Hand Control Stand Fig 4 11 Control Lever Adjustment 1 Rollpin 4 Adjusting Nut 6 Rollpin 2 Toggle Link 5 Toggle Link 7 Toggle Lever 3 Jam Nut Chain Case With Adjuster 1 Fill Plug 3 Adjusting Screw 5 Adjusting Arm amp Pinion 2 Cover 4 Jam Nut Lockwasher 6 Check Elbow And Plug A Measure Here 7 Drain Plug Operator s Manual Index Section 5 Subject Page 5 1 Tubular Boom 5 1 5 2 Lifting 5 1 Boom Live Mast Using Live Mast As A Short Boom 5 2 5 5 Boom And Mast Foot Assembly 5 2 Boom Backetops rrene 5 2 Boom Backstop Adjustment 5 3 5 8 Main Pendants And Links 5 4 Deflector Rollers 5 4 Assembly Of Crane Booms 50 to 110 Feet 15 24 33 5m in length 5 6 Boom Assembly Step 1 5 6 Boom Assembly Step 2 5 6 Boom
189. e disassembled and closely inspected to find the source Metal contamination will require complete disassembly of the converter and cleaning oil out of all internal and external circuits cooler filter and all other areas where the particles could lodge Ethylene Glycol If engine coolant containing ethylene glycol leaks into the converter oil system immediate action must be taken to prevent malfunction and possible serious damage The converter must be completely disassembled inspected and cleaned All traces of the coolant and varnish deposits resulting from coolant contamination must be removed Draining Converter General The equipment should be at operating temperature when the oil is drained While the oil is draining check for evidence of contamination Torque Converter Oil Change Remove the reservoir sump drain plug from the reservoir To remove the remaining 3 to 4 gallons 11 to 15 liters from within the converter remove the converter in line and start the engine Run the engine 20 to 30 seconds at 1000 rpm Remove strainers and filters if used CAUTION Due To Lack Of Lubrication Do Not Run The Converter More Than 30 Seconds Clean oil strainers and screens by agitating them in mineral Spirits or solvents Flush all residue and particles from the Screen mesh Dry the strainer or screen with compressed air do not use linty shop towels Should it become necessary to use a different transmission fluid
190. e electrolyte in each cell of the battery every 100 hours or 3 000 miles In warm weather however it should be checked more frequently due to a more rapid loss of water from the electrolyte The electrolyte level should be maintained in accordance with the battery manufacturer s recommendations 2 54 Item 7 Tachometer Drive Lubricate the tachometer drive every 100 hours or 3 000 miles with an all purpose grease at the grease fitting At temperatures above 30 F 1 C use a No 2 grade grease Use a No 1 grade grease below this temperature HOSES RADIATOR PUMP Cooling System ltem 4 2 51 2 55 Item 8 Air Cleaners Dry Type Clean or replace the element in the dry type Donaldson Cyclopac air cleaner when the restriction indicator instrument indicates high restriction or when a water manometer reading at the air inlet housing indicates the maximum allowable air inlet restriction Refer to the instructions in the Air System section for the servicing of the dry type air cleaner 2 22 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Dr d TURBOCHARGER 2 Fig 2 16 Turbocharger Item 5 2 52 2 56 Item 9 Drive Belts New standard V belts will stretch after the first few hours of operation Run the engine for 15 seconds to seat the belts then readjust the tension Check the belts and tighten the fan drive pump drive battery charging alternator and other
191. e front can cause accidents crane either on tires or on outriggers unless the machine being used is rated over the front Lifting loads over the front can cause damage to the carrier Also the operator s vision may be obscured by the front of the carrier If it is absolutely necessary to work over the front consult the factory for special instructions and load ratings 19 20 21 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T Don t exceed the rated capacities of the machine under any circumstances While a crane has more stability when lifting over a corner as compared to straight over the side the machine capacity is not increased Any time you exceed the rated capacities listed on the capacity chart in the operators cab you are overloading the machine Overloads can damage the machine and such damage may cause failure and accidents Don t pick loads on main hoist and jib at the same time even if total load weight is within machine capacity Loads on the jib stress the boom and drastically reduce its ability to handle loads Fig 26 ick loads on main hoist and jib at the same time Don t Don t work with jib angles greater than 30 degrees with respect to the boom The greater the angle the less capacity the jib has Working with jib angles over 22 23 30 degrees with respect to the boom may cause jib or suspension failure and may cause dangerous twisting force
192. e in the container g Replace the cap on the container Make sure the piercing shaft is all the way down 1 53 During Operation the operator should remain alert to possible malfunctioning of the machine while operating lf the machine does malfunction shut it down until the problem is found and corrected During operation the operator should a Remain alert to any unusual noises loss of power or bad response to control of the engine Consult the engine manufacturer or his nearest dealer for engine repair work b Watch the gauges Make sure they show the correct readings If any of the gauges show incorrect readings shut the machine down and determine the cause c Check the master clutch for slipping or jumping out of engagement Adjust if necessary d Make sure all controls work freely and easily with no sticking or binding Lubricate or adjust as necessary e Listen for any unusual noises from the hydraulic system or the gear train If any shut the machine down until the problem is found and corrected f Watch for oil leaks If any develop correct them before continued operation Inspect the wire rope pendants and any other riggin e as Dee nections Replace if inspection shows that it is necessary CAUTION Operation With A Machine Not In First Class Working Order In Any Respect May Be Hazardous And Can Result In Unnecessary Wear Or Breakage Or May Result In Immediate Or Eventual Accide
193. e is ready for operation at all times inspect it systematically so you can discover any defects and have them corrected before they result in serious damage or failure The charts on the next few pages contain your organizational PMCS This PMCS is divided into a Carrier PMCS and an Upper PMCS The item numbers indicate the sequence of minimum inspection requirements If you re operating the vehicle and notice something wrong which could damage the equipment if you continue operation stop operation immediately Record all deficiencies and shortcomings along with the corrective action taken on DA Form 2404 The Item Number column is the source for the numbers used on the TM Item Number column on DA Form 2404 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES 1 The item numbers of the table indicate the sequence of the PMCS Perform at the intervals shown below a Do your M PREVENTIVE MAINTENANCE once every month b Do your 5 PREVENTIVE MAINTENANCE semiannually every six months Do your PREVENTIVE MAINTENANCE at the hour interval listed 2 If something doesn t work troubleshoot it with the instructions in the Commercial Technical Manuals or notify your supervisor 3 Always do your preventive maintenance in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry 4 If anything looks wrong and you can t fix it write it down on your DA Form 2404 If you find somethi
194. e machine as explained on pages 5 6 through in this manual d Position the machine so a minimum swing is necessary and load radius is within capacity limits as shown on capacity chart Apply park brake e Ifthe lift will be made on tires they must be inflated to pressures shown on tire inflation chart in carrier cab and section 3lof this manual f If outriggers are used refer to for operation g Remember all ratings on the capacity plate are based on the machine being level A level is mounted at each corner of the carrier to assist in leveling the machine h Raise the boom and swing over the load i Drop the hook block down and fasten onto the load The following points must be noted when picking the load 1 The boom peak must be directly above the load and at the proper radius Booms are made to lift and should never be used to drag a load sideways inward or outward 2 Always use chains wire rope or slings of ample size and make periodic checks of their condition 3 Always use sufficient parts of line Consult the wire rope specifications in the parts book for proper size and type of wire rope to use Consult wire rope capacity chart on for number of parts of line needed for a given lift 4 When lifting heavy loads care should be taken to prevent sudden loading and unloading of the hoist line Ease into the load j Lift the load to the desired height Boom to the desired angle Be careful when
195. e of the point where the rope is to be cut to keep the strands in place On preformed rope one seizing on each side of the cut is enough On non preformed rope less than 7 8 22 2mm diameter two seizing are recommended On non preformed ropes over 7 8 22 2mm diameter three Fig 5 33 Wedge Type Connections are recommended A Correct Installation Three basic methods of cutting wire rope are recommended a Abrasive cutting tools b Shearing tools Wire cutters on small rope a wire rope cutter and hammer for larger ropes c Acetylene cutting torch B Incorrect Installation 5 42 Socket and Wedge Connections The correct and incorrect methods of attaching a wedge and Gr SSR SU S socket to wire rope are shown in Fig 5 33 The dead end of the wire rope must always be on the sloped portion of the socket The load line must be in a straight line pull with the eye of the socket If the rope is installed backward as shown at B in Fig 5 33 kink will develop at the point where the rope enters the socket Fig 5 34 Wire Rope Clip Installation 5 24 Operator s Manual Note The use of wire rope clips with socket and wedge connections is not recommended Addition of wire rope clips will actually weaken the connection CAUTION Use The Proper Size Wedge With A Wire Rope Socket Or Lagging The Use Of An Off Size Wedge In A Socket Or Lagging Is Dangerous As It May Not Hold Wedges
196. ear on the credit memo 15 Section 6 and 8 are reserved for factory use only Do not enter any information in these areas 16 Section 7 under labor type hours only Returning Defective Or Failed Parts To The Manufacturing Division Do not send defective parts to the factory Hold all defective parts until information is received as to their disposition If and when the parts are needed by the manufacturing division the manufacturing division will forward instructions wither verbally or in writing and or both In all cases an A T R number Authorization to Return and Authorization to Receive will be assigned with shipping instructions A T R 87 is used by the Bowling Green plant FMC Corporation Crane amp Excavator Division U S 31 W South Bowling Green Kentucky 42101 The Receiving Departments have orders not to accept any shipment of warranty parts without an A T R number clearly displayed on all parts shipping cartons tags bills of lading and other papers required by transportation companies If the part to be returned is a large item that cannot be crated Example boom sections large hydraulic cylinders frames counterweights etc it will be necessary to have the A T R number legibly marked or painted with some waterproof marking device If it is a part that is apt to be rolled over it is required that the number be marked on two or more sides of the component Parts must be returned in clean c
197. ears Mechanical brakes are used on the load shafts external band brake operates on a drum mounted on the shaft The brakes are applied and released by pedals in the operators cab through linkage Operator s Manual Section 1 Continued Operatin 1 4 TM 10 3950 263 14 amp P 1 Instructions Lowering Planetary Chain Wheel Reduction Shatt short Reverse Swing Shaft Front Drum Shaft A spring applied hydraulically released brake is used on the boom hoist shaft and on the reverse shaft for a swing brake A mechanical swing lock is used to lock the upper to the turntable bearing to prevent swinging A pawl mounted on the upper engages the teeth on the bearing It is engaged and disengaged through linkage and a control lever from the operators cab An S o M Speed o Matic hydraulic control system is used on the upper A pump belt driven by the engine provides hydraulic pressure for the system It circulates oil from a sump tank to the hydraulic power supply Oil is stored in an accumulator in the hydraulic power supply under pressure This pressurized oil is directed to control valves in the operator s cab The control valves meter oil under pressure to clutches on the horizontal shafts to engage them to lift a load Upper Operating Theory Refer to Fig 1 4 Each of the three main shafts operate in the same manner The shaft is mounted on bearings in the upper frame cable drum lagging and brake
198. ece of equipment but as with many commonly used things such as a lawn mower a motor boat or even a kitchen knife if not used properly it can be dangerous Think safety You the operator are in charge of an important piece of equipment lt is very important that you know what it can do It is also important that you know what it should not do No set of instructions can anticipate all of the situations you will run into The rules given here cover general usage and some of the more specific cases If conditions arise not covered by these rules consult the manufacturer A phone call may save someone s life Index Subject General Reference Material General Safety Rules Working Near Power Lines Crane Boom Safety Demolition Work Excavator Safety Carrier Operation Crawler Operation Hydraulic Machine Operation Wire Rope Strength Chart Hand Signal Chart This section is intended to cover operating practices on both hydraulic and non hydraulic machines Correct operating practices for both types are similar but different problems will arise on each type of machine For this reason there is a paragraph in this section on hydraulic machine safety The other sections for the most part apply to both types of machines Reference Material Additional material on safe operation is available from several sources strongly recommends that crane excavator users obtain this information SAE Society of Automotive Engineer
199. ecessary 2 Check for external leaks Repair them before operation Lubrication 1 Lubricate the machine as specified ir section 2 of this manual TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions Outriqger Power Takeoff Contro Steering Hi Lo Range Control Transmission Shifter Turn Signal Control nee erator Peda Dimmer Switch Creeper Transmission Control o O OIL PRESSURE TEMP FU TACHOMETER HIGH BEAM SPEEDOMETER SUPPLY SERVICE 1 EMERGENCY Goes EL RESERVE AIR VOLTMETER E GC N Park Emer CX Brake mmm Control O STARTER ENGINE STOP IGNITION THROTTLE LIGHTER SERIAL NUMBER LIGHTS EE DEFROST HEATER WASHER WIPER OOOD O A O O O Figure 1 6 NA213 B NA230 D Carrier Controls HC238A 047 TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions Note Even though the operator may have nothing to do with lubrication or maintenance of the machine it would be advantageous for him to read the maintenance sections of this manual Knowledge of protective maintenance may allow the operator to spot a malfunction in the machine so repairs may be made with a minimum of downtime 1 8 Carrier Operation The following series of paragraphs explain the operation of the various controls on the carrier Read the information before operating the ca
200. ection 5 Continued Crane Attachment 5 27 Reeving Fig 5 23 16 Part Boom Hoist Reeving 1 Bridle Sheaves 4 Vertical Bail Sheave 2 Dead End Anchor 5 Boom Hoist Drum 3 Horizontal Bail Sheave 6 Deflector Sheave 5 28 Boom Hoist Reeving B H bail 16 Pull the rest of the rope off of the reel Fun it The boom hoist reeving consists of 16 parts of wire rope under deflector sheave 16 Connect to the reeved between sheaves on the boom hoist bail and the socket in the drum bridle on top of the live mast To install the boom hoist rope proceed as follows Refer td Fig 5 23 a Push a pipe through the holes in the wire rope spool Set the spool on block or horses so it can rotate The rope must spool off over the top of the reel Position the reel in front of the machine b Refer to the numbers on the sheaves in Fig 5 23 Take the free end of the rope and reeve as follows 1 2 3 HC238A Over sheave 4 over the top and around sheave 13 Under the bottom and around sheave 3 Over the top and around sheave 14 Under the bottom and around sheave 2 Over the top and around sheave 15 Under the bottom and around sheave 1 Around horizontal bail sheave 9 Under the bottom and around sheave 8 Over the top and around sheave 10 Under the bottom and around sheave 7 Over the top and around sheave 11 Under the bottom and around sheave 6 Over the top and around sheave 12 Under the bottom and around
201. ed WARNING Incorrect Disassembly Of A Pin Connected Boom May Result In Machine Damage Personal Injury Or Even Death Before Disassembling Boom Read And Be Sure You 5 19 And The The Following Pages As An Alternate Disassembly Procedure Block Tightly Under The Pin Connection Before Removing Pins Never Stand Under A Boom When Removing Pins Understand Fig Disassembly Procedure On Warnings P 5 18 P 5 23 TM 10 3950 263 14 amp P 1 WARNING The Hammer And Block Method Requires Being Near Moving Machinery Perform This Operation Slowly And Cautiously The Operator And Workers Must Be Fully Informed Of The Procedures To Avoid Pinching Tools Or Body Parts In The Machine Do Not Use Your Hands To Guide The Wire Rope At The Drum Or Sheaves Or Entanglement May Result WARNING Warn Personnel In The Immediate Area Before Using Compressed Air For Cleaning Wear Safety Glasses Compressed Air Coming Into Contact With The Human Skin Or Causing Flying Metal Chips Can Cause Injury WARNING Engine Exhaust Gas Carbon Monoxide Is Deadly Carbon Monoxide Is An Odorless Colorless Gas Formed By Incomplete Combustion Of Hydrocarbon Fuels Carbon Monoxide Is A Dangerous Gas That Can Cause Unconsciousness And Is Potentially Lethal Some Of The Symptoms Or Signs Of Carbon Monoxide Inhalation Are Dizziness Intense Headache Vomiting The Best Protection Against Carbon Monoxide Inhalation Is A Regular In
202. ed for temperatures of 32 F and below but they are not recommended for temperatures above 32 F When adding oil between oil changes use the same brand and grade as various brands of oil may not be compatible when mixed together 6 13 Recommended Fuel Using ASTM 2 D or 1 D fuel with a minimum Cetane number 45 Number 2 diesel fuel gives the best economy for most operating conditions however use ASTM 1 D fuel during the following conditions a When ambient temperatures are below 32 F 0 C b During long periods of light engine load or no load Note Fuels with Cetane numbers higher than 45 may be needed in higher altitudes or when extremely low ambient temperatures are encountered to prevent misfires Use low sulfur content fuel having a pour point ability to filter of at least 10 F 6 below the lowest expected temperature Keep the fuel clean and protected from adverse weather TM 10 3950 263 14 amp P 1 Section 6 Continued Auxiliary Generator Assembly LOWER FUEL LINE NUT DELIVERY VALVE HOLDER INJECTION PUMP TRANSFER PUMP X PRIMING LEVER ALWAYS RETURN TO LOWEST POSITION Fig 6 2 Bleeding The Fuel System Leave some room for expansion when filling the fuel tank CAUTION Due To The Precise Tolerances Of Diesel Injection Systems It Is Extremely Important The Fuel Be Kept Clean Dirt In The System Can Cause Severe Damage To Both The Injector Pump And The Injection Nozzles
203. ed jd Section 1 Operating Instructions b Use 3 parts 7 8 22 2mm wire rope for a hoist line The rope may be on either the front or the rear drum c The live mast backstop bumper Must Be bolted in the horizontal position A In Fig 5 3 d The boom backstops Fig 5 4 amp 5 6 must be in their supports The anchor links 6 in must be connected between the backstop standoffs and the boom backstops e The mast used as a short boom Must Be operated between a Minimum Radius of 10 0 3 05m and a Maximum Radius of 27 0 8 2m A maximum of 60 000 pounds 27 216 kg may be lifted at a radius between 10 0 and 19 0 3 05m and 5 79m f Counterweight may be handled as follows 5 2 Change 1 TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment R1282 Fig 5 8 Boom Live Mast N45 0 A Position Of Live Mast Backstop Targets When Mast Is Used As A Short Boom 8 Position Of Live Mast Backstop Targets For Nor mal Crane Boom Cperation Main Pendant Spreader Bar Mid Point Sheave 4 Mast Tubes 5 Bridle 6 Mast Backstop Target 1 2 3 Carrier Live Mast Maximum Radius Counterweight Size On Tires 10 to 19 ft 30 000 Ibs 3 05 to 13603 kg 5 79n On Outriggers 10 to 19 ft 60 000 Ibs With All Tires 3 05 to 27716 kg Off The Ground 5 79m On Outriggers 19 to 27 ft With All Tires 5 79 to Off The Ground 8 2m 30 000 Ibs 13608 kg 5
204. el Alignment esse 3 6 Front Wheel Brake Adj 3 7 Wheel Torque Procedure Tires And Tire Inflation 3 9 Rear Wheel Brake Adjustment 3 10 Outrigger System Operation 3 11 Relief Valve Adjustment 3 5 3 12 Outrigger Throttle 3 7 3 13 Outrigger Throttle Control Adjustment HC238A TM 10 3950 263 14 amp P 1 Page TM 10 3950 263 14 amp P 1 Operator s Manual Section 3 Carrier Adjustment Operator s Manual 1 Rear Axles 2 Fuel Tank 3 Creeper Transmission 4 Outrigger Sump Tank 3 1 A GH ES ae LI Cl i LG ei d KH LA A e NAE IJ li M Ps CC b dk 7 HERE UC On LUZ Carrier Assembly 5 Main Transmission 6 Engine 7 Front Axles 8 Engine Air Cleaner Carrier General The 8 x 4 carrier is designed and manufactured by FMC Corporation Power from the engine is transferred through a clutch to the main transmission The main transmission provides 15 forward speeds and 3 in reverse Power from the main transmission is transferred to a creeper transmission near the center of the carrier The creeper transmission has two speeds direct drive and a lower Speed The creeper transmission is used in direct drive
205. elescope lengthen to allow the boom to be lowered to the ground after the backstop tubes contact the supports The live mast backstops are smaller tubes welded to the under side of the boom backstop tubes They also have a spring loaded bumper at one end These bumpers mate with a target bolted to the live mast See Fig 5 3 and are only used when using the live mast as a short boom Tie down links 5 in are used to attach the backstop tubes to the supports during transportation and when using the live mast as a short boom HC238A 2 Mast Extended 30 0 9 14m 3 Carrier On Outriggers 4 Target Horizontal 5 Boom Backstops In Rest 6 Link Connected 7 Hoist Bail 8 Boom Hoist Bridle 9 Backstop Standoffs NA251 B CAUTION Disconnect These Links When Main Boom Is On Machine If Boom Is Raised With Links Attached Boom Backstops Struts And Boom Lower Section Will Be Damaged 5 7 Boom Backstop Adjustment The main boom backstops may be adjusted to properly contact the targets on the boom lower section This adjustment is made by adding or subtracting spacers on the backstop struts 7 in Fig 5 6 The following spacers are available for this adjustment 1 18M951 Ls 1 2 Thick 12 7mm 2 18 952 3 4 Thick 19 05mm To install or remove spacers proceed as follows a Boom down until boom is on ground and pendants are slack b Unpin the inner strut
206. em Contains 7 sheaves mounted on anti friction bearings for 16 part boom hoist rope reeving Speed o Matic power hydraulics a variable pressure control system Variable pressure is transmitted through oil to all operating cylinders The System includes a pump to provide a constant flow of oil an accumulator to maintain operating pressure oil filter relief valve unloading valve and variable pressure operator controlled valves to regulate the pressure to each hydraulic cylinder Oil sump tank FMC 12 gal capacity with filter strainer assembly Counterweight 57 0003 A counterweight 27 000 held in place on two hydraulically controlled frustums frustum control valves located at rear of upper machinery cab B counterweight 30 0004 bolted in position on top of A counterweight for ease in mounting or dismounting Total counterweight power hydraulically raised from or lowered to carrier deck in Seconds Boom Tubular two section basic boom main chords alloy steel round tubular steel lattice fully copes Base section 25 long 60 wide by 54 deep with main chords 3 5 8 outside diameter Section equipped with basic pendants Boomfeet 2 3 4 wide on 60 centers Boomfoot pin removal Standard pins manually installed removed with threaded rod Optional double acting hydraulic 9 3 Operator s Manual cylinder mounted between boomfoot lugs for pin insta
207. embly of items removed in connection with repair or replacement of defective parts the Contractor will be reimbursed for labor at a rate to be negotiated between the Contracting Officer and the Contractor at the time of repairs J 7 3 3 Notification If the Government elects to have warranty repair or replacement performed by the contractor the Government shall deliver the parts or equipment to contractor s local facility or dealership for warranty corrective repair or replacement If the Government elects to effect warranty repairs or replacement itself the contractor shall be notified in writing of repairs required under the warranty within 30 days after discovery of the defect Within 10 days after receipt of such notices the contractor shall submit to the Contracting Officer a written recommendation as to the corrective action required to remedy the defect In any event the Contracting Officer may upon the expiration of the 10 day period set forth above proceed with correction or replacement as set forth in the paragraph Remedies above and the contractor shall notwithstanding any disagreement regarding the existence of a breach of warranty comply with the Contracting Officer directions related to such correction or replacement After the notice but not later than 30 days after receipt of the contractor s recommendation for corrective action The Contracting Officer will in writing notify the contractor of the parts used by the Government in
208. emover system is used to set the counterweight on the carrier deck or to lift it into place from the carrier deck It also holds the counterweight 11 After you set dimension A tighten the jam nuts 9 in place on the machine during operation 4 11 Final Adjustment Must be made with counterweight on machine Fig 4 5 4 9 Counterweight Remover Adjustment The counterweight a Raise the counterweight until the linkage is at top remover is adjusted as follows dead center position The three linkage pins are in line and the counterweight is in maximum up 4 10 Preliminary Adjustment Must be made with counterweight position Refer tol page 7 26 for operating off the machine instructions a Before placing the counterweight the b To level the counterweight when it is in the raised positioning blocks fully extend the hydraulic position correct any forward or backward tilt cylinders Refer to padg 126 Adjust the set move shims from one side of the bearing lock to screw 7 until the linkage toggles over center 1 4 the other Adjust each bearing block as 6 6mm This adjustment is very important necessary It may be necessary to readjust set Toggling over center provides a mechanical lock screws 7 after changing shims up which eliminates the requirement of hydraulic pressure to hold the counterweight in place All Note The counterweight must be lowered to down forces are transmitted into the linkage and the carrier dec
209. en starting up or down the slope Keep the upper facing downhill over the cab If necessary to face uphill keep the attachment close to the ground If the machine starts slipping sideways on a grade immediately turn the machine downgrade One workman on the job should be designa 0 27 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T ted a signal man and the operators should obey signals from him only signal to stop should be obeyed no matter who gives It See hand signal chart on rear cover of this booklet Hydraulic Machine Operation Hydraulic machines are easy to operate So easy in fact that almost anyone can do lt This very ease of operation leads to careless operation or operation by unqualified personnel Either of the above can result in an accident Fig 45 Be careful when working on hydraulic systems Never work on a hydraulic machine without doing the following a On cranes fully retract the boom Lower boom to the limit of the boom hoist cylinders or into cradle Lower the machine down off the outriggers b On excavators lower attachment until 0 28 bucket is on the ground c Disengage the master clutch Shut off the engine Work all control levers back and forth to relieve pressure and relax the attachment d If the above instructions cannot be followed block securely under the attachment so it cannot move e Hydraulic oil becomes hot d
210. ent 5 40 Unreeling Wire Rope When unreeling wire rope set the reel up horizontally so it can rotate as the rope is reeled off Reel the rope off slowly so the reel won t tend to throw the rope off Avoid reverse bends If installing rope over the top over winding drum of drum set the reel up so the rope is removed over the top of the reel When installing rope around the bottom of a drum under winding drum set the reel up so rope is removed under the bottom of the reel To obtain snug and uniform winding on the drum brake the reel with a large timber to provide back tension When uncoiling wire rope roll the coil along the ground and the rope will be as straight as it was before being coiled for shipment Don t uncoil rope where it may be run over by trucks or other equipment Note A new rope should be broken in by running it slowly through its working cycle for a short period under a light load Sheave Inspection Whenever wire rope is replaced the sheaves and grooves in drums should be checked for wear or damage and replaced if necessary Damaged worn or undersized sheaves will damage the rope On older equipment remember that new rope is always bigger in diameter than the worn rope it replaces The sheave grooves may be worn to the smaller diameter of the old rope LUT TTUOIQ TTTTT777 33 wu 5 4 nn Cutting Wire Rope When wire rope is to be cut seizings should be placed on each sid
211. ent maintenance categories appropriate work time figures will be shown for each category The number of manhours specified by the work time figure represents the average time required to restore an item assembly subassembly component module end item or System to a serviceable condition under typical field operating conditions This time includes preparation time troubleshooting time and quality assurance quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the Maintenance Allocation Chart The symbol designations for the various maintenance categories are as follows C Operator Crew O Organizational Maintenance F Direct Support Maintenance H General Support Maintenance D Depot Maintenance e Column 5 Tools and Equipment Column 5 specifies by code those common tool sets not individual tools and special tools test and support equipment required to perform the designated function f Column 6 Remarks Column 6 contains an alphabetic code which leads to the remark in Section IV Remarks which is pertinent to the item opposite the particular code A 6 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS GROUP COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE TOOL
212. er Counterweight W A or A Bumper Counterweight W 140 Ton Hook Block At Headshaft s Overall Travel Travel Length And Speed Boom Horizontal Boom Length Ft Height Boom Horiz 12 3 1 4 8 24 9m 40 MPH 74m 5 MPH 8 kph 12 8 1 2 91 8 27 9m 20 MPH iom 20 MPH en 70 13 0 101 8 30 9m 21 34m 3 90m 5 MPH 8 kph 13 2 3 4 111 8 34m 4 03m 5 e M 27 43m 4 08m 5 MPH S a 100 13 6 1 4 131 8 40m 30 48m 4 12m 5 MPH 8 koh 4 15m 5 MPH en 36 58m 417m 5 MPH U En 130 13 9 1 4 161 8 49 2m 39 62m 4 19m 5 MPH 8 kph Centerline Of Boom Horizontal 5 1 52m Pendant Pair Removed For Travel Only Must Be Installed For All Load Lifting Conditions Operator s Manual TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment CAUTION Travel With Horizontal Boom Can Create Traffic Hazards In Addition It May Be Necessary To Have An Operator In Crane Cab To Swing Upper And Boom For Proper Clearance When Traveling Local Codes And Regulations Should Be Checked To See If Such Operation Is Permissible Headshaft Link Pinned In 48 1 21m Position Live Mast Retracted 25 6 7 7m Position NA240 D Carrvina 50 Foot 15 24m Boom Over Front With Gooseneck Links 1 Boom Upper Section 2 Gooseneck Links A 14 9 1 2 4 5m Overall Height 5 23 Disconnecting Links a Disengage swing lock Swing upper until
213. er air pressure being forced through the cooling system in a direction opposite to the normal flow of coolant loosening and forcing scale deposits out The radiator is reverse flushed as follows a Remove the radiator inlet and outlet hoses and replace the radiator cap b Attach a hose at the top of the radiator to lead water away from the engine c Attach a hose to the bottom of the radiator and insert a flushing gun in the hose d Connect the water hose of the gun to the water outlet and the air hose to the compressed air outlet e Turn on the water and when the radiator is full turn on the air in short blasts allowing the radiator to fill between air blasts Note Apply air gradually Do not exert more than 20 psi 138 kPa air pressure Too great a pressure may rupture a radiator tube f Continue flushing until only clean water is expelled from the radiator The cylinder block and cylinder head water passages are reverse flushed as follows a Remove the thermostat and the water pump b Attach a hose to the water inlet of the cylinder block to drain the water away from the engine c Attach a hose to the water outlet at the top of the cylinder block and insert the flushing gun in the hose Operator s Manual d Turn on the water and when the water jackets are filled turn on the air in short blasts allowing the engine to fill with water between air blasts e Continue flushing until the wat
214. er boom extend or retract outrigger beams raise or lower jacks without first making sure no one is in the way If your vision is obscured locate a signal man so you can see him and he can see all areas you can t Follow his signals Be sure you and the signal man understand each others signals See hand signal chart on back cover Use the horn to signal or warn Make sure everyone on the job understands signals before starting work Fig 3 Watch your clearances Inspect the machine daily Don t operate a damaged or poorly maintained machine particular attention to the clutches brakes attachment and wire ropes If a component is worn or damaged replace it before operating Remember parts are cheaper than people Be sure clutch and brake surfaces are clean and dry Asmall amount of clutch or brake slippage may dry out wet linings Avoid excessive heating it shortens lining life If oil or grease gets on linings clean them immediately with a nonflammable low toxicity solvent If linings are saturated replace them Wednesday can save 50 bucks by running that rope Thursday Fig 4 Don t work with worn or damaged rope OSHA Occupational Safety And Health Act regulations state a thorough inspection of all ropes shall be made once 0 3 0 4 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T a month and a full written dated and
215. er from the engine runs clean If scale deposits in the radiator cannot be removed by chemical cleaners or reverse flushing as outlined above it may be necessary to remove the upper tank and rod out the individual radiator tubes with flat steel rods Circulate water through the radiator core from the bottom to the top during this operation 2 94 Fuel Oils For Detroit Diesel Engines 2 95 Diesel Fuel Oils General Considerations The quality of fuel oil used for high speed diesel engine operation is a very important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust Fuel selected should be completely distilled material That is the fuel should show at least 9896 by volume recovery when subjected to ASTM D 86 distillation Fuels marketed to meet Federal Specification VV F 800 grades DF 1 and DF 2 and ASTM Designation 0D0975 grades 1 D and 2 D meet the completely distilled criteria Some of the general properties of VV F 800 and ASTM D 975 fuels are shown below 2 96 Federal Specification amp ASTM Diesel Fuel Properties ASIM VV FO ASTM 2 D 125 F Carbon Residue 10 0 15 residuum max m We Water amp Sediment 96 by 0 05 vol max Distillation Temperature 9096 by vol recovery min 540 F 282 C max 572 F 550 F 626 F 640 F 300 C 288 C 330 C 338 C Specification or Classification Grade Flash Point min F E F 122 40 38 5
216. eration 3 4 5 Air Reservoirs 1 Drain accumulated water Power Steer System 1 Check oil level It should be one inch from top of reservoir when oil is at operating temperature 2 Inspect the hydraulic fluid for foreign material If contaminated drain and refill system 3 Inspect system for loose fittings worn or chafed hoses leaks etc Repair before operating 2 4 Weekly Operation Remarks First perform all operations listed under Daily Clutch Linkage 1 Lubricate the fittings on the clutch cross shaft one fitting for the clutch release bearing and one fitting on clutch shaft block Lubricate sparingly to prevent grease reaching the clutch facing 2 Lubricate pivot points on the clutch pedal and linkage with engine oil Wheel Nuts 1 Check lug nuts weekly and tighten as necessary 2 Inspect wheel rims lug nuts etc for damage Repair any damage before roading the machine or operating 2 5 Monthly or 1000 Miles 1609 3km Operation Remarks First perform all operations listed under Weekly Creeper Transmission 2 Inspect for missing components loose bolts leakage or other damage Repair any damage before roading Rear Axle Differentials the machine or operating Planetary Wheel Ends Main Transmission 1 Check lubricant level as explained later in this section Add lubricant x Chassis Lubrication 1 Provide complete chassis lubrication Force lubrication into fittings u
217. erative process caused by high chloride content solutions HC238A 2 113 2 114 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Bulk Inhibitor Additives Commercially packaged inhibitor systems are available which can be added directly to the engine coolant or to bulk storage tanks containing coolant solution Both chromate and non chromate systems are available and care should be taken regarding inhibitor compatibility with other coolant constituents Non chromate inhibitor systems are recommended for use in Detroit Diesel engines These systems can be used with either water or permanent type antifreeze solutions and provide corrosion protection pH control and water softening Some non chromate inhibitor systems offer the additional advantage of a simple on site test to determine protection level and since they are added directly to the coolant require no additional hardware or plumbing Antifreeze When freeze protection is required a permanent antifreeze must be used An inhibitor system is included in this type of antifreeze and no additional inhibitors are required on initial fill if a minimum antifreeze concentration of 3096 by volume is used Solutions of less than 3096 concentration do not provide sufficient corrosion protection Concentrations over 6796 adversely affect freeze protection and heat transfer rates Fig 2 37 Methoxy propanol base antifreeze is not recomme
218. ercome this outswing boom up as the load is lifted so fall lines remain vertical When setting the load on the ground lower boom after load touches down to avoid hook block swing when it is unhooked from load or the boom contacting the boom backstops When swinging a load from over end to over side the lean described above will increase This is especially noticeable when operating on tires Since tilt acts to increase load radius it must be compensated for when swinging the load Swing slowly Change boom angle Raise or lower boom while swinging to maintain a constant radius and prevent inswing or outswing of load If not a dangerous condition may result Know your load Don t try to guess or estimate the load Use a scale weight carefully calculated weight a hook scale or a load indicating system Remember the weight you are lifting includes the weight of any lifting slings or gear the hook block and any overhaul weights If picking off the boom with the jib installed the weight of the jib and rigging must also be considered part of the load The total load weight must never exceed the rated capacity of the machine as listed on the capacity chart for the position boom length load radius and condition of operation being used TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T Remember capacity chart ratings are based on ideal conditions a Standing on firm level surface b C
219. es air pressure front and rear 115 125 PSI 3 Parking emergency brakes air pressure 115 125 PSI 4 Supply air pressure 140 150 PSI 5 Battery voltmeter 11 8 15 2 volts CAUTION Never operate engine with oil pressures below 18 P S I 6 Engine oil pressure 30 60 PSI normal 18 PSI min 13 LIGHTS Inspect all lights for proper operation 14 WINDSHIELD WIPERS Check for proper operation condition of arms and blades 15 AIR RESERVOIRS Open drain cocks on the bottom of each tank to allow moisture and accumulated sediment to drain Close drain cocks 16 LUBRICATION REQUIREMENTS The following assemblies require lubrica tion IAW Lubrication Chart Pg 2 5 Operator s Manual A 42 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Carrier NOTE Within designated interval these checks are to be performed in the order listed B PFA D During A After W Weekly M Monthly ITEM TO BE INSPECTED ITEM Pe PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF 1 Brake cam shafts 2 Clutch release bearing 3 Clutch shaft support 4 Clutch cross shaft BATTERIES WARNING Do not get battery electrolyte on your skin clothing or in your eyes It is an acid which can cause injury Keep all sparks and flames from batter ies because battery gas is explosive CAUTION In cold wea
220. every 1 000 hours or 30 000 miles and wash the steel mesh pad in clean fuel oil This cleaning period may be reduced or lengthened according to severity of service Clean the breather cap mounted on the valve rocker cover in clean fuel oil every time the engine oil is changed Item 36 Engine Tune Up There is no scheduled interval for performing an engine tune up As long as the engine performance is satisfactory no tune up should be needed Minor adjustments in the valve and injector operating mechanisms governor etc should only be required periodically to compensate for normal wear on parts Fig 2 26 Fan Hub ltem 31 2 75 2 80 Item 39 Power Take Off Lubricate all of the power take off bearings with an all purpose grease such as Shell Alvania No 2 or equivalent Lubricate sparingly to avoid getting grease on the clutch facings On the 11 1 2 diameter clutch lubricate the clutch release collar through the fitting on the side of the clutch housing every 8 hours The clutch drive shaft pilot bearing used with the 11 1 2 diameter clutch power take off is prelubricated and does not require lubrication Lubricate the clutch drive shaft roller bearings through the grease fitting in the clutch housing every 50 hours under normal operating conditions not continuous and more often under severe operating conditions or continuous operation Lubricate the clutch release shaft through the fittings at the rear of the
221. face Remember there are tremendous loading on pontoons and blocking the weight of the entire machine plus any load Start carrier engine Let it idle with transmission in neutral Allow the system to warm up for a few minutes before proceeding Select the desired jack or beam switch on the control panel Push the switch to extend or retract If faster operation is desired push the throttle button Repeat step e for each jack and beam Always Stand In Clear View Of The Jack Or Beam Being Operated Make Sure Nothing Is In The Way When Operating A Jack Or Beam To Avoid Injury Or Damage 9 All capacities listed for the machine when on outriggers are based on all tires clear of the ground the outrigger beams fully extended and the machine sitting level A level is mounted on each corner of the machine to assist in leveling the machine Serious reductions in lifting capacity will result if above is not followed Use of outriggers with beam not fully extended may reduce capacities to those listed for on rubber If machine is not level outswing or inswing of load or side loading of boom will result This will greatly reduce lifting capacities and may cause machine damage or accident Always check outrigger footing before and during operation especially before making lifts at or near maximum rated capacity Reset outriggers before a lift if necessary If outrigger pontoons are allowed to settle into the ground they lo
222. facilities should be checked and situation corrected Primary and secondary fuel filters must be replaced following correction of fuel contamination problem This service must be conducted by trained diesel injection equipment personnel with suitable test facilities Omit this service until these conditions can be met Tighten head bolts and adjust valve clearance after first 50 hours on a new or overhauled engine 6 41 Oil Filter Change Place pan under oil filter and remove by turning counterclockwise Clean filter mounting area Install new filter oil filter gasket and turn filter on clockwise until gasket touches mounting base then tighten 1 4 to 1 2 turn 6 7 TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembly AIR CLEANERS AFTER WASHING ELEMENT IN SOLVENT OIP IN ENGINE OIL ANO SQUEEZE AS ORY AS POSSIBLE POLYURETHANE FOAM RETAINER ELBOW To injection CONNECTOR From fuet transfer pump PRIMARY SECONDARY FILTER FILTER DRAIN DUAL FUEL FILTER SYSTEM CAUTION plug on fuel filters can tolerate only a limited amount of torque Use two wrenches in combination for breaking plug loose and for final tightening Fuel Fitters Fig 6 9 Air Cleaner And Fuel Filter Maintenance TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembly CAP AND OIL BREATHER HOSE LEVEL INDICATOR INSULATOR CAP AND
223. fall lines hoist ropes gantry cab etc In such cases the warning will not sound until contact is made and the machine is electrified and deadly 0 8 These Men Are ome gt 04m P Not Protected Radius 4 Fig 14 Crane equipped with proximity device Shaded area shows sensitivity zone with probe near boom peak and adjusted for a 10 foot 3 04m clearance Contact can be made outside this zone by the fall lines hoist ropes gantry cab boom etc In such cases the warning will not sound until the machine Is electrified and deadly Fig 15 Grounding the machine to a pipe driven into the ground gives little or no protection h When operating near radio or T V transmitting stations high voltage can be induced in metal parts of cranes or in their loads This can occur even TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T if the machine is some distance from the transmitter or antenna Painful dangerous shocks may occur Consult trained electronic personnel before operating machine is begun to determine how to avoid hazards What do you do if a power line is touched by machine or load a b Keep cool think a mistake can kill someone Warn all personnel to keep clear If machine will still operate try to move it away from contact You the operator are reasonably safe in the cab unless the machine is on fire or an arc is cutting th
224. for Crane Container Handling 140 Ton Capacity Mobile Truck Mounted Model MHE 248 TM 10 3950 263 14 amp P 1 This manual contains copyright material Published with permission of FMC Corporation Cable Crane and Excavation Division TECHNICAL MANUAL HEADQUARTERS No 10 3950 263 14 amp P 1 DEPARTMENT OF THE ARMY WASHINGTON DC 15 July 1985 OPERATOR S ORGANIZATIONAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS FOR CRANE MOBILE CONTAINER HANDLING TRUCK MOUNTED 140 TON CAPACITY DED FMC MODEL HC 283A ARMY MODEL MHE 248 NSN 3950 01 110 9224 REPORTING OF ERRORS You can help improve this manual If you find any mistakes or if you know of a way to improve the procedures please let us know Mail your letter DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in the back of this manual direct to Commander U S Army Tank Automotive Command ATTN AMSTA MB Warren MI 48397 5000 A reply will be furnished direct to you TM 10 3950 263 14 amp P 1 Operator s Manual TM 10 3950 263 14 amp P 2 Service Manual Maintenance Instructions TM 10 3950 263 14 amp P 3 Parts Manual NOTE This manual is published to provide an authorized commercial manual for the use of the personnel to whom this Crane is issued Crane Manufacturer FMC Corporation Cable Crane and Excavator Division This technical manual is an authentication of the manufacturers co
225. for accumulation of fuel under the tanks Item 4 Cooling System Check the coolant level daily and maintain it near the top of the heat exchanger tank or radiator upper tank Clean the cooling system every 1 000 hours or 30 000 miles using a good radiator cleaning compound in accordance with the instructions on the container After the cleaning operation rinse the cooling system thoroughly with fresh water Then fill the system with soft water adding a good grade of rust inhibitor or a high boiling point type antifreeze refer to Engine Coolant With the use of a proper antifreeze or rust inhibitor this interval may be lengthened until normally this cleaning is done only in the spring or fall The length of this interval will however depend upon an inspection for rust or other deposits on the internal walls of the cooling system When a thorough cleaning of the cooling system 2 21 Operator s Manual is required it should be reverse flushed Inspect all of the cooling system hoses at least once every 500 hours or 15 000 miles for signs of deterioration Replace the hoses if necessary 2 52 Item 5 Turbocharger Inspect the mountings intake and exhaust ducting and connections for leaks Check the oil inlet and outlet lines for leaks or restrictions to air flow Check for unusual noise or vibration and if excessive remove the turbocharger and correct the cause 2 53 Item 6 Battery Check the specific gravity of th
226. for the first time MAKE THE FOLLOWING WALK AROUND CHECKS EXTERIOR OF VEHICLE a Check for evidence of leakage oil fuel hydraulic fluid or coolant on or under vehicle b Visually check tires for cuts or abrasions c Check tire pressure correct pressure is approximately 100 PSI d Check for loose missing or damaged parts ENGINE CRANKCASE Check dipstick for proper oil level Add oil as necessary to the FULL mark ref pg 2 21 2 47 lOperator s Manual BELTS Check all drive belts for frays cracks or deterioration EQUIPMENT IS NOT READY AVAILABLE IF Class IIl leakage exists Tires have cuts or ab rasions which would result in tire failure during operation One or more tires missing or unserviceable Low or flat tire Belts are frayed cracked unserviceable or missing A 39 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Carrier NOTE Within designated interval these checks are to be performed in the order listed B Before D During A After W Weekly M Monthly ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED NO IB D A W M FILLED OR ADJUSTED AS NEEDED EQUIPMENT IS NOT READY AVAILABLE IF 4 RADIATOR Check coolant level add coolant as re quired Level should be approximately one inch from the bottom of the filler neck 5 AIR CLEANER a Check air restriction indicator If Air restr
227. g a Push start stop switch to stop position b Release switch when set stops If stop circuit fails close fuel valve can safely handle an overload temporarily but for normal operation keep the load within nameplate rating The exhaust system may form carbon deposits during operation at light loads apply full load occasionally before shut down to prevent excessive carbon accumulations Try to connect the load in stops instead of full load at one time Most installations use a line switch that must be closed to connect a portion of the load 6 20 Emergency Operation If Battery Fails The remote type revolving armature set must always have the battery connected while operating High voltage will burn relays if battery is disconnected 6 21 Break In Procedure The unit should be run in the following sequence a One half hour at 1 2 load b One half hour at 3 4 load c Full load Continuous running under one half load during the first few hundred hours usually result in poor piston ring seating causing higher than normal oil consumption and blowby Note Drain and replace the crankcase oil after 50 hours of operation drain while the engine is still hot 6 22 Out Of Service Protection The natural lubricating qualities of No 2 diesel fuel should protect a diesel engine for at least 30 days when unit is not in Service To protect a set that will be out of service for more than 30 days proceed as follows
228. gage the master clutch Shut off the engine Engage the park brake tire mounted or travel brakes crawler mounted c Never depend upon a brake to suspend a load unless the operator is at the controls alert and ready to handle the load Brake slippage vandalism mechanical malfunctions could cause the load to drop if left in the air unattended Note The brake pedal locks are intended to allow the operator to rest his legs when suspending a load for a short period of time but the operator must remain in his seat with his feet on the pedals Failure to follow these instructions could lead to an accident An operator must not eat read or otherwise divert his attention while operating a machine Remember operating is a full time job Don t allow crane loads bucket grapple etc to pass over people or endanger their safety Remove all loose objects from load All non operating personnel should leave the immediate area when machine is operating Never leave a load in the air It may fall Fig 2 Don t let anyone hitch a ride Don t let anyone ride the hook block bucket grapple etc These machines are intended to lift objects not people They are not elevators TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T 6 sure your work area is clear Make sure you have proper clearance for machine boom or load Don t swing travel hoist or lower load raise or low
229. gine speed The throttle control can be left in any position if it is necessary to run the engine above idle speed without holding down on the accelerator Throttle should be fully pushed in when driving the carrier Otherwise speed setting may be too high for safe handling under traffic or emergency conditions Emergency Shutdown f an emergency or if after turning key switch off the engine continues to run pull this control to stop the engine After the engine stops running push the control back in and reset the emergency valve on the engine manifold Correct the malfunction in the engine before starting engine again Don t use this control for normal engine stopping Continued use will damage seals in the blower causing expensive repairs Headlight Switch The push pull switch turns on all lights except the headlights when pulled out to the first position When pulled out to the second position all lights operate Windshield Wiper Switch Turning the switch clockwise turns on the wipers The first position is for low speed and the second is for high speed Heater and Defroster Switch Turn switches clockwise to turn on the fan motor Turn all the way counterclockwise to shut off the fan motors Accelerator The accelerator controls the rate of fuel flow to the engine through the engine governor To increase engine speed depress the pedal To decrease engine speed release the pedal HC238A 1 28 1 29 1 30 1 31
230. h a chain or wire rope sling to lifting lugs at each end of outrigger box Connect to sling with hook block from helper crane or live mast reeved as a short boom Hoist to support the weight of the outrigger box Apply the hoist brake g Remove the pins as follows 1 Engage outrigger pump by pulling out on control under carrier dash Shift carrier transmission to neutral Start carrier engine Allow engine to idle 2 Retract cylinder to remove pins by moving toggle switch on control panel to retract position Increase carrier en Operator s Manual Front Cylinder 6 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Rear Cylinder S E ied Fig 1 13 Outrigger Pin Hemover System Carrier Frame System 5 Quick Disconnects Mounting Lugs Pin Remover Cylinder Mounting Lugs gine speed if necessary by pushing throttle c button Repeat procedure for other side of outrigger box If removing rear outrigger box lower until mounting lugs clear carrier frame and swing out from under e carrier Load on trailer rail car etc for f transportation i If removing front outrigger box 1 Lower box onto skids 2 Disconnect slings 3 Pull box out from under carrier on skids 4 Reconnect slings Load on trailer rail car etc for transportation i 1 48 Replacing Outrigger Boxes a Engage outrigger pump by pulling out on control j under carrier dash Shift carrier transmi
231. h control is discussed TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions 1 70 Master Clutch Control The master clutch is disengaged by pulling the lever to the rear Engage the clutch by pushing the lever forward Always engage and disengage the clutch slowly with the engine at idle Always Disengage The Master Clutch When Leaving The Operators Seat For Any Reason Or When Working On The Machine Failure To Disengage Master Clutch May Result In An Accident 1 71 Swing Lock Control The swing lock control engages a pawl with the teeth on the ring gear locking the upper in place with respect to the carrier The swing lock is operated as follows a Swing the upper to the desired position b Pull the detent handle on the control lever to unlock the lever c Pull the lever to the rear until it locks in position d To unlock pull detent handle on the lever and push forward until lever locks in position CAUTION Never Apply The Swing Lock When The Upper Is Swinging As Damage To The Machine May Result Never Attempt To Swing The Upper With The Swing Lock Engaged Note Engage the swing lock when leaving the machine for any reason Engage the swing lock when traveling or transporting the machine to avoid uncontrolled swing of the upper 1 72 Swing Brake Control The swing brake control actuates a hydraulic control valve which releases the spring applied swing brak
232. have the engine running fast enough to lift the load With engine at an idle release brake gradually while accelerating engine As load starts up increase engine speed as necessary CAUTION Regardless Of The Method Used To Control The Load Always Keep Foot On Hoist Brake Pedal Ready To Take Over Control Of The Load As Necessary b In the case of the boom a different method must be employed because the clutch is engaged and the brake released with the same control lever In this case the boom safety pawl must remain engaged until the engine speed is fast enough to raise the boom Boom safety pawl must remain engaged at all times except when lowering boom Note When suspending slowly lowering or slowly hoisting loads using method c engaging any other clutch function on the machine should be avoided The reason for this instruction is that any additional load will cause further slippage of the torque converter If a load is being hoisted slowly it may stop or begin to lower if another clutch function is engaged If the load is being suspended it may begin to lower and if it is being lowered its lowering speed will increase If load is being lowered gear train NA193 D Boom Foot Pin Removal System 1 Control Valve 2 Pin amp Cotter Pins 1 30 3 Pin Removal Cylinder 4 Pin Removed Position 5 Pin Normal Position TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating I
233. he boom Don t rely on the boom hoist brake alone to hold the boom Wear improper adjustment water or oil on linings and other factors may reduce the ability of the 10 11 12 13 14 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T brake to hold the boom Always replace protective guards and panels before operating machine Always wear hard hats safety glasses steel toe shoes and any other safety equipment required by local or job conditions on regulations Fig 7 Dress properly on the job Never get on or off a machine In motion Use both hands when climbing onto a machine f a ladder is provided use it Be careful when walking on track shoes They may be slippery and cause a fall Keep your machine clean In good repair and in proper adjustment Oil or grease on the decks may cause falls Improper adjustments can lead to machine damage load dropping other malfunction Keep a dry chemical or carbon dioxide fire extinguisher of 5BC rating or larger In the cab or In the Immediate vicinity of the machine at all times Instruct all operating and maintenance 15 16 17 18 19 20 personnel in proper use of the extinguisher Check periodically to make sure It is fully charged and is in working order Never tamper with safety devices Keep them in good repair and properly adjusted They were put on the machine for your protection Don t smoke w
234. he drain hose Open the drain cock Allow tank to drain thoroughly Close the drain cock WARNING Warn Personnel In The Immediate Area Before Using Compressed Air For Cleaning Wear Safety Glasses Compressed Air Coming Into Contact With The Human Skin Or Causing Flying Metal Chips Can Cause Injury c If no drainage occurs remove the drain hose Blow out the drain hose with compressed air Disconnect hoses from top of tank With engine running place a finger over end of hose and feel for air flow If none is felt the drains and hoses are plugged and need cleaning d Every 500 operating hours remove the cylinder block hand hole covers and check for an accumulation of liquid or sludge on the air box floor Clean out air box Remove hoses and clean them out Remove cover from the tank and clean it and the fittings on the cover out with approved low toxicity Solvent Operator s Manual Fig 2 8 Swing Bevel Gear Case 1 Check Plug 3 Fill Plug 2 Lubricant Level 4 Drain Plug 2 45 2 18 Engine Air Cleaner Although air cleaner elements are normally considered expendable proper and careful cleaning can extend their life Service intervals may vary from once a day to once a year depending upon the dust conditions the engine is working in Work out a schedule which is frequent enough to avoid down time for service on the job Over servicing is common and can be costly The air cleaner should be serviced
235. he front of the tire and E on the back indicate the amount of toe in and should equal 1 8 1 32 3 17mm 78mm A tie rod adjustment will correct any toe in variation Be sure to tighten all tie rod clamping bolts when adjustment is correct HC238A 1 2 3 4 Bearings Adjusting Nut Hub Cap Bushing TM 10 3950 263 14 amp P 1 t Fig 3 6 Front Axle Assembly 5 Thrust Bearing 6 Anchor Pin 7 Brake Cam 8 Brake Drum Check the strokes of the power steering cylinders and make sure they are centered when the left wheels are straight ahead as established in step b A ball socket adjustment on one or both ends of the cylinder may be required To establish a position of the steering wheel when the wheels are straight ahead mark the steering wheel with respect to some reference point Now count the revolutions of the steering wheel from extreme left to the extreme right Center the steering wheel Note the position of the mark made in step e It should be 3 3 Operator s Manual 1 Brake Cam 2 Adjusting Screw 3 Slack Adjustor 3 6 Fig 3 7 Brake Assembly 4 Brake Actuator 5 Brake Shoe 6 Anchor Pin within one halt a revolution of its established mark If not return the steering wheel to its reference point This again aligns the left front wheels straight ahead Remove the pitman arm from the steering gear center the steering wheel reinstall the pitman arm on t
236. he steering gear and fully tighten retaining nut Front Wheel Brake Adj Adjust the brakes periodically to compensate for lining wear and also to provide the most efficient braking Adjust the front wheel brakes as follows a Block carrier wheels so carrier cannot move b Jack up the axle until the tire clears the ground on the brake being adjusted c Turn the adjusting screw 2 in Fig 3 7 on the slack adjuster until the brake shoes contact the drum and prevent wheel rotation d Back the adjusting screw off just enough to free the wheel e Repeat the procedure for each front wheel Wheel Torque Procedure Incorrectly tightened wheels when mounted on cast spoked rims may wobble up to 3 4 The recommended procedure for tightening is by triangulation as follows Sed Fa 3 8 a Turn nut 1 until snug b Rotate the wheel rim assembly until nut 2 is in the top position Turn the nut until snug c Rotate the wheel assembly until nut 3 is in the top position Turn the nut until snug Since the entire weight of the tire wheel assembly is on the top spoke position this procedure allows even application of force against three points of the rim for alignment d Repeat the triangle procedure this time bringing each nut up to the recommended torque See torque chart later in this manual e Bring the remaining nuts up to proper torque TM 10 3950 263 14 amp P 1 Section 3 Continued Carrier Ad
237. hen fueling or fuel up near an open flame Keep the nozzle in contact with the filler neck to prevent static electric sparks Shut off the engine when fueling Before performing repairs or adjustments lower attachment to the ground or onto blocking Be sure of safe footing before standing or walking on boom or jib Use a ladder planking or lift platform to prevent falls On truck mounted machines lower machine off the outriggers If this is not possible block securely under the outrigger beams Lock the starter or remove battery cables so machine can t be started Remove ignition key Post warning signs in cab so no one will try to start the engine Always reduce pressure in hydraulic system to zero before working on any part of the system Work control levers back and forth with engine shut down to reduce the pressure to zero Keep fingers feet and clothing away from sheaves drums and ropes unless the machine is shut down and everyone knows what you are doing Never place a hand on lines when climbing to the top of the machine A sudden movement may pull them into the drum or sheaves When checking battery level use a flash light not an open flame Battery gas is explosive If the battery explodes you may get acid in your eyes which may cause blindness Don t check battery 21 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPEATING SAFETY CON T charge by shorting across posts The resulting spark cou
238. holding the load in the air with the drum brake disengaging the engine master clutch engaging the hoist clutch to whichever drum the load is attached and then releasing the brake This allows the machinery to turn backward as the load is lowered On older machines prior to the use of antifriction bearings this method assisted the brake considerably in controlling speed of descent This method is not recommended except in emergency conditions as speed can build up when line pull is high and control may become poor To better explain the operation of a torque converter in a crane we can make a direct comparison to a modern automobile equipped with an automatic transmission As an example an automobile can be headed up hill on a steep grade gear selector placed in forward gear and by regulating the engine speed the car can be made to move forward stand still or roll backwards The same thing is happening with a load on a crane outlined in method c above It is not practical to give engine speeds required to handle various loads because of parts of line single stage converter versus three stage converter size of drum etc Until the operator has gained familiarity with the machine the loads to TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions be lifted the sounds of engine and so forth it is necessary to understand and take the following steps a To prevent the load from coming down it is necessary to
239. housing every 500 hours of operation Lubricate the clutch levers and links sparingly with engine oil every 500 hours of operation Remove the inspection hole cover on the clutch housing and lubricate the clutch release levers and pins with a hand oiler To avoid getting oil on the clutch facing do not over lubricate the clutch release levers and pins Operator s Manual e Zonen SCREEN Fig 2 27 Blower Screen ltem 33 2 77 Check the clutch facing for wear every 500 hours Adjust the clutch if necessary 2 81 Item 40 Torque Converter Check the oil level in the torque converter and supply tank daily The oil level must be checked while the converter is operating the engine idling and the oil is up to operating temperature approximately 200 F or 93 The clutch must be engaged Check the oil level after running the unit a few minutes The oil level should be maintained at the proper level on the dipstick If required add hydraulic transmission fluid type C 2 see chart Do not overfill the converter as too much oil will cause foaming and high oil temperature The oil should be changed every 1 000 hours Also the oil should be changed whenever it shows traces of dirt or effects of high operating temperature as evidenced by discoloration or strong odor If the oil shows metal contamination contact an authorized Detroit Diesel Allison Service Outlet as this usually requires disassembly Under severe operat
240. hrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9 5 C 32 F APPROXIMATE CONVERSION FACTORS TO CHANGE TO MULTIPLY BY e 2 540 Feet a m E Yards Miles P Square Inches we Square Centimeters e Square Feet E Square Meters Square Yards 0 Square Meters d Square Miles p Square Kilometers Ge Lei m Square Hectometers lt Cubic Feet c E Cubic Meters Cubic Yards s ite sess Fluid E Zi 2 29 e Pints Quarts Quarts Gallons Ounces Ss KEE Pounds Kilograms aene o Short Tons Dag x Metric Tons Pound Feet m Newton Meters s Pounds per Square wes Inch Kilopascals 8 Miles per Gallon ES Kilometers per Liter Miles per Kilometers per Hour 1 609 I TO CHANGE TO MULTIPLY BY 2 Centimeters sse each 0 394 Meters Meters Ka Meters Kilometers Square Centimeters A Square Inches e Square Meters
241. ice wire rope is intended that is drag wire rope on a drag line hoist wire rope on a shovel etc i Preformed preformed When the above information is not specified the wire rope manufacturer will generally furnish right regular lay ordinary fabrication hemp center wire ropes HC238A 5 37 Wire Rope Inspection And Replacement P1 All wire rope will eventually deteriorate to the point where it must be replaced There are three basic reasons for this deterioration as follows a Abrasion or wear b Corrosion c Fatigue caused by the constant pulling bending crushing or kinking forces acting against the rope during normal usage When wire rope is replaced use the type specified in the parts manual Machines are designed to use a specific type and size of rope Using anything but the recommended rope may result in short life or even breakage All wire ropes in active service MUST BE inspected daily Dated records should be kept on this inspection A sample inspection report is shown in Fig 5 30 Fig 5 29 Measuring Wire Rope Diameter A Incorrect B Correct 5 21 Opera tor s Manual Place Of Inspection Description Of Crane Serial No Type And Arrangement Of Attachments Date Of Last Rope Inspection Hours And Type Of Service Since Last Inspection Results Of Inspection Rope Inspected Type And Size Conditions Noted Recommendation Inspector Fig
242. iction indica indicator has tripped clean or replace tor has tripped air cleaner element and reset indicator b Empty dust cups c Inspect air cleaner element Clean or Air cleaner element or replace as necessary gaskets are damaged 6 FUEL TANK Inspect fuel tank and all visible lines Loose or damaged parts and fittings for looseness damage or or Class III leakage leaks are evident 7 TURBOCHARGER a Visually inspect mountings intake and Class III oil leakage exhaust ducting and connections for leaks exists CAUTION Idle engine for three 3 minutes before shutting down to avoid damaging the turbocharger b Check for unusual noise or vibration Unusual noise or vibra tion is detected 8 POWER STEERING SYSTEM A 40 a Check for loose fittings worn or chafed hoses leaks Loose fittings unser viceable hoses or Class III oil leaks exist TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Carrier NOTE Within designated interval these checks are to be performed in the order listed B Before D During A After W Weekly M Monthly ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO IB D A W M FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF CAUTION Do not overfill Power Steering Reservoir b Check oil level It should be one inch from top of reservoir when oil is at operating temperature Add Type A Auto matic Transmi
243. ight Lay Regular Lay 88 600 40188 9 118 100 53570 1 147 700 66996 7 Capacities shown are maximum for 1 25 4mm diameter Type N rope per given parts of line Working loads may be less and 8 9 must never exceed ratings on capacity chart Fig 1 32 Wire Rope Capacity Chart c Engage the swing lock d With the engine running open the two control valves slightly e Pull the function lever to the lowering position Keep counterweight level by adjusting control valves Lower counterweight until it is supported by the blocks on the carrier bed and the linkage Is clear of the counterweight f Return function lever to neutral Close both control valves g Disengage swing lock Swing the upper around out of the counterweight Note There are two pairs of lifting lugs on top of the B counterweight Use the outer Tugs to lift the AB counterweight assembly Use the inner lugs to lift the B counterweight alone 1 85 Replacing The Counterweight a Fully extend and set all outriggers on firm level supporting surface Machine must be level with all HC238A tires clear of the ground If machine is not level AB counterweight will tip into cab when raised b Pick the counterweight and set in place on the positioning blocks on the carrier frame The counterweight may be lifted into place with the basic boom or the Live Mast used as boom See pagel Live Mast as a boom c Retract c
244. ignment must be checked periodically This is more critical on a two axle arrangement than on a single front axle The two front axles must be properly aligned with respect to each other or excessive tire wear will result The following steps outline the procedure for checking front wheel alignment Refer to an a Jack up the carrier with the hydraulic outriggers until the wheels clear the ground b Turn the steering wheel until the front left two tires are lined up with each other and are straight ahead with respect to the carrier Note Fig 3 5lillustrates one means of checking step 6 This involves placing a straight edge parallel to the carrier by measuring a distance A at each end of the straight edge Once the proper position of the straight edge is obtained measure the distance between the straight edge and the milled surface on the wheel hub used to locate the tire lugs These four dimensions are represented by the letters B and C inj Fig 3 5 Distance B must equal B and C must equal B does not necessarily have to equal C A drag link adjustment may be necessary to correct misalignment Be sure to tighten all drag link clamping bolts when adjustment is correct c Once the left front tires are lined up check for proper toe in Toe in can be checked by scribing a line around the circumference of the tire tread at the center line of the tread The difference between the distances D on t
245. ill produce a corrosive environment in the cooling system Also scale deposits may form on the internal surfaces of the cooling system due to the mineral content of the water Therefore water selected as a coolant must be properly treated with inhibitors to control corrosion and scale deposition To determine if a particular water is suitable for use as a coolant when properly inhibited the following characteristics must be considered The concentration of chlorides sulfates total hardness and dissolved solids Chlorides and or sulfates tend to accelerate corrosion while hardness percentage of magnesium and calcium present causes deposits of scale Total dissolved solids may cause scale deposits sludge deposits corrosion or a combination of these Chlorides sulfates magnesium and calcium are among but not necessarily all the materials which make up dissolved solids Water within the limits specified in Tables 1 and 2 of Fig 2 34 is satisfactory as an engine coolant when proper inhibitors are added Corrosion Inhibitors A corrosion inhibitor is a water soluble chemical compound which protects the metallic surfaces of the cooling system against corrosive attack Some of the more commonly used corrosion inhibitors are chromates borates nitrates nitrites and soluble oil Depletion of all types of inhibitors occurs through normal operation Therefore strength levels must be maintained by the addition of inhibitors at prescribed i
246. in a can Fully retract the jack cylinder to force the remaining old oil from the jack cylinder p Replace the quick disconnect on the hose Connect it to the other half of the quick disconnect q Recheck the sump tank level Add oil as necessary r Repeat steps j through q above for each of the other jack cylinders WARNING Do not service maintain or lubricate chain case unless engine is shut down and swing lock is engaged Chain Case To check a Park the machine on level ground Set the parking brake Engage swing lock Disengage the master clutch Shut off the upper engine b Clean an area around the check plug to prevent entry of foreign material c Remove the check plug The unit should be full of lubricant to the level of the check plug hole 2 15 TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication Fig 2 5 Chain Case 1 Drain Plug 3 Fill Hole 5 Oil Level 2 Check Plug Inspection Plate d Install and tighten drain plug Fill the chain case with lubricant through the fill hole on top of the chain case Replace the fill cap See capacity chart on page 2 14 for the proper lubricant WARNING Do not service maintain or lubricate planetary speed reducer unless engine is shut down and swing lock is engaged 2 34 Planetary Speed Reducer 2 35 To check a Park the machine on level ground Set the parking brake
247. ine b Clean an area around the check plug hole to 2 14 2 23 2 24 2 25 2 26 prevent entry of foreign material Use the upper plug on top of the housing when checking the steering pear c Remove the check plug The unit should be full of lubricant to the level of the check plug hole Add lubricant if necessary through this same hole See capacity chart on for the correct lubricant Replace and tighten the check plug To change a Change the lubricant after the carrier has been driven so the lubricant will be warm and foreign materials in the lubricant will be in suspension The lubricant will drain better if warm b Park the machine on level ground Set the parking brake Shut off the carrier engine c Remove the drain plug from the bottom of the unit Allow old lubricant to drain thoroughly d Install the drain plug Remove the check plug Fill the unit with kerosene or light flushing oil Install the check plug e Operate the unit for a few minutes then drain the flushing oil or kerosene f Install the drain plug Remove the check plug Fill the unit with the specified lubricant Install the check plug See capacity chart of page 2 8 for the proper lubricant Planetary Wheel Hub To check a Run the machine then park on level ground for about 5 minutes before checking b Rotate the wheel end until the arrow on the thrust cap is down as shown irl Fig 2 4 Set the parking brake Shu
248. ing brake pedal down to allow latch to engage c To disengage position foot as shown in A Depress latch and pedal at same time to disengage latch 1 76 Drum Rotation Indicators Drum rotation indicators are used on the front and rear drums Two pins are mounted in the control handle The rear pin operates when hoisting and the front pin operates when lowering The pins are solenoid actuated and move in and out as the drum shaft rotates The faster the drum shaft turns the faster the pin moves in and out By placing a finger over the pin when operating the front or rear drum shaft the operator can tell which direction the shaft is turning and with experience will be able to tell how fast the shaft is rotating The rotation indicators work only when the rotation indicator switches are in the engage position These switches are on the upper control panel above the operator s right shoulder There are two thumb wheel switches on the cover of the electronics box one for front and one for rear drum This box is located on R H side of revolving Fig 1 26 Brake Pedal Locks frame near mast foot lugs These switches adjust the frequency of movement of the buttons to compensate for changes in number of parts of line being used Determine how many parts of hoist line are being used and adjust these thumb wheels accordingly Fig 1 24 Front Drum Control Lever And Brake H0238A 1 23 Operator s Manual 1 77 Boom Ho
249. ing conditions the oil should be changed more often The converter oil breather located on the oil level indicator dipstick should be cleaned each time the converter oil is changed The full flow oil filter element should be removed the shell cleaned and a new element and gasket installed each time the converter oil is changed Lubricate the input clutch release bearing and ball bearing and the front disconnect clutch drive shaft bearing every 50 hours with an all purpose grease Grease fittings are provided on the clutch housing This time interval may vary depending upon the operating conditions Over lubrication will cause grease to be thrown on the clutch facing causing the clutch to slip The strainer in the torque transmission and the hydraulic system filters should be replaced or cleaned with every oil change HC238A TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication CRANKCASE BREATHER Fig 2 28 Crankcase Breather Item 34 2 78 Prevailing Ambient Recommended Oil Temperature Specification Above 10 F 12C Below 10 F 12C Hydraulic Transmission Fluid Type C 2 Hydraulic Transmission Fluid Type C 2 Auxiliary preheat required to raise temperature in the sump to a temperature above 10 F 12C 2 82 Engine Oil And Filter Change a The lubricating oil should be drained when the engine is warm Most of the sediment will be in suspension and will dr
250. ing upper be careful of carrier cab Swinging into the cab will damage it and probably the boom too Always engage the swing lock when roading the machine If your carrier is equipped with safety belts or shoulder harness use them They are there for your protection Brake firmly in one application Avoid fanning the brakes This may exhaust air pressure so fast the compressor can t 0 25 10 11 12 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T keep up If a machine must be towed move slowly Take up slack in chain or rope Don t jerk It may break Keep chain or rope taut while towing Before attempting to move the carrier make sure there is enough air pressure to operate the brakes Always check brake operation before driving the machine Always look before you back up or better yet post a signal man to guide you If your machine is equipped with a back up alarm make sure it is working properly If not use the horn as a signal Use a code such as one beep stop two beeps forward three beeps backward Make sure everyone on the job site knows the code If machine is equipped with a back up alarm make sure it works properly Fig 42 Back the machine safely When moving a machine around the job site with boom in the air observe the following precautions a Swing upper so boom is directly over rear of carrier Engage the swing lock b Shift carrier transmi
251. irst engages the clutch drum The heel is the pivoting point HC238A of the clutch shoe and engages after the toe A R H clutch may now be defined as one which when assembled and an arrow drawn from toe of shoe to heel of shoe it will point in a clockwise direction A L H clutch is one where an arrow drawn from toe to heel would point in a counter clockwise direction To further clarify proper clutch installation all clutches must be installed in an energized position That is so the drum rotates from the toe or live end of the clutch shoe to the heel or dead end of the clutch shoe In this way the clutches will be self energized energized by clutch drum rotation There are several applications where the load is actually the driving force and acts to energize the clutch In this case the clutch must be installed with the drum rotating from heel to toe These applications are a Front drum lowering clutch when used in crane work b The rear drum lowering clutch On the R H lowering side of the boom hoist shaft a low speed planetary is used This is a planetary speed reducer to allow for low speed and fine control when lowering the boom When the operator pushes on the control lever to lower the boom an external brake on the planetary case applies holding the case stationary The spur gear on the shaft drives the planet gears inside the unit The planet gears drive the boom hoist shaft to lower the boom C2
252. ission Main Transmission Controls The main transmission has a 5 speed front section and a high low range section which allows the operator to select 10 evenly spaced forward speeds with a single control lever and a range control switch An additional 5 deep reduction speeds may be selected by using a deep reduction valve mounted on the carrier dash The five deep reduction speeds overlap the low range speeds resulting in a total of 12 evenly spaced forward speeds The 5 deep reduction speeds are for off highway use and only when the transmission is in low range Range control button down The transmission also contains 3 reverse speeds Important Procedures Do not pre select When making the shift from a deep reduction ratio to a low range ratio move the deep reduction valve from in to out immediately before making the shift This is not a pre select valve and only torque will hold the deep reduction gear after the lever is moved to out The shift cylinder Will make the shift by air as soon as torque is released Never move the deep reduction valve lever with the transmission in high range Range control button up as the reduction gear by passes both the low and high range sections regardless of the position of the range control button 1 9 Operator s Manual MAIN HIGH RANGE TRANSMISSION o AUX TRANSMISSION SHIFT ONLY WHEN CARRIER IS NOT IN MOTION ON HIGHWAY REDUCTION DOWN OFF HIGHWAY
253. ist Control To raise the boom proceed as follows a Pull the B H control lever to the rear to raise the boom Control the speed of boom hoist by varying the engine throttle setting b When the boom reaches the desired angle return the B H control lever to neutral CAUTION Keep Boom Hoist Pawl Engaged At All Times Except When Lowering The Boom This Device Is A Reserve Safety Feature To Cover Possibility Of Loss Of B H Brake Or Clutch Action Note The boom should be raised with the pawl engaged but it must be disengaged to lower the boom To lower the boom proceed as follows a Disengage B H pawl by pulling out on pawl control b Push the B H control lever forward to lower the boom Control rate of descent by varying the engine throttle setting Note It may be necessary to boom up slightly to release B H pawl c Re engage B H pawl when lowering is complete 1 78 B H Limiting Device Override Sometimes it is necessary to boom up slightly after the boom hoist limiting device has functioned to release the B H pawl To boom up this slight amount push the override control located on the cab floor Drum Rotation Indicator Lowerinq Drum Rotation Indicator Rais ing Load Fia 1 27 Drum Rotation Indicators 1 24 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Boom Hoist Pawl Control Fig 1 29 B H Limiting Device Override
254. ist wire rope to become slack With the engine on zero the Load 8 P L Gain 12 P L Gain 11 P L Gain Main Zero R2I TP3 19 R44 RIS 10 3950 263 14 amp 1 Section 10 Overload Warning System Two Blocks 7 P L Gain 6 P L Gain 5 P L Gain 4 P L Gain R40 3 P L Gain 2 P L Gain 1 P L Gain RI3 R39 RI2 R42 Ril CARD A 14 OR 15 NA428 A 440 A meter as follows aa Refer to Fig 10 3 Find load amplifier card A 14 for left hook or A 15 for right hook Locate main zero potentiometer R15 on the load amplifier Card A 14 or A 15 Using a small jewelers screwdriver slowly adjust screw at potentiometer R15 until Load meter reads 0 Hoist boom to angle that the radius can easily and accurately be measured Lift a known weight If the Load meter does not indicate the known weight adjust the gain potentiometer for the parts of line as follows aa Refer to Fig 10 3 Find Load Amplifier card A 14 A 15 Locate the gain potentiometer that corresponds to the parts of line reeved on the hook block Using a jewelers screwdriver slowly Operator s Manual 9 10 adjust screw at parts of line gain potentiometer until the load meter reads the known weight For example if 12 parts of line is reeved on the hook block the 12 P L gain potentiometer R19 on Load Amplifier card A 14 or A 15 would be adjusted The weight of the known weight is the total of the following i
255. isten for exhaust leaks Any leaks detected inside the cab b Visually inspect the muffler shield and pipes for damage and security of hardware AIR BOX DRAINS Drain accumulated oil and water from the air box BATTERIES UPPER AND GENERATOR WARNING Do not get battery electrolyte on your skin clothing or in your eyes It is an acid which can cause injury Keep all sparks and flames from batter ies because battery gas is explosive CAUTION In cold weather operations charge batteries immediately after adding water Water must combine with electrolyte by means of charging Delay in charging can result in freezing water Be careful not to over fill when servicing batteries a Check level of electrolyte If level of electrolyte is below top of battery plates add distilled water to cover the plates Visually inspect batteries and Batteries are missing battery box for damage damaged or if engine will not crank A 51 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Lifting Sling for End Item NOTE Within designated interval these checks are to be performed in the order listed B pem D During A After W Weekly M Monthly ITEM TO BE INSPECTED EI PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO sm Lem FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF WARNING Trying to lift the machine with damaged components in the Lifting Sling can cause an acciden
256. ists of the following components a Lifting spreader It consists of 4 lengths of H beam bolted together into a rectangle There are angle braces bolted across each corner of the rectangle for added strength b Front and rear slings The slings consist of a pair of pendants connected to a link The slings pin to lugs on top of the spreader The front sling assembly is shorter than the rear sling assembly c Support pendants Four of these are used They connect to lugs on the bottom of the spreader The other end of each pendant connects to the machine d Lifting arm assembly One of these attaches to the bottom of the front and rear outrigger box at each end of the box The support pendants pin to them 1 100 Inspection Before using the lifting sling assembly it must be thoroughly inspected Look for the following a Cracked welds cracks in the H beams lugs corner braces b Damage to the slings or pendants such as kinks broken wires in the cables corrosion evidence of stretching c Damage to links or pins such as cracks scoring evidence of stretching or bending If any components are damaged replace them WARNING Trying To Lift The Machine With Damaged Components In The Lifting Sling Can Cause An Accident A Very Heavy Load Is Being Lifted If It Falls The Machine Will Be Damaged Personnel Nearby May Be Injured Or Killed 1 101 Lifting Sling Installation a Assemble the four beams which
257. ity through a cable assembly leading to the main electronics the main electronics black wire connects to the positive lead and the main electronics white wire connects to the negative lead of the crane s electrical supply The electricity goes to the main electronics From the main electronics the electricity is sent to the Power PWP switch on the display then back to the main electronics where it is fused to supply power to the System sensors and relays These sensors and relays provide the raw data to the main electronics The main electronics processes this data and displays the information on the meters and signals the operator with warning devices Note Where electricity is fused to the system at the main electronics there is a fuse on the bottom If it needs replaced use a type 3AG fuse with 4 Amp capacity slow blow 10 5 Operating Instructions WARNING The Overload Warning System Is Not Fail Safe It Can Malfunction Do Not Depend Upon This System To Do The Operator s Job The Operator MUST Use The Information On The Metal Capacity Plate Located In The Upper Cab And Operate The Crane Within The Guidelines Spelled Out In P Crane Operation In The Operator s Manual Visually check that the components and cables are connected Position PWR power switch to On Set the Reeve Select on the main electronics to the parts of line reeved on the hook block Set the Boom Select switch on the main electronic
258. justment Note After 50 to 100 miles 80 4 to 160 9km of operation tighten the nuts to recommended torque once again The wheel rim assembly will then remain tight barring accident such as stud breakage or clamp failure Tires And Tire Inflation Dual wheels and tires are installed so the valve stem of the inner tire is 180 opposite the valve stem of the outer tire All tires of the same size and weight are interchangeable Inspect wheel rim clamps nuts studs etc on weekly basis If any damage is apparent repair or replace before operating the carrier or making lifts on tires Check the tires daily for proper inflation pressures for type of operation The inflation chart rig 3 9 1 lists the recommended pressure for different operating conditions Check pressures with the tires cool A tire inflation hose assembly is available This hose assembly can be connected to the carrier air brake system and used to inflate the tires A gauge is included in the inflation hose assembly to check pressures The hose is equipped with a clip on chuck and is long enough to allow the person checking or inflating tires to stand to one side away from the lock ring A guard should be provided to protect against a lock ring flying off when inflating or deflating tires To assure best vehicle performance and increased tire life use highway pressures as much as possible When making lifts on rubber use static maximum lift pressures shown The c
259. k GALVE Wal hA HOSE CLAMP KEEP OIL Sans Ait AT THIS LEVEL __ LL O RING Z ASS NEVER OPERATE ENGINE WITH OIL BELOW THIS LEVEL e a Low ALWAYS REPLACE CAP TIGHTLY OR OIL LEAKAGE MAY OCCUR a Si P q Do not remove dipstick with engine running Remove hose clamp breather hose breather cap clamp will ut causi asible Injury and insulator haives to release breather cap and vaive Siwi blow oute SS I SZ assembly Wash and valveassembly and the baffle in suitable solvent and reinstall CRANKCASE BREATHER OIL LEVEL INDICATOR YALVE CLEARANCES TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembly 6 42 Onan Diesel Starting Guide AIR CLEANER IMPORTANT AIR HEATER KEEP ENTIRE FUEL SYSTEM CLEAN AND FREE FROM INJECTION WATER NOZZLE DIESEL INJECTION PUMPS WILL FAIL IF SYSTEM CLEANLINESS 15 NEGLECTED INJECTION PUMPS AND NOZZLES ARE NOT FIELD REPAIRABLE WHEN TROUBLESHOOTING CHECK ALL OTHER COMPONENTS FIRST FUEL RETURN LINE CONNECTION DO NOT USE ETHER STARTING 3 AIDS ETHER IS EXTREMELY EX INJECTION PUMP PLOSIVE AND MAY CAUSE SERIOUS PERSONAL IN JURY ENGINE DAMAGE IS ALSO LIKELY FUEL TRANSFER PRIME FUEL SYSTEM IF FUEL FILTERS WERE DRAINED OR CHANGED SYSTEM WAS JUST INSTALLED FUEL TANK RAN DRY TO PRIME PUMP MOVE PRIMING LEVER UP AND DOWN UNTIL FUEL FLOWS STEADILY FROM RETURN LINE DISCONNECTED PREHEAT COLD
260. k and Services Upper M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY FUEL STRAINER AND FILTER Replace both elements at indicated time or when plugged ref Operator s Manual EMERGENCY SHUTDOWN Check emergency shutdown system to be sure it will operate when needed FUEL TANKS Open drain at bottom of tank to remove any water or sediment COOLING SYSTEM a Inspect all hoses for cracks bulges or signs of deterioration Replace hoses if necessary b Check coolant condition IAW TB 750 651 Clean flush refill with coolant and rust inhibitors if necessary WIRE ROPE Inspect wire rope to insure that reductions of nominal diameter do not exceed 1 3 64 inch for diameters 9 16 to 3 4 inch 2 1 16 inch for diameters 7 8 to 1 1 8 inches 3 3 32 inch for diameters 1 1 4 to 1 1 2 inches Replace if necessary ref Operator s Manual AIR BOX DRAIN TANK Remove cylinder block hand hole covers and check for an accumulation of liquid or sludge on air box floor Clean air box hoses fittings and cover and reassemble AIR BOX DRAIN TUBES With engine running check for flow of air from the air box drain tubes If tubes are clogged remove clean and reinstall A 65 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Upper M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHEC
261. k before moving the bearing set screw instead of into the hydraulic cylinders block and shims Tighten jam nuts on the set screws after adjustment 4 12 Planetary Brake Adjustment Fig 4 6 b The counterweight may now be positioned on the blocks on the carrier bed The planetary brake is hydraulicaly applied and spring c Check dimension A in Fig 4 5 Dimension A released As lining wear takes place the initial dimension at measures 26 1 2 673 1mm from the bottom of A gradually decreases When the dimension the adjusting screw 11 to the inside surface of reaches zero the counterweight Refer to To set dimension A loosen the jam nuts 9 Next add or remove shims 12 on the adjusting screws HC238A 4 3 TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Continued Upper Adjustments A Lowered Raised NA217 C Counterweight Hemover Assembly 26 1 2 673 1mm B Position Of Linkage Toggled 1 4 C Position Of Linkage Top Dead Center 6 6mm Over Center 1 Shims b Upper Frame 9 Jam Nut 2 3 Carrier Frame 6 Cylinder 10 Spacer Positioning Block 7 Set Screw W Nut 4 Counterweight 8 Bearing 4 13 the brake must be readjusted Before adjusting check to make sure that the lining rivets are not worn through and riding on the drum To adjust tighten the band bolt nut until the dimension at A equals 3 8 9 5mm with the brake applied Front And Rear Drum Brake Adjus
262. k pressure Switch by fully extending all 5 jacks Then retract the mid ships jacks until the carrier horn honks If the horn doesn t honk by the time the mid ship jacks are no longer touching the pontoons immediately extend the jacks and correct the problem TM 10 3950 263 14 amp P 1 Section 3 Continued Carrier Adjustment Front Jack and Relief Valve To Beams 10 G P M Press Blocking amp Relief Valve ASS Y 1 Test Gauge Assembly 1 18A2061 1 2 QD Nipple 1 18A788 3 4 QD Nipple 2 18A2062 1 2 QD Coupler 2 18A786 3 4 QD Coupler 3 1X2260 1 2 Street Tee 3 1X3318 3 4 Street Tee 4 1X1319 1 2 x 3 8 Bushing 4 1X907 3 4 x 3 8 Bushing 5 5 80 Orifice Drill 1 8 Pipe 80 Orifice Drill 1 8 Pipe Plug Plug 6 1J189 Drill amp Tap 1 8 NPT 6 1J189 Drill amp Tap 1 8 NPT for Installation of Orifice for Installation of Orifice 7 1X152 3 8 x 1 4 Bushing 7 1X1852 3 8 x 1 4 Bushing 8 Pressure Gauge 8 Pressure Gauge TM 10 3950 263 14 amp P 1 Operator s Manual Section 3 Continued Carrier Adjustment Outrigger Throttle Control 1 Floorboard 4 Target 2 Accelerator Pedal 5 Air Cylinder 3 Jam Nuts 6 Air Line 3 12 Outrigger Throttle Control The outrigger throttle control is actuated by a button on the outrigger control panels and the toggle switch at the front bumper outrigger control station They actuate a
263. ke air pressure must be exhausted from the park or emergency diaphragm and air pressure must be applied to the locking mechanism To apply the park or emergency brake pull the control out To release the brakes push the control in and at the same time apply the service brake depress the pedal to full System pressure for 10 seconds Release the pedal and brakes will unlock If air pressure is lost in the brake system the park or emergency control trips at 40 psi 275 8 kPa and applies the brakes 1 14 Reserve Air Control If air pressure is lost from the service brake system while the carrier is being operated the emergency brakes will apply Pushing on the reserve air control will route air from the emergency reservoirs to the park or emergency brake control on the cab dash Pushing this control will release the brakes long enough to move the carrier off the road Pulling on the park or emergency brake will apply the brakes one last time There is only enough pressure available to release and then apply the brakes once 1 15 Low Pressure Warning System There is a warning buzzer under the cab dash If air pressure drops below 60 psi 275 8 kPa in the service brake system the buzzer will sound If buzzer sounds while driving the carrier stop the carrier immediately and determine what is wrong Repair the problem before driving the carrier again or an accident may occur 1 16 Engine Oil Pressure This gauge registers the pressu
264. kly W PREVENTIVE MAINTENANCE weekly Do your monthly M PREVENTIVE MAINTENANCE once a month If something doesn t work troubleshoot it with the instructions in the Operator s Manual or notify your supervisor Always do your PREVENTIVE MAINTENANCE in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If anything looks wrong and you can t fix it write it on your DA form 2404 The Item Number column is the source for the numbers used on the TM Item Number column on DA Form 2404 If you find something seriously wrong report it to Organizational Maintenance RIGHT NOW While performing PMCS observe caution notes and warning paragraphs preceeding those operations which could endanger your safety or result in damage to the equipment 10 When you do your PREVENTIVE MAINTENANCE take along a rag or two A 36 11 TM 10 3950 263 14 amp P 1 WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and don t 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 contact with skin or clothing is made flush with water If contact with eyes is made wash your eyes with water and get medical aid immediately a Keep it clean Dirt grease oil and debris only ge
265. l Bearing Use it to engage the clutch while reading the torque 4 Thrust Ring 14 Snap Ring required t6 SEN Ee de Ge GE See Adjust the clutch as follows 7 Toggle Assembly 17 Lock Spring a Remove the access cover from the top of the 8 Toggle Liner Pin 18 Lock Pin clutch housing Ze 9 Snap Ring 19 Washer b SE Ma engine the starter until the clutc 10 Toggle Strap Pin 20 Spring E e c Disconnect the clutch actuating linkage d Remove the lock pin Rotate the adjustment collar clockwise facing engine flywheel to increase the engagement force 7 gt Swing Lock Assembly A 3 8 to 1 2 9 5 to 12 7mm B 8 1 4 209 5mm Centering Bracket 5 Nut Linkage Linkage Rod 4 Stop Bolt 8 Bell Crank 1 2 3 6 7 Linkage Rod HC238A 4 1 TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Continued Upper Adjustments Fig 4 3 NA210 D Swing Lock Swing Brake Master Clutch Controls 1 Swing Brake Control 7 Brake Drum 2 Swing Lock Control 8 Toggle Link Assy 3 Detent Control 9 Control Valve 4 Master Clutch Control 10 Push Pull Cable 5 Set Screws Detent Lever e Replace the lock pin Make sure the pin has engaged one of the 24 holes in the hub plate Failure to engage the pin securely will allow the clutch to lose adjustment 4 3 Swing LocK Fig 4 2 The swing lock is engaged and disengaged with a control lever on the RH c
266. l Information Boom Hoist Limiter Kickout Boom Live Mast Boom Transportation of Brake B H Adjustment Brake F D R D Adjustment Brake Planetary Adjustment Brake Swing Adjustment Brakes Front Wheels Brakes Rear Wheels Break in Period Cable Wire Rope Clips Use of Cable Wire Rope General Information Cable Wire Rope Inspection Cable Wire Rope Lubrication Cab Operator s Carrier Clutch Assembly Carrier General Information Carrier Operation of Chain Case Chain Adjustment Chart Hand Signals Clutch Adjustment Carrier Clutch Clutch Adjustment Drum Clutch Clutch Adjustment Master Clutch Control B H Override Control Boom Hoist Control Brake Pedal Locks Control Ctwt Remover Control Emergency Shutdown Upper Control Engine Shutdown Upper Control Engine Throttle Upper Control Foot Throttle Upper Control Front amp Rear Drum Control Lever Adjustment S o M Control Live Mast Control Master Clutch HC238A TM 10 3950 263 14 amp P 1 Section 11 Alphabetical Index R783 Subject Control Panel Upper Control Park Emergency Brake Carrier Control Reserve Air Carrier Control Swing Brake Control Swing Clutch Control Swing Lock Controls Main Transmission Counterweight AB Upper Assembly Counterweight A Carrier Assembly Counterweight Assembly Counterweight Removal Counterweight Replacing Counterweight Useage Crane Procedure for Shutting Down Deflector
267. lank Forms and mail direct to Commander US Army Tank Automotive Command ATTN DRSTA MB Warren MI 48090 A reply will be furnished directly to you 00 5 Equipment Improvement Recommendations EIR Equipment Improvement Recommendations will be submitted IAW TM 38 750 00 6 Equipment Readiness Reporting Readiness reporting will be accomplished as required by the current TM 38 750 00 7 Shipment and Storage a Shipment and Storage Refer to B 740 97 2 for procedures covering preservation of equipment for shipment and storage General procedures for shipment are found in FM 5 15 Refer to Appendix E for further transportation guidance b Administrative Storage Refer to TM 740 90 1 for instructions covering administrative storage of equipment c Weight Classification The gross vehicle weight of the 140 ton Crane in a fully operational configuration is approximately 303 350 Ibs For component weight breakdown see page 9 4 00 8 Maintenance of New Vehicles Upon delivery of the 140 ton Mobile Crane perform the checks and services listed on page 1 6 paragraphs 1 5 7 NOTE For your protection make a thorough inspection of the vehicle immediately upon delivery If any discrepancies are noted notify the transit agent and have delivering carrier make a notation on the freight Bill of Lading AT ONCE 00 9 Destruction to Prevent Enemy Use Refer to TM 750 244 3 for procedures covering destruction of equipment to preven
268. ld cause the battery to explode Check with a tester or hydrometer Don t smoke near batteries especially when they are being charged Fig 8 Never use an open flame to check a battery When using jumper cables to start an engine be sure to connect negative post to negative post and positive post to positive post Always connect the two positive posts together first and the two negative posts last to prevent a spark when the cables are connected This spark could cause the battery to explode When working Inside a building check clearance to avoid a collision Check load limits on floors or ramps so you won t crash through Always check work areas for dangerous features Don t operate close to an overhang or deep ditch Avoid caving edges falling rocks slides etc Never park machine where a bank can fall on It or it can fall In an excavation Don t park where rain can wash out footings 22 Pinch points which result from relative motion between mechanical parts can cause Injury Keep clear of rotating upper or moving parts Fig 9 Be careful when removing radiator caps 23 Use extreme caution when removing radiator caps drain plugs grease fittings hydraulic pressure caps etc They may fly off and hit you or you may be burned by hot oil water or steam 24 Always wear safety glasses when drilling grinding or hammering on metal If you do not wear safety glasses flying chips may Injure the eyes W
269. le n ko e m ie E ER nV ERR P EN ER Exi d I n5 x jj J IRA AR El mn 1 En NIN aL oko Em 1 Em iD Em Rm Ko N 1 1 EN EN TL 3 Fake ca Ga w I 10 Ss MININ APPENDIXES APPENDIX Equipment Publications Warranty Maintenance Allocation Chart MAC Introduction I Assignment of Maintenance Functions I Tool and Test Equipment Requirements Remarks D Additional Maintenance Instructions Shipment and Storage E Troop Authorized or Installed Item List Maintenance Operating and Supply List MAOSL Preventive Maintenance Checks and Services PMCS Operator Crew Preventive Maintenance Checks and Services Organizational Preventive Maintenance Checks and Services ASL PLL 10 3950 263 14 amp 1 v gt O m 6 CA 6 Co NO N gt CA gt D D Co n2 e D T CO 1 2 blank Nomenclature Safety Inspection and Testing of Lifting Devices Safe Use of Cranes Near Electric Power Lines Storage Handling and Shipment of Truck Mounted Cranes TM 10 3950 263 14 amp P 1 APPENDIX A EQUIPMENT PUBLICATIONS DA Equipment Publications Equipment Publication Number TB 43 0142 13 Apr 79 TB 385 101 w Chg 1 15 Jun 79 TB 740 358 11 Oct 72 TM 10 3950 263 14 amp P 1 APPENDIX B WARRANTY INFORMATION 1 FMC Corporation h
270. length of main boom on the crane The Reeve Select Switch must be set to the parts of line reeved on the hook block s These switches match the system s electronics to the boom length and reeving of the crane Note The operator must make sure these switches are in the positions which match the actual boom length and reeving of the crane or the system will not function properly Angle Sensor The angle sensor assembly serves a dual purpose t is a junction box for the electrical cable coming down the boom It also contains a device which senses the angle of the boom and outputs an electrical signal from which the radius can be calculated Head Amplifier The dual head amplifier assembly takes the electrical signal from the load sensor s and boosts it down the boom cable Load Sensors The load sensor assemblies are the shafts of the idler sheaves located directly behind the boom point sheaves The load sensors sense the line pull through the idler sheaves when a load is put on the main hoist hook block s The electrical signal goes from the load sensor s directly to the dual head amplifier Cables The cable assemblies are used to connect all the electrical assemblies together to make a complete assembly HC238A TM 10 3950 263 14 amp P 1 Section 10 Overload Warning System Two Blocks 10 4 General System Operation The crane supplies the electricity to power the overload warning system The system receives the electric
271. life Pump grease into each fitting until clear grease appears around the bearing shield Rotate the upper and again pump grease into each fitting Repeat this procedure until clean grease appears all around the bearing Inspect valve spools and linkage for rust or corrosion If any appears clean it off Lubricate valve spools with clean S o M oil TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 12 Every 250 Hours First perform all operations listed under Every 50 Hours S o M Filter 1 Change the filters every 250 operating hours The procedure is explained later in this section Outrigger System Filter Master Clutch 1 Check adjustment Adjust if necessary Boom Hoist Brake 1 Visually check band connecting lugs actuating linkage related pins and the mounting bracket pin hole for any Front Drum Brake signs of wear or damage Repair or replace if required Rear Drum Brake 2 Visually check and for any indications of bending interference or unusual linkage wear which would indicate excessive wear of the brake parts Repair or replace is required 3 Check condition of the band adjusting bolt and nut Make sure the locking nut will hold against rotation during operation 2 13 Every 500 Hours First perform all operations listed under Every 250 Hours Boom Hoist Brake 1 Remove the band and all related parts for a detailed visual inspection If any
272. line point must be between 200 F 250 F Test method ASTM text 0611 H Open Gear Grease This grease shall be homogeneous combination of carefully blended mineral oil and calcium soap Mineral oil specifications API Gravity 18 9 Flash COC F 410 Viscosity at 210 F S U S 178 Grease specifications Penetration ASTM Worked at 77 F 276 Unworked at 77 F 242 Dropping Point 224 F Calcium Soap 9 196 J SAE 140 Extreme Pressure Gear Lubricant An extreme pressure gear lubricant containing defoamant additives It must meet or exceed U S A Government specifications No MIL L 2105 APIGYAV ity 45 a 17 0 Min Flash Point 380 F Min S U Viscosity at 210 F ni ener 125 180 Viscosity Index aciei eet inerenti ri ti tte nde 65 Min Channel Point 0 Max Timken Test 70 Lb Containing Defoamant Additives M SAE 50 Oil A refined petroleum base product with anti rust and anti oxidation inhibitors meeting the following specifications Viscosity at 100 F 1050 SUV Approx Viscosity at 210 F 88 92 SUV Pour Point 10 F Note Use in temperatures above 32 F 2 20 Gear Case Check And Change Procedures 2 21 Main Transmission Creeper Transmission Steering Gear Rear End Differentials 2 22 To Check a Park machine on level ground Set the parking brake Shut off the carrier eng
273. links in the 48 1 21m position Connect the 19 8 5 99m basic pendants between the headshaft links and the bridle spreader bar Disconnect the carrying links Pin links in storage position Boom up and swing around until boom is over front of machine Rest boom on boom guide bar Retract mast to 25 6 7 8m position as explained on Position boom one inch above guide bar for travel Maximum Travel Speed With 50 Foot 15 24m Boom Over Front Of Carrier W A Upper Ctwt W A Bumper Ctwt 5 MPH 8 04 kph W 140 Ton Hook Block W A Upper Ctwt W 0 A Bumper Ctwt 5 MPH 8 04 kph W 140 Ton Hook Block W O Upper Ctwt W O Bumper Ctwt 20 MPH 32 2 kph W 140 Ton Hook Block 5 26 Removing Gooseneck Links b c 5 16 Extend mast to 30 0 9 14m position as explained on Swing boom around over rear of machine Boom down until boom peak is on ground and pendants are slack Unpin carrying links and allow them to drop down Chart E TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment Boom down until the carrying links may be attached to the boom lugs Boom up until boom hoist ropes are taut But With Boom Peak Resting On The Ground Remove the boom connecting pins from the gooseneck links Remove the gooseneck links from the boom pin connection hubs Lower mast until boom pin connection holes line up Insert boom pins Insert keeper pins in boom pins Disconnect car
274. llation removal Extensions Available in 10 20 30 and 40 lengths with appropriate length pendants and one hoist line deflector roller per extension Top section 25 long six 21 root diameter head sheaves 2 hoist line deflector rollers and back stay lines for jib if ordered Permissible boom lengths without jib minimum 50 maximum 230 Maximum boom length when using jib 200 Boom stops Dual lever type with spring loaded bumper ends Boomhoist bridle and spreader bar Serves as connection for boom suspension system Bridle contains eight 15 root diameter sheaves for 16 part boomhoist reeving mounted on anti friction bearings and two 15 root diameter auxiliary load hoist sheaves mounted on bronze bushings which enable boom live mast to be used for machine assembly or disassembly Boom live mast Supports boomhoist bridle Required for all boom lengths Hydraulically extends from 25 6 to 30 0 working position mechanically retracts to 25 6 position Boom live mast stops Incorporated with boom stops manually positioned when using live mast as short boom Boom angle indicator Pendulum type mounted on boom base section Load hoist line deflector rollers To minimize line chafing on top side of boom Rollers mounted on anti friction bearings One roller furnished with each extension 2 boom pendants standard Furnished in pairs for basic boom lengths plus approp
275. ller plug in the fuel filter cover and install the primer Prime the system Remove the primer and install the filler plug HC238A 2 86 2 87 2 88 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Engine Cooling System Maintenance Engine Coolant The function of the engine coolant is to absorb the heat developed as a result of the combustion process in the cylinders from the component parts such as exhaust valves cylinder liners and pistons which are surrounded by water jackets In addition the heat absorbed by the oil is also removed by the engine coolant in the oil to water oil cooler For the recommended coolant refer to the Engine Coolant section Cooling System Capacity The capacity of the basic engine cooling system cylinder block cylinder head thermostat housings and oil cooler housing is shown in the table below To ascertain the complete amount of coolant in the cooling System the additional capacity of the radiator hoses and accessories such as a heater must be added to the capacity of the basic engine The capacity of the radiator and related equipment should be obtained from the equipment supplier or the capacity of a particular cooling System may be obtained by filling the system with water then draining and measuring the amount required Cooling System Capacity Chart Basic Engine 6V92 5 1 2 2 89 Fill Cooli
276. llison now approves and recommends the use of the new generation 15W 40 lubricating oils providing the following ash limits zinc requirements oil performance levels and conditions are met 1 The sulfated ash ASTM D 874 content of the lubricant shall not exceed 1 000 by weight except lubricants that contain only barium detergent dispersant salts where 1 5 by weight is allowed Lubricants having a sulfated ash content between 0 55 and 085 percent by weight have a history of excellent performance in Detroit Diesel engines Lubricants having a sulfated ash content greater than 0 85 percent by weight are prone to produce greater deposit levels in the ring belt and exhaust valve areas of the engine 2 The lubricant shall meet the performance requirements shown in API Service Classification TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication CD SE 2 The iron content is greater than 150 parts per 3 The zinc content xinc diogranodithiphosphate of million all the lubricants recommended for use in Detroit 3 The coagulated pentane insolubles total Diesel engines shall be a minimum of 0 0796 by weight However the zinc requirement is waived where EMD lubricants are used 4 Evidence of satisfactory performance in Detroit Diesel engines has been shown to the customer and to Detroit Diesel Allison by the oil supplier 10W 3D 20W 40 amp Other Multigrade Oils Detroit
277. loped and a serious accident may occur 1 11 Supply Air Pressure This gauge indicates the pressure available from the compressor before it is reduced to operate the service brakes The gauge should register 140 to 150 psi 965 1034 kPa A tire inflation hose may be plugged into the air brake system to use this pressure to inflate carrier tires See tire inflation chart Dee of this manual 1 12 Emergency Air Pressure This gauge indicates the amount of air pressure available to operate the park or emergency brake The gauge should register 115 to 125 psi 792 861 kPa If the gauges do not register the correct pressure correct the problem before driving the carrier or sufficient emergency braking force may not be developed and a serious accident may occur Note There must be at least 60 psi 413 kPa pressure in both service and emergency brake systems before the carrier will move Otherwise the park brake will not release If air pressure is lost while roading the machine the emergency brakes will automatically apply when air pressure drops to approximately 40 psi 275 8 kPa 1 13 Park And Emergency Brake Control When the park or emergency brake control is actuated air under pressure from the emergency brake system is directed to the park or emergency brake diaphragm in the rear actuators applying the rear brakes At the same time a mechanical lock locks the actuator in place so the brakes can t release unlock the bra
278. m Lifting Assembly Inspect Service Revolving Frame Undecking Replace Repair A 22 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS GROUP COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT 7411 Turntable Bearing Service Replace Catwalk Replace Repair ch Clutch Assemblies Inspect Service Adjust Replace Repair Clutch Rotating Joint Replace Repair ADM NN lt n gt N Boom Hoist Shaft Assembly Service Replace Repair Rear Drum Shaft Assembly Service Replace Repair Reverse Swing Shaft Assembly Service Replace Repair Front Drum Shaft Assembly Service Replace Repair Reduction Shaft Assemblies Service Replace Repair Vertical Swing Shaft Assembly Service Replace Repair A 23 TM 10 3950 263 14 amp P 1 MAINTENANCE ALLOCATION CHART FOR CRANE MOBILE CONTAINER HANDLING 140 TON CAPACITY TRUCK MOUNTED DED FMC MODEL HC 238A NSN 3950 01 110 9224 SECTION II ASSIGNMENT OF MAINTENANCE FUNCTIONS COMPONENT ASSEMBLY MAINTENANCE MAINTENANCE NUMBER FUNCTION CATEGORY EQUIPMENT A 24 Low Speed Planetary Assembly Shaft Brake Assemblies Boom Hoist Assembly Boom Hoist Pawl Boom Hoist Wire Rope Cable Main Hoist Assembly M
279. make up the lifting spreader Each corner is connected by four capscrews and locknuts Install the four corner braces Each end of each brace is secured by a capscrew and locknut Install a turnbuckle assembly at each rear corner of the lifting spreader b Pin the front sling assembly to the lugs on the spreader Pin the rear sling assembly to the turnbuckles X Install a keeper pin in each mounting pin Pin the two sling assemblies to the lugs on top of the spreader assembly Install a keeper pin in each mounting pin c Pin a support pendant to each of the four sets of lugs on the bottom of the spreader assembly Install a keeper pin in each mounting pin Operator s Manual Section 1 Continued Operatin TM 10 3950 263 14 amp 1 Instructions Fig 1 39 Lifting Sling Installation 5 Lifting Spreader 6 Rear Slings 7 Connecting Pins 8 Support Pendants Rear 9 Turnbuckles 1 Support Pendants Front 2 Connecting Pins 3 Front Slings 4 Hook Block From Lifting Equipment d Refer to Figure 1 40 Install the lifting arm assemblies on the outrigger boxes Connect the arm to the lugs on the bottom of the outrigger box with a pin Install a keeper pin in the mounting pin e Lift the arm until the socket on the arm contacts the outrigger jack cylinder rod Move the outrigger beam in or out as necessary to center the jack cylinder rod in the pocket Install two hitch pins through holes in the pocket Thi
280. me on either side of the back up lights The machine must be secured to the transport unit from each of the four hooks Anchoring Machine With Cable Blocking Each Side Of Each Wheel Tie Downs Hook 2 Front 4 Attaching Point On 2 Rear Transportation Unit TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Chain load binders should be used Adjust them so the chains are taut when the load binder handle snaps over center Wire the handle of the load binder to the body so it can t loosen Cable tie down can be used Use at least 1 2 cable Use new cable only Never use discarded or used cable for tie downs Loop the cable through the tie down hook and the anchor on the transport unit Connect the ends of the cable with cable clips to form a loop Stick a pipe through the loop Twist the loop until it is tight Secure the pipe to the transportation unit or to the machine so the loop won t untwist Hook On Cable Loop Machine Cable Clips Place Pipe Through Loop Twist Un til Tight Anchor On Transport Unit Secure Pipe After Twisting Fig 1 42 Machine Tie Down Cable Or Chain Operator s Manual Index Section 2 Subject HC238A General Lubrication Information 2 1 Carrier Maintenance And Lubrication Schedule Monthly Or 1000 Miles 1609 3km Semi Annually Or 5
281. meter Over outside of front bumper 9 8 Brakes Type Actuators Size and area Parking Emergency 9 9 Electrical System Carrier Upper TM 10 3950 263 14 amp P 1 Tulsa 28HG6 Onespeed disengage system FMC 85 gal Racine hydraulics 3 4 valve stack jacks 3 8 valve stack beams Electric solenoid operated FMC Full width double box pin connected to carrier frame FMC Double acting hydraulic Power assist Hydraulic Ross HSP 70 120 ft 8 wheel air brakes Single diaphragm on front double diaphragm on rear Rear wheels total braking area 574 sq inches per axle Front wheels total braking area 248 sq inches per axles Brakes on 4 rear wheels apply and air chamber push rods mechanically lock Con trolled by air from dash Brakes on 4 rear wheels apply and mechanically lock if air pressure drops below 40 P S I 12 volt with 2 225 amp hour batteries 12 volt with one 225 amp hour battery 9 1 Operator s Manual Section 9 Specification and General Information Mounts on front bumper hooks 11 400 Ibs 9 10 Bumper Counterweight 9 11 Carrier Speeds Transmission Gear Ratios Based on GM 6V 92TA engine at 2 100 r p m governed full load speed Main Auxiliary Eaton AT 1202 Eaton 1 00 1 00 2 036 1 00 Gear RTO 915 81 9 15 Swing System Reduction Creep speed in deep reduction low 1st based on peak engine torque of 1 400 r p m for GM Creep speed I
282. mmercial literature and does not conform with the format and content specified in AR 310 3 Military Publications This technical manual does however contain available information that is essential to the operation and maintenance of the equipment TM 10 3950 263 14 amp P 1 Operator s Manual Warnings P 1 12 WARNING Always Stand In Clear View Of The Jack Or Beam Being Operated Make Sure Nothing Is In The Way When Operating A Jack Or Beam To Avoid Injury Or Damage WARNING Handle With Care The Starting Fluid Is Toxic And Flammable WARNING Always Disengage The Master Clutch When Leaving The Operator s Seat For Any Reason Or When Working On The Machine Failure To Disengage Master Clutch May Result In Accident WARNING Trying To Lift The Machine With Damaged Components In The Lifting Sling Can Cause An Accident A Very Heavy Load Is Being Lifted If It Falls The Machine Will Be Damaged Personnel Nearby May Be Injured Or Killed WARNING Be Careful Not To Get Battery Electrolyte On Your Skin Clothing Or Especially In Your Eyes It Is Acid And Can Cause Injury Don t Smoke Or Use Open Flame Near A Battery Battery Gas Is Explosive P 2 10 WARNING Moving Machinery Do Not Service Maintain Or Lubricate Unless Master Clutch Is Disengaged And Rotation Machinery Has Stopped Or Severe Personal Injury May Result WARNING Use Fuel Oil Or Cleaning Solvent In A Well Ventilated Area
283. mp inlet restriction must not exceed 6 inches of mercury At normal operating speeds 1600 2100 rpm the fuel pressure is 45 to 70 psi 310 to 483 kPa Change the fuel filer elements whenever the inlet restriction suction at the fuel pump reaches 12 inches of mercury at normal operating speeds and whenever the fuel pressure at the inlet manifold falls to 45 psi 310 kPa Item 14 Coolant Filter If the cooling system is protected by a coolant filter and conditioner the filter element should be changed every 500 hours or 15 000 miles After replacing the filter and cover gasket start the engine and check for leaks UEL FUEL FILTER STRAINER Fuel Strainer And Filter Item 13 2 60 2 62 2 63 2 64 2 65 2 66 2 67 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Fig 2 22 Starting Motor Item 15 2 62 Item 15 Starting Motor The electrical starting motor is lubricated at the time of original assembly Oil can be added to the oil wicks which project through each bushing and contact the armature shaft by removing the pipe plugs on the outside of the motor The wicks should be lubricated whenever the starting motor is taken off the engine or disassembled The Sprag overrunning clutch drive mechanism should be lubricated with a few drops of light engine oil whenever the starting motor is overhauled Item 16 Air System Check all of the connections in the air sys
284. nd etc Machines should be stored under cover to reduce the possibility of rust and deterioration If stored outside certain procedures must be followed to protect the machine as much as possible from the elements 11 12 HC238A Clean the unit thoroughly removing all dirt and other foreign material Lubricate the entire machine as outlined in this section Touch up any spots where paint has been knocked off to reduce rust and deterioration Cover all unpainted machined surfaces except friction surfaces such as clutch and drum brake surfaces with a coating of heavy grease to reduce rusting Cover all clutch and brake friction Surfaces with cover of water proof paper or plastic to protect these surfaces from rust Bring all tires up to proper operating pressure Check periodically while stored to make sure tires don t go flat If possible block machine up so tires are clear of the ground Do not use outriggers for this purpose Use sound blocking and place so machine cannot fall off or topple blocking If this is not possible set machine on planks so tires will not sink into around Apply parking brakes Leave digging brakes released Drain accumulated water and sludge from air brake reservoirs to reduce rust and deterioration Cover intake and exhaust openings on both carrier and upper engine to reduce moisture entry Fully retract all outrigger beams and Jacks If anti freeze is not to be used completely drain
285. nd kelly bar lengths with drilling attachments and in pile hammer attachments further complicate the manner in which lifting capacities are reduced The weight of each piece of auxiliary equipment is to be considered a part of the live load acting at the radius of the center of gravity of the piece Demolition Work Demolition work can be particularly TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T hazardous Shock loadings and side loadings from demolition ball and clamshell bucket work can be severe The repetitive nature of such work Imposes heavy demands on all parts of the machine Restrict demolition ball weights to not exceed over 5096 of machine capacity on tire capacities for truck cranes at maximum radius at which you handle the ball with the boom length you are using In no case however should the ball weight exceed 50 of the available line pull Fig 37 Use caution when using demolition ball When using a clamshell bucket be sure you stay within the boom length and load limitations shown in the lifting capacity chart in the machine Failure to do so may create fatigue which can lead to eventual failure When using demolition ball avoid sudden clutch and brake applications Work steadily and smoothly Don t try to knock the whole structure down with one blow Use good aim f the ball misses its target out swing could cause machine tipping or overload When swinging b
286. nded for use in Detroit Diesel engines due to the presence of the fluoroelastomer Viton 0 seals in the cooling system Before installing ethylene glycol base antifreeze in an engine previously operated with methoxy propanol flushed with clean water and examined for rust scale contaminants etc If deposits are present the cooling system must be chemically cleaned with a commercial grade heavy duty descaler Ethylene glycol base antifreeze is recommended for use in Detroit Diesel engines Methyl alcohol antifreeze is not recommended because of its effect on the non metallic components of the cooling system and because of its low boiling point The inhibitors in permanent antifreeze should be replenished at approximately 500 hours or 20 000 mile intervals with a non chromate inhibitor system Commercially available inhibitor systems may be used to re inhibit antifreeze solutions 2 35 Operator s Manual 2 115 2 116 2 36 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication COOLANT INHIBITOR CHART Sealer Additives Inhibitor or Inhibitor System Sodium chromate Potassium dichromate Perry filter elements 5020 Type OS S 453 Spin on S 373 Spin on 5070 Type OS S 473 Spin on Lenroc filter element Fleetguard filter elements DCA Canister DCA Spin on AC filter elements DCA Canister DCA Spin on Luber Finer filter elements LW 4739 Canister LFW 47
287. nding or lowering a boom with a load 11 12 load radius Increases As radius Increases capacity decreases f capacity Is exceeded the boom may bend as the safety factor in the boom hoist cylinders exceeds the strength of the boom or the machine may tip over Sometimes at low angles a hydraulic crane boom can be extended with a load but cannot be retracted This ls because more power Is available In the boom cylinders to extend than to retract If an operator extends his boom under load thinking he can retract If he gets Into a precarious condition it may cause an accident Fig 48 Avoid two blocking Most capacities on hydraulic machines are based on strength of materials In these cases overloads will cause something on the machine to break before it will tip Never use signs of tip as warning of overload When operating off the boom with the Jib Installed deductions from the capacity chart must be made The weight of the jib backstops stays etc must be subtracted 0 30 13 14 15 from the capacity on the chart to obtain a net capacity Failure to do so will result in an overload condition which can cause boom failure or machine tipping The boom must be extended In the correct manner before making a lift On machines with single lever control the smallest boom section extends first then the next largest etc If one section starts to extend before the next smaller section Is fully extended
288. ne is started In the event the engine is equipped with warning lights rather than pressure indicators the pressure should be checked and recorded at the interval indicated Item 24 Overspeed Governor Lubricate the overspeed governor if it is equipped with a hinge type cap oiler cup with 5 or 6 drops of engine oil every 500 hours Avoid excessive lubrication and do not lubricate the governor while the engine is running Item 26 Throttle Delay Inspect and adjust if necessary The throttle delay system limits the amount of fuel injected during acceleration by limiting the rate of injector rack movement with a hydraulic cylinder The initial location of this cylinder must be set with the proper gauge to achieve the appropriate time delay Inspect the check valve by filling the throttle delay cylinder with diesel fuel and watching for valve leakage while moving the throttle from the idle to the full fuel position Item 27 Battery Charging Alternator Lubricate the battery charging alternator bearings bushings with 5 or 6 drops of engine oil at the hinge cap oiler every 200 hours or 6 000 miles Some alternators have a built in supply of grease while others use sealed bearings In these latter two cases additional lubrication is not necessary HC238A 2 72 2 73 2 74 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication On alternators the slip rings and brushes can be in
289. ne should be periodically cleaned by operating under load at high speeds until normal lube oil and coolant temperatures are reached Prolonged idling has several ill effects which can eventually result in engine failure This is especially true if the ambient temperatures are low Ignition in diesel engines especially 2 cycle types takes place as a result of a sufficiently high temperature being generated by the compression of the intake air and proper injection of fuel The loss of compression pressure heat loss from the engine and loss of heat generation from cylinder combustion all reduce the possibility of reaching a sufficiently high compression temperature for combustion to take place The lower engine speed IDLE allows more time for gas leakage past compression rings and heat transfer away from the cylinder 3 Boom Repair The Service Manual Volume 2 contains repair procedures and instructions for boom and extension sections This information has been provided as a quide to aid users of this equipment in the event that the prime contractor subcontractor welders are not available such as a contingency event or condition Boom repair procedures in the commercial Technical Manuals were provided as Information only Field requirements for boom repair may be exercised in the form of a Contractor Support Service Contract or a commercial repair or as an in house repair when approved by the National Maintenance Point NMP DRSTA MVM This au
290. nes to operate on diesel fuels classified by the ASTM as Designation D0975 grades 1 D and 2 D These grades are very similar to grades DF 1 and DF 2 of Federal Specification VV F 800 Residual fuels and furnace oils generally are not considered satisfactory for Detroit Diesel engines In some regions however fuel suppliers may distribute one fuel that is marketed as either diesel fuel ASTM D 975 or domestic heating fuel ASTM D 396 sometimes identified as furnace oil In this case the fuel should be investigated to determine whether the properties conform with those shown in the Fuel Oil Selection Chart presented in this specification The Fuel Oil Selection Chart also will serve as a guide in the selection of the proper fuel for various applications The fuel used must be clean completely distilled stable and noncorrosive Distillation Range Cetane Number and Sulfur Content are three of the most important properties of diesel fuels that must be controlled to insure optimum combustion and minimum wear Engine speed load and ambient temperature influence the selection of fuels with respect to distillation range and cetane number The sulfur content of the fuel must be as low as possible to avoid excessive deposit formation premature wear and to minimize the sulfur dioxide exhausted into the atmosphere To assure that the fuel you use meets the required properties enlist the aid of a reputable fuel oil supplier The res
291. ng System Before starting the engine close all of the drain cocks and fill the cooling system with water If the unit has a raw water pump it should also be primed since operation without water may cause impeller failure The use of clean soft water will eliminate the need for de scaling solutions to clean the cooling system A hard mineral laden water should be made soft by using water softener chemicals before it is poured into the cooling System These water softeners modify the minerals in the water and greatly reduce or eliminate the formation of scale Start the engine and after the normal operating temperature has been reached allowing the coolant to expand to its maximum check the coolant level The coolant level should be within 2 of the top of the filler neck 2 29 Operator s Manual 2 90 2 91 2 92 2 30 Should a daily loss of coolant be observed and there are no apparent leaks there is a possibility of gases leaking past the cylinder head water seal rings into the cooling system The presence of air or gases in the cooling system may be detected by connecting a rubber tube from the overflow pipe to a water container Bubbles in the water in the container during engine operation will indicate this leakage Another method for observing air in the cooling system is by inserting a transparent tube in the water outlet line Drain Cooling System Drain the coolant by opening the drain cocks in the water
292. ng seriously wrong report it to direct support as soon as possible 5 While performing PMCS observe caution notes and warning paragraphs preceding those operations which could endanger your safety or result in damage to the equipment A 54 TM 10 3950 263 14 amp P 1 WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in well ventilated area Avoid contact with skin eyes and clothes and don t 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 contact with skin or clothing is made flush with water If contact with eyes is made wash your eyes with water and get medical aid immediately Air Compressed air used for cleaning purposes will not exceed 30 psi Use only with effective chip guarding personnel protective equipment goggles shield gloves etc a Keep it clean Dirt grease oil and debris only get in the way and may cover up a serious problem Clean as 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 of course but look for chipped paint bare metal or rust around bolt heads Tighten any that you find loose c Welds Look for loose or chippe
293. nkcase Breather Item 34 2 78 Torque Converter Item 40 2 80 Filter Mounting Upper Engine Filter Mounting Carrier Engine Typical By Pass Filter Mounting Spin On Fuel Filter and Strainer Water Characteristics Heat Transfer Capacity Coolant Inhibitor Chart Coolant Freezing and Boiling Tempera tures versus Antifreeze Concentration Carrier Assembly Clutch Linkage Carrier Clutch Steering Mechanism Front Wheel Alignment Front Axle Assembly Brake Assembly Wheel Torque Procedure Tire Inflation Chart Rear Axle Assembly Outrigger System Schematic Test Gauge Assembly Outrigger Throttle Control Master Clutch Assembly Swing Lock Assembly Swing Lock Swing Brake Counterweight Remover Assembly Planetary Brake Front and Rear Drum Brakes Boom Hoist Brake Clutch Assembly Air Box Drains Control Lever Adjustment Chain Case With Adjuster Machine With Basic 50 Ft 15 24m Boom Working Area Definition Label Boom Live Mast Live Mast Used As Short Boom Boom And Mast Foot Assemblies Boom Backstop Assemblies Main Pendants and Links Deflector Roller Assembly Deflector Roller Location Boom Assembly Step 1 Boom Assembly Step 2 Boom Assembly Step 3 Boom Assembly Step 4 Boom Assembly Step 1 Boom Assembly Step 2 Boom Assembly Step 3 Boom Assembly Step 4 Inline Pin Tubular Boom Disassembly Inline Pin Tubular Boom Assembly Carrying Link Assembly Carrying Boom Horizontal Over Rear Carrying 50 Ft
294. nment 100 of its charge out rate which must be on record with the company at the time the claim is received for performance of work related to the campaign a If FMC has established the work time required to effect the campaign only the time so established will be recognized in establishing the amount of the claim b If FMC has not established the hours required to effect the campaign the company will accept actual documented time expended by the distributor provided the time is reasonable and can be substantiated B Travel Time Per Diem 1 FMC will compensate the Government at 10096 of their charge out rate on record with the company for actual travel time expended in the performance of campaign work up to a maximum of eight hours 2 The standard 1096 add on clause as found in the warranty labor program will not apply to computing the credit amount on the warranty claim 3 In addition to travel time a reasonable per diem will be allowed for living expenses Per diem receipts must accompany claim 4 of 5 viii TM 10 3950 263 14 amp P 1 Warranty C Overtime 1 Overtime charges will not be accepted unless agreed to by the company prior to the performance of the work D Limits of FMC Responsibility 1 FMC reserves the right to make alterations or modifications in their equipment at any time which in their opinion may improve the performance and efficiency of the machine FMC shall not be obligated to make such alterations
295. nnually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY STEERING GEAR a Check the lubricant level fill as necessary with SAE 90 Extreme Pressure Gear Lubricant b Inspect for leakage or damage PLANETARY WHEEL HUB a Check the oil level ref page 2 14 para 2 25 Operator s Manual b Change oil ref page 2 14 para 2 26 Operator s Manual TRANSMISSION AIR FILTER Replace air filter POWER STEERING RESERVOIR Change oil ref page 2 5 Operator s Manual FRONT WHEEL BEARINGS Inspect replace any unserviceable parts and repack with grease BRAKES a Check adjustment ref page 3 4 para 3 6 and page 3 5 Operator s Manual b Inspect linings drums and cylinders for excessive wear scoring or leaking OUTRIGGER HYDRAULIC SYSTEM NOTE Change filter after the first 50 hours of machine opera tion Thereafter change at specified intervals a Change filter page 2 15 Operator s Manual b Change oil ref Operator s Manual Clean strainer when sump tank is drained A 57 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Carrier M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY COOLING SYSTEM a Inspect all hoses for cracks bulges or signs of deterioration b Check coolant condition IAW TB 750 651 Clean flush refill with coola
296. nstructions Live Mast Control Fig 1 37 Live Mast Control will be turning in a direction that is the reverse of normal direction of rotation for that function or operation thus if a clutch function is engaged the operation will be backwards This same effect occurs when lowering or holding a boom by means of torque converter and throttle 1 92 Boom Foot Pin Removal System A hydraulic cylinder is mounted between the boom foot pins This cylinder pulls the pins from the boom foot lugs for easy removal of the boom lower section Pressure to operate the cylinder comes from the S o M system A control valve mounted under the R H platform of the machine controls the cylinder 1 93 Removing Boom Foot Pins Remove all boom but lower section Refer to section 5 of this manual b Position boom lower section directly over rear of carrier Apply swing lock c End of boom lower section must be on the ground Block securely between lower section and carrier frame under each chord so boom section cannot move when pins are removed d Remove cotter pins from boom foot pin keeper pins Remove keeper pins e Start upper engine let it run at an idle with master clutch disengaged f Pull control lever toward front of upper to withdraw pins g Remove lower section from machine with helper crane or live mast used on short boom 1 94 Replacing Boom Foot Pins a Withdraw pins as explained earlier b Using
297. nt 1 54 Upper Control Panel The control panel shown in is mounted in the ceiling of the operators cab near the R H cab wall 1 55 Ignition Switch Turn the key clockwise to turn on The switch must be on for the starter button to operate Turn the switch off and remove the key when machine is not in use to prevent starting by unauthorized person Operator s Manual 1 56 1 57 1 58 1 59 1 60 1 61 1 62 1 63 1 64 Starter Button Depressing the starter button actuates the engine starter The button should not be actuated over 15 seconds at a time when starting the engine If the engine doesn t start in this length of time something is usually wrong Continued grinding on the starter causes unnecessary wear and discharges the battery Engine Shutdown The engine shutdown is cable operated with Detroit Diesel engines Pull out on the control until the engine stops then push the control back in Emergency Shutdown machines equipped with Detroit Diesel engines pull out on this control if the engine shutdown does not function until the engine stops running After use reset manual reset on the engine before restarting This should not be used as normal engine shut off as it can damage blower seals Windshield Wiper The machine is equipped with two speed electric windshield wipers Turn the control to low for low speed operation or to high for high speed operation Turn the control to off to t
298. nt spur gear driven Precision control Hoisting through power hydraulic 2 shoe clutch lowering through low speed planetary drive unit Wire rope drum 12 1 4 root diameter smooth involute splined to shaft Drum locking pawl Operator controlled spring applied hydraulically released Boom hoist clutch 23 diameter 6 face width Planetary lowering Mounts on outer end of shaft planetary external contracting band brake hydraulically controlled by boom hoist lowering control lever Boom hoist lowering brake External contracting band spring applied hydraulically released as hoist clutch or lowering planetary engaged Brake drum involute splined to shaft brake 28 diameter 5 face width Boomhoist limiting device Provided to restrict hoisting boom above recommended minimum radius located on exterior right hand side of operators cab When hydraulic device is contacted by boom in near vertical position control oil is bled from clutch and brake sump tank disengaging clutch and applying B H brake Section 9 Continued Specifications And General Information 9 18 Control System Speed o Matic 9 19 Counter weight 9 20 Total AB Attachment TM 10 3950 263 14 amp P 1 Gantry Mounted to upper frame supports boom suspension system Bail Integral of machinery side housings with cross over sheave frame pinned to supports boom suspension syst
299. nt and rust inhibitors if necessary CLUTCH LINKAGE Lubricate pivot points on the clutch pedal and linkage with engine oil ENGINE Change oil replace filter and clean crankcase breather cap ref Operator s Manual NOTE For Army Oil Analysis Program Procedure refer to TB 43 0210 DRIVE BELTS Check tension of belts and adjust as necessary ref page 2 22 Operator s Manual AIR COMPRESSOR WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in well ventilated area Avoid contact with skin eyes and clothes and don t 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 contact with skin or clothing is made wash your eyes with water and get medical aid immediately Clean air strainer element using dry cleaning solvent ref Operator s Manual A 58 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Carrier M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY FUEL STRAINER AND FILTER Replace both elements at indicated time or when plugged ref Operator s Manual EMERGENCY SHUTDOWN Check emergency shutdown system to be sure it will operate when needed FUEL TANK Open drain at bottom of tank to remove any water or sediment
300. ntervals Always follow the supplier s recommendations on inhibitors usage and handling Chromates Sodium chromate and potassium dichromate are two of the best and more commonly used water system corrosion inhibitors However the restrictive use of these materials due to ecology considerations has de emphasized their use in favor of non chromates Care should be exercised in handling these materials due to their toxic nature Chromate inhibitors should not be used in permanent type antifreeze solutions Chromium hydroxide commonly called green slime can result from the use of chromate inhibitors with permanent type antifreeze This material deposits on the cooling system passages reducing the heat transfer rate Fig 2 35 and results in engine overheating Engines which have operated with a chromate inhibited water must be chemically cleaned before the addition of permanent TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication antifreeze A commercial heavy duty descaler should be used in accordance with the manufacturer s recommendation for this purpose PARTS PER GRAINS PER MILLION GALLON Chlorides Maximum 40 Sulfates Maximum 100 Total Dissolved Solids Maximum 340 Total Hardness Maximum 170 Refer to Table 2 for evaluation of water intended for use in a coolant solution Determine The Concentrations Of Chlorides Sulfates And Total Dissolyed Solids In The Water Chlori
301. ntil old lubricant dirt and water are Drag Links King Pins expelled Tie Rod Ends Etc Universal And Slip Joints 1 Lubricate with a low pressure gun to avoid seal damage 1 2 Lubricate master shifter control with a grease gun Pump in grease until it extrudes around the boot on shift lever 3 Lubricate all pivot points on transmission creeper transmission and throttle control linkages with engine oil Steering Gear 1 Check lubricant level Fill if necessary 2 Inspect for leakage or damage Repair any damage before roading or operating the machine Control Linkage Lubricate U joints on main transmission shifter with a grease gun Rear Axle Vents 1 Clean 2 2 TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 6 Semi Annually or 5 000 Miles 8046 7 km First perform all operations listed under Monthly Or 1 000 1609 3 km Miles Main Transmission 1 Drain flush and refill as explained later in this section Creeper Transmission 2 Refer to capacity chart LE for proper type and amount of lubricant to use Rear Axle Differentials Planetary Wheel Ends Front Wheel Bearings 1 Repack with grease 2 Inspect Replace any worn parts 2 7 Carrier Capacity Chart Rear Axle Differential Each 35 Pints 16 5 Liters E Rear Axle Planetary Hub Each 8 Pints 3 78 Liters E Main Transmission 28 Pints 13 2 Liters D Creeper
302. nued Troubleshooting Procedures 1 Defective swing clutch 1 Turntable bearing binding up 2 Worn bevel gears 3 Swing brake dragging 1 Adjusted wrong control adjusted wrong 2 or grease on linings Worn linings 1 Swing brake control adjusted wrong 2 Swing brake adjusted wrong 3 Rusty or bound up pins and linkage 1 Master clutch not engaged 2 Mechanical failure of drive chain or reduction shafts 1 No lubricant on gears 2 Worn gear teeth 3 Bad bearing on one or more shafts TM 10 3950 263 14 amp P 1 1 Adjust clutch see p 4 6 Check clutch shoes and drum for scoring glazing oil on surface Clean or replace parts as necessary see Shop Manual Check S o M pressure at clutch cylinder Should be 900 1050 P S I If not adjust control stand linkage Set pressure in system seep 4 8 7 2 Make sure clutch is assembled in energized position see Shop Manual 5 9 2 0 Check clutch shoes and arms for binding on pins Free up and lubricate Refer to lubrication chart Thoroughly lubricate the bearing If this doesn t help contact factory service department 2 Repair or replace see Shop Manual 3 Disengage Adjust if required cedo col Check linings for scoring or foreign objects Repair or replace as necessary see Shop Manual 1 Adjust see p 4 2 2 Clean or replace linings see Shop Manual 1 Adjust see p 4 6 2
303. nuts cotter pins and other fasteners If any tighten or replace before operating 3 Inspect all welds for cracking If any are noted consult manufacturer Do not operate until properly repaired 1 Check oil level Add oil as necessary 1 Lubricate throwout collar sparingly so grease won t get on the clutch linings 2 Lubricate fittings on clutch cross shaft 1 Check oil level Add oil as necessary 2 Check for leakage Repair if any before operating the machine 1 Checkoil level Add oil as necessary 1 Inspect wire rope and fittings daily as explained irj Section Sot this manual 1 Check oil level Add oil as necessary 2 Inspect the system for leaks wear or other damage Repair before operation 1 Maintain a thin film of grease on all open gears including swing pinion and turntable bearing at all times Upper engine must be shut down and swing lock engaged when applying the grease 1 Check fuel level Add fuel as necessary 2 Don tsmoke when fueling or fuel up a machine near an open flame Keep the nozzle in contact with the filler neck to prevent static electric sparks Shut off the engine when fueling 1 Check and fill if necessary 2 Check anti freeze in winter 1 Check electrolyte level Fill with distilled water if necessary 2 Keep batteries clean at all times Corroded posts or accumulation of grit electrolyte etc on top of a battery can cause it to become discharged WAR
304. ny rights afforded to the Government by any other clause in the contract Exceptions To Warranty The following supplies are not covered under the 1500 hour or 15 month warranty 1 Tires 2 Batteries 3 Light Bulbs 4 Windshield wipers 5 Electrical Wires 6 Lubricants 7 Filters 2of5 vi TM 10 3950 263 14 amp P 1 Warranty Preparation Of Warranty Claims 1 Use warranty claim no 531 for all claims over 25 These forms are available at no charge from the factory 2 Claims less than 25 00 will not be processed 3 Campaigns A 25 00 minimum will be paid on all claims identified as a campaign and listing the campaign only on the individual warranty claim 4 Delivery and applicable follow up reports must be on file before warranty consideration will be given 5 Warranty Claim must be typed and mailed to the manufacturing division where the particular machine was manufactured no later than 45 days after work is completed Do not type on the reverse side of the warranty claim form If additional space is required on the warranty claim form attach an additional sheet 6 The upper right hand corner of the claim must be completely and correctly filled out Information about description of the job must also be furnished 7 Under Section 1 and 2 of the warranty claim explanation must be given covering problem as diagnosed and corrective action taken The statement installed or replaced will not be accepted as a satisfacto
305. o grade the route move the load by stepping Pick the load and set it down along side the travel route Travel unloaded machine beyond load pick load swing and set down farther along route Continue procedure until load is at its destination c Carry load as close to the ground as possible d Avoid side swing of load If tethering won t hold load directly below boom swing until boom points directly down hill While this may reduce stability of the machine it will reduce boom side loadings also Carrying the load near the ground will reduce the danger of overturning e Don t attempt to carry loads which approach the machine s rating f Don t travel with a load on soft ground If machine sinks into ground stability can be affected to the point of tipping the machine over 25 g Keep all personnel clear of machine and load Be prepared to set load down quickly at any time h When traveling up or down slopes keep the upper facing downhill to reduce the tendency for the boom to fall over the cab If necessary to face uphill keep the boom down i Fully extend outrigger beams Extend or retract jacks until pontoons just clear the ground j Inflate carrier tires as shown on tire inflation chart for making lifts on rubber w Fig 28 Avoid using multiple cranes lift Lifts where two or more cranes work together can be hazardous and should be avoided Such lifts should be made only under the
306. o hit something Make sure the load being lifted will remain within capacity as it is lifted and the boom deflects See rule 2 page 19 also Fig 46 ever use a hydraulic crane boom to push or pull 7 Never use a hydraulic crane boom to push or pull I is not designed for this purpose Such action car damage the boom and lead to an accident later on Never operate a hydraulic crane at radii or boom lengths where capacity chart shows no capacity n some cases the machine can tip over with no load on the hook This is particularly true over the side when on rubber where these machines are the least stable Also if the boom Is fully extended at a low angle the machine may tip until the boom touches the ground In any case Injury or machine damage may result Fig 47 When boom retracts load will lower When lowering or retracting the boom the load will lower To compensate for this the operator must take up on the hoist rope Otherwise movement of the load may cause an accident When extending the boom the load will raise The operator must let off on the hoist rope to keep the load in place Extending the boom without letting off on the rope can lead to two blocking This is when the head sheaves contact the hook sheaves or ball Two blocking can lead to machine damage rope breakage and load dropping 0 29 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T 10 When exte
307. o the retract position e Pinthe mast in position f Leave the control knob in retract position Note The live mast may be pinned in the extended position or fully retracted See page 5 2 for more information 1 97 Retracting The Live Mast a Boom down until the boom contacts the ground If the boom isn t on the machine block under the live mast near the standoffs to hold it horizontal b Position the mast standoffs as shown in Fig 1 38 then pay out on B H rope until the standoffs contact the lugs on the boom lower section c Remove the two pins from the mast tubes d Control valve must be in retract position Slowly take up on B H ropes to retract the mast 1 98 General Information Lifting Sling The lifting sling assembly is designed to lift the entire machine after removal of the following equipment a Upper ctwt b Bumper ctwt c All boom sections and pendants except the lower section After these removals the machine will weigh approximately 117 000 Ibs Lifting equipment must be provided that can safely lift this weight This equipment must be in good condition properly adjusted and reeved before attempting to lift the machine 1 32 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Refer to the capacity chart in the lifting equipment and make sure it can do the job before proceeding 1 99 Lifting Sling Assembly The lifting sling assembly cons
308. oads When a submerged load reaches the surface don t attempt to lift it out of the water all at once It may be saturated with water and weigh many times what you expect Allow it to drain as you raise the load slowly Be patient since draining may take a long time A load when removed from the water even when fully drained will have a greater effective weight than it will when submerged because of buoyancy Don t extract piling casings or other such loads by yanking or jerking on them The practice of pulling on the load until the machine has tipped then releasing the hoist line allowing the machine to drop back and catching the hoist line on a clutch or brake may break the boom f the piling or casing won t pull out with a smooth steady pull use an extractor pulling frame or some similar 0 22 45 rigging intended for this purpose Pulling on a load that is not free to be lifted can develop loadings in the machine far in excess of the normal weight of the load Imposing such loads on a machine can damage the machine and may cause disastrous failure When using a pile extractor use a shock or vibration insulator unit Fig 36 Use caution when extracting pilin casing etc Operation with auxiliary equipment such as pile driver leads pile hammers or caisson boring attachments imposes additional loading on the machine This causes a major reduction in lifting capacities of the machine Changes in augers a
309. of the Warranty Supervisor 2 If material is required for inspection the claim will be accepted and credit issued within 45 days of receipt of the part or parts at the factory or a designated location If inspection reveals the part or parts were not defective the factory will re invoice the Government to cancel the credit previously issued 3 Government will be notified by phone followed by confirming letter with shipping instructions for alleged defective parts If parts not received within 3 days a follow up letter will be sent to distributor If parts not received within 30 days after follow up letter mailed warranty claim will be cancelled 4 A disputed warranty settlement must be presented in writing to Construction Equipment Distribution Operation 2800 Lakeside Drive Bannockburn Illinois 60015 Attention Service Department no later than 45 days after the warranty claim status report is dated If the Government does not reply to FMC within the 45 day time frame the warranty claim will not be opened to any further discussion at a later date Listed below are the mailing addresses and models for the Manufacturing Division Direct claims to the attention of the Warranty Departments FMC Corporation Crane and Excavator Division Box 9500 Bowling Green Kentucky 42101 Campaign Procedures Safety Recall A Labor compensation for announced factory modification and retrofits implemented by CCED 1 FMC will compensate the Gover
310. oint 85 feet 25 9m from the boom foot E18 Install the spacer capscrew lockwasher and hex nut which holds the two link halves together Pin the main pendants to these links Insert a cotter pin in each end of link pin A maximum 45 feet 13 7m of boom including the upper section may be added on from the 85 foot 25 9m point for a total maximum boom length of 130 feet 39 6m Booms from 120 to 130 feet 36 5 to 39 6m in length may be assembled by varying the length of boom added on The boom extensions are installed as follows a Line up the two upper pin connecting holes between the two sections being pinned together Insert the two top boom pins Install keeper pins in each boom pin b Boom up until the bottom boom pin holes line up Install the two bottom boom pins connection Install a keeper pin in each c Repeat steps a and b above until a maximum of 45 feet 13 7m of additional boom is connected to the 85 foot 25 9m point d To install peak install upper pins then raise until lower pins can be installed Don t lift peak off the ground or damage to boom may occur Boom down until pendants are slack Disconnect pendants from assembly links Assemble the necessary length of main pendants to connect between the headshaft links and bridle spreader bar Install a cotter pin in each pendant pin Refer to Chart A earlier in this section for pendant length per given boom length Note
311. om lower section and the backstop tubes 5 12 Boom Assembly Step 2 A maximum of 85 feet 25 9m of boom including the upper section may be cantilevered extended beyond point of suspension with pendants connected as shown in Any boom length from 50 to 110 feet 15 24 33 5m may be assembled by varying the length of boom added to the lower section The following Connect a 19 8 5 99m basic pendant pair to these links points Must Be noted before proceeding Connect the other ends of these pendants to the bridle 1 Whenever possible assemble boom with short sections spreader bar See Figs 5 3 and 5 10 close to the boom foot Two short sections will weigh more per equivalent length than one long section so keeping short sections close to boom foot will improve machine stability Install the assembly links over the pin connection hubs at the end of the boom lower section Install the spacer capscrew hex nut and lockwasher which hold links together Note All boom assembly and disassembly must be done with the upper swung to face directly over the rear of the carrier TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment Fig 5 11 Boom Assembly Step 2 1 85 25 9m Maximum Additional Boom 2 Top Boom Pins b All boom assembly must be done with the upper swung between the two sections being pinned together Insert to face directly over the rear of the carrier the two top boom pins In
312. om or for many conditions which may occur and which may create hazards lt requires all the skil experience judgment and safety consciousness that a good operator can develop to attain safe operation Many safety devices can assist the TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T operator in performing his duties but he should not depend on them to keep him out of trouble WORKING AREAS 35 Don t lash a machine down unless you are using an operable load indicating system or are sure of the weight of every load Lashing a machine down encourages overloading and If machine can t tip you can be seriously overloaded with no Indication of it Machine damage or injury may result CARRIER ON OUTRIGGERS OVER SIDE NOTE THESE LINES DETERMINE THE LIMITING POSITION OF ANY LOAD FOR OPERATION WITHIN WORKING AREAS INOICATEO OVER SIDE FRONT WHEEL TRACK LONGITUOINAL OF CARRIER x EE CENTER ON REAR AXLE ROTATION BOGIE FRONT AXLE CARRIER ON BOGIE WHEELS SEE NOTE Fig 33 OVER SIDE Use mid point suspension where required 36 If the boom length is such that mid point or intermediate suspension is required make sure It is installed and properly adjusted Long booms may buckle In the middle from their own weight without this suspension CENTER OF ROTATION 37 Working areas for machines are defined as over front overside over rear or 360 degrees
313. om boom pins Install a keeper pin in each connection pin Fig 5 16 Boom Assembly Step 3 85 Foot Point 25 9m 5 Live Mast Extended 30 0 8 Spacer Capscrew Washer Assembly Links 9 14m Position Hex Nut 1 2 n 20 Foot Pendants 6 1m 6 Upper Pin Connection Luq 9 Pendant Pin amp Cotter Pin 25 Spreader Bar 63 5cm 7 Mid Point Links 10 Main Pendant 11 19 8 5 99m Basic Pendant Operator s Manual TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment Fig 5 17 Boom Assembly Step 4 4 20 Pendants 6 10m 5 20 6 10m Pendants 6 25 63 5cm Bridle Spreader Bar 7 Live Mast Fully Extended 30 0 9 14m 1 Two Position Headshaft Link 2 6 76 2cm Position 19 8 5 99m Basic Pendant Pair 5 1 52m Pendant Pair Must Be Used On All Booms 90 Feet 27 32m and Longer 2 3 c Repeat steps a and b above until 60 feet 18 29m of additional boom is connected to the boom lower section 5 18 Boom Assembly Step 3 Boom down until the 19 8 5 99m 5 19 Boom Assembly Step 4 5 10 pendants are slack Disconnect the pendants from the assembly links Assemble two more 20 foot 6 10m pendant pairs to the 19 8 5 99m pendant pair already connected to the bridle spreader bar Total pendant length must be 59 8 18 1m Insert cotter pin in each pendant pin See Fig 5 16 Install the assembly links over the top pin connection hubs at a p
314. ompare readings to those nable 10 1 EUR aa If the meters values are the same as Table 10 11 replace the angle sensor and recalibrate the system bb If the meters values are different than rabie 16 1 replace the cable assembly and recalibrate the system Recalibrate the system Refer o Fig 10 2 Rewire the load pin terminal strip Remove the round screw on cover Remove cover from load sensor assembly Reverse wires at terminal 2 and 3 Replace cover and tighten round screw Contact the FMC Service Department Check out the system Set 4 P L and 100 ft on select switches on main electronics box regardless of parts of line reeved on main hoist or of boom length now on crane Select Both position on hook select switch on display panel Disconnect the angle sensor main electronics cable assembly at the main electronics connection Perform self test procedure i If meters values match those in Table 10 1 there is problem in either a cable assembly or component between the main electronics assembly and the load sensor assemblies Reconnect the cable assembly at main electronics connection Disconnect each cable assembly connection between the load sensor assemblies and main electronics assembly one at a time Start at a load sensor head amplifier cable at dual head amplifier and work on down the boom until reach the main electronics each time performing the self test procedure When the values on the meters m
315. on Spring O Ring Valve Cap Shims WARNING Reduce S o M System Pressure To Zero As Explained In Steps A And B Before Unscrewing The Relief Valve Cap Or Before Removing The Pipe Plug From The Unloading Valve Pieces Of The Valve May Explode Under Pressure Otherwise And Could Cause Injury Shut off the engine Feduce system pressure to zero by working the control levers back and forth Remove the pipe plug from the unloading valve Replace the return line leading to the sump tank Operator s Manual Index Section 8 Subject Carrier and Upper Engine S ection 8 Troubleshooting Procedures Braking System Transmission and Clutch Steering and Drive Line v loo eo AJ o Hydraulic Outrigger System co Speed o Matic Hydraulic Control System g N Torque Converter and Master Clutch EN Load Hoist System Boom Hoist System kl g Swing System Gear Train Subject TM 10 3950 263 14 amp P 1 Page TM 10 3950 263 14 amp P 1 Operator s Manual Section 8 Troubleshooting Procedures TM 10 3950 263 14 amp P 1 Operator s Manual Section 8 Troubleshooting Procedures Troubleshooting Procedures Carrier and Upper Engines Engine does not crank 1 Battery defective or discharged 1 Charge or replace battery 2 lgnition switch starter motor Replace components as necessary or solenoid defective see Shop Manual 3
316. ondition Hydraulic parts must be sealed to prevent contamination Any parts received without covering port plugs etc will not be inspected or forwarded to the vendor as vendors refuse any warranty consideration of hydraulic components not properly protected 3 Shipping of parts for more than one claim in one shipment is discouraged However if for some reason or other this must be done than each individual part must be identified by item number claim number and A T R number 2 3 of 5 vii TM 10 3950 263 14 amp P 1 Warranty Submitting Of Warranty Claims a Prepare claim as outlined under PREPARATION OF WARRANTY CLAIMS b Distribute copies as follows Copy 1 White Forward copies to the Manufacturing Division Copy 2 Yellow responsible for the model involved For your Copy 3 White assistance we are listing below the mailing Copy 4 Pink address of each of the models manufactured Copy 5 Green Copy 6 Blue Government copy Copy should be retained for your records c You will be advised on the disposition of any alleged defective parts d Approximate time for processing claims that are within the time frame of normal warranty will fall in the following categories 1 If material is not required for inspection the claim will be accepted or rejected within 45 days of receipt of the 3 copy The Government will assume the responsibility for destroying and scrapping related parts under the direction
317. onirol stand A detent on the control lever latches it in the engaged or disengaged position 4 4 Swing Lock Adjustment The swing lock must be kept adjusted as follows a Adjust the linkage 3 to a maximum length to provide firm tooth engagement with the control lever locked in its detent Back off adjustment one full turn for proper clearance Tighten nut 5 b Adjust rod length at B to 8 1 4 209 5mm 4 5 4 6 4 7 c Adjust the stop bolt 4 to allow linkage 5 to toggle over center 3 8 to 1 2 9 5 to 12 7 mm when the pawl is engaged and the lever is locked in its detent d Adjust the linkage 6 until the pawl teeth will clear the ring gear teeth by 3 16 4 76mm with the pawl disengaged and the lever in its detent WARNING Anchor The Upper Machinery Against Rotation By Lowering The Attachment To The Ground Before Working On Swing Lock Swing Brake The swing brake is an external band brake which clamps against a drum splined to the reverse shaft to resist swinging of the upper The brake is spring applied and hydraulically released If adjusted properly it will apply if control pressure is lost A small brake drum and band assembly is connected to the swing brake control This brake will hold the control in any desired position to enable the operator to work with the brake partially applied to retard swinging of the upper Swing Brake Adjustment Check the adjustment of the swing brake on deli
318. oom installed check to see the maximum radius that can be used to lift the particular load and don t exceed it The following facts about the capacity chart should be noted at all times 1 The lifting capacities are shown in pounds and are based on 85 of tip with the machine on firm level ground if stability establishes the ratings Capacities marked with an asterisk are based upon factors other than tip The most notable of these factors is strength of material Exceeding the rated capacity overloads the machine and could result in boom or rope failure or damage to the machine It could also tip the machine over 2 The capacity chart lists ratings for operation under several different circumstances a With A or AB ctwt b 360 capacities on outriggers Side rear capacities on outriggers d Side rear capacities on tires The label shown in defines the working areas for both on or off outriggers 360 capacities working over the front is permissible only when all outriggers including the front bumper outrigger are properly set 3 Several attachments are available for use with this machine Separate capacity charts are available for use with each attachment The allowable capacities with this machine vary with type of attachment being used Make sure you are using the correct capacity chart for the attachment your machine is equipped with HC238A Throttle c Assemble the desired length of boom on th
319. orking near power lines 1 Allelectrical power lines are dangerous Contact with them whether insulated or not can cause death or injury When operating near power lines the best rule is to have the power company cut off the power and ground the lines However in some cases you will be unable to have the power cut off Follow these rules whether the power is cut off or not a Be alert you are working around conditions which can cause death b Keep all parts of the machine fall lines hook block and load at least TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T 15 ft 4 75m from the line or other distance specified by TB 385 101 Slow down machine operation Assume that every line is hot Appoint a reliable person equipped with a loud signal whistle or horn to warn the operator when any part of the machine or load moves near the power line This person should have no other duties while the machine is working around the power line Fig 10 Stay away from power lines e Warn all personnel of danger Allow no unnecessary person in the area Don t allow anyone to lean against or touch the machine Don t allow sling men or load handlers to hold load lines or rigging gear unless absolutely necessary Use dry hemp or dry plastic ropes as tether lines Make certain everyone stays 15 ft 4 75m away from the load or such distance as required by applicable code f E
320. orrosive short fiber grease of excellent A straight mineral gear oil Meets MIL L VV 765a Amend 1 M90 mechanical and storage stability API Gravity 21 7 Min The mineral oil shall meet the following specifications Flash Point 425 F Viscosity at 2100 F S U S 80 100 S U Viscosity at 210 F 80 Viscosity Index 65 Min Viscosity Index 60 Timken Test Lever Load 40 Min Channel Point 0 F Max Pour Point 15 F Max E SAE 80W 90 Multigear Lubricant The grease shall have the following physical and chemical properties An extreme pressure gear lubricant containing defoament additives Penetration Worked 770 F Meets or exceeds MIL L 2104C 60 Strokes Units 265 295 Penetration Change After API Gravity 25 1 10 000 Strokes 15 Max Flash Point 400 F Dropping Point 350 F Min SU Viscosity at 210 F 80 Lithium Soap 6 14 Viscosity Index 97 Water 0 10 Max Channel Point 0 F Max Timken Test 50 Lb Applications Bearings C SAE 10W30 Detergent Engine Oil A heavy duty refined petroleum product with detergent and anti oxidant additives to meet internal combustion engine supplement one Specifications HC238A 2 13 TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication R783 Containing Defoamant Additives F Automatic Transmission Fluid Type A Suffix A Armour Research Qualified A high grade heavy duty refined mineral oil lubricant Ana
321. ossible to obtain long life and best engine and not to a new engine or one that has not been performance from a Detroit Diesel engine The intervals operated for a considerable period of time For new or indicated on the chart are time or miles in thousands of stored engines carry out the instructions given under actual operation Preparation for Starting Engine First Time under Operating Instructions in INDUSTRIAL TIME INTERVALS OFF HIGHWAY HRS NN NE s m NEN NN NE NEN AND MARINE mles 01 X 1 Lubricating Oil X 2 Fuel Tank X X 3 Fuel Lines X 4 Cooling System X X X 5 Turbocharger X 6 Battery X 7 Tachometer Drive X 8 Air Cleaners X X 9 Drive Belts X X 10 Air Compressor X 11 Throttle and Clutch Controls X 12 Lubricating Oil Filter X X 13 Fuel Strainer and Filter X 14 Coolant Filter X 15 Starting Motor 16 Air System X 17 Exhaust System X 18 Air Box Drain Tube X 19 Emergency Shutdown X 21 Radiator X 22 Shutter Operation X 23 Oil Pressure X 24 Overspeed Governor X 26 Throttle Delay X 27 Battery Charging Alternator X 28 Engine and Transmission Mounts X 29 Crankcase Pressure X 30 Air Box Check Valves 31 Fan Hub X 32 Thermostats and Seals X 33 Blower Screen X 34 Crankcase Breather X 36 Engine Tune Up 37 Heat Exchanger Electrodes X X 38 Row Water Pump X 39 Power Take Off X X X 40 Torqmatic Converter X X X X 2 2
322. outlet elbow oil cooler housing the fresh water pump heat exchanger radiator and on certain engines the water hole cover located on the blower side toward the rear of the cylinder block Components of the cooling system that do not have a drain cock are drained through the oil cooler housing drain cock Remove the cooling system filler cap to permit the coolant to drain completely from the system To ensure that all of the coolant is drained completely from a unit all cooling system drains should be opened Should any water that may be trapped in the cylinder block or radiator freeze it will expand and may cause damage When freezing weather is expected drain a unit not adequately protected by antifreeze Leave all drain cocks open until refilling the cooling system Drain raw water pumps by loosening the cover attaching Screws It may be necessary to tap the raw water pump cover gently to loosen it After the water has been drained tighten the screws Flushing Cooling System Flush the cooling system each spring and fall The flushing operation cleans the system of antifreeze solution in the Spring and removes the summer rust inhibitor in the fall preparing the cooling system for a new solution The flushing operation should be performed as follows a Drain the previous season s solution from the engine b Refill the cooling system with soft clean water If the engine is hot fill slowly to prevent rapid cooling and
323. ow set to warm up before connecting a heavy load Continuous generator overload may cause high operating temperatures that can damage the windings The generator 6 16 Pre Heating And Starting Extremes in starting temperatures may require additional preheating If engine fails to start quickly rest engine several seconds and repeat starting sequence applying preheat for a longer interval using heater switch Sed page 6 10 for comprehensive engine starting guide a For cold engine starting below 55 13 depress the manifold heater switch for one minute b Push start stop switch to its start position c Release switch after engine starts and reaches speed d Oil pressure should read at least 20 psi 13 kPa pressure relief valve is not adjustable CAUTION Do Not Apply Overvoltage To The Starting Circuit At Any Time Overvoltage Will Destroy The Glow Plugs And Air Heater In 2 Or 3 Seconds If It Becomes Necessary To Use An Additional Source Of Power To Start The Set Use A 12 Volt Battery Connected In Parallel 6 17 Automatic Starting And Stopping Separate controls may be used for automatic start and stop but must provide engine preheating The automatic control has a time delay relay to preheat glow plugs and the manifold heater for about 20 seconds before cranking occurs The time delay relay prevents immediate engagement of the starter in case the load is reapplied before the engine stops 6 18 Stoppin
324. parts of line than shown Check code requirements and use them where applicable Use special care when handling loads on single part line with boom at a short radius This Is especially Important when hoist line is off rear drum The boom may be whipped back over machine In single line operation make sure Angle A is always greater than Angle B See Fig 21 Test the hoist brake by raising the load a few inches and holding It should hold easily It takes more brake to hold a load in the air when the drum Is full of rope than a few inches above the ground with only one wrap on the drum Don t pull sideways on the boom not even a little bit Lift straight up on every load Moving trucks rail cars barges or TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T anything else by pulling sideways with the hoist line Is liable to buckle the boom It may also damage the swing mechanism Pulling sideways on a boom set at a high angle can turn the machine over sideways Fig 22 Never use a boom to pull loads sideways 13 Never move a crane away from the load while handling near capacity loads Due to load inertia weight the load will tend to stay in position when the machine starts to move and then will swing in toward the machine The inertia effect will tend to increase load radius and decrease stability This could lead to boom failure or machine tipping 14 When operating on outrigger
325. pins d Remove jack assembly from end of outrigger beam 1 43 Jack Oylinder Installation a Attach a chain or wire rope sling to eye bolt on top of jack cylinder Connect to sling with hook block from helper crane or live mast reeved as a short boom b Lift jack assembly and set in place on end of outrigger beam Install the two mounting pins Install rod ends and capscrews to retain mounting pins c Remove dust caps and plugs from quick disconnects Connect quick disconnects d Remove sling from eye bolt 1 44 Outrigger Box Removal The outrigger boxes can be removed under the machine s own power with the live mast reeved as a boom or with a helper crane The procedure is as follows a Connect a chain or wire rope sling to the lifting lugs on the outrigger boxes b Connect hook block to sling Lift to support weight of outrigger box and secure by setting hoist brake HC238A TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions c Remove outrigger box connecting pins d Disconnect hydraulic lines leading to outrigger box at quick disconnects Install dust caps and plugs on all quick disconnects e Lower assembly to the ground and slide it out from under the carrier Left front jack must be removed from front outriggers as explained previously before assembly will slide out from under carrier 1 45 Replacing Outrigger Box a Connect a chain or wire rope sling to the lifting lugs
326. pipes from the backstops one at a time allowing the inner pipes to slide into the outer pipe c Push the assembly forward and lay it on the boom d Remove the inner pipe from the outer pipe Add or subtract spacers as necessary then replace inner pipe e Lift assembly until inner pipe may be slid out of outer pipe and connected to backstop f Connect other inner pipe to backstop tube 9 Boom up and check adjustment Operator s Manual 5 8 Main Pendants And Links 5 9 A 19 8 5 99m long basic pendant is used with all boom lengths and remains pinned to the bridle spreader bar On booms 90 feet 27 43m in length and over a 5 foot 1 52m pendant is added to the pendant system and remains pinned to the headshaft links booms shorter than 90 feet 27 43m use of the 5 foot 1 52m pendants will cause the weight of the live mast to pull the unloaded boom into the backstops when minimum radius is reached and require boom to be pulled away from backstops by hanging load on hook When booming down to minimum radius on booms 90 feet 27 43m and longer failure to use the 5 foot 1 52m pendants will reduce effectiveness of live mast and over load boom mast pendants and boom hoist system when handling near capacity loads The main pendants connect to a two position link which mounts over the boom headshaft The links are pinned in the 2 6 76 2cm position at all times except when transporting boom horizontally over
327. ponsibility for clean fuel lies with the fuel supplier as well as the operator 2 31 Operator s Manual 2 98 Fuel Oil Selection Chart Final Typical Boiling Cetane Sulfur Application Classification Point No Content All Applica tions 2 99 2 100 2 32 During cold weather engine operation the cloud point the temperature at which wax crystals begin to form in diesel fuel should be 10 F 6 C below the lowest expected fuel temperature to prevent clogging of the fuel filters by wax crystals At temperatures below 20 F 29 C consult an authorized Detroit Diesel Allison service outlet since particular attention must be given to the cooling system lubricating system fuel System electrical system and cold weather starting aids for efficient engine starting and operation Note When prolonged idling periods or cold weather conditions below 32 F 0 C are encountered the use of lighter distillate fuels may be more practical The same consideration must be made when operating at altitudes above 5 000 ft Lubricating Oils For Detroit Diesel Engines Diesel Lubricating Oils General Considerations All diesel engines require heavy duty lubricating oils Basic requirements of such oils are lubricating quality high heat resistance and control of contaminants Lubricating Quality The reduction of friction and wear by maintaining an oil film between moving parts is the primary requisite of a lubri
328. properly engaging 2 Clutch disc s worn 3 Oil on clutch disc s 1 Adjust clutch see p 3 1 2 Replace clutch assembly see Shop Manual 3 Disassemble and repair Re place clutch assembly see Shop Manual Steering and Driveline Driveline and or rear axle noise Worn or damaged components Vibration or defective steering 1 Misalignment or ineffective power steering e Tires out of balance Damaged wheels or tires 1 Realign steering sed p 3 3 Check and repair steering system see Shop Manual 2 Balance tires 3 Replace wheels or tires 1 Repair or replace see Shop Manual Hydraulic Outrigger System A beam or jack cylinder will not operate No beams or jacks will operate Jacks will not lift machine off ground Defective switch or electrical connection Defective solenoid Mechanical interference between outrigger box and beam Relief valve set incorrectly Pump failure Power take off not engaged Jacks only defective blocking valve Low oil level Relief valve set wrong Pump failure Check switch and electrical system Repair or replace components Replace solenoid see Shop Manual Determine what is causing the interference Correct the problem see Shop Manual Adjust relief valve setting see p 3 3 Repair or replace see Shop Manual 3 Engage power take off see p 1 12 Repair or replace valve see Shop Manual Refill
329. r Reinstall and check for signs of blower seal leakage CRANKCASE BREATHER Remove crankcase breather assembly and wash in clean solvent ENGINE AND TRANSMISSION MOUNTS Check condition of mounting bolts and mounting pads Repair or replace as necessary AIR BOX CHECK VALVES Remove valves clean in solvent and blow out lines with compressed air Inspect for leaks after servicing LUBRICATION REQUIREMENTS Perform all other lubrication as specified in lubrication charts on 2 20 in the Operator s Manual A 60 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Upper M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY NOTE Perform Operator Crew PMCS prior to or in conjunction with Organizational PMCS if There is a delay between the daily operation of equipment and the Organizational PMCS b Regular operator is not assisting participating CRANE OVERLOAD WARNING SYSTEM Verify load and radius calibration with actual measurements If recalibration is necessary follow procedures given in Section 18 of the commercial Shop Technical Manual a Check load by lifting a known load that is at least 50 of the rated capacity for the given part of line b Check radius by booming to a radius that can be conveniently measured with a tape measure WARNING Do not service maintain or lubricate the gear cases
330. r an equivalent Lithium base multi purpose grease every 700 hours Fig 2 25 Alternator Item 27 2 71 2 76 2 77 2 26 Every 4000 hours clean inspect and repack the fan bearing hub assembly with the above recommended grease At a major engine overhaul remove and discard the bearings in the fan hub assembly Pack the hub assembly using new bearings with Texaco Premium RB grease or an equivalent Lithium base multi purpose grease Item 32 Thermostats And Seals Check the thermostats and seals preferably at the time the cooling system is prepared for winter operation Replace the seals if necessary Item 33 Blower Screen WARNING Warn Personnel In The Immediate Area Before Using Compressed Air For Cleaning Wear Safety Glasses Compressed Air Coming Into Contact With The Human Skin Or Causing Flying Metal Chips Can Cause Injury WARNING Use Fuel Oil Or Cleaning Solvent In A Well Ventilated Area Away From Flames Inspect the blower screen and gasket assembly every 1 000 hours or 30 000 miles and if necessary clean the screen in fuel oil and dry it with compressed air Install the screen and gasket assembly with the screen side of the assembly toward the blower Inspect for evidence of blower seal leakage 2 78 2 79 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication Item 34 Crankcase Breather Remove the externally mounted crankcase breather assembly
331. r can be introduced into the fuel supply through poor maintenance loose or open fuel tank caps contaminated fuel supply or condensation Condensation is particularly prevalent on units which stand idle for extended periods of time Ambient temperature changes cause condensation in partially filled fuel tanks Water accumulation can be controlled by mixing isopropyl alcohol dry gas into the fuel oil at a ratio of one pint per 125 gallons fuel or 0 1096 by volume Microbe growth can be eliminated through the use of commercially available biocides There are two basic types on the market The water soluble type treats only the tank where it is introduced Microbe growth can start again if fuel is transferred from a treated to an untreated tank Diesel fuel soluble type such as Biobor manufactured by U S Borax or equivalent treats the fuel itself and therefore the entire fuel system Units going into storage should be treated as follows Add the biocide according to the manufacturer s instructions This operation is most effective when performed as the tank is being filled Add dry gas in the correct proportions If the fuel tanks were previously filled add the chemicals and stir with a clean rod Item 3 Fuel Lines Make a visual check for fuel leaks at the cross over lines and at the fuel tank suction and return lines Since fuel tanks are susceptible to road hazards leaks in this area may best be detected by checking
332. rain plug Replace the system filter as explained later in this section Refill the system with oil as specified earlier in this section When adding oil use a clean funnel equipped with a screen filter The importance of cleanliness cannot be stressed too highly when pouring oil into the hydraulic system Dirt dust lint or water must not be allowed to enter the system Submerge the breather cap in heavy lubricating oil before installing it on the sump tank 7 4 S o M System Filter 7 5 To change a b c d e Decrease the system pressure to zero by working the levers back and forth Remove the filter housing and element Remove the filter element from the housing Remove the gasket from the filter head and the rubber washer from the filter housing Thoroughly clean all parts in approved low toxicity non flammable solvent Use good ventilation Kerosene or diesel fuel can be used but don t smoke while using Never use gasoline or other highly flammable solvents Install a new rubber washer in the housing 7 1 Operator s Manual Section 7 Continued Speed o Matic Control System pa Fig 7 2 S o M System Filter Head Gasket Element Body Washer Install a new gasket in the head g Install a new filter element in the housing h Screw the housing into the head Tighten to 150 ft Ibs 200 4 N m torque 7 6 Relief Valve Assembly During normal machine operation the S o
333. rake Shoes 12 Axle Shaft 13 Slack Adjustor 14 Brake Chamber Operator s Manual Priority Flow Suction To Sump 011 From Relief Valve Return Line The gauge quick disconnects plug into the carrier quick disconnects near the outrigger boxes b Install a pressure gauge into the right front jack retract control line quick disconnect c Operate the jack switches to bottom out the cylinder d Increase the carrier engine speed by depressing the outrigger throttle control button Read the gauge It should read 1550 50 psi 10 867 545 kPa If the pressure is incorrect set it The relief valve is set screw adjusted Loosen the jam nut turn the set screw out than back in until the correct pressure is reached Tighten the jam nut e Install a pressure gauge in the front bumper outrigger pressure top port It is located in a tee connected to the lock valve Note Always set pressures at full engine throttle Push the throttle switch on outrigger control panel to fast position when setting the pressures Obtain final pressures by bringing the pressure up to the final setting not by backing down f Extend the jack Read the gauge It should read 500 psi 3447 5 kPa If the pressure is incorrect set it The relief valve is set screw adjusted Loosen the jam nut turn the set screw out than back in until the correct pressure is reached Tighten the jam nut g Check operation of the front bumper jac
334. rating time Use the running time meter optional equipment to keep a record of operation and servicing Regular service periods are recommended for normal service and operating conditions For continuous duty extreme temperature etc service more frequently For infrequent use light duty etc service periods can be lengthened accordingly Refer tol Figs S 5 and for engine maintenance information WARNING Before Commencing Any Maintenance Work On The Engine Generator Control Panel Automatic Transfer Switch Or Associated Wiring Disconnect Batteries Failure To Do So Could Result In Damage To The Unit Or Serious Personal Injury In The Event Of Inadvertent Starting Operator should periodically make complete visual inspection with set running at rated load Some of the things to check for are as follows a Check all fuel and oil lines for possible leakage b Inspect exhaust lines and mufflers daily for possible leakage and cracks c Periodically or daily remove moisture from sediment bowl d Inspect air shrouds for leaks and security sure cooling fins are clean e Inspect electrical wires and connections for security and fray damage Note If generator requires major repair or servicing contact an authorized Onan dealer or distributor 6 38 AC Generator Periodic inspections that coincide with engine oil changes will ensure good performance 6 39 Batteries Check the condition of the s
335. ration 28 When operating near minimum radius be ready to boom down as you set the load down to compensate for the tendency of the boom to move back against the backstops when the load is released This action occurs because of the elasticity in the boom and boom hoist system Severe bending in the boom can occur if it 0 18 is allowed to bear against the backstops too heavily Fig 29 Use caution when booming to minimum radius 29 Watch out for two blocking pulling hook block into boom sheaves This can cause rope breakage or can pull the boom back over the cab resulting In an accident Point of suspension LJ lt lt L Fig 30 Cantilevering boom 30 Know the maximum amount of boom that can be cantilevered projected beyond point of suspension during boom assembly and disassembly Exceeding this amount can cause boom or boom suspension failure 31 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T Fig 31 er section before unpinnin Block under u Block under the boom upper section before unpinning from extensions Since the upper section is tapered it will fall to the ground when unpinned possibly resulting in an accident Pendants reconnected behind pins being removed pendants must be tight centerline of boom straight boom peak lower pins may be on ground removed here pendants hooked in front of pin removed
336. re of the lubricating oil in the engine As soon as the engine starts the gauge should begin to register If the gauge does not register pressure listed in the chart below stop the engine and determine why Correct the problem before running the engine again or engine damage may result 1200 RPM 18 p s i 124 kPa Min 30 60 p s i 207 414 kPa Normal 2100 RPM amp Up 30 p s i 207 kPa Min 40 60 p s i 276 414 kPa Normal Operator s Manual 1 17 1 20 1 21 1 22 1 23 1 24 1 25 1 26 1 27 Water Temperature The engine coolant temperature is registered on this gauge Normal running temperatures are 160 to 185 F 71 to 850 C If the temperature exceeds this shut down the engine and determine the cause Correct the problem before running the engine again or engine damage may result Voltmeter The engine voltmeter measures the voltage produced by the alternator and indicates the condition of the battery Refer to Fig 1 18 for voltmeter readings Fuel Gauge The fuel gauge indicates the amount of fuel in the carrier tanks Refill when it nears E to avoid running out of fuel Tachometer The tachometer indicates the number of RPM s the carrier engine is turning Speedometer The speedometer indicates the speed in MPH that the carrier is traveling It also contains an odometer which indicates the number of miles the carrier has traveled Throttle Pulling out on the throttle decreases en
337. re D During A After W Weekly M Monthly ss ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO B D AIW M FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF 16 TORQUE CONVERTER Check the torque converter and the supply tank fluid level Fluid must be checked at operating temperature and engine must be running Add oil as necessary to bring the level to the FULL mark ret pg 2 27 Operator s Manual LIGHTS Inspect all lights for proper operation WINDSHIELD WIPERS Check for proper operation condition of arms and blades DRUM TURN INDICATOR Check operation of the audio visual drum turn indicator CONTROL LEVERS AND PEDALS Check for proper operation Controls perform im properly BRAKES PAWLS AND CLUTCHES WARNING Correct adjustment is required for safe load handling and to avoid injury to personnel Apply every brake pawl and clutch and Brakes pawls and check for proper engagement Adjust or clutches do not engage have repaired any faults properly A 50 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Upper NOTE Within designated interval these checks are to be performed in the order listed B D During A After W Weekly M Monthly ITEM TO BE INSPECTED EI PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO von Lem FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF EXHAUST SYSTEM a L
338. re crushing or other damage resulting in distortion of the rope structure Evidence of any heat damage resulting from a torch or arc caused by contact with electrical wires g Reduction from nominal diameter of more than 3 64 1 19mm for diameters up to and including 3 4 1 58mm 1 16 1 58mm for diameters 7 8 to 1 1 8 22 22mm to 28 6mm 3 32 2 38mm for diameters 1 1 4 to 1 1 2 25 6mm to 38 1mm Marked reduction in diameter indicates deterioration of the core resulting in lack of proper support for the load carrying strands Excessive rope stretch or elongation may also be an indication of internal deterioration h Evidence of bird caging or other distortion resulting in some members of the rope structure carrying more load than others i Noticeable rusting or development of broken wires in the vicinity of attachments Note f this condition is localized in an operating rope and the section in question can be eliminated by making a new attachment this can be done rather than replacing the entire rope Operator s Manual Classification Effect Crushed or bruised 1 Excessive amount of rope wire rope shipping reel causing weight of reel to be carried on wire rope 2 Dropping reel off truck dock etc onto hard surface 3 Open drum reels 1 Rolling reel over large stones or other objects Rust 1 Poor storage facilities Doglegs or Kinks 1 Improper procedure for
339. read correctly but Reach meter does not Reach meter and Alert meter read correctly but Load meter does not read correct weight of known weight Reach meter and Alert meter read correctly but Load meter value decreases as more weight is hoisted Reach meter and Alert meter read correctly but Load meter reads zero or full scale Replace the defective meter To replace a defective meter Remove display panel unplug meter loosen the two screws on side of meter and remove meter If the Reach meter does not indicate the horizontal distance from the upper center of rotation to the hook block adjust the angle sensor until Reach meter is correct If the Reach meter does not move when the boom is raised or lowered a See if the cable assembly between the main electronics and angle sensor is securely connected b Check for a faulty cable assembly or angle sensor i Set the reeve select switch on the main electronics box to 4 P L regardless of main hoist reeving i Select Both position on the hook select switch located on the display assembly ii Disconnect angle sensor main electronics cable assembly at the main electronics connection iv Press test button and hold Record the readings on the meters v Reconnect angle sensor main electronics cable assembly at main electronics connection then disconnect cable at angle sensor connection vi Press test button and hold Record the readings on the meters C
340. red before lifting Be sure that the rigging can t slip off or pull away from the load or get out of position on the load Be sure load is rigged so it won t fall over Chains and slings must be of adequate size in good condition and not twisted around each other The load must not catch on an obstruction when lifting or swinging Be sure load fall lines or any other part of machine does not snag or strike any obstruction Avoid sudden starts and stops Lift carefully swing gently brake smoothly lower and set loads carefully Jerking the load swinging and plugging the swing clutches roughly 0 9 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T lowering the load rapidly and slamming on the brakes will put shock loadings and possible side loadings on the boom Cowboys sometimes use rough treatment to break horses rough treatment can also break a machine Unnecessary abuse labels the operator as a beginner Be a professional Fig 16 Make sure load doesn t get caught e Never wrap the hoist line around the load Never use discarded worn or damaged rope for slings It may break and drop the load f The machine must be level before making a lift Use levels if the machine is so equipped If not use a good carpenter s level placed on a smooth horizontal surface on the upper or lower frame Remember a 3 degree side tilt can reduce capacities by 5096 or more The hook block
341. removing rope from reels 2 Rope Jumping sheaves 3 Pulling or dragging rope around post sill or relatively sharp corner Excessive Abrasion 1 Improper reeving causing rope to rub against equipment or agains itself 1 Improper socketing splicing or seizing 2 Driving nails or other objects between strands In Use Crushed or Bruised 1 Improper drum winding 2 Pinching of rope 3 Peening against equipment 4 Running over rope with equipment 1 Jumping sheaves 2 Bad drum winding 3 Lifting sharp cornered objects without corner protection Corrosion and Rust 1 Lack of lubrication 2 Corrosive fluids 3 Atmosphere 1 Momentary compressive force on rope which pushes strands apart crushing on drums Excessive Abrasion 1 Improper reeving 2 Improper alignment of sheaves 3 Presence of abrasive materials 1 Fatigue from excessive bending over small sheaves or reverse bends 2 Incorrect rope size 3 Excessive rope speeds 4 Collapse of core due to overloading 5 Vibration set up by worn bearings 6 Broken sheave or drum 7 Corrugated sheaves 1 Too sudden release of load 1 Condition starts at some localized area such as dogleg crushed section improperly attached end fitting or splices 1 Wrong size wedge used or socket deformed from consistent overloading Shipping Doglegs or Kinks Installing High Strands Doglegs or Kinks Popped Core Broken Wire
342. requency multiplied by 30 on a 4 pole generator thus 1800 rpm gives 60 hertz frequency Preferred Speed does not vary more than 3 hertz from no load to full load operation sure throttle linkage and governor mechanism operate smoothly 6 31 Speed Adjustment To change the governor speed change the spring tension by turning the governor spring nut 6 5 Turn the nut clockwise more spring tension to increase rpm and counterclockwise to reduce governed speed Hold a tachometer against flywheel capscrew 6 32 Sensitivity Adjustment To adjust governor sensitivity no load to full load speed droop turn the sensitivity adjusting ratchet accessible through a covered access hole on the side of the blower housing Counterclockwise gives more sensitivity less speed droop when full load is applied clockwise gives less sensitivity more speed droop If the governor is too sensitive a rapid hunting condition occurs alternate increasing and decreasing speed Adjust for maximum sensitivity without hunting After sensitivity adjustment the speed will require readjustment After adjusting the governor replace the knockout plug in the blower housing and secure speed stud lock nut Note Excessive droop may be caused by engine misfiring Correct this condition before adjusting governor 6 33 Charge Rate Adjustment The adjustable resistor slide tap in the charging circuit is set to give approximately 2 ampere charging rate For
343. riate lengths with each boom extension Section 9 Continued Specifications And General Information 9 21 Components Weights Crane upper w 27 000 Ib A ctwt boom lowering planetary rear drum lowering clutch GMC 6 71 engine w single stage torque convertor 8 x 4 11 10 wide FMC carrier with GMC 6V92TA engine 14 00 x 24L custom high miler tires front and rear 11 400 lb bumper Total combined weight of upper and carrier described above Boom lowering planetary B H rope 675 7 8 Front drum rope 1050 1 Rear drum rope 1050 1 Upper ctwt A Upper ctwt B Upper ctwt AB 30 basic boom w accessories 25 top section Boom stops Boom live mast bridle spreader bar 10 extension w pendants 20 extension w pendants 30 extension w pendants Carrier A bumper ctwt Front or rear outrigger box beams jacks Outrigger floats each side Outrigger float front bumper TM 10 3950 263 14 amp P 1 67 810 Ibs 76 600 Ibs 144 410 Ibs 790 Ibs 970 Ibs 1 940 Ibs 1 940 lbs 27 000 Ibs 30 000 Ibs 57 000 Ibs 6 720 Ibs 4 610 Ibs 660 Ibs 7 000 Ibs 785 Ibs 1 320 Ibs 11 400 Ibs 7 500 Ibs 170 Ibs 130 Ibs TM 10 3950 263 14 amp P 1 Operator s Manual Section 9 Continued Specifications And General Information 9 22 Dimensions ug 459 Www i PITY pom HO pk I EE UA d EG rau 15 38 a et Ge iim 1y
344. rol lever oil under pressure from the S o M system enters the clutch cylinder See Fig 1 3 The cylinder extends forcing the clutch shoes into contact with the clutch drum This couples the drum and gear which are moving to the shaft and cable drum forcing them to move The gear drum on each end of the shaft turn in opposite directions By engaging one clutch or the other the direction of rotation of the shaft changes to either raise or lower a load or the boom or to swing right and left All clutches used on Link Belt machines operate in the same way Each has two shoes which are hydraulically applied and spring released The clutches are controlled by a hand lever on the operator s control stand Actuating the lever opens control valve allowing Speed o Matic oil under pressure to flow to the clutch cylinder and apply the clutch When the control lever is returned to neutral porting is opened in the valve allowing oil in the clutch cylinder to flow back to sump tank The clutch return springs then disengage the clutch The clutch assemblies on any given machine may be assembled for right or left hand rotation depending upon their use on the machine Clutch assemblies of the same size and type are interchangeable from one location to another but may or may not be assembled for the right rotation To define L H and R H clutches two other terms must be defined toe and heel end The toe is the end of the clutch shoe which f
345. rough the cab near you Move away from contact in reverse to that which caused the contact Example If you swing left into wire swing to the right to break contact Remember once an arc has been struck it will stretch out much further than you think before it breaks Keep moving away from the line until arc breaks When arc breaks continue moving until you are at least 15 Ft 4 57m away or as specified by local code Stop the machine Thoroughly Inspect machine for damage Repair any damage before further use If you cannot disengage from the line and machine is not on fire or no arc is cutting through the cab stay in your seat until power line can be shut off If you must leave the machine Don t step off Leap From The Machine as far as you can 3 When using a magnet a Lifting magnet generators produce voltages in excess of 200 volts and present an electrical shock hazard Only trained personnel should work on the magnet controller or wiring Never open the controller door with the generator running Do not let workmen touch magnet or load Do not let workmen get between magnet and a metal object If necessary to position a load use a dry wooden stick Open magnet disconnect switch at magnet control panel before connecting or disconnecting leads Crane Boom Safety 1 The operator supervisor or person in charge of the load must observe the following rules a Loads must be well secu
346. rranty A Warranty ALL of COMPANY s products are of high quality and are manufactured in conformity with the best commercial practices in the various lines The COMPANY warrants all products manufactured by it to be free from defects in material and manufacture at the time of shipment for six 6 months from date of shipment or 1000 hours of operation whichever shall occur first The COMPANY will furnish without charge f o b its factory replacements for such parts as the COMPANY finds to have been defective at the time of shipment or at the COMPANY s option will make or authorize repairs to such parts provided that upon request such parts are returned transportation prepaid to the factory from which they were shipped This warranty shall not apply to any product which has been subjected to misuse misapplication neglect including but not limited to improper maintenance accident improper installation modification including but not limited to use of unauthorized parts or attachments adjustments or repair Engines motors and any accessories furnished with the COMPANY s products but which are not manufactured by the COMPANY are not warranted by the COMPANY but are sold only with the express warranty if any of the manufacturers thereof THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED INCLUDING THOSE OF MERCHANTABILITY AND FITNESS OF ANY PRODUCT FOR A PARTICULAR PURPOSE AND OF ANY OTHER OBLIGATION
347. rrect Pendant Lengths Can Cause Boom Or Boom Suspension Failure Fig 5 14 Boom Assembly Step 1 NA252 D 1 Boom Lower Sectton 4 Upper Pin Connection Link 7 Pendant Pin amp Cotter Pin 2 Live Mast Extended 30 9 14m 5 Assembly Link 8 19 8 Pendant 5 99m Position 6 Capscrew Spacer Lock Use a pair 3 Boom Backstops Tie Down Link washer Hex Nut 9 Bridle Spreader Bar Disconnected 5 8 Operator s Manual TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment Fig 5 15 Boom Assembly Step 2 1 60 18 92m Additional Boom 2 Top Boom Pins sections weigh more per equivalent length than one long section so keeping short sections close to boom foot will improve machine stability All boom assembly must be done with the upper swung to face directly over the rear of the carrier WARNING Do Not Get Under Any Part Of Boom Especially While Boom Sections Are Being HC238A Raised Lowered Or Positioned 5 17 Boom Assembly Step 2 Add on 60 feet 18 29m of additional boom See Fig 5 15 This will leave a boom connection at the 85 foot 25 9m point for installation of the assembly links The boom extensions are added on as follows a Line up two upper pin connection holes between the two sections being pinned together Insert the two top boom pins Install keeper pins in each boom pin b Boom up until the bottom boom pin holes line up Install the two bott
348. rrier 1 9 Starting And Stopping The Engine The ignition switch is operated with a key This prevents unauthorized persons starting the engine Turn the key to the on position before starting the engine Push starter button while depressing accelerator to start the engine Note Don t operate the starter more than 15 seconds at a time when starting the engine The key must be in the on position for accessories to Work Run the engine at part throttle and no load for about 5 minutes allowing it to warm up before applying a load During long engine idling periods the engine coolant temperature may fall below the normal operating range The incomplete combustion of fuel in a cold engine will cause crankcase dilution formation of lacquer or gummy deposits on the valves pistons and rings and rapid accumulation of sludge in the engine Note When prolonged engine idling is necessary maintain at least 800 RPM To stop the engine turn key to off position Depress engine stop button until engine stops running After engine stops running remove key and take it with you to prevent starting by unauthorized persons 1 10 Service Brake Pressure Gauge This gauge indicates the air pressure available to operate the service brakes The gauge should read between 115 and 125 psi 792 861 kPa If the gauge doesn t show the correct pressure repair the system before operating the carrier Otherwise sufficient braking force may not be deve
349. ry explanation of the diagnosis of problem and corrective action taken Neither will the statement making reference to a previous report be accepted in lieu of information correctly filled out explaining the problem and correct action taken 8 Section 3 entitled Name of Part s That Failed or Caused Failure must be completely filled out to enable the factory to determine disposition of defective parts The serial number of the replacement part is also required to ensure future warranty of the part replaced 9 Section 4 of the claim entitled Other is reserved to list things not provided for elsewhere on the form Examples A freight bill outside purchase of parts outside labor for machine shop etc A copy of the paid invoice must accompany each claim 10 Section 5 is to list item number of part description of part quantity of part invoice number and cost covering parts claimed 11 If part or parts were supplied from your stock type the word stock in the invoice section provided in Area 5 12 If parts were ordered where a 5 or 1096 added cost was assessed for emergency shipment a copy of the invoice must be attached 13 If a large group of parts were ordered from the factory for warranty repair a legible copy of the FMC invoice attached in lieu of filling out Section 5 if preferred 14 If an incorrect FMC part number is listed or a part claimed that cannot be identified it will be eliminated from the claim and will not app
350. rying links and pin in stored position Pin headshaft links in 2 6 76 2cm position Assemble desired length of boom on machine as explained earlier in this section Tubular Boom And Boom Jib Machine Can Travel At 1 MPH 1 6 kph at 80 Boom Angle Bom Bom With A Upper Ctwt 50 50 4 30 15 2m 15 2m 9 14m With A Bumper Ctwt 180 180 60 54 86m 54 86m 18 29m With A Upper Ctwt 190 57 91m 190 20 57 91 9 14m With A Bumper Ctwt 200 60 70 1m 60 9m 18 29m 5 27 Travel On Tires Job Site Moves Only This machine may be moved around on the job site with the boom in the air per the chart above Chart E The following conditions must be met Boom must be on centerline of machine over the rear Swing lock must be engaged Boom must be at minimum radius Approximately 800 boom angle Tires must be inflated to values shown in inflation chart for Maximum Static Lifts Outrigger beams must be fully extended jacks extended so that pontoons just clear the ground Travel must be on smooth level hard surface adequate to support the weight of the machine Travel must be done at creep speed Creeper transmission in low main transmission in first gear deep reduction Seb Section 1 Operating Instructions CAUTION Exercise Extreme Caution To Avoid Contacts With Hazards When Moving The Machine With The Boom In The Air TM 10 3950 263 14 amp P 1 Operator s Manual S
351. s Bird Cage High Strands Failure at Socket Fig 5 31 Wire Rope Cable Failure Chart HC238A TM 10 3950 263 14 amp P 1 Section 5 Continued Crane Attachment 5 38 Lubrication Wire rope is a machine Each time a wire rope bends over a sheave or straightens from a slack position many wires move against each other Lubrication is necessary to help prevent wear caused by this movement Lubrication also helps prevent deterioration of wire rope due to rust and corrosion Note Rusty rope is dangerous since there is no way of determining its remaining strength Most wire ropes are lubricated during manufacture but the lubricant doesn t last the life of the rope The lubricant is squeezed out of the rope as it turns over sheaves under tension washed off by rain etc For the previous reasons wire ropes MUST BE periodically re lubricated Crude or used oils and grease should not be used as lubricants because they may be grit or acid laden Either of these conditions would be bad for the rope No set rule can be given for lubrication frequency This will depend on the conditions the rope is operating under A rope operating in wet conditions would need lubrication more often than one operating under dry conditions to prevent rust and corrosion Lubricants used for wire rope lubrication should have the following properties a They must contain no acids or alkalis b They must have enough adhesive strength to st
352. s Inc 400 Commonwealth Drive Warrendale Pa 15096 publishes a list called Safety Considerations For The Operator SAE J153 in their Recommended Practices Manual PCSA Power Crane and Shovel Association Construction Industry Manufacturers Association 111 Wisconsin Avenue Milwaukee Wisc 53202 standard No 1 Mobile Power Crane and Excavator Standards contains a section on safety Safety booklets on crane and excavator operating safety are also available from PCSA The Department of Labor occupational Safety and Health Administration publishes safety and health regulations and standards under authority of the Occupational Safety and Health Act OSHA Its address is Occupational Safety and Health Administration U S Dept of Labor Washington D C 20210 American National Standards Institute ANSI C O The American Society Of Mechanical Engineers United Engineering 0 2 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T Center 345 East 47th Street New York N Y 10017 includes standards for safe operation inspection and maintenance in their ANSI B30 5 1968 and B30 15 1973 General Safety Rules Read he operator s manual and heed it The manual contains Important Information Whenever an operator leaves the control station for any reason the following must be done a Lower the bucket grapple load etc to the ground b Engage the swing lock Disen
353. s followed Air Cleaner Governor Speed And Sensitivity Adjustments 011 Filter Fig 6 1 Auxiliary Generator Assembly 6 1 Operator s Manual 6 11 Operation WARNING Engine Exhaust Gas Carbon Monoxide Is Deadly Carbon Monoxide Is An Odorless Colorless Gas Formed By Incomplete Combustion Of Hydrocarbon Fuels Carbon Monoxide Is A Dangerous Gas That Cause Unconsciousness And Is Potentially Lethal Some Of The Symptoms Or Signs Of Carbon Monoxide Inhalation Are Dizziness Intense Headache Weakness and Sleepiness Vomiting Muscular Twitching Throbbing In Temples If You Experience Any Of The Above Symptoms Get Out Into Fresh Air Immediately The Best Protection Against Carbon Monoxide Inhalation Is A Regular Inspection Of The Complete Exhaust System If You Notice A Change In The Sound Or Appearance Of Exhaust System Shut The Unit Down Immediately And Have t Inspected And Repaired At Once By A Competent Mechanic 6 12 Crankcase Oil Use an oil with the API designation CD SD or CD SE However to reduce oil consumption to a normal level in the shortest time possible on a new or rebuilt engine use CC oil for the first fill only 50 hours Then use the recommended oil only Select the correct SAE grade oil by referring to the following Above 32 F 0 C stt SAE 30 0 F to 32 F 18 Cto 0 C SAE 10W or 5W 30 Below Ok SAE 5W 30 Multigrade oils are recommend
354. s the beams must be fully extended Jacks must be extended so tires are clear of ground and machine is level Be sure that blocking or pontoons are set on firm surface adequate to support the blocking or pontoon loading without settling slipping or collapse Blocking or matting under pontoons must form a smooth level surface under the entire pontoon However do not also block under outrigger beams inside of 0 14 pontoons as this reduces stability Remember there are tremendous loadings on pontoons and blocking the weight of the entire machine plus any load ul Machine Beams Fully Level Extended ji d d Z UN xw Use of outriggers When blocking or matting under pontoons be sure that each pontoon is supported fully no unsupported pontoon area is permissible Be sure pontoons are on a smooth surface Rough surface rocks etc under pontoon will cause unequal loadings may puncture it and cause collapse Capacities are based on outriggers fully extended Working with outriggers partially retracted will reduce capacities and machine stability considerably and may cause an accident f it is absolutely necessary to operate a machine with outrigger beams partially retracted reduce capacities to those shown on the chart for on rubber Remember the machine must be level Avoid working with only rear outriggers 15 16 17 18 TM 10 3950 263 14 amp P 1 O
355. s 1 1 m p h 1 77 km hr Rear axle ratio 9 00 to 1 00 9 12 Cab Carrier One man offset fully enclosed steel construction Shatterproof windows Headliner Floor mats One man bucket seat Cab Upper One man modular type Isolated from machinery house Tempered glass 9 16 Load Hoist windows Cushioned seat Lowering System with head rest Cab Machinery All steel Hinged doors on two sides Removable panels for machinery access Skid resistant finish on roof 9 13 Upper Machinery Full function design Gear Train Two directional power available to all opera ting shafts Operating shafts mounted in line bores on anti friction bearings All operating functions independent of one another 9 14 Clutches Speed o Matic power hydraulic actuated for all clutch controlled functions except engine master clutch Internal expanding 2 shoe type aluminum alloy shoes clutch drums bolted to TM 10 3950 263 14 amp P 1 Spur gears units mounted on shafts on anti friction bearings clutch spiders involute splined to shafts Spur gear driven single bevel gears enclosed and running in oil on horizontal and vertical swing shafts Swing pinion involute splined to ver vertical swing shaft meshes with external teeth of swing gear integral with outer race of turntable bearing Swing clutches 23 diameter x 6 face width aluminum alloy shoes Swing brake External contracting band spring applied
356. s System Is Designed To Function With Crane Power From 10 Volts DC To 14 Volts DC Voltages Outside Of These Limits Will Cause Erroneous Readings Or Damage To The System The System Must Be Connected With Black Wire To Positive And White Wire To Negative Crane Power Supply WARNING The Overload Warning System Is Not Fail Safe It Can Malfunction Do Not Depend Upon This System To Do The Operator s Job The Operator MUST Use The Information On The Metal Capacity Plate Located In The Upper Cab And Operate The Crane Within The Guidelines Spelled In Paragraph 1 81 Crane Operation In The Operator s Manual CAUTION Always Turn The Power Switch On The Display Assembly OFF Before Connecting Or Disconnecting A Cable Assembly Or Component Otherwise A Power Surge Or Damage To The System Can Occur WARNING Do not service maintain or lubricate open gears chain case planetary speed reducer swing bevel gear case reduction shaft pinion case gear cases gears drive chains or chain case unless engine is shut down and swing lock is engaged 3 of 3 Operator s Manual Quick Reference System Operating Safety Operating Instructions Preventive Maintenance And Lubrication Carrier Adjustments Upper Adjustments Crane Attachment Auxiliary Generator Assembly Speed o Matic Control System Operator Trouble Shooting Specifications Overload Warning System Alphabetical Index How To Use This Manual The man
357. s before travelin Travel safely Watch for narrow bridges or openings low clearances etc When maneuvering in tight places post a signal man on the ground to guide you Check load limits and know your machine weight When transporting machine on a trailer make sure it is securely tied down Engage the swing lock Use proper warning signs flags and So forth Check local regulations before transporting and follow them to the letter When towing machines move slowly Take up slack in chain or rope Don t jerk it may break Keep taut while towing Disengage traction brakes or crawlers before towing In cold weather park where machine won t freeze down Power train failure can result when trying to move a machine that is frozen down Fig 44 If possible go around obstacles Avoid traveling over obstacles rough terrain rocks logs curbs ditches etc if at all possible The size and type of obstacle that can be safely crossed will depend on many factors including good judgment When obstructions must be crossed do so with extreme caution at an angle if possible and at slow speed Ease up to the break over point balance on the obstruction ease down to minimize jolt of contract on the other side Cross a gully or deep ditch at an angle and very slowly Carry boom at a low angle for increased stability Avoid sidehill travel whenever possible Travel up or down the slope Shift machine to lowest travel speed wh
358. s holds the lifting arm on the jack cylinder rod f Before attaching the sling to the crane check the following 1 Counterweight must be off the machine 2 All boom except the lower section must be off the machine 3 Any gear that is on the luggage carriers on deck has to be removed 4 Swing the upper to face the front of the carrier Engage the swing lock g Connect the hook block from the lifting equipment to the slings Lift the assembly and position over the crane Note The short slings go to the front of the crane Connect the four support pendants to the lifting arms with pins Install keeper pins in each connecting pins WARNING Before Lifting Crane Inspect Lifting Sling Again Make Sure Everything Is Assembled Right Make Sure All Pins Have Keepers Don t Let Anyone Near The Machine While It Is Being Lifted 1 2 3 4 h i Lift the crane slightly and check for levelness If not level set the crane down and slack off on the slings Adjust turnbuckles until crane hangs level Tighten jam nuts on turnbuckles Insert a cotter pin in each threaded turnbuckle rod Wrap the legs of the cotter around the turnbuckle body so it can t turn After the crane has been lifted and repositioned lower the sling assembly until the support pendants are slack Unpin them from the lifting arms Set the lifting spreader on the ground Remove the support pendants and slings
359. s in the boom Never use longer jibs than specified for your machine Never use a jib on a longer boom than specified for your machine Tipping may result Know how much counterweight is on the machine Some capacity charts list different capacities with differing amounts of counterweight Make sure you know how your machine is equipped and use the correct column on the chart Fig 27 Don t add extra counterweight Don t increase the counterweight above that specified Don t add anything to the machine that will act as additional counterweight Remember that anything which has weight if carried behind machine s tipping point acts as counterweight Adding counterweight affects backward stability of the machine particularly 24 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T when working over the side It also encourages overloading of the machine which can cause a disastrous accident Traveling with a suspended load should be avoided if possible It is especially hazardous when terrain is rough or irregular on a side slope or in hilly areas When traveling with a load observe the following rules a Tether the load to reduce load swing Don t tether to boom structure b Travel by the smoothest most level route If a smooth level route is not available don t travel with a suspended load unless the route to be taken is graded to provide a smooth level path If its not possible t
360. s of blower seal leakage A 66 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Upper M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY WARNING Dry cleaning solvent P D 680 is toxic and flammable Wear protective goggles and gloves and use only in well venti lated area Avoid contact with skin eyes and clothes and don t breathe vapors Do not use near open flame or ex cessive heat If you become dizzy while using cleaning solvent get fresh air immediately and get medical aid If contact with skin or clothing is made flush with water If contact with eyes is made wash your eyes with water and get medical aid immediately Air Compressed air used for cleaning purposes will not exceed 30 psi Use only with effective chip guarding and personnel protective equipment goggles shield gloves etc CRANKCASE BREATHER Remove crankcase breather assembly and wash in clean solvent ENGINE AND TRANSMISSION MOUNTS Check condition of mounting bolts and mounting pads Repair or replace if necessary AIR BOX CHECK VALVES Remove valves clean in solvent and blow out lines with compressed air Inspect for leaks after servicing LUBRICATION REQUIREMENTS Perform all lubrication as specified in lubrication charts on bages 2 111 2 13 and 2 20 Operator s Manual A 67 TM 10 3950 263 14 amp P 1 APPENDIX I
361. s on dolly c Lash down or otherwise restrain the hook block d Check operator s manual for maximum allowable travel speed maximum amount of boom that can be transported and any other travel limitations Don t exceed these maximums Machine damage or accident will result e When traveling with outriggers retracted secure them in retracted position If they should accidentally extend while the machine is traveling a serious accident may result f When roading a machine store pontoons in storage areas provided and fasten them securely If a pontoon should fall off machine it could cause a serious accident Check tires daily for correct pressure Never stand in front of a tire when inflating The lock ring may fly off and injure you Use a clip on inflator and stand behind the tire tread Use a guard in front of tire Fig 40 Be careful when inflating tires When working on rubber tires must be inflated to pressures shown on tire infla tion chart to make the lifts shown on the capacity chart Shift carrier transmission to neutral before operating upper Machine rocking may damage transmission or drive line Apply the operating or digging brakes if working on rubber If necessary leave the engine running to maintain air pressure When parking a wheeled crane shift to neutral and apply park brake Block wheels if on a hill m C _ l o Om A i Fig 41 Be careful of carrier cab When swing
362. s to the length of boom on the m machine Set the Hook Selector switch on the display panel to the hook block arrangement being used Press the Test button on the display assembly Note the meter readings and if the warning devices come on Compare the meter readings to those in Table 10 1 If the meter readings and Table 10 1 do not match trouble shoot the system 10 6 Adjustments The system is calibrated for specific reeving parts of line at the hook block System must be calibrated for that parts of line If the reeving at the hook block s is changed the The system s calibration for the parts of line being used should be verified at least every six months or whenever a parts of line which was calibrated once before is reused 10 3 Operator s Manual 10 4 CRANE POWER POWER SUPPLY SV REGULATOR Fig 10 3 10 P L Gain 9 P L Gain R37 R29 Main Electronics Adjustments Calibrate the system as follows 1 2 Visually verify the components and cables are connected Position the Power switch to On 3 Set the Reeve Select switch to the parts of line reeved on the main hoist hook block Set the Boom Select switch to length of boom on the machine Set the Hook Selector switch to either L left or R right Loosen the cover retaining screws on the main electronics assembly and remove the cover Lower the hook block and boom onto the ground Allow the main ho
363. sary 1 Check and fill if necessary 2 Check anti freeze in winter 1 Check fuel level Add fuel as necessary 2 Don tsmoke when fueling or fuel up a machine near an open flame Keep the nozzle in contact with the filler neck to prevent static electric sparks Shut off the engine when fueling 1 Check electrolyte level Fill with distilled water if necessary 2 Keep battery clean at all times Corroded posts or accumulation of grit electrolyte etc on top of a battery can cause it to become discharged WARNING Be Careful Not To Get Battery Electrolyte On Your Skin Or Clothing Or Especially In Your Eyes It Is Acid And Can Cause Injury Don t Smoke Or Use Open Flame Near A Battery Battery Gas Is Explosive 1 Check for proper tire pressures for type of operation See tire inflation chart in Section 3 pf this manual 2 Inspecttires for wear cracks bulges breaks or other damage Replace damaged tires before roading the machine or operating on rubber 3 See shop manual SM1 69 2 0 for more information HC238A 2 1 TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication Daily Continued Remarks Brake System 1 Check air pressure 15 125 PSI 792 861 kPa maximum 2 Check low air pressure warning devices for proper operation at 60 PSI 413 kPa Check digging brake operation Check foot brake operation Check emergency brake op
364. score drums remove as necessary SIDE HOUSING BEARINGS ALL HORIZONTAL SHAFTS Pump 8 to 10 shots of grease at each lubrication point Wipe off excess grease to keep clutch linings clean REDUCTION SHAFT BEARING HOUSING a Check oil level Fill to level of check plug hole if oil is low b Drain clean and refill with the proper lubricant CLUTCH HEEL BLOCKS CONTROL LEVER LINKAGE SWING LOCK LINKAGE SWING BRAKE LINKAGE AND PINS S O M VALVE SPOOLS a Lubricate all pivot points with engine oil b Check valve caps for rust and corrosion clean if any is present Lubricate with engine oil A 62 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Upper M Monthly S Semiannually H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY AUXILIARY GENERATOR Perform the following checks and services on the auxiliary generator For additional information refer to the indicated areas of the Operator s Manual Change crackcase oil pg 6 1 Fig 6 1 Drain moisture from sediment bowl Clean crankcase breather pg 6 9 Replace oil filter pg 6 1 Fig 6 1 Check generator slip rings and brushes replace if worn to 5 8 ref Sec SM 18 10 11 0 Shop Manual f Check valve Adjust as necessary pg 6 5 Fig 6 6 and Fig 6 7 9 Change primary fuel filter Fig 6 1 h Change secondary fuel filter pg 6 1 Fig 6 1 A 63 TM 10 3950 26
365. se their effectiveness making continued operation unsafe If you are going to work over the front set the front bumper outrigger Push down on the control switch to lower the outrigger Pull up on the switch to raise the outrigger Lower it with engine running at an idle Always raise and level the machine with the four side outriggers before lowering the front bumper outrigger If the outriggers must be reset raise the front bumper outrigger first After resetting side outriggers lower front bumper outrigger When lowering the machine off outriggers always raise the front bumper outrigger first It is not strong enough to support the machine by itself The outrigger or carrier frame may be damaged if these instructions are not closely followed Operator s Manual Front Outrigger Box Removal 1 Quick Disconnects 5 Rod End Capscrew 2 Jack Cylinder 6 Removable Beam End 3 Eye Bolt 7 Outrigger Beam 4 Pin 1 42 Jack Cylinder Removal a Disconnect the lines leading to the jack cylinder check valve at the quick disconnects Install dust plugs or caps on each quick disconnect b Install an eye bolt in the threaded hole in top of the jack cylinder Connect a chain or wire rope sling to the eye bolt on top of the jack cylinder Connect to sling with hook block from crane Hoist on hook block to support the weight of the jack cylinder assembly Apply hoist brake c Remove rod end and capscrew from pins Remove
366. should be sufficient in most operating conditions 1 38 Skip Shifting After becoming proficient shifting the transmission the operator may want to skip some shifts Skip shifting may be done going up providing the range button is pulled up before the shift which passes 5th Skip shifting is possible going down provided the range button is pushed down to the low range position before the shift which passes 6th 1 39 Outrigger System The hydraulic outriggers operate with pressure from a vane type pump driven by a power take off on the main transmission This power take off is shifted in and TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions NA197 D Machine Top And Side View 1 L H Pontoon Storage 2 R H Pontoon Storage 3 Front Outrigger Pontoon Storage out of gear by a pull cable under the carrier dash See Fig 1 6 Always disengage pump before traveling to prevent damage to outrigger system The pressure is routed to the outrigger jack and beam cylinders through a pair of solenoid valve stacks mounted on the carrier The valve stacks are actuated by toggle switch on the outrigger control panels A second control is located on the R H side of the machine near the front bumper See Fig 1 10 This Switch operates the front bumper outrigger Square steel pontoons are used with each outrigger jack One pontoon is used with the front bumper jack Three pon
367. 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 A HREFzhttp www liberatedmanuals com Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
368. signed report of rope condition kept on file where readily available Replace any worn or damaged rope Pay particular attention to boom hoist ropes and pendants Check end connections pins sockets wedges etc for wear or damage Don t let the load or bucket hit the boom Don t let the boom rest on or hit against a building or any other object A dented Just a little bump can cause Fig 5 Don t let the load hit the boom or damaged boom may result which will weaken the boom f the damage is severe the boom may collapse If a lattice or diagonal bracing member is broken or cracked replace it If bent straighten it Important Detailed information on boom repair is available from your distributor Some of the steel used in booms is a special type which can be ruined by wrong repair procedures If a chord is damaged or bent even a small amount Don t Use It Don t try to repair it Chords are so vital to the strength of the boom that it is not practical to attempt repairs Chord Pin Connection Lug Diagonal Latt ce Picture Frame Fig 6 Boom extension nomenclature If the boom mast gantry etc are struck or damaged by anything stop The loading on a boom increases as the boom is lowered therefore a damaged boom or boom suspension system may collapse during lowering Use a helper crane to assist in lowering a damaged boom Be sure the boom hoist pawl is always engaged except when lowering t
369. sition or by setting the operating characteristics to specified parameters e Align To adjust specified variable elements of an item to bring about optimum or desired performance f Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipment used in precision measurement Consists of comparisons of two instruments one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared 9 Install The act of emplacing seating or fixing into position an item part or module component or assembly in a manner to allow the proper functioning of an equipment or system h Replace The act of substituting a serviceable like type part subassembly or module component or assembly for an unserviceable counterpart i Repair The application of maintenance services or other maintenance actions to restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly end item or system j Overhaul That maintenance effort service action necessary to restore an item to a completely serviceable operational condition as prescribed by maintenance standards i e DMWR in appropriate technical publications Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to
370. solenoid valve in the carrier air brake system which admits air under pressure to the cylinder 5 in Fig 3 13 The cylinder depresses the accelerator pedal in the carrier cab to increase the engine speed and provide faster outrigger operation 3 13 Outrigger Throttle Control Adjustment Adjust the throttle control to give an engine speed of 1550 R P M s with the air cylinder fully extended as follows a With carrier transmission in neutral and parking brake applied start the engine b Depress the throttle button Wait until engine accelerates fully and read the speed off the tachometer in the carrier cab c Loosen jam nuts 3 on target 4 Turn targets in or out until engine runs at proper speed with button depressed d Tighten the jam nuts HC238A 3 7 3 8 blank TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Upper Adjustments Index Section 4 Subject Page Subject Page Engine And Power Take 4 1 Adjusting Master Clutch 4 3 Swing 4 4 Swing Lock Adjustment 4 2 Swing Brake a tig Les mas 4 6 Swing Brake Adjustment 4 7 Swing Brake Control Adjustment 4 2 Counterweight 4 9 Counterweight Remover Adjustment 4 10 Preliminary Adjustment
371. some cases for boom make up extremely cautious about raising boom above horizontal with the links connected If you boom up too far the live mast legs and boom throat will engage and damage the mast and boom When operating a crane equipped with torque convertor or fluid coupling remember to speed up engine before engaging boom hoist or load hoist clutch If the engine Isn t running fast enough the boom or load may go down instead of up Keep your foot on the brake until engine speed is fast enough to raise the load The boom hoist pawl should be engaged at all times except when lowering the boom Make sure there is a latch on the hook and that it works properly Without a latch it Is possible for slings or chains to come off the hook and allow the load to fall When lifting submerged loads the suction caused by the load resting on the bottom acts to increase the weight of the load in some cases to many times the actual load weight This same effect can occur on land for example when a load is imbedded in mud To break a load loose from suction Don t pull sideways or a boom may collapse If possible rig the load so it is lifted from one end Don t yank or jerk on the load A steady pull maintained for some time will often free 0 21 TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T the load without overloading the equipment 44 Fig 35 Use caution when lifting submerged l
372. spected through the end frame assembly If the slip rings are dirty they should be cleaned with 400 grain or finer polishing cloth Never use emery cloth to clean the slip rings Hold the polishing cloth against the slip rings with the alternator in operation and blow away all dust after the cleaning operation If the slip rings are rough or out of round replace them Inspect the terminals for corrosion and loose connections and the wiring for frayed insulation Item 28 Engine And Transmission Mounts Check the engine and transmission mounting bolts and the condition of the mounting pads every 2000 hours Tighten and repair as necessary Item 29 Crankcase Pressure Check and record the crankcase pressure every 2000 hours Item 30 Air Box Check Valves WARNING Warn Personnel In The Immediate Area Before Using Compressed Air For Cleaning Wear Safety Glasses Compressed Air Coming Into Contact With The Human Skin Or Causing Flying Metal Chips Can Cause Injury WARNING Use Fuel Oil Or Cleaning Solvent In A Well Ventilated Area Away From Flames RADIATOR ig 2 24 Radiator Item 21 2 67 2 25 Operator s Manual 2 75 Every 3000 hours remove clean in solvent and blow out lines with compressed air Inspect for leaks after servicing Item 31 Fan Hub If the fan bearing hub assembly is provided with a grease fitting use a hand grease gun and lubricate the bearings with one shot of Texaco Premium RB grease o
373. spection Of The Complete Exhaust System If You Notice A Change In The Sound Or Appearance Of Exhaust System Shut The Unit Down Immediately And Have It Inspected And Repaired At Once By A Competent Mechanic WARNING Smoke While Servicing Explosive Gases Are Do Not Batteries Emitted From Batteries In Operation Ignition Of These Gases Can Cause Severe Personal Injury Muscular Twitching Weakness and Sleepiness Throbbing In Temples Operator s Manual P 6 10 WARNING Before Commencing Any Maintenance Work On The Engine Generator Control Panel Automatic Transfer Switch Associated Wiring Disconnect Batteries Failure To Do So Could Result In Damage To The Unit Or Serious Personal Injury In The Event Of Inadvertent Starting WARNING Do Not Remove Dipstick With Engine Running Oil Will Blow Out Causing Possible Injury WARNING Do Not Use Ether Starting Aids Ether Is Extremely Explosive And May Cause Personal Injury Engine Damage Is Also Possible WARNING Use Fuel Oil Or Cleaning Solvent In A Well Ventilated Area Away From Flames WARNING Reduce S o M System Pressure To Zero As Explained In Steps A And B Before Unscrewing The Relief Valve Cap Or Before Removing The Pipe Plug From The Unloading Valve Pieces Of The Valve May Explode Under Pressure Otherwise And Could Cause Injury HC238A Warnings P 10 1 P 10 3 TM 10 3950 263 14 amp P 1 R482 CAUTION Thi
374. ssion Fluid as necessary c Turn steering wheel to left and right Steering is binding or Check for binding difficulty in steering unresponsive or un or unusual noise usual noise exists 9 OUTRIGGER SUMP TANK Fully retract allbeams and jacks Check hydraulic S O M fluid level Add fluid as necessary to bring level to FULL mark on dipstick 10 BRAKE SYSTEM a Check low air pressure warning system for proper operation System is activated at 60 P S I or lower b Check foot and emergency brake for Brakes do not operate proper operation unusual noise chatter properly or side pull 11 EXHAUST SYSTEM a Listen for exhaust leaks Any leaks detected in side cab b Visually inspect the muffler shield and pipes for damage and security of hard ware 12 CAB INSTRUMENTS GAUGES a Inspect for obvious damage A 41 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Carrier NOTE Within designated interval these checks are to be performed in the order listed B Before D During A After W Weekly M Monthly ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO IB D A W M FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF b Check normal operating readings for the Instruments are instruments as follows within normal operating range 1 Engine water temperature 1600 1850F 2 Service brak
375. ssion into the 0 26 13 14 lowest possible gear Never move faster than creep speed c The terrain must be smooth and solid If not grade the area before moving the machine d Tie down the hook block to prevent its swinging when moving e Fully extended outrigger beams Extend or retract jacks until pontoons just clear the ground f Inflate carrier tires to pressure shown on tire inflation chart for making lifts on rubber before attempting to move the machine This pressure is higher than normal and will provide better machine stability Reduce pressures to those shown for highway travel before driving carrier any great distance g Lower the boom to the lowest possible angle for better machine stability and to avoid overhead obstructions before moving h Engage clutch smoothly Keep a steady foot on the accelerator Don t jerk the machine i Position a signal man to guide you j Avoid traveling on a grade particularly a side slope If you must travel up a slope go straight up or better yet back up the grade for maximum machine stability and minimum side loadings Never coast down hill with clutch disengaged or transmission in neutral Either practice makes control of the vehicle more difficult and less safe Never leave carrier unattended with the engine running TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T Crawler Operation Fig 43 Check load limit
376. ssion to neutral Start carrier engine Allow engine to idle If replacing front bumper box assembly place on Skids and slide underneath carrier 1 3 h 1 2 6 Pin Extended Position 3 Solenoid Valve 7 Pin Retracted Position 4 8 Jl NA219 8 9 Front Pin Cylinder 10 Rear Pin Cylinder Connect a sling to lifting lugs on top of outrigger box Hook to sling with helper crane or live mast reeved as a short boom Lift outrigger box until lugs on box enter lugs on carrier frame Set hoist brakes to secure load Connect jack cylinder hoses at quick disconnects Operate outrigger jacks as explained previously in this section to raise or lower boxes until pin holes line up Extend pin cylinders to install pins by moving toggle Switch on control panel to extend position Increase carrier speed if necessary by pushing throttle button Repeat procedure for other side of outrigger box Unhook pin remover cylinder hoses at quick disconnects Connect outrigger beam cylinder hoses Install dust plugs or caps on quick disconnects on pin remover cylinder hoses Install left front outrigger jack on machine as explained earlier in this section Remove slings TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions 1 49 Operators Cab The operators cab is equipped with a sliding door To open cab side door a Install carrier ladder in holes provided in carrier fender St
377. st outlet Check warning tag on oil base and verify that oil viscosity is still correct for existing ambient temperature Clean and check battery Measure specific gravity 1 260 at 77 F 25 C and verify level to be at split ring If specific gravity is low charge until correct value is obtained If level is low add distilled water and charge until specific gravity is correct DO NOT OVERCHARGE WARNING Do Not Smoke While Servicing Batteries Explosive Gases Are Emitted From Batteries In Operation Ignition Of These Gases Can Cause Severe Personal Injury h i Check that fuel injectors and fuel lines are secure and correctly torqued Connect batteries Verify that no loads are connected to generator Start engine Note After engine has started excessive blue smoke will be exhausted until the rust inhibitor or oil has burned away After start apply load to at least 50 percent of rated capacity Check all gauges to be reading correctly Unit amp ready for service 6 24 High Temperatures a b See that nothing obstructs air flow to and from the set Keep cooling fins clean Air housing should be properly installed and undamaged 6 25 Low Temperatures a Use correct SAE No oil for temperature conditions Change oil only when engine is warm If an unexpected temperature drop causes an emergency move the set to a warm location or apply externally heater air until oil flows freely never
378. stall keeper pins in each boom pin Proceed to add on a maximum of 85 feet 25 9m of boom b Boom up until the boom pin holes line up Install the two including the upper section as follows bottom boom pins Install a keeper pin in each a Line up the two upper pin connection holes connecting pin c Repeat steps a and b above until desired boom length maximum 110 feet 33 5m is reached Fig 5 12 Boom Assembly Step 3 1 Boom Resting On Ground 2 Pendant Connected To Assembly Links 5 13 Boom Assembly Step 3 Boom down until boom peak is resting on ground Continue to boom down until pendants are slack Fig 5 13 Boom Assembly Step 4 110 Foot 33 53m Boom Shown N142 A 1 2 Position Headshaft Link 3 20 Pendant 6 1m 7 25 63 5cm Spreader 2 6 76 2 Position 4 20 Pendant 6 1m 8 Live Mast Fully Extended 2 5 1 52m Basic Pendant 5 20 Pendant 6 1m Req d 90 27 4m Booms A 6 19 8 Basic Pendant Over 5 99m 5 14 Boom Assembly Step 4 Assemble the necessary lengths spreader bar On booms 90 feet 27 43m in length and of main pendants to connect between the headshaft link and the bridle spreader bar Use the 19 8 5 99m basic pendants in all boom make ups They remain connected to the bridle HC238A over a pair of 5 foot 1 52m pendants are also used These pendants remain connected to the headshaft links Refer to Chart A for proper pendant length per boom TM
379. sule for ease of handling TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions Reor Drum Front Drum e en CN Heater Overhead Windihietg Rotation Rototion Per A Medium QU p eQ Starter Ignition Elecincal On Power On Off Gon Low gt Hgh Blower BlowerSpeed gn 22PI327 Fig 1 16 NA368 A Upper Control Panel The starting aid consists of a cylindrical container and a Screw cap A sliding piercing shaft is mounted in the cap A tube leads from the container to a hand operated pump Another tube leads from the pump to an atomizing nozzle in the engine air intake The container is mounted vertically away from any heat Use the fluid starting aid as follows a Remove the threaded cap Insert a fluid capsule in the container Handle With Care The Starting Fluid Is Toxic And Flammable b Pull the piercing shaft all the way out of the cap Install and tighten the cap on the container c Push the piercing shaft all the way down This ruptures the capsule and fills the container with starting fluid d Move the engine throttle to the full speed position e Engage the starter while pulling the pump plunger all the way out Push the plunger In slowly forcing starting fluid into the engine Continue to push on the pump until the engine starts Push the plunger in slowly until it locks in the in position f Remove and discard the capsule Never leave an empty capsul
380. sump tank see Adjust relief valve setting see p 3 5 Repair or replace see Shop Manual Speed o Matic Hydraulic Control System Gauge reading too high Note Gauge should read between 900 1050 P S I 1 Unloading valve set too high 2 Unloading valve defective 3 Defective gauge Adjust unloading valve pressure setting see Shop Manual Replace unloading valve see Shop Manual Replace TM 10 3950 263 14 amp P 1 Operator s Manual Section 8 Continued Troubleshooting Procedures Problem Probable Cause Gauge reading too low 1 Relief valve set too low 1 Adjust relief valve see p 7 2 2 Unloading valve set too low 2 Adjust unloading valve pressure setting see Shop Manual Unloading valve or relief valve 3 Replace see Shop Manual defective Defective gauge 4 Replace Defective pump 5 Replace Low oil level 6 Refill with oil sed p 7 2 Restricted suction hose 7 Replace hose No pressure Pump belt slipping or broken 1 Replace belt Adjust tension Pump defective 2 pump see Shop Manual Clogged inlet strainer 3 Clean or replace strainer Change system oil see p 7 2 Torque Convertor and Master Clutch Master clutch slips or jumps out 1 Adjusted wrong 1 Adjust see p 4 1 of engagement 2 Clutch discs worn 2 Replace see Shop Manual 3 Oil on clutch discs 3 Repair oil leak Replace clutch discs see Shop Manual Master clutch
381. t Pinion Case Fig 2 9 HC238A 2 41 2 42 2 43 2 44 TM 10 3950 263 14 amp P 1 Section 2 Continued Preventive Maintenance And Lubrication To check a Park the machine on level ground Set the parking brake Engage swing lock Disengage master clutch Shut down upper engine b Clean an area around check plug on side of case c Remove the plug The case should be full of lubricant to the level of the check plug hole To change a Operate the machine to warm up and stir up the lubricant b Park the machine on level ground Set the parking brake Engage swing lock Disengage the master clutch Shut down upper engine c Remove the drain plug from the bottom of the case Allow the old lubricant to drain thoroughly d Install the drain plug and remove the check plug Remove the fill plug Fill the case with lubricant through the fill elbow until lubricant is level with the check plug hole Install pipe plug on fill elbow and check plug See capacity chart on page 2 12 for the proper lubricant Air Box Drain Tank Eig 2 10 An air box drain tank is installed on machines with a Detroit Diesel engine in the upper The tank collects water and sediment discharged from the engine air box so it won t run down onto the carrier The tank must be drained periodically Draining The Tank Drain the tank every 50 operating hours as follows a Position upper crosswise to carrier b Hold a can under t
382. t enemy use 00 1 00 2 blank Operator s Manual Index Section 1 2 c o BE SES m m 1 8 Page General Information Truck Carrier Assembly Upper Machinery 1 3 Upper Operating Theory 1 4 On Delivery o Break in Period Before Starting Operations Carrier Operation Starting And Stopping The Engine 1 8 m collo Service Brake Pressure Gauge 1 8 Supply Air Pressure 1 8 Emergency Air Pressure 1 8 Park And Emergency Brake Control 1 8 Reserve Air Control 1 8 Low Pressure Warning System 1 8 Engine Oil Pressure 1 8 Water Temperature Voltmeter Fuel Gauge 1 9 Tachometer 1 9 Speedometer Throttle Emergency Shutdown 1 9 Headlight Switch 1 9 1 25 Windshield Wiper Switch Heater And Defroster Switch 1 27 Accelerator 1 28 Brake Pedal 1 9 1 29 Clutch Pedal Dimmer Switch 1 31 Creeper Transmission Shift Lever 1 9 1 32 Main Transmission Control 1 9 Important Procedures Upshifting 1 10 1 35 Alternative Shift Procedures 1 10 Speed Progression Down Shifting 1 38 Skip Shifting 1 10 _1 39 Outrigger System 1 10 Overload Warning System 1 41 Outrigger Operation 1 12 1 42 Jack Cylinder Removal 1 13 1 43 Jack Cylinder Installation 1 13 1 44 Outrigger Box Removal 1 1 Replacing Outrigger Box 1 13
383. t in the way and may cover up a serious problem Clean as you work and as needed Use dry cleaning solvent SD 2 on all metal surfaces Use soap and water when you clean rubber or plastic material b Bolts nuts and screws Check them all for obvious looseness missing bent or broken condition You can t try them all with a tool of course but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose tighten it Report it to Organizational Maintenance if you can t tighten it 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 Organizational Maintenance d Electric wires and connectors Look for cracked or broken insulation bare wires and loose or broken connectors Tighten loose connectors and make sure the wires are in good shape e Hoses and fluid lines Look for wear damage and leaks and make sure clamps and fittings are tight Wet spots show leaks of course But a stain around a fitting or connector can mean a leak If a leak comes from a loose fitting or connector tighten it If something is broken or worn out report it to Organizational Maintenance It is necessary for you to know how fluid leakage affects the status of your vehicle The following are definitions of the types classes of leakage you need to know to be able to determine the status of your vehicle Learn then be familiar with them and REMEMBER WHEN
384. t off the engine c Remove the lubricant level check plug from the thrust cap The wheel end lubricant must be even with the bottom of the check hole Add lubricant as necessary through the fill drain plug hole in the top of the hub Install the check plug and fill drain plug See capacity chart on page 2 3 or the proper lubricant To change a Operate the carrier to warm up and stir up the lubricant Park the machine on level ground b Rotate the wheel until the fill drain plug is at bottom dead center Set the park brake Shut off the carrier engine c Remove the plug and allow the lubricant to drain thoroughly d After draining the wheel ends should be flushed Install the fill drain plug and fill the hub to the proper level with a light flushing oil or kerosene Release park brake Operate the wheel end for a short period of time then drain the flushing oil e Rotate the wheel until the fill drain plug is on top and the arrow on the thrust cap is pointing straight down Set the park brake Remove the check plug Operator s Manual g Planetary Wheel Hub 1 Oil Level 2 Wheel Hub Fill Drain Hold In This Area f Fill the wheel end with lubricant until it is level with the check plug hole See capacity chart on page 2 3lfor the proper lubricant g Clean and install the fill drain plug and check plug 2 27 Outrigger Sump Tank Fig 2 6 2 28 To check a Fully retract all outrigger be
385. t since a very heavy load is being lifted If it falls the machine will be damaged and personnel nearby may be injured or killed BEAMS Inspect for cracked welds or cracks in the Any cracks are found H Beams Lugs or Corner Braces FITTINGS Inspect Links and Pins for damage such as Any damage is found cracks scoring or evidence of stretching or bending SLINGS AND PENDANTS Inspect wire rope for damage wear corro a There is more than sion fatigue and rope lubrication one broken wire in one rope lay b Aloss of 1 3 the original diameter of outside wires by abra sion scrubbing or peening c Rope deterioration from rust or corrosion d Severe kinking or crushing or evidence of birdcaging e Obvious reduction in wire rope diameter A 52 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Lifting Sling for End Item NOTE Within designated interval these checks are to be performed in the order listed B Before D During A After W Weekly M Monthly PER ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT NO B D AIW M FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF 4 PINS Coat pins and pin holes with preservative WIRE ROPE Coat with grease to preserve the wire rope A 53 TM 10 3950 263 14 amp P 1 Section Il Organizational Preventive Maintenance Checks and Services PMCS GENERAL To make sure that your vehicl
386. tarting batteries at least every two weeks See that connections are clean and tight Keep the electrolyte at the proper level above the plates by adding distilled water Check specific gravity recharge if below 1 260 6 40 Maintenance Schedule Use this factory recommended maintenance schedule based on favorable operating conditions to serve as a guide to get long and efficient set life Neglecting routine maintenance can result in failure or permanent damage to the set TABLE 1 OPERATOR AND SERVICE MAINTENANCE SCHEDULE HOURS OF MAINTENANCE TASK OPERATION Inspect generator set Check fuel supply see Note 1 Check oil level Check exhaust system 50 Check air cleaner see more often in Figure 14 dusty conditions e Clean governor linkage See Figure 15 Change crankcase oil Drain moisture from sediment bowl Clean crankcase breather see Figure 13 Replace oil filter Check battery condition Check generator slip rings and brushes replace if worn to 5 16 500 Check start disconnect circuit e Grind valves it required Clean holes in rocker box oil line Check nozzle spray pattern see Note 2 Clean generator Replace anti flicker points Change secondary fuel filter General overhaul if required see Note 3 Water or foreign material in fuel can ruin the injection system If daily inspection shows water or excessive dirt in sediment bowl fuel handling and storing
387. tary wheel hubs The front axles are Shuler tubular axles The axles are connected by a steering linkage The steering is mechanical with hydraulic power assist A Vickers power steering pump driven off the carrier engine a Ross steering gear and two hydraulic cylinders comprise the power steering system Air brakes are used on all four axles They are powered by a compressor driven from the carrier engine The actuators on the two rear axles are two section section provides service brakes and the other provides a park or emergency brake The park or emergency brake section contains a mechanical lock This lock keeps the park or emergency brake applied even if air pressure is lost HC238A 1 3 TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions The carrier uses hydraulic outriggers They are used to lift the machine clear of the ground and to level it when picking up heavy loads A hydraulic system consisting of a pump sump tank valves and cylinders operate the outriggers The Vickers pump is driven off the main transmission by a Tulsa products power take off The pump delivers oil under pressure to two control valve stacks One valve stack controls the outrigger beam cylinders The other controls the outrigger jack cylinders The valves are electrically actuated from control panels on the carrier Four control panels are used with one located near each hydraulic outrigger jack The be
388. tem to be sure they are tight Check all hoses for punctures or other damage and replace if necessary Item 17 Exhaust System Check the exhaust manifold retaining nuts exhaust flange clamp and other connections for tightness Check for proper operation of the exhaust pipe rain cap if one is used Item 18 Air Box Drain Tube With the engine running check for flow of air from the air box drain tubes every 1 000 hours or 30 000 miles If the tubes are clogged remove clean and reinstall the tubes The air box drain tubes should be cleaned periodically even though a clogged condition is not apparent If the engine is equipped with an air box drain tank drain the sediment periodically Item 19 Emergency Shutdown Check the shutdown system every 300 operating hours or each month to be sure it will function when needed Item 21 Radiator Inspect the exterior of the radiator core every 1 000 hours or 30 000 miles and if necessary Operator s Manual 2 68 2 69 2 70 2 71 25 2 z s 0 LANE kee i eos ds i i didi Fig 2 Air Box Drains 18 2 65 clean it with a quality grease solvent such as mineral spirits and dry it with compressed air Do not use fuel oil kerosene or gasoline It may be necessary to clean the radiator more frequently if the engine is being operated in extremely dusty or dirty areas Item 23 Oil Pressure Under normal operation oil pressure is noted each time the engi
389. ter Then add warm 100 F 37 7 C water until the proper mixture is reached Soak the element in the solution for at least 15 minutes Agitate the element for 2 minutes to loosen and remove the dirt Rinse the element with clean water until the water coming through the element is clean The water pressure should not be over 40 206 kPa PSI Thoroughly air dry the element before using After cleaning the filter element inspect for damage Look for dust on the clean air side the slightest rupture or damaged gaskets good way to detect ruptures in the element is to place a lighted light bulb inside the element and look toward the light from the outside Any hole in the element even a tiny one will pass dirt to the engine and cause unnecessary wear Inspect the air cleaner when servicing the elements Replace any parts that are missing worn or damaged Inspect the following items 1 Air cleaner mounting hands loose missing nuts and bolts breaks 2 Welded Joints and seams on air cleaner body and inlet and outlet tubes Fig 2 12 Cleaning Element With Water Fig 2 13 Inspecting The Element 3 Connections between air cleaner and engine 4 Restriction tap plug loose or missing 5 Dust cup or end cover holes dents sealing edge damaged 6 Dust cup retaining clamp broken threads stripped 7 Dust cup gasket if used damaged 8 Gasket washer on element wing nut or bolt missing worn
390. the boom assembly links B at the end of boom TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment MID POINT LINKS MOUNTED AT 85 FOOT POINT 25 9m 120 To 130 Ft Booms 36 58 To 39 6m ASSEMBLY LINKS MOUNTED AT END OF BOOM LOWER SECTION Cc BOOM PEAK MUST BE ON THE GROUND 50 To 110 Ft Booms 15 24 To 33 53m Fig 5 18 Inline Pin Tubular Boom Disassembly NA252 D A 59 8 18 1m Of Main Pendants Connected To Mid Point Links At 85 Foot 25 9m Point B 19 8 5 99m Basic Pendant Connected To End Of Boom Lower Section C Ahead Of Suspension Point D Behind Suspension Point B 85 Foot 25 9m Point F End Of Boom Lower Section 1 Pin Connection Hub 6 Live Mast Fully Extended 11 Assembiy Links 2 Capscrew Spacer Nut 7 59 18 1m Main Pendants 12 Pin amp Cotter Pins 3 Assembly Links 8 19 8 5 99m Pendant Pair 13 Main Pendants 4 Pin amp Cotter Pins 9 Pin Connection Hub 5 Main Pendants 10 Capscrew Spacer Nut HC238A ree TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment Pendant Reconnected Behind Pins Being Removed Pendant Must Be Taut Center Line Of Boom Straight Boom Peak On Ground Removed Here Pendant Hooked In Front Of Pin Removed Lower Pins Removed WRONG BOOM WILL FALL Pendant Reconnected Behind Pins Being Removed Boom Peak Was Not On The Ground Upper Pins Removed
391. the boom to where the radius can easily and accurately be measured Also hoist the hook block off the ground Accurately measure the horizontal distance from the upper center of rotation to the hook block with a tape measure This distance must match the Reach meter reading within 1 foot Lift a known weight of at least 5096 of the maximum crane capacity for the reeving of the main hoist as shown on the TM 10 3950 263 14 amp P 1 Section 10 Overload Warning System Two Blocks capacity chart This known weight must match the Load meter reading 9 The Alert meter must read the same as the maximum allowable lifting weight on the capacity chart for the radius indicated on the Reach meter Note When in the both position mode the Alert Limit will be twice that of the single block reeving Unless the total allowable load as indicated on the crane capacity chart for the radius indicated on the Reach Meter is less than the sum of the individual allowable loads Example Allowable load for left hook is 25 000 pounds Allowable load for right hook is 25 000 pounds Total allowable for both hooks is 35 000 pounds When in the both position mode the Alert Meter will show 35 000 pounds 10 7 Trouble Shootin Self Test Procedure 1 Select Both position on the Hook Select switch 2 100 ft 30 4m main boom length on the main electronics assembly Boom Select switch regardless of actual boom length on machin
392. ther damage before operating Check lubricant level Add lubricant if necessary Inspect for leakage or other damage Repair if any before operating machine Remove hand hole cover and inspect clutch for wear or damage Pay particular attention to the throwout collar and the grease hose and fittings leading to it If the hose breaks or works loose the throwout collar will not receive adequate lubrication This may cause damage to the clutch assembly Pump in 8 to 10 shots of grease at each lubrication Three bearings are being lubricated thru one fitting Wipe up any excess grease to keep it off the clutch linings Change the filters after the first 50 hours of operation on a new machine The procedure is explained later in this section Drain accumulated oil and water as explained later in this section Lubricate all pivot points with engine oil Check valve caps for rust or corrosion clean if any is apparent Lubricate with clean S o M oil Check all clutches and brakes for proper adjustment Adjust as explained later in this manual if necessary See Section 4 Greasy aged or worn linings should be replaced because continued operation may be unsafe Check linings for foreign particles which may score the drums If any particles are evident replace linings before continued operation Lubricate all remaining 50 hour points as listed on the lubrication chart This bearing must be kept full of grease for proper lubrication and long
393. ther operations charge batteries immediately after adding water Water must combine with the electrolyte by means of charging Delay in charging can result in freezing water Be careful not to over fill when servicing batteries a Check level of electrolyte If level of electrolyte is below top of battery plates add distilled water to cover the plates b Inspect batteries and battery box for Batteries are missing damage or damaged or if engine will not crank A 43 TM 10 3950 263 14 amp P 1 Operator Crew Preventive Maintenance Checks and Services Carrier NOTE Within designated interval these checks are to be performed in the order listed B Before D During A After W Weekly M Monthly ITEM TO BE INSPECTED ITEM INTERVAL PROCEDURE CHECK FOR AND HAVE REPAIRED EQUIPMENT IS NOT FILLED OR ADJUSTED AS NEEDED READY AVAILABLE IF NOTE PERFORM WEEKLY AS WELL AS BEFORE PMCSs IF a You are the assigned operator but have not operated crane upper since the last weekly b You are operating the upper for the first time MAKE THE FOLLOWING WALK AROUND CHECKS EXTERIOR OF CRANE UPPER a Check for evidence of leakage oil Class III leakage fuel or coolant on or under the upper exists b Check for loose missing or damaged parts ENGINE CRANKCASE Check dipstick for proper oil level Add oil as necessary to the FULL mark ref Operator s Manual BELTS Check all drive belts for cracks frays
394. thorization will be granted upon written request to the NMP stating that all criteria listed in the Commercial Technical Manual boom repair section can be met or exceeded by the requesting unit Crane serial number and US Army registration number are to accompany any such request This action is required to insure that the structural integrity designed into the cranes is preserved at all times Additional information is contained in TB 43 0142 A 29 TM 10 3950 263 14 amp P 1 APPENDIX E SHIPMENT AND STORAGE Transportability Review TR 81 4f Q for the 140 ton Crane is available from the Military Traffic Management Command MTMC Transportation Engineering Agency 12388 Warwick Blvd P O Box 6276 Newport News VA 23606 Phone AUTOVON 927 4646 The manufacturer s loading recommendations are listed below Loading Recommendation Rail Domestic 112 720 Ib 1 60 flat car 1 HC 238A crane with gentry base and outriggers 1 GO flat car 1 A upper counterweight 31 000 Ib 1 B upper counterweight 31 000 Ib 1 A bumper counterweight 13 500 Ib 1 B bumper counterweight 15 000 Ib 1 60 flat car 1 10 extension 577 b 2 20 extension 1 984 Ib 1 30 extension 1 392 Ib 1 60 flat car 1 peak 4 950 Ib 1 parts box 2 500 Ib 3 hookblocks 5 650 Ib 3 reel of cable 3 900 Ib 1 spare tire 150 Ib Rail Export 1 60 flat car 1 HC 238A with front outrigger 99 320 Ib 1 60 flat car 1 A upper counterweight 31 000 I
395. tions 6 4 Controls The standard control box has a battery charge rate ammeter pre heat switch a start stop switch and fuse The following is a brief description of typical controls Preheat Switch Manifold heater and glow plug Start Stop Switch Charge Rate Anmeter Fuse AC Generator 011 Fill Tube Dil Pressure Gauge Fuel Filters 0i Drain TM 10 3950 263 14 amp P 1 Section 6 Auxiliary Generator Assembly 6 5 Start Stop Switch Starts and stops the unit locally 6 6 Battery Charge Rate DC Ammeter Indicates the battery charging current 6 7 Pre Heat Switch Provides pre heat control for manifold heater and glow plug for cold diesel engine starting 6 8 Oil Pressure Gauge Indicates pressure for lubricating oil in engine located on the engine 6 9 Fuse Protects the fuel solenoid ignition and general control components including the wiring harness 6 10 Pre Startin Preparations for the initial and each additional starting operation should include careful checks of the oil fuel cooling exhaust and electrical systems The cylinder air housing door should be closed with all air shrouds in place Before operating generator set check all components for mechanical security If an abnormal condition defective part or operating difficulty is detected repair or service as required The generator set should be kept free of dust dirt and spilled oil or fuel Be sure proper operating procedure i
396. tment Fig 4 7 Check the front and rear drum brake adjustment upon delivery of a new machine and every 50 hours thereafter as follows a Brake lining wear is taken up by means of an adjusting bolt and nut located at the split in the band Tightening this bolt will take up on the band while loosening will increase clearance between the drum and the band The band should be adjusted tight enough to hold the load when the pedal is operated in the lower half of its travel By adjusting the band in this manner the maximum available leverage is being used Over tightening the band will result in a much harder working brake improper brake release abnormal lining wear and will make it difficult to lock the pedal in the fully applied position b Adjust the stand off bolts so there is even Planetary Brake clearance between the band and the brake drum A 3 8 Clearance 9 5mm when the brake is released all the way around the 1 Rotation Anchor 3 Brake Cylinder drum This is required for maximum brake band 2 Brake Spring 4 Band Bold cooling and to prevent TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Continued Upper Adjustments Front And Rear Drum Brakes A 122 3 8 3 34m 1 Front Drum Pedal B 73 7 16 1 86m 5 2 Pedal Latch 6 Band Bolts 7 3 Rear Drum Pedal 4 Bell Crank 7 Rear Drum Brake 8 Live End Pins brake band drag when powering down a load c The brake b
397. to 40 ft lbs To change the setting of valve clearance adjust the locknut which secures the rocker arm to the cylinder head Loosen the locknut to increase clearance and tighten it to reduce clearance d Check valve clearance with a feeler gauge between the rocker arm and the valve Fig 6 7 Increase or reduce the clearance until the proper gap is established Correct valve ROCKER ARM WRENCH LOCK NUT TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembl END OF SPRING DECOMPRESSION BEHIND STOP SPRING DECOMPRESSION RELEASE ARM EXHAUST VALVE ROCKER ARM DECOMPRESSION Nz DECOMPRESSION DECOMPRESSION SOLENOID RELEASE ARM IN PLUNGER RELEASED IN STOPPED RELEASE ARM AND d POSITION RUNNING POSITION SET SCREM IN STOPPED POSITION EXHAUST HOLD ARM ROCKER ARM AGAINST SNAP g BROKEN LINEIINDICATES RINGS an K 5 MOVEMENT WHEN UNLOCKED Fig 6 8 Decompression Mechanism clearance is 0 011 inch intake and 0 008 inch exhaust b Release mechanism to allow compression and check the clearance between screw and rocker arm Insert a feeler 6 35 Decompression Release gauge between valve and rocker arm to take up valve clearance for this check If there is no clearance back The decompression release mechanism holds the off set screw until it just clears rocker arm exhaust valve open long enough for cranking speed rpm s to build up without opposition from compression
398. to limit spring stroke to 1 15 32 37 3mm drums by adding or subtracting shims between the dead end lug and the dead end bracket on the revolving frame The following shims are available for use at this point Note Reach rod dimensions don t need 1 VB92 eren 16 Ga 1 51mm checking unless rod has been replaced or 2 22 Ga 759mm satisfactory brake adjustment cannot be c With brake applied the bell crank 2 arm must be accomplished through above procedure parallel to the upper frame horizontal members as shown by dimensions C and D These dimensions 4 14 Boom Hoist Brake Fia 4 8 must be equal If not adjust brake band bolt until they are The boom hoist brake is spring applied and hy draulically d The brake must be adjusted when dimension B released If S o M pressure should be lost and the boom the amount the piston protrudes hoist brake was adjusted properly it would automatically apply HC238A 4 5 Operator s Manual 4 17 Fig 4 8 Boom Hoist Brake A 14 5 8 371 4mm Brake Applied B 7 16 11 1mm Brake Applied Adjust When Flush Or Less C D 23 1 4 590 5mm Brake Applied 1 Long Band Section 7 Push Rod 2 Bell Crank 8 Grease Fitting 3 Adjusting Nut 9 Bell Crank 4 Band Bolt 10 Spring Rod 5 Short Band Section 11 Spring 6 Cylinder 12 Adj Nut amp Jam Nut from the cylinder is zero piston flush with cylinder Tighten the band bolt until dimension 4 18 B eq
399. to the 19 8 5 99m basic pendant The 5 foot 1 52m pendant connects to the headshaft links Fig 5 8 Deflector Roller Assembly N71 A e 40 082m a 60 18 3 o gt 70 213 o_o 280 244m oT 90 274m OTT gt 100 30 6m a p 1 110 33 60 ot p oT 1 39m Fig 5 9 Deflector Roller Location Roller required when using front drum for hoist Roller required under all circumstances HC238A 5 5 TM 10 3950 263 14 amp P 1 Operator s Manual Section 5 Continued Crane Attachment 5 10 Assembly of crane booms 50 to 110 feet 1524 33 5m in length Note A bumper ctwt required on carrier NA252 D Fig 5 10 Boom Assembly Step 1 1 Boom Lower Section 2 Live Mast Extended 30 9 14m Position 3 Boom Backstops Tie Down Link 4 Upper Pin Connection Hub 5 Boom Assembly Link 6 Capscrew Spacer Lock washer Hex Nut 7 Pendant Pin amp Cotter Pin 8 19 8 5 99m Pendant Used In Pairs 9 Bridle Spreader Bar Unpinned 5 11 Boom Assembly Step 1 Reeve live mast as a short boom See Use the short boom to install the boom lower section on the machine WARNING Don t Get Under Any Part Of The Boom Especially When Boom Sections Are Being Raised Lowered Or Positioned Reposition the live mast backstop target to the vertical position Unpin the backstop tie down links Fig 5 4 Install the backstop struts Eo 7 between the bo
400. toons and an adaptor are used with each of the four side jacks There are racks on the carrier to store five of the pontoons when roading the carrier The other pontoons can be carried on the carrier luggage racks Fasten them securely If a pontoon should fall off a machine it could cause a serious accident Transport the adaptors on an auxiliary truck when roading the machine HC238A 4 Outrigger Controls 5b Front Bumper Outrigger 6 Front Outriggers Fig 1 10 Bumper Outrigger Assembly 1 Control Switch B Bumper Ctwt 3 Outrigger Box M Outrigger Jack 5 Pontoon Operator s Manual ENGINE THROTTLE PUSH TO INCREASE ENGINE SPEEO 2242433 OPPOSITE SIDE USE ONLY FOR FINAL Fig 1 11 Outrigger Control Panel NA215 A The machine has 360 capacities when all outriggers are properly set There are two columns on the capacity chart one for 360 and one for working over the end Always make sure you refer to the correct column when making a lift Use of the wrong capacities can result in machine damage or injury 1 40 Overload Warning System An overload warning system 1 41 a Shift the carrier transmission into neutral is incorporated into the front bumper outrigger If the jack is overloaded for any reason the carrier horn will sound This system is not intended to be used for load weighing Under normal circumstances the horn will not sound during operation as long as you are operating within the
401. ture is below 10 F 23 C an auxiliary preheat is required to raise the temperature in the sump reservoir to at least 10 F 23 Note Only certain C 2 fluids have been approved for use in Allison converters Check with Detroit Diesel Distributor In your area to make sure you are using an approved brand Oil and Filter Check Generally the oil and filter should be changed every 1000 hours of operation However if the equipment operates under severe dust and dirt conditions the oil and filter should be changed more frequently Change the oil immediately if it has been subjected to severe overheating Change the oil any time it shows evidence of contamination Oil Contamination Water In Oil At each oil change examine the oil which is drained for evidence of dirt or water A normal amount of condensation will emulsify in the oil during operation of the transmission 2 37 Operator s Manual 2 125 2 126 2 127 2 128 2 38 However if there is evidence of water check the cooler heat exchanger for leakage between the water and oil areas Oil in the water side of the cooler or vehicle radiator is another sign of leakage This however may indicate leakage from the engine oil system Metal Particles Metal particles in the oil except for the minute particles normally trapped in the oil filter indicate damage has occurred in the converter When these particles are found in the sump the converter must b
402. ty to the Government To the extent the terms of such greater warranty are inconsistent with or conflict with this warranty the provisions of this warranty shall govern J 7 3 Remedies J 7 3 1 New Replacement Supplies With respect to defective supplies wherever located the warranty shall include the furnishing without cost to the Government F O B contractor s plant branch or dealer facility or F O B original CONUS destination or F O B US Port of Embarkation at the Government s option new supplies to replace any that prove to be defective within the warranty period J 7 3 2 Corrective Action Options In addition the Government shall have the option a to return the equipment or parts thereof to the contractor s plant branch or dealer facility for correction or b to correct the supplies itself When the Government elects to return the equipment or parts to the contractor s plant branch or dealer facility the cost of labor involved in the correction of the defective supplies shall be borne by the contractor When the equipment or parts thereof are returned to the contractor for correction the contractor shall bear all transportation costs to the contractor s plant and return With respect to defective supplies when the Government elects to correct them itself the cost of labor involved in the correction of defects shall be borne by the Government If the Government requires the assistance of Contractor personnel in disassembly reass
403. ual is divided into twelve major sections as shown above Each section can be located with the tabs on the right hand edge of the page as shown in this picture The first page of each section is an index of the subjects covered in that section An alphabetical index of the whole book is Section 11 i ii TM 10 3950 263 14 amp P 1 Tab Index Operator s Manual TITLE 1 1 140 Ton FMC Link Belt R Crane Upper Machinery 1 3 Clutch Schematic Shaft Schematic Boom Lowering Planetary Carrier Control Transmission Shift Decal Shifting Diagram Machine Top and Side View Bumper Outrigger Assembly Outrigger Control Panel Front Outrigger Box Removal Outrigger Pin Removal System Pin Remover Controls Fluid Starting Aid Upper Control Panel Front Instrument Panel Voltmeter Readings Upper Controls Master Clutch Control Swing Lock Control Swing Brake Control Swing Control Front Drum Control Lever and Brake Rear Drum Control Lever and Brake Brake Pedal Locks Drum Rotation Indicators Boom Hoist Control Boom Hoist Limiting Device Override Engine Throttle Controls Hand Signal Chart Wire Rope Capacity Chart Counterweight Removal Controls AB Upper Counterweight Bumper Counterweight Boom Foot Pin Removal System Live Mast Control ER ER ER ER co All A aL DP are ary ry ry pop pl La mre mary ary pare ho RF 1 18 1 20 E 1 Klee ER EN
404. uals 7 16 11 1mm e Check the spring length It must equal 14 5 8 371 4mm measured inside the spring seats If not adjust the spring length with the adjusting nut and jam nut 12 Note Adjustments made necessary by lining wear should be made with the adjusting nuts on the band bolt only providing Step C above has been established The centering adjustment and adjustment of the spring bolt nut are ordinarily necessary only when the band has been removed 4 16 Clutch Adjustment Fig 4 9 The clutch adjustment must be checked on delivery of a new machine and every 50 hours thereafter as follows a Loosen the locknut on the adjusting bolt b Turn the adjusting bolt until the toe of the lining just contacts the clutch drum c Remove the cotter pin and shim cover from the dead end of the shoe TM 10 3950 263 14 amp P 1 Section 4 Continued Upper Adjustments d Add shims as necessary between the bottom of the dead end block and the shoe until the head of the shoe contacts the drum e Turn the adjusting bolt and check for 015 to 025 38 to 63mm clearance It may be necessary to add or subtract shims in conjunction with turning the bolt to obtain even clearance of 015 to 025 38 to 63 mm the length of the shoe The following shims are available for use at this point 1 Ers netto 12 Ga 2 65mm 2 22652 16 Ga 1 51mm 3 22 28 Ga 378mm f
405. uring operation In some cases it becomes hot enough to cause severe burns Be careful not to let hot hydraulic oil contact the skin f On machines equipped with a pressurized or pre charged sump tank relieve the pressure before working on the hydraulic system This pressure can push oil out of a connection drain plug etc as itis loosened This could cause an injury When setting pressures never exceed manufacturers ratings Always follow instructions to the letter Over pressure can cause hydraulic component damage or failure Over pressure in hydraulic circuits can also lead to damage or failure of mechanical parts on a machine Any of the above can lead to an accident Never put any part of your body into a hole on a hydraulic boom A sudden movement of the boom could cut it off Never make a lift which is not in plain sight without a signal man This is particularly true on hydraulic yard cranes where the operator does not swing with the boom This can lead to an accident or machine damage TM 10 3950 263 14 amp P 1 OPERATOR S MANUAL SECTION 0 OPERATING SAFETY CON T When you pick a load with any crane the load radius will increase Due to the design of hydraulic crane booms cantilever boom supported by cylinders overlapping sections this increase is much more pronounced The Increase or outswing of the load can overload the boom and lead to boom failure or tipping Also movement of the load can cause it t
406. urn the wipers off A wiper is provided on both the front and top windows Blower A forced air blower is used to circulate air from the heater or fresh air from outside through the cab To turn the blower on push switch to on Push blower speed switch to one of the three operating positions low medium high To turn the blower off push the switch to the off position Drum Rotation To actuate the drum rotation indicators push the switches to engage To turn off the rotation indicators push the switches to disengage For more information on drum rotation indicators see Dome Light To turn on the dome light move the switch to on To turn off the dome light move the switch to off Live Mast Control This control operates the hydraulic extendable live mast See operating instructions pagel 1 32 S o M Pressure Gauge This gauge indicates the pressure available in the S o M control system Under normal machine use the gauge will fluctuate between a low of 900 psi 6205 kPa and a high of 1 050 psi 7239 kPa If the system malfunctions and is working over relief pressure the gauge would indicate 1 250 psi 8618 kPa If the gauge fluctuates rapidly or reflect a reading other than described above the S o M system is malfunctioning Repair before further use HC238A TM 10 3950 263 14 amp P 1 Section 1 Continued Operating Instructions Engine Oil Pressure Engine Water Temperature Voltmeter
407. use open flame Use fresh fuel Protect against moisture condensation Keep fuel system clean and batteries in a well charged condition Partially restrict cool air flow but use care to avoid overheating In extreme cold temperatures it may be necessary to maintain preheating up to 2 minutes after the engine starts to obtain firing CAUTION Do Not Use Preheat For More Than One Minute Before Cranking This Will Help To Prevent Burn Out And Conserve Battery Power TM 10 3950 263 14 amp P 1 Operator s Manual Section 6 Continued Auxiliary Generator Assembly Sed page 6 10 for comprehensive engine setting guide 6 26 Dust And Dirt a Keep set clean Keep cooling fins free of dirt etc Service air cleaner as frequently as necessary Change crankcase oil every 50 operating hours Keepoil and fuel in dust tight containers Keep governor linkage clean 6 27 High Altitude Maximum power will be reduced approximately 4 percent of each 1000 feet above sea level after the first 1000 feet 6 28 Adjustments 6 29 Anti Flicker Points The anti flicker breaker points are adjusted while wide open Loosen and move stationary contact to correct gap Replace burned or faulty points If only slightly burned dress smooth with file or fine stone Measure gap with thickness gauge 6 30 Governor The governor controls engine speed Rated speed and voltage appear on the nameplate see Specifications Engine speed equals f
408. utch and shut down engine before working on machine Replace all guards and panels before operating machine 2 10 Fig 2 2 Upper Lubrication Chart TM 10 3950 263 14 amp P 1 Operator s Manual Section 2 Continued Preventive Maintenance And Lubrication 2 16 Upper Lubrication Chart Ref No 10 50 250 500 1000 Hrs Ne Description Points Hours Hours Hours Or Seasonal Front Rear Drum Brake 2 Each Pedal 2 Master Clutch Swing Lock Swing Brake Linkage A11 M 3 Control Stand Linkage A11 M 4 Drum Brake Linkage Pivots 3 A 5 Turntable Bearing 2 6 RH Front Drum Shaft Brg 1 A 7 Reverse Bevel Gear Case 1 ii CH J 8 Swing Brake Pivot 1 A 9 RH Rev Shaft Bearings 1 A 10 RH R D Shaft Bearings 1 A 11 Outboard Bearing 1 A 12 Red Shaft Bearing Housing 1 CH M 18 Two Speed Planetary A11 CH Jor E 14 Fuel Tank 1 15 BH Brake Pivot 1 A 16 Chain Case 1 CH C 17 Throwout Collar 1 A 18 Clutch Cross Shaft 2 A 19 Air Cleaner 1 See Chart pg 2 20 20 Torque Converter A11 See Chart pg 2 20 21 Engine A11 See Chart pg 2 20 22 Ctwt Remover Linkage 8 A 23 Ctwt Remover Cylinder 4 A 24 Oil Filter A11 See Chart pg 2 20 25 Fuel Filter A11 See Chart pg 2 20 26 Battery 1 27 Radiator 1 28 S o M Sump Tank 1 CH 29 S o M Filter 1 CH 30 L H BH Shaft Brgs 1 A 31 Drum Brake Cross Shaft 1 A 32 RD Brake Pivot 1 A 33 LH RD Shaft Bearings 1 A 1 Dismantle and inspect 34 LH Rev Shaft Bearings 1
409. ver to the rear while simultaneously releasing the brake to spool on rope Raise a load b Disengage the drum pawl push the lever forward while simultaneously releasing the brake to power off rope Lower a load c Simultaneously return the control lever to neutral and depress the brake to stop the unit and hold a load CAUTION The Brake Pedal Locks Are Intended To Allow The Operator To Rest His Legs When Suspending A Load For A Short Period Of Time But The Operator Must Remain In His Seat With His Feet On The Pedals Failure To Follow These Instructions May Result In An Accident Never Leave Machine With A Load In The Air It May Fall d A load can be lowered on the brake Release the brake with foot pedal and allow load to lower by gravity Control rate of descent by partially applying brake Loads can be lowered with lever engaged in hoist position by varying engine speed and letting gear train run backwards through slippage in the hoist converter Sed page 1 29 for more information Fig 1 23 Swing Control 1 22 TM 10 3950 263 14 amp P 1 Operator s Manual Section 1 Continued Operating Instructions 1 75 Brake Pedal Locks The brake pedal locks are operated as follows a Operator s foot is in position shown at A during normal machine operation Foot holds latch in disengaged position b Tolatch pedal in place depress pedal fully with foot in position 1 Pivot foot to position 2 while hold
410. very of a new machine and every 50 hours thereafter as follows a The brake must be adjusted if the cylinder piston is flush with the edge of the cylinder when the brake is applied To adjust the brake back off on the locknut and tighten the adjusting nut until the Spring length A is 13 5 8 346 1mm with the brake applied This dimension is spring length only and does not include the spring guides Swing Brake Control Adjustment Sed Fig 4 3 The brake band tension may be adjusted by tightening the spring loaded nut 5 on the band Adjust the control valve linkage as follows a Adjust toggle link assembly so that valve cap is just short of bottoming when toggle link assembly is on center b Adjust set screw 6 so that linkage can toggle slightly over center when lever is fully engaged c Adjust rear set screw and jam nut to stop lever travel in line with swing lock and master clutch when lever is in rear position Make sure control valve is fully releasing Counterweight Remove The counterweight remover consists of two hydraulic cylinders connected to linkage TM 10 3950 263 14 amp P 1 Operator s Manual Section 4 Continued Upper Adjustments R882 Fig 4 4 Swing Brake A 13 5 8 346 1mm Brake Applied 1 Connecting Pin 5 Lever Arm 8 Piston Stop 9 Cylinder Piston 10 Cylinder Body Pin 6 Adjusting Nut Pivot Pin Pin 7 Spring at the rear of the upper frame The r
411. ves the machine to prevent starting by unauthorized persons Operator s Manual Engine not running or running at slow idle 1 Dead or disconnected battery Discon nected or badly connected meter battery unless circuit was completed around battery 2 Very low battery charge Engine might not start 3 Low battery charge Constant reading in this area would indicate need for a check on the alternator and voltage regulator 4 Well charged battery This indicates a good battery and also that alternator and voltage regulator are operating properly 5 The pointer might remain in this pos ition temporarily when the engine has been stopped after considerable use due to a surface charge in the battery to get a correct reading turn on the ignition for a few minutes 67 Under normal conditions a 12 V Battery is fully charged at 12 8V A Slightly higher reading may occur under the conditions outlined in no 5 but gen when the engine is stopped is not a true reading erally speaking any reading above 12 8 V S ection 1 Continued Operatin n 12 1344465 1 eg m 16 Su 12_13 1446 aere 1 6 Gey H GAN 12 1344 15 A vous 1 12 13 14 5 10 GAN 16 Ge A VOLTS Fig 1 18 Voltmeter Readings TM 10 3950 263 14 amp 1 Instructions Engine running fast enough to make alternator produce
412. will not engage 1 Adjusted wrong 1 Adjust sed p 4 1 2 Clutch defective 2 Repair or replace see Shop Manual Converter slipping 1 Low oil level 1 Refill with oil see 2 Defective converter 2 Repair or replace see Shop Manual Converter overheats 1 Low oil level 1 Refill with oil seelp 2 37 m 2 Converter has been stalled 2 Stop machine operations until During operation converter cools down Load Hoist System Machine will not lift load 1 Load too heavy for machine as 1 Compare load weight to capacity Set up chart Make sure load is with in capacity Make sure enough parts of line are being used See chart in operator s cab Adjust boom length or load radius until load is within capacity Too many wraps of cable on the drum will decrease line pull Reduce amount of cable on drum 2 Clutches are slipping 2 Adjust clutches sed p 4 6 Check clutch shoes and drum for Scoring glazing oil on surface Clean or replace parts as necessary see Shop Manual Check S o M pressure at clutch Cylinder Should be 900 1050 P S I If not adjust control Stand linkage Set pressure in system sed p 4 6 7 2 HC238A 8 3 Operator s Manual Problem Machine will not lift load cont 3 Load will not lower Free fall Cannot hold load with brake 1 2 Section 8 Continued Troubleshooting Procedures Torque converter slipping Master clutch slipping
413. y H Hours ITEM TO BE INSPECTED PROCEDURE CHECK FOR AND REPAIR FILL OR ADJUST AS NECESSARY NOTE Perform Operator Crew PMCS prior to or in conjunction with Organizational PMCS if a There is a delay between the daily operation of equipment and the Organizational PMCS b Regular operator is not assisting participating TRANSMISSION MAIN and CREEPER and REAR DIFFERENTIALS a Check oil level with machine on level ground by removing the check plug Add lubricant until level reaches bottom of opening b Change oil when warm Drain oil fill with light oil DE 5 run a few minutes drain and refill with proper lubricant ref page 2 5 and page 2 14 Operator s Manual c Inspect for missing components loose bolts leakage or damage Repair before roading the machine CONTROL LINKAGE a Lubricate master shifter control Pump in grease until it ex trudes around the boot on the shift lever b Lubricate all pivot points on transmission creeper trans mission and throttle control linkages with engine oil CHASSIS Provide complete chassis lubrication Force grease into fittings until old lubricant dirt and water are expelled WHEELS Inspect wheels rims and nuts for damage Check lug nuts for proper torque ref page SMI 69 2 0 Shop Manual REAR AXLE VENTS Clean the vents A 56 TM 10 3950 263 14 amp P 1 Organizational Preventive Maintenance Check and Services Carrier M Monthly S Semia
414. ylinders completely Swing the upper around until the cones on the counterweight remover arms line up with the seats in the counterweight Open the two control valves slightly Move the function lever to the raising position Make sure the remover linkage seats properly in the counterweight when raising Keep the counterweight level by adjusting the control valves Extend the cylinders to their maximum stroke f Close both control valves Return the function lever to neutral ee See page 4 2 for counterweight remover adjustment procedures 1 27 Operator s Manual 1 86 Counterweight Assemblies Either an A or AB counterweight may be used on the upper of the machine and the capacity chart lists capacities for machines equipped both ways 1 87 Ctwt Usage Machine On Outriggers CAUTION No Capacities Are Listed For AB Upper Ctwt On Tires When Machine Is Equipped With AB Upper Ctwt When On Rubber Upper Must Face Directly Rearward If Machine Is Swung Over Side It May Tip Over Machine cannot be roaded with either AB ctwt assembly installed Machine can be roaded with either or both A ctwt assemblies installed Refer to charts in Crane Boom Attachment for more information 1 88 AB Upper Counterweight Assembly a Fully extend and set all outriggers on firm supporting surface Machine must be level with all tires clear of ground b Using the live mast as a short boom or the basic boom

tm 10-3950-263-14&p-1 technical manual for crane, mobile

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tm 10-3950-263-14&amp;p-1 technical manual for crane, mobile

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tm 10-3950-263-14&p-1 technical manual for crane, mobile