TM 5-3810-307-24-1-1 TECHNICAL MANUAL
ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR ALL-TERRAIN CRANE (ATEC) AT422T DIESEL ENGINE DRIVEN, 22 TON CAPACITY TRUCK MOUNTED WITH CAB NSN 3810-01-448-2619 3810-01-448-2619
WARNING OPERATIONS ADJACENT TO OVERHEAD LINES ARE PROHIBITED UNLESS ONE OF THE FOLLOWING CONDITIONS ARE SATISFIED. 1
POWER HAS BEEN SHUT OFF AND POSITIVE MEANS TAKEN TO PREVENT LINES FROM BEING ENERGIZED.
2
POSITION AND BLOCK EQUIPMENT INSURING NO PARTS, INCLUDING CABLE, CAN COME WITHIN THE FOLLOWING CLEARANCES:
VOLTAGE REQD CLEARANCE UNDER 50 KV 69 KV 115-161 KV 230-285 KV 345 KV 500 KV
-
10 FEET 12 FEET 15 FEET 20 FEET 25 FEET 35 FEET
TM 5-3810-307-24-1-1 CHANGE NO. 1
HEADQUARTERS, DEPARTMENT OF THE ARMY WASHINGTON, D.C. 1 July 2006 July 2006 TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR All-Terrain Crane (ATEC) Diesel Engine Driven, 22 Ton Capacity Truck Mounted With Cab NSN 3810-01-448-2619
DISTRIBUTION DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TM 5-3810-307-24-1-1, 1 August 2000, is updated as follows: 1. 2.
3. 4.
File this sheet in front of the manual for reference. This change is a result of changes documented against the configuration of the crane. Extreme weather equipment including engine coolant and hydraulic reservoir heaters have been added as an option. New or updated test is indicated by a vertical bar in the outer margin of the page. Added illustrations are indicated by a vertical bar adjacent to the figure number.
Remove Pages
Insert Pages
2-8-21 and 2-8-22 2-8-29 and 2-8-30 2-8-31 and 2-8-32 2-8-37 and 2-8-38 2-8-43 and 2-8-44 2-8-47 and 2-8-48 2-8-53 and 2-8-54 2-8-61 thru 2-8-64 2-9-5 and 2-9-6 2-9-17 and 2-9-18 2-10-3 and 2-10-4 2-10-11 and 2-10-12 2-16-1 and 2-16-2
2-8-21 and 2-8-22 and 2-8-22 2-8-29 and 2-8-30 and 2-8-30 2-8-31 and 2-8-32 and 2-8-32 2-8-37 and 2-8-38 and 2-8-38 2-8-43 and 2-8-44 and 2-8-44 2-8-47 and 2-8-48 and 2-8-48 2-8-53 and 2-8-54 and 2-8-54 2-8-61 thru 2-8-61 thru 2-8-64 2-8-64 2-9-5 and 2-9-6 and 2-9-6 2-9-17 and 2-9-18 and 2-9-18 2-10-3 and 2-10-4 and 2-10-4 2-10-11 and 2-10-11 and 2-10-12 2-10-12 2-16-1 and 2-16-1 and 2-16-2 2-16-2
Appendix A (A-1 thru thru A-21/(AA-21/(A-2 22 blank)
Index-1 and Index-22
Appendix A (A-1 thru (A-1 thru A-2 A-21/ 1/(A(A-2 22 blank) blank)
Index-1 and Index-20 and Index-20
By Order of the Secretary of the Army:
PETER J. SCHOOMAKER General, United States Army Chief of Staff
Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 0615301
Distribution: To be distributed in accordance with the initial distribution number (IDN) 256626, requirements for TM 5-3810-307-24-1-1.
TM 5-3810-307-24-1-1 INSERT LATEST CHANGED PAGES. DESTROY SUPERCEDED DATA. LIST OF EFFECTIVE PAGES NOTE:
The portion of text affected by the changes is indicated by a vertical line in the outer margins of the pages. Changes to illustrations are also indicated by vertical lines in the outer margins. Dates of issue for original and changed pages are:
Original: 01 August 2000; Change 1: 01 July 2006 TOTAL NUMBER OF PAGES FOR THIS MANUAL IS 644 CONSISTING OF THE FOLLOWING: Page No. Cover Blank Warning Blank i – ii iii iv – vi
*Change No. 0 0
0 0 1 0 1
Page No. Divider Blank 2-1-1 – 2-1-2 2-1-3 2-1-4 – 2-1-24 2-1-25 2-1-26–2-1-31
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TM 5-3810-307-24-1-1 LIST OF EFFECTIVE PAGES - Continued Page No. 2-10-1 –2-10-3 2-10-4 2-10-5 –2-10-10 2-10-11 2-10-12–2-10-22
2-11-1–2-11-16 2-12-1–2-12-14 2-13-1–2-13-12 2-14-1–2-14-30 2-15-1–2-15-10
2-16-1–2-16-2 2-16-3 –2-16-4 A-1 – A-22 Index-1 – Index-20 FO-1 – FO-14
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TM 5-3810-307-24-1-1 HEADQUARTERS, DEPARTMENT OF THE ARMY
WASHINGTON D.C., 1 AUGUST 2000
COMMERCIAL SERVICE MANUAL ALL-TERRAIN CRANE (ATEC) DIESEL ENGINE DRIVEN, 22 TON CAPACITY TRUCK MOUNTED WITH CAB GROVE MODEL AT422T CONTRACT NO. DAAE07-97-D-X001 NSN 3810-01-448-2619 3810-01-448-2619 CAGE 12361 PART NUMBER 1140000513 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. publication. If you find any mistakes mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended (Recommended Changes to Equipment Technical Publications), through through the Internet, Internet, on the Army Electronic Electronic Product Support Support (AEPS) website. The Internet address is http://aeps.ria.army.mil http://aeps.ria.army.mil.. The DA Form 2028 is located located under the Public Applications Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter letter or DA Form 2028 direct to: to: AMSTA-LC-LPIT / TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The email address is TACOM-TECH-PUBS
[email protected] @ria.army.mil.. The fax number is DSN 793-0726 or Commercial (309) 782-0726.
TM 5-3810-307-24-1-1
TABLE OF CONTENTS - Continued Page CHAPTER TWO - DETAILED DESCRIPTION AND MAINTENANCE SECTION 1 - CABS . . . . . Cabs . . . . . . . . . . Carrier Ca Cab . . . . . . Superstructure Cab Maintenance . . . . .
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. 2-1-1 . 2-1-7 . 2-1-8 . 2-1-8 . 2-1-9
SECTION 2 - ENGINE . . . . . Engine . . . . . . . . . . . Fuel System . . . . . . . Air Intake System . . . . Water Cooling System Exhaust System . . . . .
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. . 2-2-1 . . 2-2-5 . 2-2-19 . 2-2-25 . 2-2-32 . 2-2-38
SECTION 3 - DRIVE TRAIN . . . . . . . . Drive Train . . . . . . . . . . . . . . . Transmission/Torque Converter . Transmission Control Valve . . .
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. . 2-3-1 . . 2-3-5 . . 2-3-7 . 2-3-10
TM 5-3810-307-24-1-1
TABLE OF CONTENTS - Continued Page SECTION 6 - AXLE OSCILLATION SYSTEM . Axle Oscillation System . . . . . . . . . . . Lockout Cylinders . . . . . . . . . . . . . . Double Solenoid Valves . . . . . . . . . .
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. 2-6-1 . 2-6-3 . 2-6-4 . 2-6-6
SECTION 7 - AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-1 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5 Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-8 SECTION 8 - HYDRAULIC SYSTEM. . . . . Hydraulic System . . . . . . . . . . . . . Supply Pressure and Return Circuit Hydraulic Pump . . . . . . . . . . . . . . Hydraulic Pump Disconnect . . . . . . Valves . . . . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . .
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. 2-8-1 . 2-8-9 2-8-14 2-8-19 2-8-21 2-8-23 2-8-56
SECTION 9 - SWING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-1 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5
TM 5-3810-307-24-1-1
TABLE OF CONTENTS - Continued Page SECTION 13 - SWIVELS. . . . . . . . Swivels. . . . . . . . . . . . . . . 14 Port Air/Hydraulic Swivel. Electrical Swivel. . . . . . . . .
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2-13-1 2-13-3 2-13-5 2-13-9
SECTION 14 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5 SECTION 15 - EMERGENCY STOWAGE SYSTEM Emergency Stowage System . . . . . . . . . . . 3-Way Valve Assembly . . . . . . . . . . . . . . . Pump/Motor Assembly . . . . . . . . . . . . . . . Electrical Control Box Assembly . . . . . . . . .
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2-15-1 2-15-3 2-15-4 2-15-6 2-15-8
SECTION 16 - PREPARATION FOR SHIPMENT AND STORAGE . . . . . . . . . . . . . . . . . . . . 2-16-1
APPENDICES
TM 5-3810-307-24-1-1
TABLE OF CONTENTS - Continued VOLUME 2 SERVICE MAINTENANCE PACKAGES SM01-001-0 SM01-002-0
Air Intake System Water Cooling System
SM02-025-0 SM02-027-0
Transmission/Torque Converter Torque Converter with Lockup
SM03-026-0
Kessler Axle
SM04-019-0 SM04-020-0
Steering Pump Miter Gear
SM07-005-0 SM07-006-0 SM07-008-0 SM07-012-0 SM07-014-0 SM07-017-0
Reservoirs Low Pressure Indicating Switch Throttle Control Cylinder Pressure Protection Valve R-12 Relay Valve Stop Light Switch
TM 5-3810-307-24-1-1
TABLE OF CONTENTS - Continued APPENDICES B C D E F G H I J K
Red Dot Heavy Duty Air Conditioning and Heating Service Training Manual (P/N RD-5-5900-0) Cummins Master Repair Manual - Holset Air Compressors, Bulletin No. 3810321-01 Delco Remy 21-S1 Delctron Generator (Alternator), Service Manual 1G-286 Delco Remy Cranking Motors, Service Bulletin 1M-157 and Delco Remy Service Test Specifications, Service Bulletin 1M-188 Not Used PAT DS350 LMI Troubleshooting Handbook for Grove AT422T ZF Semi-Integral Power Steering Gear, Type 7421 Instructions for Operation, Maintenance, and Inspection Cummins Field Service Procedures for Wabco Air Compressor Winterizing the ATEC Crane AT422T Berminghammer Pile Driver System, Instructions for Maintenance, Troubleshooting, and Repair
TM 5-3810-307-24-1-1
HOW TO USE THIS MANUAL This manual contains troubleshooting and maintenance instructions for the Army's AT422T, 22-ton AllTerrain Crane (ATEC). Other manuals in the set contain operation instructions and operator maintenance and diesel engine maintenance. Although these manuals do not conform with the format specified for other Army vehicles, the technical data presented herein is essential for properly operating and maintaining the vehicle. These manuals were developed to help you operate and maintain the equipment. All task descriptions will take you step-by-step through the procedure. Don't take shortcuts. Before you begin any task, you should read through the complete procedure, make sure you know what needs to be done, then go back and follow the steps as written. Pay particular attention to WARNINGS , CAUTIONS, and NOTES. This will prevent injury to personnel, damage to equipment, and provide clear instructions. Use the alphabetical index at the back of the manual to find a topic not listed in the tables of contents. The definitions of WARNING, CAUTION, and NOTE as used in this manual apply as follows: WARNING A warning or danger is used to emphasize that if an
TM 5-3810-307-24-1-1
(8)
APPENDIX H. Instructions for Installation/Operation of Pile Driver System (Berminghammer),
(9)
APPENDIX I.
Determination of ATEC Weight Distribution,
(10)
APPENDIX J.
Transportability Guidance,
(11)
APPENDIX K.
Winterizing the ATEC Crane,
(12)
APPENDIX L.
Instructions for Installation/Operation of Pile Driver (Linkbelt),
(13)
APPENDIX M.
Lubrication,
(14)
Alphabetical Index.
TM 5-3810-307-24-1 - Maintenance Manual with Supplemental Data. This manual consists of two volumes: Volume one is the basic service manual and Volume two is the Service Maintenance (SM) packages. Volume one, the service manual, is divided into chapters and sections. Chapter One contains 5 sections that cover: general maintenance information; preventive maintenance; lubrication; and troubleshooting. Chapter Two, divided into 16 sections, covers specific vehicle component removal/replacement procedures. At the beginning of each section is a Table of Contents listing the specific system/components contained in the section. Where vehicle components are repairable, the replacement procedure may refer to an SM package for repair. Volume One also contains the Maintenance Allocation Chart (MAC) as Appendix A. Volume Two, the SM packages, contains repair procedures for selected components of the
TM 5-3810-307-24-1-1
WARNINGS GENERAL It is mandatory that all hydraulic hoses and fittings be correctly tagged and identified before they are disconnected to effect repairs or service. Failure to correctly tag and identify hoses and fittings can cause wrong reconnection, which can result in death or injury to personnel. Review warning summaries included at the beginning of each section. Structural repairs and/or modifications must be approved by the manufacturer. Repair requests should be submitted to Manitowoc Crane® CARE, P.O. Box 21, Shady Grove, PA 17256-0021, USA. Any unauthorized repairs and/or modification could void any remaining crane warranty and/or result in serious injury and equipment damage.
CHAPTER ONE
TM 5-3810-307-24-1-1
SECTION 1 GENERAL DESCRIPTION TABLE OF CONTENTS Page GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3 List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3
TM 5-3810-307-24-1-1
GENERAL DESCRIPTION DESCRIPTION This Manual provides information for the maintenance personnel of the AT422T Grove AllTerrain Crane (ATEC). The lift capacities are listed on the Load Chart in the cab. The all terrain crane incorporates an all welded steel frame, using planetary drive axles to provide selectable four-wheel drive. Axle steering is accomplished utilizing hydraulic steer cylinders. The engine is mounted at the front of the crane and provides motive power through a six speed transmission. Hydraulic, double box, sliding beam outriggers are integral with the carrier frame.
rotation in either direction. All crane functions are controlled from the fully-enclosed cab mounted on the superstructure. On-site travel can also be accomplished using driving controls located in the superstructure cab. The crane is equipped with a threesection, trapezoidal, cable synchronized boom. Lifting is provided by a main hoist and an auxiliary hoist. The crane is also capable of supporting and operating a clamshell bucket, a pile driver, a concrete bucket, and a grapple. Special hardware adapters and hydraulic quick disconnects have been provided for attaching these components.
NOTE The carrier frame incorporates oscillation lockout cylinders to which the axles are mounted. Axle oscillation is provided through the front and rear axle suspension cylinders.
Throughout this manual, reference is made to left, right, front, and rear when describing locations. These reference locations are to be considered as those viewed from the
TM 5-3810-307-24-1-1 CAPACITIES. Fuel Tank (Reservoir Capacity). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 gal. (166.6 L) (Draw Capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 gal. ( 160.0 L) Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid - 10.5 gal. (39.7 L) Radiator only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 qts (33.1 L) Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3 qts (16.4 L) Hydraulic Tank (Total Reservoir Capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.8 gal. (275.6 L) (Full Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.4 gal. (243.0 L) (Low Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.9 gal. (226.7 L) Hoist Grove Model HO-15C-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 qt (8.5 L) Swing Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 qts (1.9 L) Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 pt (.24 L) Axle Planetary Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 qts (1.5 L) Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 qts (13 L) Transmission and Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 qts (26.5 L) ENGINE. Make and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins B5.9-190 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder Diesel Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.02 in. (102.1 mm) Stroke 4 72 in (120 0 mm)
TM 5-3810-307-24-1-1 AXLES. Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kessler Model (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LT 51 PL 375 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,475 lbs @ 55 mph (10,194 kg @ 88 km/h) Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.06:1 Track (Front and Rear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.38 in. (199.1 cm) BRAKES. Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perrot Air Twin Wedge 410 x 180 DE Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perrot Air Single Wedge 410 x 180 ZE Service Brake Actuators. Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WABCO Size Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 16 (2 per wheel) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 20 (1 per wheel) Parking Brake Actuator. Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WABCO Size Front Type 16 (1 per wheel)
TM 5-3810-307-24-1-1 CARRIER STEERING. System . . . . . Manufacturer . Model. . . . . . Type . . . . . . Steering Ratio
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ZF semi-integral, dual circuit steering gear . . . . . . . . . . . . . . . . . . . . . . . . . Z.F. . . . . . . . . . . . . . . . . . . . 7421 965 112 . . . . . . . Recirculating Ball w/Worm Gear . . . . . . . . . . . . . . . . . . . . . . . . 18:1:1
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STEERING PUMP PRIMARY. Manufacturer . Part Number . Type . . . . . . Output . . . . .
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. . . . . Dana Corporation . . . . . . PVP16-115C-JU Gear, Clockwise Rotation . . . . . . 8 gpm (30.2 lpm) controlled flow
STEERING PUMP EMERGENCY. Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Corporation Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SSP2-85-DRW 3 Displacement per rev . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68 in SUPERSTRUCTURE STEERING CONTROL VALVE. Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-1012-002 Displacement 14 8 cu in (242 5 cu cm) per rev
TM 5-3810-307-24-1-1 BOOM. Elevation. Sections . Length . . Power . .
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. . . . . . . . . . . . . . . . . . . -3º to 78º . . . . . . . . Three, fully synchronized . . . . . . . . . . . 27-70 ft (8.2-21.3 m) . Single stage telescoping cylinder w/ cable synchronization
HOISTS - MAIN AND AUXILIARY. Manufacturer . . . . . . Model. . . . . . . . . . . Type . . . . . . . . . . . Drum Dimension Diameter . . . . . Length . . . . . . Wire Rope Size . . . . . . . . Length . . . . . . Permissible Line Pull .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HO-15C-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary gear reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 in. (30.5 cm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 in. (40.6 cm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.625 in. (16 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 ft (111.0 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Load Chart
OUTRIGGERS. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double box beam and inverted jack Spread Extended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 ft (5.6 m) Retracted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 ft (2.3 m) AIR COMPRESSOR.
TM 5-3810-307-24-1-1 ELECTRICAL SYSTEM - Continued. Alternator Manufacturer . Type . . . . . . . Model . . . . . . Rating . . . . . . Slip Ring Assembly Manufacturer . Type . . . . . . . Part Number. .
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. . . . . . . . . . . . Delco-Remy 21-SI Series, Negative-Ground . . . . . . . . . . . . . . 1117900 . . . . . . . . . . . . 70 amperes
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CAB HEATING AND AIR CONDITIONING. Carrier Heater. Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hunter Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HW30-5 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Water Carrier Air Conditioner. Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Dot Corporation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove PN 7576001682 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roof Mounted Refrigerant R134A
TM 5-3810-307-24-1-1 FIRE EXTINGUISHER. Manufacturer . Type . . . . . . Rating . . . . . Weight . . . . .
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Mellits Fire Equipment . . . . . . Dry Chemical . . . . . . . 1-A:10-B:C . . . . 2.50 lb (1.13 kg)
TM 5-3810-307-24-1-1
SECTION 2 GENERAL MAINTENANCE TABLE OF CONTENTS Page GENERAL MAINTENANCE Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Row, Tapered Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleeve Bearings
1-2-3 1-2-3 1-2-3 1-2-4 1-2-4 1-2-4 1-2-4 1-2-4 1-2-4 1-2-4 1-2-4 1-2-5 1-2-5 1-2-5 1-2-5 1-2-5
TM 5-3810-307-24-1-1
WARNING SUMMARY Page
WARNING
1-2-5
Exercise extreme care around pressurized hydraulic systems. Do not work on a hydraulic system while it is in operation or until all pressure is released.
WARNING Loctite® type adhesives contain chemicals that may be harmful if misused. Read and follow the instructions on the container.
1-2-6
TM 5-3810-307-24-1-1
MAINTENANCE These general suggestions should be helpful in following the instructions in this manual. In analyzing a system malfunction, use a systematic procedure to locate and correct the problem. 1.
Determine the problem.
2.
List possible causes.
3.
Devise checks.
4. Conduct checks in a logical order to determine the cause.
apply when access covers or inspection plates are removed. Clean and inspect all parts. Be sure all passages and holes are open. Cover all parts to keep them clean. Be sure parts are clean when they are installed. Leave new parts in their containers until ready for assembly. Clean the rust preventive compound from all machined surfaces of new parts before installing them. REMOVAL AND INSTALLATION.
5. Consider the remaining service life of components against the cost of parts and labor necessary to replace them. 6.
Make the necessary repair.
7. Recheck to ensure that nothing has been overlooked.
When performing maintenance, do not attempt to manually lift heavy parts when hoisting equipment should be used. Never locate or leave heavy parts in an unstable position. When raising a portion of a crane or a complete crane, ensure the crane is blocked securely and the weight is supported by blocks rather than by lifting equipment.
TM 5-3810-307-24-1-1 If a part resists removal, check to be certain all nuts and bolts have been removed and that an adjacent part is not interfering.
cables, tag each one to ensure proper identification during assembly. GROUNDS.
DISASSEMBLY AND ASSEMBLY. When assembling or disassembling a component or system, complete each step in turn. Do not partially assemble one part and start assembling some other part. Make all adjustments as recommended. Always check the job after it is completed to see that nothing has been overlooked. Recheck the various adjustments and verify complete functional performance by operating the machine before returning it to the job.
Effective mechanical grounding of electrical components and systems is important for proper operation as well as reducing EMI/EMC effects. The following procedures apply to all mechanical ground points, where grounding may occur: •
•
PRESSING PARTS. When pressing one part into another, use an antiseize compound or a molybdenum disulfide base compound to lubricate the mating surfaces. Assemble tapered parts dry. Before assembling parts with tapered splines, be sure the splines are clean, dry, and free from burrs. Position the parts together by hand to mesh the splines before applying
directly, through the inherently-grounded (case-grounded) mounting hardware of a component. through a discrete wire, connected to a single component's insulated ground terminal, or to several components (e.g. as in a ground wire emanating from a harness assembly).
To ensure adequate grounding, it is essential that all paint, rust, grease, etc. is removed from the contact area of the frame, component, and any intermediate contact surfaces, before the connection is made. It is also important that the various components making
TM 5-3810-307-24-1-1 The life of an antifriction bearing will be shortened if not properly lubricated. Dirt in an antifriction bearing can cause the bearing to lock resulting in the shaft turning in the inner race or the outer race turning within the cage. Double Row, Tapered Roller. Double row, tapered roller bearings are precision fit during manufacture and components are not interchangeable. The cups, cones, and spacers are usually etched with the same serial number and letter designator. If no letter designator are found, wire the components together to assure correct installation. Reusable bearing components should be installed in their original positions.
Sleeve Bearings. Do not install sleeve bearings with a hammer. Use a press and be sure to apply the pressure directly in line with the bore. If it is necessary to drive on a bearing, use a bearing driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part. GASKETS. Be sure the holes in the gaskets correspond with the lubricant passages in the mating parts. If it is necessary to make gaskets, select material of the proper type and thickness. Be sure to cut holes in the right places. Blank gaskets can cause serious damage.
Heating Bearings. Bearings which require expansion for installation should be heated in oil not to exceed 250 degrees F (121 degrees C). When more than one part is heated to aid in assembly, they must be allowed to cool and then pressed together again. Parts often separate as they cool and contract.
When removed, always install new cylinder head and manifold gaskets using recommended gasket compound on head gaskets to allow uniform sealing. BATTERIES. Clean batteries by scrubbing them with a solution of
TM 5-3810-307-24-1-1 Keep The System Clean. When removing components of a hydraulic system, cover all openings on both the component and the crane.
The following are known high stress areas applicable to Grove machines, and visual inspection of these areas should be made part of an owner's planned preventive maintenance program:
If evidence of foreign particles is found in the hydraulic system, flush the system.
a. Power Telescope Boom - wear pad retaining structures, hydraulic cylinder attaching points, boom pivot shaft retaining structures.
Disassemble and assemble hydraulic components on a clean surface.
b. Outrigger pads, attachment structures.
Clean all metal parts in a nonflammable cleaning fluid. Then lubricate all components to aid in assembly.
c. Main frames - generally in the area of doubler plates and crossmembers; at the junction of front and rear frame members on truck cranes.
Sealing Elements.
d. Turntable bearing connection (where bearing is welded to the crane superstructure or chassis).
Inspect all sealing elements (O-rings, gaskets, etc.) when disassembling and assembling the hydraulic system components. Installation of new elements is always recommended. Hydraulic Lines. When installing metal tubes, tighten all bolts finger-
beams,
boxes
and
e. Counterweight support structures. f. Chassis axle and suspension mounting structures. g. Hydraulic cylinder end connections.
TM 5-3810-307-24-1-1 The following types of Loctite® brand adhesives are available from Grove Worldwide, Product Support. Loctite® Number 277 242 592
Grove Part Number 9999100806 9999100805 9999100804
FASTENERS AND TORQUE VALVES. Use bolts of the correct length. A bolt which is too long may bottom before the head is tight against the part it is to hold. If a bolt is too short, there may not be enough threads engaged to hold the part securely. Threads can be damaged. Inspect them and replace fasteners, as necessary. Hardened flat washers must be used with high strength fasteners (Grade 5 and 8). Be sure a hardened flat washer is installed under the end to be rotated/torqued. Torque values should correspond to the type bolts, studs, and nuts being used. The torque tables in this section are provided by Grove Worldwide for reference when performing
lubricant, plating, or other factors that might require variation from standard torque values. When maximum recommended torque values have been exceeded. the fastener should be replaced. When referring to the applicable torque charts, use values as close as possible to the torque values shown to allow for wrench calibration tolerance. An erratic or jerking motion of the wrench can easily result in excessive torque. ALWAYS use a slow wrench movement and STOP when the predetermined value has been reached. Torque wrenches are precision instruments and are to be handled with care to ensure calibrated accuracy. Calibration checks should be made on a scheduled basis. Whenever the wrench might be either over stressed or damaged, it should immediately be removed from service until recalibrated. KNOW YOUR TORQUE WRENCH! Flexible beam type wrenches, even though they might have a preset feature, must be pulled at right angles and the force must be applied at the exact center of
TM 5-3810-307-24-1-1
TM 5-3810-307-24-1-1
T M 5 3 8 1 0 3 0 7 -2 4 -1 -1
1 -2 -1 0
T o r q u e V a l u e s R a n g e ( M e t r i c )
TM 5-3810-307-24-1-1
SECTION 3 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) TABLE OF CONTENTS Page ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMCS Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMCS Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1-3-3 1-3-3 1-3-4 1-3-4
LIST OF TABLES Title
Page
Organizational Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3-5
TM 5-3810-307-24-1-1 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
GENERAL To ensure the crane is ready for operation at all times, inspect it systematically so that any defects can be discovered and corrected before they result in serious damage or failure. The table on the next few pages contains the organizational level PMCS. Record all deficiencies and shortcomings, along with the corrective action taken on a DA Form 2404. The Item Number column of the table is the source for the numbers used in the TM Number column on DA Form 2404. PMCS GUIDANCE WARNING Dry cleaning solvent PD-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 breather vapors. Do not use near open flame or excessive heat. The flash point is 100º to 138ºF (38º to 59ºC). If you become dizzy while using solvent, get fresh air immediately and get medical aid. If contact with eyes is made, wash your eyes with water and get medical aid immediately.
TM 5-3810-307-24-1-1 LEAKAGE DEFINITIONS The following are definitions of the types/classes of leakage you need to know to be able to determine the status of your equipment. CLASS I
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
CLASS II
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected.
CLASS III
Leakage of fluid great enough to form drops that fall from the item being checked/inspected. CAUTION Equipment operation is allowable with minor leakage (Class I or II). Of course consideration must be given to the fluid capacity in the item/system being checked/inspected. When operating with Class I or II leaks, continue to check fluid levels as required on your PMCS. Class II leaks should be reported to your supervisor.
PMCS TABLE
TM 5-3810-307-24-1-1
Organizational Preventive Maintenance Checks and Services (1)
(2) Interval
Item No.
M
(1)
•
Q
S
A
B
(3) H 50
Item To Be Inspected
(4)
(5)
Procedure
Equipment Is Not Ready/Available If:
Cold Start System [If a. Check contents of temperature is fluid cylinder. below 30ºF (-1ºC)] b. Inspect valve assembly for cleanliness and damage. c. Inspect tubing and nozzles for cleanliness, loose connections, and other damage. d. Inspect wiring and connectors for security and damage. e. Test system operation.
Improper operation, any component damaged or clogged, fluid cylinder empty, or leaks detected.
TM 5-3810-307-24-1-1 Organizational Preventive Maintenance Checks and Services - Continued (1) Item No.
(2) Interval M
Q
S
A
B
(3) H
Item To Be Inspected
(4)
(5)
Procedure
Equipment Is Not Ready/Available If:
(6)
•
Air Dryer
Check/test air dryer, refer to Section 7.
Air dryer not operating as required.
(7)
•
Air System Pressure Perform operating and Protection Valves leakage checks, refer to Section 7.
Valve operating improperly or leaking.
(8)
•
Tie Rod Ball Joints
Check ball joints for excessive wear.
Ball joints worn excessively.
(9)
•
Drag Link U-joint
Check U-joint for excessive wear.
U-joint worn excessively.
(10)
•
Drag Link Ends
Check ends for excessive Ends worn excessively. wear.
(11)
•
Steering Knuckles
Check knuckles for excessive wear.
(12)
•
Lubrication
Perform Quarterly Lubrication Chart
Knuckles worn excessively.
TM 5-3810-307-24-1-1 Organizational Preventive Maintenance Checks and Services - Continued (1) Item No. (18)
(2) Interval M
Q
S
•
A
B
(3) H 500
Item To Be Inspected Batteries
(4)
(5)
Procedure
Equipment Is Not Ready/Available If:
WARNING Do not smoke or allow flame or spark in the vicinity while checking the batteries. The batteries generate hydrogen, a highly explosive gas. WARNING Battery electrolyte is toxic to skin, eyes, and respiratory tract. Avoid all contact. Skin and eye protection and vapor control are required. a. Clean batteries, refer
a. Battery has bulging
TM 5-3810-307-24-1-1 Organizational Preventive Maintenance Checks and Services - Continued (1) Item No. (19)
(2) Interval M
Q
S
A
B
(3) H 500
•
Item To Be Inspected Engine Fuel Filters
(4)
(5)
Procedure
Equipment Is Not Ready/Available If:
Replace filter elements. NOTE For secondary fuel filter only. If filter change is occurring in temperatures at or below 30ºF (-1°C), use the filter installation procedures annotated on cartridge PLUS 1/4 turn.
(20)
(21)
• •
500
Air Governor Filter (Strainer) Elements
500
Inspect and clean or replace filter (strainer) elements as required.
Hoist Mounting Bolts Check for proper torque [250 lbs-ft (339 Nm)].
Two (2) each filters (NSN 4730-002250710) required.
TM 5-3810-307-24-1-1 Organizational Preventive Maintenance Checks and Services - Continued (1) Item No.
(2) Interval M
Q
S
A
B
H
(3)
(4)
(5)
Item To Be Inspected
Procedure
Equipment Is Not Ready/Available If:
(27)
•
1000
Brakes
Using feeler gauge, check Brakes improperly for [0.006 ± 0.0015 in. adjusted. (0.152 ± 0.04 mm)] clearance between brake lining and brake drum.
(28)
•
1000
Engine Valves
Check/adjust valve clearance: Intake - 0.010 in. (0.254 mm). Exhaust - 0.020 in. (0.508 mm).
(29)
•
1000
Air Cleaner Element Replace air cleaner element.
(30)
•
1000
Boom Wear Pads
(31)
Air Dryer
Clean wear pads and inspect for wear and security. Replace desiccant
Out of adjustment.
Wear pads loose or worn excessively.
TM 5-3810-307-24-1-1 Organizational Preventive Maintenance Checks and Services - Continued (1) Item No.
(2) Interval M
Q
S
A
B
(3) H
Item To Be Inspected
(4)
(5)
Procedure
Equipment Is Not Ready/Available If:
(37)
•
Spring Brake Control Valve
Disassemble valve, clean components, and inspect for wear and damage.
(38)
•
Air System Service and Park Brake Relay Valves
Disassemble valves, clean components, and inspect for wear and damage.
(39)
•
Air System Carrier and Superstructure Cab Brake Valves
Disassemble valves, clean components, and inspect for wear and damage.
(40)
•
Air Conditioners
Perform Annual PMCS schedule, refer to Appendix B.
(41)
•
Joystick Pilot Control System
Replace inline filter.
Filter is located under an access panel, left-rear
TM 5-3810-307-24-1-1 Organizational Preventive Maintenance Checks and Services - Continued (1) Item No.
(2) Interval M
Q
S
A
B
H
(3)
(4)
(5)
Item To Be Inspected
Procedure
Equipment Is Not Ready/Available If:
(47)
•
Brake Actuator
Disassemble actuator, clean components, and inspect for wear and damage.
(48)
•
Lubrication
Perform Biannual Lubrication Chart requirements.
