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

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

August 2000
 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 VOLTAGE REQD CLEARANCE
EQUIPMENT INSURING
NO PARTS, INCLUDING UNDER 50 KV - 10 FEET
CABLE, CAN COME 69 KV - 12 FEET
WITHIN THE FOLLOWING 115-161 KV - 15 FEET
CLEARANCES: 230-285 KV - 20 FEET
345 KV - 25 FEET
500 KV - 35 FEET

CHECK WITH YOUR LOCAL POWER SUPPLIER FOR

CORRECT LINE VOLTAGE

NOTE

READ AND UNDERSTAND ALL OF THE SAFETY

WARNINGS AND CAUTIONS CONTAINED IN SECTION 2
OF THE OPERATOR'S MANUAL BEFORE OPERATING
OR MAINTAINING THE CRANE, DIRECT ANY
QUESTIONS THAT YOU MAY HAVE TO YOUR
SUPERVISOR FOR CLARIFICATION.

a
 TM 5-3810-307-24-1-1

CHANGE HEADQUARTERS, DEPARTMENT OF THE ARMY

NO. 1 WASHINGTON, D.C. 1 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 STATEMENT A: Approved for public release; distribution is unlimited.
TM 5-3810-307-24-1-1, 1 August 2000, is updated as follows:

1. File this sheet in front of the manual for reference.

2. 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.
3. New or updated test is indicated by a vertical bar in the outer margin of the page.
4. Added illustrations are indicated by a vertical bar adjacent to the figure number.
Changed illustrations are indicated by change bars in the outside margin adjacent to
the updated area and a change bar adjacent to the figure number.
5. Remove old pages and insert new pages as indicated below:

Remove Pages Insert Pages

List of Effective Pages List of Effective Pages

i thru ix i thru ix
1-1-3 and 1-1-4 1-1-3 and 1-1-4
1-1-7 and 1-1-8 1-1-7 and 1-1-8
1-2-5 and 1-2-6 1-2-5 and 1-2-6
1-3-5 thru 1-3-10 1-3-5 thru 1-3-10
1-4-5 thru 1-4-8 1-4-5 thru 1-4-8
2-1-3 and 2-1-4 2-1-3 and 2-1-4
2-1-25 and 2-1-26 2-1-25 and 2-1-26
2-1-31 thru 2-1-34 2-1-31 thru 2-1-34
None 2-1-101 and 2-1-102
2-2-27 thru 2-2-30 2-2-27 thru 2-2-30
2-5-1 and 2-5-2 2-5-1 and 2-5-2

None 2-5-23/(2-5-24 blank)

2-7-1 thru 2-7-4 2-7-1 thru 2-7-4
2-7-11 and 2-7-12 2-7-11 and 2-7-12
2-7-17 and 2-7-18 2-7-17 and 2-7-18
2-7-21 thru 2-7-36 2-7-21 thru 2-7-36
None 2-7-37/(2-7-38 blank)
2-8-1 and 2-8-2 2-8-1 and 2-8-2
None 2-8-18a/(2-8-18b blank)
Remove Pages Insert Pages
2-8-21 and 2-8-22 2-8-21 and 2-8-22
2-8-29 and 2-8-30 2-8-29 and 2-8-30
2-8-31 and 2-8-32 2-8-31 and 2-8-32
2-8-37 and 2-8-38 2-8-37 and 2-8-38
2-8-43 and 2-8-44 2-8-43 and 2-8-44
2-8-47 and 2-8-48 2-8-47 and 2-8-48
2-8-53 and 2-8-54 2-8-53 and 2-8-54
2-8-61 thru 2-8-64 2-8-61 thru 2-8-64
2-9-5 and 2-9-6 2-9-5 and 2-9-6
2-9-17 and 2-9-18 2-9-17 and 2-9-18
2-10-3 and 2-10-4 2-10-3 and 2-10-4
2-10-11 and 2-10-12 2-10-11 and 2-10-12
2-16-1 and 2-16-2 2-16-1 and 2-16-2
Appendix A (A-1 thru A-21/(A-22 blank) Appendix A (A-1 thru A-21/(A-22 blank)
Index-1 and Index-22 Index-1 and Index-20
 By Order of the Secretary of the Army:

PETER J. SCHOOMAKER
General, United States Army
Official: Chief of Staff

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. *Change No. Page No. *Change No. Page No. *Change No.
Cover 0 Divider 0 2-7-22 0
Blank 0 Blank 0 2-7-23 1
Warning 0 2-1-1 2-1-2 0 2-7-242-7-25 0
Blank 0 2-1-3 1 2-7-262-7-27 1
i ii 1 2-1-4 2-1-24 0 2-7-282-7-29 0
iii 0 2-1-25 1 2-7-302-7-38 1
iv vi 1 2-1-262-1-31 0 2-8-1 1
vii 0 2-1-32 1 2-8-2 2-8-18 0
viii x 1 2-1-33 0 2-8-18a2-8-18b 1
Divider 0 2-1-34 1 2-8-192-8-20 0
Blank 0 2-1-352-1-100 0 2-8-21 1
1-1-1 1-1-2 0 2-1-1012-1-102 1 2-8-222-8-29 0
1-1-3 1 2-2-1 2-2-26 0 2-8-30 1
1-1-4 1-1-6 0 2-2-27 1 2-8-31 0
1-1-7 1 2-2-282-2-29 0 2-8-32 1
1-1-8 1-1-10 0 2-2-30 1 2-8-332-8-36 0
1-2-1 1-2-5 0 2-2-312-2-42 0 2-8-37 1
1-2-6 1 2-3-1 2-3-36 0 2-8-382-8-42 0
1-2-7 1-2-10 0 2-4-1 2-4-36 0 2-8-43 1
1-3-1 1-3-4 0 2-5-1 0 2-8-442-8-46 0
1-3-5 1-3-6 1 2-5-2 1 2-8-47 1
1-3-7 0 2-5-3 2-5-22 0 2-8-482-8-52 0
1-3-8 1 2-5-232-5-24 1 2-8-53 1
1-3-9 0 2-6-1 2-6-6 0 2-8-542-8-60 0
1-3-10 1 2-7-1 2-7-4 1 2-8-612-8-63 1
1-3-111-3-12 0 2-7-5 2-7-10 0 2-8-642-8-78 0
1-4-1 1-4-4 0 2-7-112-7-12 1 2-9-1 2-9-5 0
1-4-5 1-4-6 1 2-7-132-7-17 0 2-9-6 1
1-4-7 0 2-7-18 1 2-9-7 2-9-17 0
1-4-8 1 2-7-192-7-20 0 2-9-18 1
1-4-9 1-1-14 0 2-7-21 1
1-5-1 1-5-34 0
* Zero in this column indicates an original page.
A C-1
 TM 5-3810-307-24-1-1

LIST OF EFFECTIVE PAGES - Continued

Page No. *Change No. Page No. *Change No. Page No. *Change No.
2-10-12-10-3 0
2-10-4 1
2-10-52-10-10 0
2-10-11 1
2-10-122-10-22 0
2-11-12-11-16 0
2-12-12-12-14 0
2-13-12-13-12 0
2-14-12-14-30 0
2-15-12-15-10 0
2-16-12-16-2 1
2-16-32-16-4 0
A-1 A-22 1
Index-1
Index-20 1
FO-1 FO-14 0

* Zero in this column indicates an original page.

C-1 B
 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
CAGE 12361
PART NUMBER 1140000513

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical
Publications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet
address is http://aeps.ria.army.mil. The DA Form 2028 is located under the Public 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 or DA Form 2028 direct to: AMSTA-LC-LPIT / TECH PUBS, TACOM-RI, 1 Rock Island
Arsenal, Rock Island, IL 61299-7630. The email address is TACOM-TECH-PUBS@ria.army.mil. The fax
number is DSN 793-0726 or Commercial (309) 782-0726.

TABLE OF CONTENTS

VOLUME 1

Page

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

CHAPTER ONE - GENERAL DESCRIPTION AND MAINTENANCE

SECTION 1 - GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1

SECTION 2 - GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1

SECTION 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) . . . . . . . . . . . 1-3-1

SECTION 4 - LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1

SECTION 5 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1

i C-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

Page

CHAPTER TWO - DETAILED DESCRIPTION AND MAINTENANCE

SECTION 1 - CABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1

Cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9

SECTION 2 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38

SECTION 3 - DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-1

Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-5
Transmission/Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Transmission Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Automatic Powershift Control (APC 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13

SECTION 4 AXLES AND BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-1

Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Axle Proximity Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Rear Axle Steering Unlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Chamber (Front Wheels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Brake Chamber (Rear Wheels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Air Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-36

SECTION 5 - STEERING SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-1

Steering Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Miter Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Integrated Outrigger Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Emergency (Standby) Steering Valve and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Steering System Filter Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23

ii C-1
 TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

Page

SECTION 6 - AXLE OSCILLATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-1

Axle Oscillation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
Lockout Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Double Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-1

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-9
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19
Hydraulic Pump Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56

SECTION 9 - SWING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-1

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Swing Gearbox and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11

SECTION 10 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-1

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Boom Extension and Retraction Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
Boom Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19

SECTION 11 - HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-1

Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Vane Type Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Cable Idler Drum and Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
Hoist Drum Rotation Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14

SECTION 12 - OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1

Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
Outrigger Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Integrated Outrigger Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
Solenoid Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-13
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14

iii
 TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

Page

SECTION 13 - SWIVELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-1

Swivels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
14 Port Air/Hydraulic Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Electrical Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9

SECTION 14 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-1

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5

SECTION 15 - EMERGENCY STOWAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-1

Emergency Stowage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-3
3-Way Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Pump/Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Electrical Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8

SECTION 16 - PREPARATION FOR SHIPMENT AND STORAGE . . . . . . . . . . . . . . . . . . . . 2-16-1

APPENDICES

A Maintenance Allocation Chart (MAC)

FOLDOUTS

Page

FO-1 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-1

FO-2 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-9
FO-3 Air System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-13

iv C-1
 TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

VOLUME 2

SERVICE MAINTENANCE PACKAGES

SM01-001-0 Air Intake System

SM01-002-0 Water Cooling System

SM02-025-0 Transmission/Torque Converter

SM02-027-0 Torque Converter with Lockup

SM03-026-0 Kessler Axle

SM04-019-0 Steering Pump

SM04-020-0 Miter Gear

SM07-005-0 Reservoirs
SM07-006-0 Low Pressure Indicating Switch
SM07-008-0 Throttle Control Cylinder
SM07-012-0 Pressure Protection Valve
SM07-014-0 R-12 Relay Valve
SM07-017-0 Stop Light Switch

SM08-015-1 Hydraulic Pump

SM08-017-1 Integrated Outrigger Valve
SM08-018-0 Outrigger Solenoid Valve Stack
SM08-041-0 Holding Valve

SM09-004-0 Swing Gearbox and Brake

SM11-010-1 Grove Model HO-15 Hoist

SM11-011-0 Vane Type Motor (HO-15C Hoist)

SM13-006-0 Swivel Assembly

SM13-007-0 Electrical Swivel

SM14-001-0 Diesel Heater

v C-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

APPENDICES

B Red Dot Heavy Duty Air Conditioning and Heating Service Training Manual
(P/N RD-5-5900-0)
C Cummins Master Repair Manual - Holset Air Compressors,
Bulletin No. 3810321-01
D Delco Remy 21-S1 Delctron Generator (Alternator), Service Manual 1G-286
E Delco Remy Cranking Motors, Service Bulletin 1M-157 and Delco Remy Service
Test Specifications, Service Bulletin 1M-188
F Not Used
G PAT DS350 LMI Troubleshooting Handbook for Grove AT422T
H ZF Semi-Integral Power Steering Gear, Type 7421 Instructions for
Operation, Maintenance, and Inspection
I Cummins Field Service Procedures for Wabco Air Compressor
J Winterizing the ATEC Crane AT422T
K Berminghammer Pile Driver System, Instructions for Maintenance, Troubleshooting, and
Repair

vi C-1
 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 All-
Terrain 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
operation, procedure, or practice is not followed exactly,
death or injury to personnel may result.
CAUTION
A caution is used to emphasize that if an operation,
procedure, or practice is not followed exactly, equipment
damage may result.

NOTE
A note is used to emphasize an important procedure or
condition.

The following paragraphs provide a general description of each ATEC technical manual.

TM 5-3810-307-10 - Operator's Manual. Contains general theory of operations, operator safety,

instructions for driving and operating the crane, operator troubleshooting, and operator maintenance. The
manual also contains appendices for:

(1) APPENDIX A. References - Forms and Publications,

(2) APPENDIX B. Components of End Item and Basic Issue Items List (COEI/BII),
(3) APPENDIX C. Additional Authorization List (AAL),
(4) APPENDIX D. Expendable/Durable Supplies and Materials List (EDSML),
(5) APPENDIX E. Load Chart,
(6) APPENDIX F. Location/Description of Signs/Decals/Data Plates,
(7) APPENDIX G. Load Moment Indicator (LMI) Operator's Handbook,
vii
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
vehicle. Each SM package is complete with its own Table of Contents. Any requirements for tools and
materials to perform each repair task are also listed. Volume Two also includes Appendices consisting of
vendor repair data for components not addressed elsewhere in the manual and instructions for winterizing
the ATEC (AT422T).

TM 5-3810-307-24-2 - Diesel Engine Operation and Maintenance Manual. This manual also consists of
two volumes: Volume one is the Cummins operation and maintenance handbook while volume two
contains engine repair information. Each manual has been edited specifically for the ATEC. Included are
preventive maintenance, troubleshooting, adjustment/repair/replacement specifications/torques values,
and warranty data.

TM 5-3810-307-24P Repair Parts and Special Tools List (RPSTL). Contains a complete illustrated
parts breakdown for the ATEC. Also included are:

(1) Introduction Work Package,

(2) Repair Parts List Work Package,
(3) Special Tools Work Package,
(4) Cross-Reference Index Work Packages.

viii C-1
 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.

ix/(x Blank) C-1

 CHAPTER ONE
GENERAL DESCRIPTION AND MAINTENANCE
 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

1-1-1/(1-1-2 Blank)
 TM 5-3810-307-24-1-1

GENERAL DESCRIPTION

DESCRIPTION

This Manual provides information for the rotation in either direction. All crane functions are
maintenance personnel of the AT422T Grove All- controlled from the fully-enclosed cab mounted on the
Terrain Crane (ATEC). superstructure. On-site travel can also be accom-
plished using driving controls located in the super-
The lift capacities are listed on the Load Chart in the structure cab. The crane is equipped with a three-
cab. section, trapezoidal, cable synchronized boom.
Lifting is provided by a main hoist and an auxiliary
The all terrain crane incorporates an all welded steel hoist.
frame, using planetary drive axles to provide select-
able four-wheel drive. Axle steering is accomplished The crane is also capable of supporting and
utilizing hydraulic steer cylinders. The engine is operating a clamshell bucket, a pile driver, a concrete
mounted at the front of the crane and provides motive bucket, and a grapple. Special hardware adapters
power through a six speed transmission. Hydraulic, and hydraulic quick disconnects have been provided
double box, sliding beam outriggers are integral with for attaching these components.
the carrier frame.
NOTE
The carrier frame incorporates oscillation lockout
cylinders to which the axles are mounted. Axle Throughout this manual, reference is made
oscillation is provided through the front and rear axle to left, right, front, and rear when describing
suspension cylinders. locations. These reference locations are to
be considered as those viewed from the
The superstructure is capable of continuous 360 carrier cab operator seat with the
degree superstructure facing forward over the front
of the carrier frame.

LIST OF SPECIFICATIONS

GENERAL.

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT422T
Rated Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Load Chart, Appendix E
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4x4x4
Gross Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Lifting and Transportation decal located
on the side of the right-front deck
DIMENSIONS.
NOTE

Dimensions listed are with all components fully retracted.

Overall Crane Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.00 in. (1005.84 cm)

Overall Crane Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.00 in. (243.8 cm)
Overall Crane Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.00 in. (320.04 cm)
Track Width . . . . . . . . . . . . . . . . . . . . . . . ...... . . ...... . . ...... . . . . . 78.38 in. (199.1 cm)
Turning Radius (2 Wheel Steering) . . . . . . . . ...... . . ...... . . ...... . . . . . . 331 in. (840.7 cm)
Turning Radius (4 Wheel Steering) . . . . . . . . ...... . . ...... . . ...... . . . . . . 198 in. (509.9 cm)
Wheel Base . . . . . . . . . . . . . . . . . . . . . . . ...... . . ...... . . ...... . . . . . 121.0 in. (307.3 cm)
Centerline of Rotation . . . . . . . . . . . . . . . . ...... . . ...... . . ...... . . . . . 40.0 in. (101.6 cm)

1-1-3 C-1
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)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 in. (5.9 L)
Max Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 hp @ 2300 rpm
Governed RPM
No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2875
Full Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500
Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 840 (+ 25)
Power at Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 hp @ 2500
Torque (Net) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 lb ft (644 Nm) @ 1500 RPM
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Turbocharged
and Charge Air Cooled
TRANSMISSION.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clark
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9 LFHR24658 w/APC 100 Auto Shift
Speeds. . . . . . . . . . . . ..................................................... 6
Gear Ratios
Fwd 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.07:1
2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19:1
6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.83:1
Rev 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.07:1
2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19:1
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote mounted
Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote mounted
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clark 13.9 w/Lockup and Freewheel

1-1-4
 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)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 24 (1 per wheel)

WHEELS AND TIRES.

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc
Rim Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 in. (25.4 cm)
Bead Seat Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.0 in. (53.3 cm)
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,050 lbs-55 mph (5,012 kg-88 km/h)
Lugs
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 Ft-Lbs (651 Nm)
Tires:
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 R21
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Ply
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,540 lbs-55 mph (6,595 kg-88 km/h)
Load Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ M
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For roading and lifting pressures
see the Tire Inflation Decal

SUSPENSION.

Front and Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leaf Spring w/Hollow

rubber helper spring
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,046 lb (10,000 kg) each at ground

1-1-5
TM 5-3810-307-24-1-1

CARRIER STEERING.

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF semi-integral, dual circuit steering gear

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z.F.
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7421 965 112
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recirculating Ball w/Worm Gear
Steering Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18:1:1

STEERING PUMP PRIMARY.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana Corporation

Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVP16-115C-JU
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, Clockwise Rotation
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 gpm (30 lpm)

MAIN HYDRAULIC PUMP.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 3
GPM @ 2500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 gpm (147 lpm)
39 gpm (147 lpm)
16 gpm (61 lpm)
SWING MOTOR.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H Series
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit
Displacement per rev . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 in (15.7 cm)

SWING GEARBOX.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary Gear Reduction
Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.98:1

1-1-6
 TM 5-3810-307-24-1-1

BOOM.
Elevation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3 to 78
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three, fully synchronized
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-70 ft (8.2-21.3 m)
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single stage telescoping cylinder w/
cable synchronization
HOISTS - MAIN AND AUXILIARY.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HO-15C-16
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary gear reduction
Drum Dimension
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 in. (30.5 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 in. (40.6 cm)
Wire Rope
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.625 in. (16 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 ft (111.0 m)
Permissible Line Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
NOTE
Check the identification plate on the air compressor to determine which model (Holset or
Wabco) is installed on your crane.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . . . . . . . Holset

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . . . . . QE296B
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... .......... 1
Piston Displacement @ 1250 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 ft/min (62,297 cm/sec)

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins/Wabco
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250CC
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................. 1
Piston Displacement @ 1250 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 ft/min (71,736 cm/sec)
AIR/HYDRAULIC SWIVEL.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove
Ports
Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL SYSTEM.
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC negative ground (chassis ground)
Starter
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delco Remy
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37MT
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1993904 (Delco Remy) 10479108 (Cummins)
Cranking Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max: 75
Min: 50
Batteries
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6TL (MS52149-2)

1-1-7 C-1
TM 5-3810-307-24-1-1

ELECTRICAL SYSTEM - Continued.

Alternator
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delco-Remy
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-SI Series, Negative-Ground
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1117900
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 amperes
Slip Ring Assembly
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . United Equipment Accessories
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Conductor, RC850 A Series
Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S15AP49GR1

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
Refrigerant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 lbs
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAG
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 oz

Superstructure Heater.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hunter
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DH22-17A
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Combustion
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volts
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid State (6000 V)
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,000 BTU/hr

Superstructure Air Conditioner.

Refrigerant Compressor
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Dot Corporation
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grove PN 6332000552
Max Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 rpm
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134A
Refrigerant Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 lbs
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAG
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 oz

1-1-8
 TM 5-3810-307-24-1-1

FIRE EXTINGUISHER.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mellits Fire Equipment

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Chemical
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A:10-B:C
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 lb (1.13 kg)

1-1-9/(1-1-10 Blank)
 TM 5-3810-307-24-1-1

SECTION 2
GENERAL MAINTENANCE

TABLE OF CONTENTS

Page

GENERAL MAINTENANCE
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Double Row, Tapered Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Heating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Sleeve Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Keep the System Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Sealing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Fasteners and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7

LIST OF FIGURES

Title Page

Fastener and Nut Identification Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-8

Torque Values Range (Pounds - Foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-9
Torque Values Range (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-10

1-2-1
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 1-2-6

Loctite type adhesives contain chemicals that

may be harmful if misused. Read and follow the
instructions on the container.

1-2-2

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.
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.
8. Functionally test the failed part in its system.
NOTE
Your safety and that of others is always
the number one consideration when
working around machines. Safety is a
matter of thoroughly understanding the job
to be done and the application of good
common sense. It is not just a matter of
do's and don'ts. Stay clear of all moving
parts.
CLEANLINESS.
An important item in preserving the long life of the
machine is keeping dirt out of working parts.
Enclosed compartments, seals, and filters have been
provided to keep the supply of air, fuel, and lubricants
clean. It is important that these enclosures be
maintained.
Whenever hydraulic, fuel, lubricating oil lines, or air
lines are disconnected, clean the adjacent area as
well as the point of disconnect. As soon as the
disconnection is made, cap, plug or tape each line or
opening to prevent entry of foreign material. The
same recommendations for cleaning and covering
TM 5-3810-307-24-1-1
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.
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.
When using hoisting equipment, follow the hoist
manufacturers recommendations and use lifting
devices that will allow you to achieve the proper
balance of the assemblies being lifted and to ensure
safe handling.
Unless otherwise specified, all removals requiring
hoisting equipment should be accomplished using an
adjustable lifting attachment. All supporting members
(chains and cables) should be parallel to each other
and as near perpendicular as possible to the top of
the object being lifted.
CAUTION
The capacity of an eyebolt diminishes as
the angle between the object becomes
less than 90 degrees. Eyebolts and
brackets should never be bent and should
only have stress in tension.
Some removals require the use of lifting fixtures to
obtain proper balance. The weights of some
components are given in their respective sections of
the manual.
1-2-3
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.
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.
PRESSING PARTS.
When pressing one part into another, use an anti-
seize 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
pressure.
Parts which are fitted together with tapered splines
are always very tight. If they are not tight, inspect the
tapered splines, discard the part if splines are worn.
LOCKS.
Lockwashers, flat metal locks, or cotter pins are used
to lock nuts and bolts.
Flat metal locks must be installed properly to be
effective. Bend one end of the lock around the edge
of the part. Bend the other end against one flat
surface of the nut or bolt head.
Always use new locking devices on components
which have moving parts.
When installing lockwashers on housings made of
aluminum, use a flat washer between the lockwasher
and housing.
WIRES AND CABLES.
Batteries should always be disconnected prior to
working on the electrical system.
When removing or disconnecting a group of wires or
1-2-4
cables, tag each one to ensure proper identification
during assembly.
GROUNDS.
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:
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
up the connection are installed in the exact order/
locations depicted (e.g. mounting hardware).
To prevent subsequent formation of rust, fungus, etc.
that may grow between the contact surfaces, and
thus eventually impair the ground connection, each
ground connection is to be sprayed with fungus-
resistant varnish per MIL-V-173 or commercial
equivalent, immediately following installation.
SHIMS.
When shims are removed, tie them and identify them
as to location. Keep shims clean and flat until they
are reinstalled.
BEARINGS.
Antifriction Bearings.
When an Antifriction bearing is removed, cover it to
keep out dirt and abrasives. Wash bearings in non-
flammable cleaning solution and allow them to drain
dry. The bearing may be dried with compressed air
BUT DO NOT spin the bearing.
Discard the bearings if the races and balls or rollers
are pitted, scored, or burned. If the bearing is
serviceable, coat it with oil and wrap it in clean waxed
paper. Do not unwrap new bearings until time of
installation.

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.
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.
Installation.
Lubricate new or used bearings before installation.
Bearings that are to be preloaded must have a film
ofoil over the entire assembly to obtain accurate
preloading. When installing a bearing, spacer, or
washer against a shoulder on a shaft, be sure the
chamfered side is toward the shoulder.
When pressing bearings into a retainer or bore,
uniformly apply pressure to the outer race. If the
bearing is pressed on the shaft, uniformly apply
pressure on the inner race.
Preload.
Preload is an initial load placed on the bearing at the
time of assembly. Whether a tapered roller bearing
should have preload could depend on any of several
conditions: rigidity of the housings and shaft, bearing
spread, speed of operation, etc.
To determine whether a bearing requires preload or
end clearance, consult the disassembly and
assembly instructions pertaining to that bearing.
Care should be exercised in applying preload.
Misapplication of preload to bearings requiring end
clearance can result in bearing failure.
TM 5-3810-307-24-1-1
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.
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
baking soda and water. Rinse with clear water. After
cleaning, dry thoroughly and coat terminals and
connections with anticorrosion compound or grease.
If the machine is to be stored or not used for an
extended period of time, the batteries should be
removed. Store the batteries in a warm, dry place,
preferably on wooden shelves. Never store on
concrete. A small charge should be introduced
periodically to keep the specific gravity rating at
recommended level.
HYDRAULIC SYSTEMS.
WARNING
Exercise extreme care around press-
urized hydraulic systems. Do not work
on a hydraulic system while it is in
operation or until all pressure is
released.
Cleanliness.
Contaminants in a hydraulic system affect operation
and will result in serious damage to the system
components. Dirty hydraulic systems are a major
cause of component failures.
1-2-5
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.
If evidence of foreign particles is found in the
hydraulic system, flush the system.
Disassemble and assemble hydraulic components on
a clean surface.
Clean all metal parts in a nonflammable cleaning
fluid. Then lubricate all components to aid in
assembly.
Sealing Elements.
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-
tight. Then, in order, tighten the bolts at the rigid end,
the adjustable end, and the mounting brackets. After
tubes are mounted, install the hoses. Connect both
ends of the hose with all bolts finger-tight. Position
the hose so it does not rub the machine or another
hose and has a minimum of bending and twisting.
Tighten bolts in both couplings.
Due to manufacturing methods there is a natural
curvature to a hydraulic hose. The hose should be
installed so any bend is with this curvature.
FATIGUE OF WELDED STRUCTURES.
Experience has shown that highly stressed welded
structures when repeatedly subjected to varying
stresses caused by twisting, shock bending and
intentional and/or unintentional overloads, often
become subject to weld cracking which may be
attributed to fatigue of the welded joint. This
condition is not uncommon in construction
equipment.
Equipment should be periodically inspected for
evidence of weld fatigue. The frequency of these
inspections should be commensurate with the age of
the equipment, the severity of the application, and the
experience of the operators and maintenance
personnel.
1-2-6 C-1
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:
a. Power Telescope Boom - wear pad
retaining structures, hydraulic cylinder attaching
points, boom pivot shaft retaining structures.
b. Outrigger pads, beams, boxes and
attachment structures.
c. Main frames - generally in the area of
doubler plates and crossmembers; at the junction of
front and rear frame members on truck cranes.
d. Turntable bearing connection (where
bearing is welded to the crane superstructure or
chassis).
e. Counterweight support structures.
f. Chassis axle and suspension mounting
structures.
g. Hydraulic cylinder end connections.
The above is provided only as a guide, your
inspection plan should not be limited to the areas
listed. A thorough visual inspection of all weldments
is good practice.
Anyone requiring more detailed inspection
instructions and/or procedures many request same
by contacting: Manitowoc Crane CARE, PO Box 21,
Shady Grove, PA. 17256-0021
LOCTITE.
WARNING
Loctite type adhesives contain chem-
icals that may be harmful if misused.
Read and follow the instructions on the
container.
Always follow the directions on the Loctite container
as not all Loctite types are suitable for all
applications..
Various types of Loctite are specified throughout the
Service Manual.

The following types of Loctite brand adhesives are
available from Grove Worldwide, Product Support.
Loctite Number Grove Part Number
277 9999100806
242 9999100805
592 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
maintenance. These tables shall be followed unless
specific values are cited in the detailed maintenance
instruction.
Use of proper torque values is extremely important.
Improper torquing can seriously affect performance
and reliability. Identification of fastener grade is
always necessary. When marked as a high strength
part (Grade 5 and 8.), the mechanic must be aware
that he is working with a highly stressed component
and the fastener should be torqued accordingly.
NOTE
Some special applications require
variation from standard torque values.
Reference should always be made to
component overhaul procedures for
recommendations.
Special attention should be given to the existence of
TM 5-3810-307-24-1-1
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
the handle. Force value readings must be made
while the tool is in motion.
Rigid handle type torque wrenches are available
with torque limiting devices that can be preset to
required values and which eliminate dial
readings.
NOTE
Metric tools may be marked using either
Newton-meter (N-m), or kilogram /meter
(kg/m) units. To convert pounds-foot of
torque to metric units, multiply the
pounds-foot value by 1.36 for the (N-m)
equivalent, or multiply by 0.014 for the
(kg/m) value,
NOTE
When multiplier and/or special tools are
used to reach hard to get at spots,
ensure torque readings are precisely
calculated.
1-2-7
TM 5-3810-307-24-1-1

Fastener and Nut Identification Markings

1-2-8
 TM 5-3810-307-24-1-1

Torque Values Range (Pound Foot)

1-2-9
TM 5-3810-307-24-1-1
Torque Values Range (Metric)
1-2-10
 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-3
PMCS Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-3
Leakage Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4
PMCS Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4

LIST OF TABLES

Title Page

Organizational Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-5

1-3-1/(1-3-2 Blank)
 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 100 to 138F
(38 to 59C). 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.
WARNING
Compressed air, used for cleaning purposes will
not exceed 30 psi. Use only with effective chip
guarding and personnel protective equipment
(goggles/ shield/ loves, etc.).

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 (PD-680) to clean metal surfaces. Use soap and water when you
clean rubber or plastic material.

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 bolt, nut, or screw
that you find loose.

Welds: Look for loose or chipped paint, rust or gaps where parts are welded together. If you find a bad weld,
report it to direct support maintenance.

Electric wires and connectors: Look for cracked or broken insulation, bare wires and loose or broken connectors.
Tighten loose connections and make sure the wires are in good condition.

Hoses and fluid lines: Look for wear, damage, and leaks. Make sure clamps and fittings are tight. Wet spots
show leaks, but a stain around a fitting or connector can also mean a leak. If leakage comes from a loose fitting
or connector, tighten the fitting or connector. If something is broken or worn out, either correct it or report it to
direct support maintenance (refer to the Maintenance Allocation Chart).

If something doesn't work, troubleshoot it according to the instructions in this manual.

If anything looks wrong and you can't fix it, write it down on your DA Form 2404.

1-3-3
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

The items listed in the table indicate the minimum inspection requirements. Perform at the intervals shown below:

a. Do your (M) PREVENTIVE MAINTENANCE monthly (once a month).

b. Do your (Q) PREVENTIVE MAINTENANCE quarterly (every three months).

c. Do your (S) PREVENTIVE MAINTENANCE semi-annually (every six months).

d. Do your (A) PREVENTIVE MAINTENANCE annually (once every year).

e. Do your (B) PREVENTIVE MAINTENANCE bi-annually (once every two years).

f. Do your (H) PREVENTIVE MAINTENANCE at the hour interval listed.

1-3-4
 TM 5-3810-307-24-1-1

Organizational Preventive Maintenance Checks and Services

(1) (2) (3) (4) (5)

Interval
Item Item To Be Equipment Is Not
No. M Q S A B H Inspected Procedure Ready/Available If:
(1) 50 Cold Start System [If a. Check contents of Improper operation, any
temperature is fluid cylinder. component damaged or
below 30F (-1C)] clogged, fluid cylinder
b. Inspect valve
empty, or leaks detected.
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.

(2) Wheel Lug Nuts Check torque Lug nuts loose.

[435 lbs-ft (590 Nm)]
(2a) 40 Clamshell and/or Check all attaching Any attaching hardware
Grapple hardware for damage/missing/loose.
damage/security.
(2b) Engine Coolant Startup and run engine Engine coolant heater
Heater (If Installed) coolant heater for fifteen inoperative (cold weather
minutes. operation only).
(3) Lubrication Perform Lubrication Chart
requirements.
(4) 200 Electric Swivel a. Check collector ring a. Collector ring and
and brush assembly brush assembly
for corrosion, pitting, corroded, pitted,
arcing, and wear. worn, or shows signs
of arcing.
b. Check that collector b. Setscrews loose.
ring setscrews are
tight.
c. Check that brush and c. Spring tension weak.
arm assembly springs
are holding brushes
firmly against collector
rings.

1-3-5 C-1
TM 5-3810-307-24-1-1

Organizational Preventive Maintenance Checks and Services - Continued

(1) (2) (3) (4) (5)

Interval
Item Item To Be Equipment Is Not
No. M Q S A B H Inspected Procedure Ready/Available If:
(6) Air Dryer Check/test air dryer, Air dryer not operating
refer to Section 7. as required.
(7) Air System Pressure Perform operating and Valve operating
Protection Valves leakage checks, refer to improperly or leaking.
Section 7.
(8) Tie Rod Ball Joints Check ball joints for Ball joints worn
excessive wear. excessively.
(9) Drag Link U-joint Check U-joint for U-joint worn excessively.
excessive wear.
(10) Drag Link Ends Check ends for excessive Ends worn excessively.
wear.
(11) Steering Knuckles Check knuckles for Knuckles worn
excessive wear. excessively.
(12) Lubrication Perform Quarterly
Lubrication Chart
requirements.
(12a) 80 Clamshell and/or Lubricate all pivot points
Grapple at grease fittings
provided.
(13) 300 Turntable Bolts Check torque on turntable
(1st attaching bolts. Refer to
time) Section 9, Swing Bearing
then for torque and tightening
every sequence.
500
(14) 500 Axle Mounting Bolts Check for proper torque
as follows:
Lockout Cylinder Lower
Retaining Pin - 75 lbs-ft
(102 Nm).
Drag Link to Steering Arm
- 215 lbs-ft (291 Nm) then
back off to nearest cotter
pin hole.

(15) 500 Differential Clean breathers or

Breathers replace as necessary.
(16) 500 Transmission Check for proper torque
Mounting Bolts [250 lbs-ft (339 Nm)].
(17) 500 Engine Mounting Check for proper torque
Bolts [50 lbs-ft (68 Nm)].

1-3-6 C-1
 TM 5-3810-307-24-1-1

Organizational Preventive Maintenance Checks and Services - Continued

(1) (2) (3) (4) (5)

Interval
Item Item To Be Equipment Is Not
No. M Q S A B H Inspected Procedure Ready/Available If:
(18) 500 Batteries WARNING
Do not smoke or allow
flame or spark in the
vicinity while checking
the batteries. The bat-
teries generate hyd-
rogen, a highly explo-
sive gas.
WARNING
Battery electrolyte is
toxic to skin, eyes, and
respiratory tract. Avoid
all contact. Skin and
eye protection and
vapor control are re-
quired.

a. Clean batteries, refer a. Battery has bulging

to Section 2, and sides, sides are hot
inspect for bulging to the touch,
sides, sides hot to the electrolyte is boiling
touch, electrolyte out vents, or any
boiling out of vents, other obvious
and other damage. damage.

b. Remove battery caps b. Specific gravity

and check specific indicates charge
gravity (refer to Table below 50% or
below) and level of electrolyte level is
electrolyte in each cell. below bottom of
Charge batteries and battery caps.
add distilled water as
necessary.

Battery State Specific Gravity

of Charge @27C[80F]
100% 1.260-1.280
75% 1.230-1.250
50% 1.200-1.220
25% 1.170-1.190
Discharged 1.110-1.130

1-3-7
TM 5-3810-307-24-1-1

Organizational Preventive Maintenance Checks and Services - Continued

(1) (2) (3) (4) (5)

Interval
Item Item To Be Equipment Is Not
No. M Q S A B H Inspected Procedure Ready/Available If:
(19) 500 Engine Fuel Filters Replace filter elements.

NOTE
For secondary fuel
filter only. If filter
change is occurring in
temperatures at or
below 30F (-1C),
use the filter install-
ation procedures an-
notated on cartridge
PLUS 1/4 turn.

(20) 500 Air Governor Filter Inspect and clean or Two (2) each filters
(Strainer) Elements replace filter (strainer) (NSN 4730-002250710)
elements as required. required.
(21) 500 Hoist Mounting Bolts Check for proper torque
[250 lbs-ft (339 Nm)].
(22) 2000 Boom Check hoist to boom
alignment. Refer to
Section 11 for
procedures.
(23) 500 Hook Block Disassemble hook block, Hook deformed or
inspect hook for nut/threaded areas
deformation, and nut and corroded or improper fit.
threaded areas for
corrosion and proper fit.
(24) Air System Disassemble valve, clean
Automatic Drain parts, inspect for wear
Valve and deterioration, and
lubricate.
(25) Lubrication Perform Semiannual
Lubrication Chart
requirements.
(26) 1000 Brake Linings Inspect linings for Linings worn or
excessive wear (to rivet saturated with grease.
heads) or grease
saturation.

1-3-8 C-1
 TM 5-3810-307-24-1-1

Organizational Preventive Maintenance Checks and Services - Continued

(1) (2) (3) (4) (5)

Interval
Item Item To Be Equipment Is Not
No. M Q S A B H Inspected Procedure 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 Out of adjustment.
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 Clean wear pads and Wear pads loose or worn
inspect for wear and excessively.
security.
(31) Air Dryer Replace desiccant
cartridge.
(32) Diesel Fuel Heater Clean combustion
chamber, check
adjustments, and perform
operating checks.
(33) Cold Start System a. Clean and check a. Metered orifice elbow
metered orifice elbow damaged.
for damage. Replace
filter.

b. Test temperature b. Temperature switch

switch. defective.
(34) Throttle Air Cylinder Disassemble cylinder,
clean components, and
inspect for wear and
damage.
(35) Air System Double Disassemble valves,
Check Valves clean components, and
inspect for wear and
damage.
(36) Air System Perform operating and Valve operating
Safety Valves leakage checks, refer to improperly or leaks
Section 7. detected.

1-3-9
TM 5-3810-307-24-1-1

Organizational Preventive Maintenance Checks and Services - Continued

(1) (2) (3) (4) (5)

Interval
Item Item To Be Equipment Is Not
No. M Q S A B H Inspected Procedure Ready/Available If:
(37) Spring Brake Disassemble valve, clean
Control Valve components, and inspect
for wear and damage.
(38) Air System Service Disassemble valves,
and Park Brake clean components, and
Relay Valves inspect for wear and
damage.
(39) Air System Carrier Disassemble valves,
and Superstructure clean components, and
Cab Brake Valves inspect for wear and
damage.
(40) Air Conditioners Perform Annual PMCS
schedule, refer to
Appendix B.
(41) Joystick Pilot Replace inline filter. Filter is located under an
Control System access panel, left-rear
Filter (bottom) of turntable.
(42) Lubrication Perform Annual
Lubrication Chart
requirements.
(43) 2000 Air Compressor Perform air compressor Excessive carbon build-
discharge inspection, up in discharge line.
refer to Engine Manual.
(44) 2000 Engine Damper a. Check index lines on a. Index lines more
hub and inertia than 1/16 in. (1.59
member. mm) out of
alignment.
b. Inspect elastic
member for deter- b. Elastic member
ioration, missing deteriorated, pieces
pieces, and excessive missing, or worn
wear. excessively [1/8 in.
(3.18 mm) below
metal surface].
(45) 3000 Air Governor Disassemble governor,
clean components, and
inspect for wear and
damage.
(46) 7200 Air System Dual Disassemble valve, clean
Brake Valve components, and inspect
for wear and damage.

1-3-10 C-1
 TM 5-3810-307-24-1-1

Organizational Preventive Maintenance Checks and Services - Continued

(1) (2) (3) (4) (5)

Interval
Item Item To Be Equipment Is Not
No. M Q S A B H Inspected Procedure Ready/Available If:
(47) Brake Actuator Disassemble actuator,
clean components, and
inspect for wear and
damage.

(48) Lubrication Perform Biannual

Lubrication Chart
requirements.

1-3-11/(1-3-12 Blank)
 TM 5-3810-307-24-1-1

SECTION 4
LUBRICATION

TABLE OF CONTENTS
Page

LUBRICATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-4
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-11

LIST OF FIGURES
Title Page

Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-11

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-12

1-4-1/(1-4-2 Blank)
 TM 5-3810-307-24-1-1

LUBRICATION

GENERAL

Following the designated lubrication procedures is important in ensuring maximum crane lifetime and utilization.
The procedures and lubrication charts in this section include information on the types of lubricants to be used, the
location of the lubrication points, the frequency of lubrication, and other information.

The service intervals specified are for normal operation where moderate temperature, humidity, and atmospheric
conditions prevail. In areas of extreme conditions, the service periods and lubrication specifications should be
altered to meet existing conditions.

LUBRICANTS

CAUTION

Chassis grease lubricants must not be applied

with air pressure devices as this lubricant is
used on sealed fittings.

SYMBOL DESCRIPTION

AFC Anti-Freeze Coolant. Formulated for engine coolant systems to provide effective engine cooling
and anti-freeze properties as provided in MIL-A-46153.

ASC Anti-Seize Compound. This compound is of such composition, structure, and consistency to
prevent the seizure of mating components and meet the requirements of MIL-A-907.

GAA Multipurpose Grease. Lubrication grease of such composition, structure, and consistence to meet
the performance requirements of MIL-G-10924. Grease is inhibited to prevent rusting and have
excellent resistance to both heat and water.

HFC R-134a Refrigerant. Environmentally friendly refrigerant formulated to meet the requirements of
Grove Specification A6-829-013460 and SAE J1503.

GO Extreme Pressure Multipurpose Gear Lubricant. This gear lubricant is compounded to achieve high
load carrying capacity and meet the requirements of MIL-2105C. SAE 85/140 viscosity will be used
for year-round service except as specified for specific components.

OE/HDO A high quality multipurpose engine\hydraulic oil formulated to provide desired engine performance
levels, chatter-free performance of wet brake and wet clutches, good gear lubrication, and hydraulic
performance. Shall meet the requirements of MIL-L-2104. Refer to specific component for
viscosity and temperature requirements.

OEA Multipurpose Arctic Lubricant. This is a high quality multipurpose oil formulated to meet the
performance requirements of MIL-L-46167 and provide desired component performance in
temperatures between -50F and +10F (-59C and 50C).

PAG Refrigeration Oil. Specially formulated oil for use with refrigeration components. Meets the
requirements of Grove Specification A6-829-013436 and compatible with R-134a.

1-4-3
TM 5-3810-307-24-1-1

LUBRICATION POINTS

All oil levels are to be checked with the crane parked on a level surface in transport position, and while the oil is
cold, unless otherwise specified.

On plug type check points, the oil levels are to be at the bottom edge of the check port.

On all hoists with a check plug in the drum, the fill plug shall be directly on top of the hoist, and the check plug
level.

All grease fittings are SAE STANDARD unless otherwise indicated. Grease nonsealed fittings until grease is
seen extruding from the fitting. One pump of a standard one pound (0.45 kg) grease gun equals one ounce (28
grams) of GAA.

Over lubrication on non-sealed fittings will not harm the fittings or components, but under lubrication will definitely
lead to a shorter lifetime.

On sealed U-joints, care must be exercised to prevent rupturing seals. Fill only until expansion of the seals first
becomes visible.

Unless otherwise indicated, items not equipped with grease fittings, such as linkages, pins, levers, etc., should be
lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help
prevent the formation of rust. An Anti-Seize compound may be used if rust has not formed, otherwise the
component must be cleaned first.

Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check ball, must be
replaced.

Where wear pads are used, cycle the components and relubricate to ensure complete lubrication of the entire
wear area.

The following describe the lubrication points and gives the lube type, lube interval, lube amount, and application
of each. Each lubrication point is numbered, and this number corresponds to the index number shown on the
Lubrication Chart.

1. Angle Gearbox.

Lube Type - GAA

Lube Interval - 1000 miles (1600 km)
Lube Amount - Until grease extrudes
Application - 1 fitting

2. Not Used

3. Differentials.

Lube Type - GO-85/140 [0F to +120F (-18C to 49C)]

GO-75 [-50F to +120F (-46C to 49C)]
Lube Interval - Check every 200 hours. Drain and fill every 6,000 miles (10,000 km), 1000 hours, or
yearly.
Lube Amount - 14 quarts (13 liters)
Application - Check/fill plug in differential housing

1-4-4
 TM 5-3810-307-24-1-1

4. Planetary Ends and Wheel Bearings.

Lube Type - GO-85/140 [0F to +120F (-18C to 49C)]

GO-75 [-50F to +120F (-46C to 49C)]
Lube Interval - Check every 200 hours. Drain and fill every 6000 miles (10,000 km), 1000 hours, or
yearly.
Lube Amount - 2.5 quarts (2.4 liters)
Application - Fill plug in axle end. The oil should be at the edge of the port opening

5. Upper Kingpin Bearings.

Lube Type - GAA

Lube Interval - 500 hours or 3000 miles (5000 km)
Lube Amount - Until grease extrudes
Application - 4 fittings

6. Lower Kingpin Bearings.

Lube Type - GAA

Lube Interval - 500 hours or 3000 miles (5000 km)
Lube Amount - Until grease extrudes
Application - 4 fittings

7. Lockout Cylinder Pivot Pins.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Until grease extrudes
Application - 8 fittings

8. Torque Rod Bushing.

Lube Type - GAA

Lube Interval - 1000 miles (1600 km)
Lube Amount - Until grease extrudes
Application - 2 fittings

9. Not Used

10. Engine.

Lube Type - OE/HDO-15/40 [-5F to +120F (-21C to 49C)]

OEA [-50F to +10F (-46C to -12C)]
OE/HDO-40 [100F to +120F (38C to 49C)]
Lube Interval - Check level daily. Drain and refill every 250 hours, 6000 miles (10,000 km), or semi-
annually. Change oil filter elements when changing oil.
(Text Deleted)

NOTE

If oil filter elements are being changed in temperatures at or below 30F (-1C) or oil is being
changed to arctic grade (OEA), use filter element installation procedures annotated on
cartridge plus turn.

1-4-5 C-1
TM 5-3810-307-24-1-1

Lube Amount - 17.3 quarts (16.4 L)

Application - Fill to full mark on dipstick.

Complete the following steps after each engine oil change to make sure the engine receives the correct oil
flow through the lubricating oil system.

Disconnect electrical wire from fuel pump solenoid valve.

Rotate the crankshaft, using the starter motor, until oil pressure appears on the gauge, or warning
light goes out.
Connect electrical wire to fuel pump solenoid valve.
Start engine, refer to Section 5, TM 5-3810-307-10.
Refer to Fuel System Bleeding, Section 5, for instructions to vent the fuel system.

25. Transmission and Torque Converter.

Lube Type - OE/HDO-10 [-10F to +120F (-23C to 49C)]

OEA [-50F to +10F (-46C to -12C)]
OE/HDO-30 [100F to +120F (38C to 49C)]

NOTE

When checking oil level, the oil temperature must be stabilized at 180 degrees to 200
degrees F (82.2 degrees to 93.3 degrees C) to properly check the oil level. Do not at-tempt
an oil level check with cold oil. To bring the oil temperature to this range, it is necessary to
either work the crane or stall the converter. Converter stall should be accomplished by
engaging the shift levers in forward and high range with the brakes applied and then
accelerating the engine to half or three-quarter throttle. Hold the stall until the desired
converter temperature is reached and stabilized.

CAUTION

Full throttle stall speeds for an excessive length of time will over-heat the converter and
cause serious damage.
(Text Deleted)
Lube Interval - Check level daily. Drain and refill every 1000 hours. Change oil filter element when
changing oil.

NOTE
If oil filter element is being changed in temperatures at or below 30F (-1C) or oil is being
changed to arctic grade (OEA), use filter element installation procedures annotated on
cartridge plus turn.

Lube Amount - 28 quarts (26.5 L)

Application - Fill to full mark on dipstick.

25. Drive Line Slip Joints and U-joints.

Lube Type - GAA

Lube Interval - 1000 miles (1600 km)
Lube Amount - Until grease extrudes
Application - 6 fittings

1-4-6 C-1
 TM 5-3810-307-24-1-1

25. Engine Cooling System.

Lube Type - AFC

Lube Interval - Check level daily. Drain and refill every 6000 hours.
Lube Amount - 10.5 gallons (39.7 L)
Application - Fill radiator to top of filler neck and coolant recovery bottle to marking on bottle.

14. Not Used

25. Outrigger Beams.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Thoroughly coat bottom of outrigger beams
Application - By brush

25. Jack Cylinder Support Tubes.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Thoroughly coat inside of jack cylinder support tubes before installing jack cylinders
Application - By brush

25. Turntable Swing Box.

Lube Type - GO-85/140

CAUTION
When checking the swing gear box oil level, place the dipstick into the sleeve until the cap is
flush with the end of the sleeve. Do not screw the cap onto the sleeve to check the level.
Lube Interval - Check every 200 hours. Drain and refill every 1000 hours
Lube Amount - Capacity 2 quarts (1.89 L)
Application - Fill to full mark on dipstick

25. Turntable Gear and Drive Pinion.

Lube Type - GAA

Lube Interval - Check daily and apply as necessary

NOTE
Apply after each pressure wash.
Lube Amount - Coat all teeth
Application - By brush

25. Turntable Bearing.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Until grease extrudes the whole circumference of the bearing
Application - 2 grease fittings at the front of the turntable
Rotate the turntable 90 degrees and apply grease to the fittings. Continue rotating 90 degrees and grease
the fittings until the whole bearing is greased.

1-4-7
TM 5-3810-307-24-1-1

25. Swing Brake.

Lube Type - OE/HDO-10

Lube Interval - Check every 1000 hours. Drain and refill every 2000 hours.
Lube Amount - 0.5 pint (0.2L)
Application - Drain oil from lower bleed plug. Fill through upper bleed plug until level with bottom of
upper plug.

21. Not Used

25. Upper Lift Cylinder Pivot.

Lube Type - GAA

Lube Interval - 500 hours
Lube Amount - Until grease extrudes
Application - 1 fitting

25. Lower Lift Cylinder Pivot.

Lube Type - GAA

Lube Interval - 500 hours
Lube Amount - Until grease extrudes
Application - 1 fitting

24. Not Used

25. Hydraulic Tank.

(Text Deleted)
Lube Type - OE/HDO-10
Lube Interval - Check level daily. Drain and refill every 2000 hours. Replace both hydraulic filters.
Lube Amount - Capacity 64.4 gallons (243 L)
Application - Fill through the cap on top of the tank. When tank is drained, clean the magnetic pipe
plug. Replace both the in-tank and steering system hydraulic filters when changing oil.

26. Not Used

27. Pintle Hook.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Until grease extrudes
Application - 3 fittings

28. Air Conditioners.

Lube Type - HFC

Lube Interval - Drain and refill annually
Lube Amount - As required to fully charge system
Full Charge:
Superstructure - 3.50 lbs
Carrier - 2.50 lbs.
Application - Charge ports on applicable compressor

1-4-8 C-1
 TM 5-3810-307-24-1-1

29. Air Conditioners.

Lube Type - PAG

Lube Interval - Drain and refill annually
Lube Amount - 5.0 ozs when charging system
Application - Charge ports on compressor

30. Door Hinges.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Until grease extrudes
Application - 3 fittings

31. Boom Rest.

Lube Type - GAA

Lube Interval - 1000 hours
Lube Amount - Thoroughly coat top surface of boom rest
Application - By brush

32. Hook Block Trunnion Bearings.

Lube Type - GAA

Lube Interval - 100 hours
Lube Amount - Until grease extrudes
Application - 3 fittings

33. Hook Block Thrust Bearing.

Lube Type - GAA

Lube Interval - 100 hours
Lube Amount - Until grease extrudes
Application - 1 fitting

34. Hook Block Sheaves.

Lube Type - GAA

Lube Interval - 100 hours
Lube Amount - Until grease extrudes
Application - 1 fitting per sheave

35. Boom Nose Sheaves.

Lube Type - GAA

Lube Interval - 100 hours
Lube Amount - Until grease extrudes
Application - 1 fitting per sheave

36. Telescope Cylinder Wear Pads.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Thoroughly coat the area the wear pad moves on
Application - By brush, 3 places
The wear pads are located on the cylinder support foot.

1-4-9
TM 5-3810-307-24-1-1

37. Adjustable Wear Pads.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Thoroughly coat the area the wear pad moves on
Application - By brush, 8 places

38. Boom Section Wear Pads.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Thoroughly coat bottom rails, top plates of boom, and inside surface of side plates
Application - By brush, 12 places

39. Telescope Cylinder Pivot Pin.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Until grease extrudes
Application - 1 fitting

40. Retract and Extend Pulleys.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Until grease extrudes
Application - 2 fittings

41. Boom Pivot Shaft.

Lube Type - GAA

Lube Interval - 250 hours or monthly
Lube Amount - Until grease extrudes
Application - 2 fittings

42. Pile Driver Attachment Shafts.

Lube Type - ASC

Lube Interval - 250 hours
Lube Amount - Thoroughly coat surfaces of shafts
Application - By brush

43. Cable Follower Arms.

Lube Type - GAA

Lube Interval - 250 hours
Lube Amount - Until grease extrudes
Application - 2 fittings

1-4-10
 TM 5-3810-307-24-1-1

44. Main Hoist.

Lube type - GO-85/140

Lube Interval - Drain and refill every 1000 hours
Lube Amount - 9 quarts (8.5 L)
Application - The oil should be level with the bottom of the check-fill plug.

45. Auxiliary Hoist.

Lube type - GO-85/140

Lube Interval - Drain and refill every 1000 hours
Lube Amount - 9 quarts (8.5 L)
Application - The oil should be level with the bottom of the check-fill plug

46. Hoist Cables (Wire Rope).

Lube Type - OE/HDO-10

Lube Interval - 500 hours
Lube Amount - Thoroughly coat cables
Application - By spray, drip, or brush

WIRE ROPE LUBRICATION

Wire rope is lubricated during manufacturing so the strands, and individual wires in strands, may move and adjust
as the rope moves and bends. A wire rope cannot be lubricated sufficiently during manufacture to last its entire
life. Therefore, new lubricant must be added throughout the life of a rope to replace factory lubricant which is
used or lost.

The surface of some ropes may become covered with dirt, rock dust, or other material during their operation.
This covering can prevent field applied lubricants from properly penetrating into the rope. Therefore, these ropes
should be cleaned before being lubricated.

Lubricant may be applied effectively by various methods. It may be dripped on, sprayed on, or put on by
brushing, but in any case it should be applied at a place where the rope is being bent, such as at a sheave. It
should be applied at the top of the bend, because at that point the strands are spread by bending and are more
easily penetrated. The service life of rope will be directly proportional to the amount of lubricant reaching the
working parts of the rope.

When properly applied, the lubricant will reduce friction, protect against corrosion, adhere to every wire, and be
pliable and not crack or separate when cold and yet not drip when warm.

Wire Rope Lubrication

1-4-11
TM 5-3810-307-24-1-1

Lubrication Chart (Sheet 1 of 3)

1-4-12
 TM 5-3810-307-24-1-1

Lubrication Chart (Sheet 2 of 3)

1-4-13
TM 5-3810-307-24-1-1

OIL SAMPLE POINTS

Lubrication Chart (Sheet 3 of 3)

1-4-14
 TM 5-3810-307-24-1-1

SECTION 5
TROUBLESHOOTING

TABLE OF CONTENTS
Page

TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3
Organizational Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3
Direct/General Support Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . 1-5-11

LIST OF TABLES
Title Page

Organizational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5

Direct/General Support Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14

1-5-1/(1-5-2 Blank)
 TM 5-3810-307-24-1-1

TROUBLESHOOTING

GENERAL

This section includes troubleshooting tables for use by Organizational level and Direct/General Support level
maintenance personnel. The tables list common symptoms of trouble, probable cause, and the corrective action
to remedy the trouble. The tables are to assist maintenance personnel in diagnosing and correcting trouble that
may occur during normal operation. Tests/inspections and corrective actions should be performed in the order
listed.

The tables cannot list all symptoms that may occur, nor all tests or inspections and corrective actions. If symptom
occurs that is not listed or is not corrected by listed corrective actions, notify your supervisor.

Refer to the appropriate appendix for troubleshooting components and systems listed in appendices and refer to
engine manual for engine troubleshooting.

ORGANIZATIONAL TROUBLESHOOTING

SYMPTOM INDEX

Symptom Troubleshooting
Procedures
Page

TRANSMISSION

Transmission OIL TEMP gauge indicates transmission overheating . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5

Low Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5

HYDRAULIC SYSTEM

No oil flow in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5

Excessive pressure buildup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5
Hydraulic pump noisy and oil foaming in reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5

AIR SYSTEM

Air dryer constantly cycling or purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5

Safety valve on air dryer popping off or exhausting air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5
Constant exhaust of air at air dryer purge valve exhaust or system pressure does not build . . . . . . . . . . . 1-5-5
Air dryer does not purge or exhaust air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-6

STEERING SYSTEM

Hard to steer left and right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-6

Hard to steer either left or right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-6
Steering is erratic left and right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-6
Steering pump noisy (cavitating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-6

SWING SYSTEM

Boom swing operation erratic in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-7

Boom swing operation erratic in one direction only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-7

1-5-3
TM 5-3810-307-24-1-1

SYMPTOM INDEX - Continued

Symptom Troubleshooting
Procedures
Page

Swing operation slow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-7

Swing brake operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-7
Swing motor noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-7
Swing motor turning in wrong direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-7

TELESCOPE SYSTEM

Telescope cylinder operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-8

Telescope cylinder will not extend/retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-8

LIFT CIRCUIT

Boom lift circuit operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-8

Boom lift circuit operation slow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-8

OUTRIGGER CIRCUIT

Slow or erratic operation of outrigger extension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-8

Slow or erratic operation of outrigger jack cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-8
Outrigger system will not activate from stowed, extended, or down position . . . . . . . . . . . . . . . . . . . . . 1-5-9
Outrigger system activates, but selected outrigger will not stow, extend, or lower . . . . . . . . . . . . . . . . . 1-5-9
One/two outriggers will not stow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9
Individual outrigger will not set or stow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9

HOISTS

Hoist will not raise or lower load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9

Hoist operation slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9
Hoist up operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9
Hoist down operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9

HOIST MOTOR

Hoist motor leaking at fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9

Hoist motor excessively noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-9

DIESEL HEATER

Heater fails to start - motor does not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-10

Heater fails to start - motor runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-10
Inadequate heat output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-10
Fan fails to go to high speed during burner cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-10
Excessive smoke in exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-10

1-5-4

Organizational Troubleshooting
SYMPTOM PROBABLE CAUSE
TRANSMISSION
1. Transmission OIL TEMP a. Transmission oil pump
gauge indicates suction line loose (sucking
transmission over- air).
heating.
2. Low power. a. Low engine rpm at converter
stall.
HYDRAULIC SYSTEM
1. No oil flow in system. a. Reservoir to pump supply
line broken or restricted.
b. Suction line fittings loose
allowing air to enter system.
c. Hydraulic system
contaminated blocking flow.
2. Excessive pressure Restricted pump to control
buildup. supply line.
3. Hydraulic pump noisy a. Suction line fittings loose
and oil foaming in allowing air to enter system.
reservoir.
b. Excessive engine rpm.
AIR SYSTEM
1. Air dryer constantly Excessive system leakage.
cycling or purging.
2. Safety valve on air dryer Defective fittings, hose, or
popping off or exhausting tubing between air dryer and
air. primary reservoir.
3. Constant exhaust of air at a. Purge control line connected
air dryer purge valve to reservoir or exhaust port
exhaust or system of governor.
pressure does not build.
b. Inlet and outlet lines to air
dryer reversed.
c. Kinked or blocked discharge
line.
d. Excessive system leakage.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
a. Check and tighten oil line
connections.
a. Check and adjust idle speed.
a. Replace or clear line as
necessary.
b. Check and tighten suction line
fittings.
c. Drain, flush, and refill system.
Clear restriction.
a. Check and tighten suction line
fittings.
b. Check and adjust engine idle
speed as necessary.
Test system for excessive leakage.
Tighten or replace tubing/hoses as
necessary.
Inspect for and replace kinked
tubing or hose.
a. Purge control line must be
connected to unloader port of
governor. Reconnect as
necessary.
b. Reconnect lines properly.
c. Reposition, clear, or replace
discharge line.
d. Refer to Symptom 1.
1-5-5
TM 5-3810-307-24-1-1

Organizational Troubleshooting - Continued

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

4. Air dryer does not purge a. Broken, kinked, plugged, or a. Reposition, clear, connect, or
or exhaust air. disconnected purge control replace line.
line.

b. Excessive system leakage. b. Refer to Symptom 1.

STEERING SYSTEM
1. Hard to steer left and a. Clogged or loose hydraulic a. Clean or tighten lines or fittings.
right. lines or fittings.
b. Lubricate steering cylinder rods.
b. Insufficient lubricant on
steering cylinder rods.
2. Hard to steer either left or a. Clogged or loose hydraulic a. Clean or tighten hydraulic lines
right. lines or fittings. or fittings.

b. Insufficient lubricant on b. Lubricate cylinder rods.

steering cylinder rods.

c. Defective steering cylinder. c. Repair or replace cylinder.

3. Steering is erratic left and
right.
4. Steering pump noisy
(cavitating).
a. Clogged or loose hydraulic a. Clean or tighten lines or fittings.
lines or fittings.
b. Lubricate steering cylinder rods.
b. Insufficient lubricant on
steering cylinder rods.
a. Oil too heavy. a. Clear line or check size.
Replace as necessary.

b. Suction line plugged or too b. Change to proper oil.

small.

1-5-6

Organizational Troubleshooting - Continued
SYMPTOM
1. Boom swing operation
erratic in either direction.
2. Boom swing operation
erratic in one direction
only.
3. Swing operation slow.
4. Swing brake operation
erratic.
5. Swing motor noisy.
6. Swing motor turning in
wrong direction.
PROBABLE CAUSE
SWING SYSTEM
a. Restricted or partially
clogged hydraulic lines or
fittings.
b. Clogged joystick pilot control
system filter.
c. Loose suction line or fittings
allowing air in system.
d. Insufficient lubrication on
turntable bearing.
e. Improperly torqued swing
motor attaching capscrews.
f. Improperly torqued turntable
capscrews.
a. Restricted or partially
clogged hydraulic lines or
fittings.
b. Insufficient lubrication on
turntable bearing.
a. Restricted or partially
clogged hydraulic lines or
fittings.
b. Clogged joystick pilot control
system filter.
c. Insufficient lubrication on
turntable bearing.
Kinked or damaged hydraulic
lines.
Air in hydraulic system
Port connections reversed.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
a. Clear lines or fittings. Replace
as necessary.
b. Replace filter as necessary.
c. Tighten suction line or fittings.
d. Lubricate turntable bearing.
e. Retorque swing motor attaching
capscrews.
f. Retorque turntable capscrews.
a. Clear lines or fittings. Replace
as necessary.
b. Lubricate turntable bearing.
a. Clear lines or fittings. Replace
as necessary.
b. Replace filter as necessary.
c. Lubricate turntable bearing.
Straighten or replace lines as
necessary.
Bleed air from system.
Reverse port connections.
1-5-7
TM 5-3810-307-24-1-1
Organizational Troubleshooting - Continued
SYMPTOM
1. Telescope cylinder
operation erratic.
2. Telescope cylinder will
not extend/retract.
1. Boom lift circuit operation
erratic.
2. Boom lift circuit operation
slow.
1. Slow or erratic operation
of outrigger extension
cylinders.
2. Slow or erratic operation
of outrigger jack cylinder
1-5-8
PROBABLE CAUSE
TELESCOPE SYSTEM
a. Clogged, broken, or loose
hydraulic lines or fittings.
b. Insufficient lubrication on
boom sections.
c. Insufficient lubrication on
boom nose sheaves.
d. Worn boom wear pads.
Clogged, broken, or loose
hydraulic lines or fittings.
LIFT CIRCUIT
a. Air in lift circuit.
b. Clogged joystick pilot control
system filter.
a. Return hydraulic line
restricted.
b. Clogged joystick pilot control
system filter.
OUTRIGGER CIRCUIT
a. Loose hydraulic pump
suction line or fittings.
b. Damaged electrical wiring to
solenoid valve.
c. Directional selector switch
sticking.
a. Loose hydraulic pump
suction line or fittings.
b. Damaged electrical wiring to
solenoid valve.
c. Directional selector switch
sticking.
CORRECTIVE ACTION
a. Clean, tighten, or replace lines
or fittings.
b. Lubricate boom sections.
c. Lubricate boom nose sheaves.
d. Replace worn wear pads and
properly lubricate.
Clean, tighten, or replace lines or
fittings.
a. Bleed air from lift circuit.
b. Replace filter as necessary.
a. Clear restriction or replace line
as necessary.
b. Replace filter as necessary.
a. Tighten suction line or fittings.
b. Repair or replace wiring.
c. Clean or replace switch.
a. Tighten suction line or fittings.
b. Repair or replace wiring.
c. Clean or replace switch.

Organizational Troubleshooting - Continued
SYMPTOM
3. Outrigger system will not
activate from stowed,
extended, or down
position.
4. Outrigger system
activates, but selected
outrigger will not stow,
extend, or lower.
5. One/two outriggers will
not stow.
6. Individual outrigger will
not set or stow.
1. Hoist will not raise or
lower load.
2. Hoist operation slow.
3. Hoist up operation erratic.
4. Hoist down operation
erratic.
1. Hoist motor leaking at
fitting.
2. Hoist motor excessively
noisy.
PROBABLE CAUSE
a. Clogged, broken, or loose
hydraulic lines or fittings.
b. Loose or broken electrical
wire on control switch or
solenoid valve.
a. Clogged, broken, or loose
hydraulic lines or fittings.
b. Loose or broken electrical
wire on control switch or
solenoid valve.
Hydraulic lock
Loose or broken electrical wire
on control switch or solenoid
valve.
HOISTS
a. Clogged, broken, or loose
hydraulic lines or fittings.
b. Clogged joystick pilot control
system filter.
a. Loose hydraulic pump
suction line or fittings.
b. Clogged joystick pilot control
system filter.
Loose hydraulic pump suction
line or fittings.
a. Loose hydraulic pump
suction line or fittings.
b. Air in brake release line.
HOIST MOTOR
a. Fitting threads damaged.
b. Damaged o-ring.
Air in system.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
a. Clean, tighten, or replace lines
or fittings.
b. Repair or replace wiring.
a. Clean, tighten, or replace lines
or fittings.
b. Repair or replace wiring.
Recycle individual outrigger(s).
Repair or replace wiring.
a. Clean, tighten, or replace lines
or fittings.
b. Replace filter as necessary.
a. Tighten suction line or fittings.
b. Replace filter as necessary.
Tighten suction line or fittings.
a. Tighten suction line or fittings.
b. Bleed pilot pressure line going
into brake housing.
a. Replace fitting.
b. Replace o-ring.
Bleed off air and check fittings for
tightness.
1-5-9
TM 5-3810-307-24-1-1
Organizational Troubleshooting - Continued
SYMPTOM
1. Heater fails to start -
motor does not run.
2. Heater fails to start -
motor runs.
3. Inadequate heat output.
4. Fan fails to go to high
speed during burner
cycle.
5. Excessive smoke in
exhaust.
1-5-10
PROBABLE CAUSE
DIESEL FUEL HEATER
a. Loose or broken electrical
connections at control panel
or heater.
b. No or insufficient power at
heater.
a. Poor ground connection.
b. Inadequate or incorrect fuel.
Loose or broken electrical
leads.
Loose or broken electrical
leads.
a. Loose or broken electrical
leads.
b. Incorrect fuel.
CORRECTIVE ACTION
a. Check and tighten connections
as necessary.
b. Check for broken wires or loose
connections in heater power
circuit.
a. Check ground wire. Clean and
tighten as necessary.
b. Check for clogged fuel line or
incorrect fuel. Clean or replace
fuel line. Drain and refill tank
with correct fuel.
Check electrical connections.
Tighten loose connections.
Check electrical connections.
Tighten loose connections.
a. Check electrical connections.
Tighten loose connections.
b. Drain and refill tank with correct
fuel.
 TM 5-3810-307-24-1-1

DIRECT/GENERAL SUPPORT TROUBLESHOOTING

SYMPTOM INDEX

Symptom Troubleshooting
Procedures
Page

TRANSMISSION/TORQUE CONVERTER

Transmission OIL TEMP gauge indicates transmission overheating . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14

Converter noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14
Low Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14
Low clutch pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14
Low converter charging pump output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14

HYDRAULIC SYSTEM

No oil flow in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14

Excessive pressure buildup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14
Sticking valve spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14
External leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-15
Solenoid failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-15
Poor system performance or failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-15

AIR SYSTEM

Air dryer constantly cycling or purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-16

Excessive water in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-16
Safety valve on air dryer popping off or exhausting air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-17
Constant exhaust of air at air dryer purge valve exhaust or unable to build system pressure . . . . . . . . . . 1-5-17
Air dryer does not purge or exhaust air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-17
Desiccant material being expelled from air dryer purge valve exhaust
(may look like whitish liquid, paste, or small beads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-18
Constant seepage of air at air dryer purge valve exhaust (non-charging mode). . . . . . . . . . . . . . . . . . . 1-5-18
Air dryer purge piston cycles rapidly with compressor unloaded (non-compressing mode). . . . . . . . . . . . 1-5-18

STEERING SYSTEM

Hard to steer left and right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-18

Hard to steer either left or right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-18
Steering is erratic left and right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-19
Steering pump shaft seal leaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-19
Steering pump overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-19

SWING SYSTEM

Boom swing operation erratic in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-19

Boom swing operation erratic in one direction only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-20
Boom will not swing in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-20
Swing operation slow in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-20
Swing brake operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-21
Swing brake system will not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-21
Swing motor continues to operate when swing control is in neutral position . . . . . . . . . . . . . . . . . . . . . 1-5-21
Swing motor noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-21

1-5-11
TM 10-3810-307-24-1-1

SYMPTOM INDEX - Continued

Symptom Troubleshooting
Procedures
Page

TELESCOPE SYSTEM

Boom extends erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-21

Boom retracts erratically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-21
Telescope cylinder will not extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-22
Telescope cylinder will not retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-22

LIFT CIRCUIT

Boom raises erratically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-22

Boom lowers erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-23
Boom raises slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-23
Boom lowers slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-23
Boom will not raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-23
Boom will not lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-24

OUTRIGGER CIRCUIT

Outrigger extension cylinder operation slow or erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-24

Outrigger jack cylinder operation slow or erratic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-25
Jack cylinder retracts under load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-26
Jack cylinder extends while crane is moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-26
Outrigger system will not activate from stowed, extended, or down position . . . . . . . . . . . . . . . . . . . . . 1-5-26
Outrigger system activates, but selected outrigger will not stow, extend, or lower . . . . . . . . . . . . . . . . . 1-5-26
Two outriggers operate from single control switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-26
Individual outrigger will not set or stow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-26

HOISTS

Hoist will not raise load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-26

Hoist will not lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-27
Hoist down operation slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-27
Hoist up operation slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-27
Hoist up operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-28
Hoist down operation erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-28
Sticking spool in control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-28
Leaking seals in control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-29
Unable to move control valve spool in or out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-29
Load drops when control valve is moved from neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-29

HOIST MOTOR

External leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-29

Leakage at fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-30
Loss in speed under load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-30
Poor speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-30
Motor fails to start turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-30
Shaft play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-30
Bursting of fluid supply - inlet or outlet lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-31

1-5-12
 TM 5-3810-307-24-1-1

SYMPTOM INDEX - Continued

Symptom Troubleshooting
Procedures
Page

Excessive noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-31

DIESEL HEATER

Heater fails to start - motor does not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-31

Heater fails to start - motor runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-31
Motor runs but there is no ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-32
Inadequate heat output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-33
Fan fails to go to high speed during burner cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-33
Burner remains on burner cycle after heat demands are met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-34
Excessive smoke in exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-34

1-5-13
TM 10-3810-307-24-1-1
Direct/General Support Troubleshooting
SYMPTOM
TRANSMISSION/TORQUE CONVERTER
1. Transmission OIL TEMP
gauge indicates
transmission overheating.
2. Converter noisy.
3. Low power.
4. Low clutch pressure.
5. Low converter charging
pump output.
1. No oil flow in system.
2. Excessive pressure
buildup.
3. Sticking valve spool.
1-5-14
PROBABLE CAUSE
a. Worn oil sealing rings.
b. Oil pump defective.
a. Oil pump defective.
b. Worn or damaged bearings.
a. Low engine rpm at converter
stall.
b. Worn oil sealing rings.
c. Oil pump defective.
a. Clutch pressure regulating
valve spool stuck open.
b. Faulty charging pump.
c. Broken or worn clutch shaft
or piston sealing rings.
d. Clutch piston bleed valve
stuck open.
a. Suction screen plugged.
b. Air leaks a pump intake hose
and connections or
collapsed hose.
c. Defective oil pump.
HYDRAULIC SYSTEM
Hydraulic pump defective.
System relief valve set too high.
a. Dirt in system.
b. Distortion caused by
overtorquing tie bolts.
CORRECTIVE ACTION
a. Disassemble and rebuild
transmission/converter
assembly.
b. Replace pump.
a. Replace pump.
b. Disassemble, determine faulty
bearing, and replace.
a. Adjust engine.
b. Disassemble and rebuild
transmission/converter
assembly.
c. Replace pump.
a. Clean valve spool and housing.
b. Replace pump.
c. Replace sealing rings.
d. Clean bleed valves thoroughly.
a. Clean suction screen.
b. Tighten all connections or
replace hose if necessary.
c. Replace pump.
Repair or replace pump.
Use appropriate pressure gauge
and adjust relief valve as
necessary.
a. Change oil and flush system.
b. Retorque tie bolts.

Direct/General Support Troubleshooting - Continued
SYMPTOM
3. Sticking valve spool
(continued).
4. External leakage.
5. Solenoid failure.
6. Poor system performance
or failure.
PROBABLE CAUSE
c. Flow in excess of valve
rating.
d. Pressure in excess of valve
rating.
e. Electrical failure.
a. Damaged o-rings or quad
rings.
b. Loose tie bolts.
c. Damaged solenoid.
a. No current.
b. Damaged solenoid
assembly.
c. Short in solenoid.
d. Loss of solenoid force.
a. Damaged hydraulic pump.
b. Dirt in system relief valve.
c. System relief valve
defective.
d. Worn cylinder(s) or motor(s).
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
c. Limit flow through valve to rated
flow. Check pump output and
cylinder ratio.
d. Check relief valve setting or
pump compensation to rated
flow.
e. Check wiring and solenoids.
a. Check for damaged seals and
replace as necessary.
b. Retorque tie bolts.
c. Replace damaged parts.
a. Ensure incoming power is at
least 85% of coil rating.
b. Replace Solenoid.
c. Replace coil.
d. Decrease time of energization
and cycle rate.
a. Repair or replace pump.
b. Disassemble and clean relief
valve.
c. Replace valve.
d. Repair or replace damaged
components.
1-5-15
TM 5-3810-307-24-1-1
Direct/General Support Troubleshooting - Continued
SYMPTOM
1. Air dryer is constantly
cycling or purging.
2. Excessive water in
system.
1-5-16
PROBABLE CAUSE
AIR SYSTEM
a. Defective check valve
assembly in air dryer end
cover.
b. Defective governor.
c. Leaking purge valve housing
assembly and/or o-rings in
air dryer end cover.
d. Compressor unloader
mechanism leaking
excessively.
e. Rapid cycling of the
governor due to air
starvation at the RES port of
governor.
a. Air dryer desiccant requires
replacement.
b. Air dryer purge valve stuck
closed.
c. Air bypassing desiccant
cartridge.
CORRECTIVE ACTION
a. Remove check valve. Apply air
pressure to delivery side of
valve. Apply soap solution at
opposite end and check for
leakage (1" bubble in 5 seconds
permissible). If excessive
leakage is present, replace the
check valve assembly.
b. Test governor for proper cut-in
and cut-out pressures and
excessive leakage in both
positions. Replace governor if
defective.
c. With supply port open to
atmosphere, apply 120 psi air
pressure at the control port.
Apply a soap solution to the
supply port and exhaust port
(purge valve seat area).
Permissible leakage - 1" bubble
in 5 seconds. Replace
defective components.
d. Remove air strainer or fitting
from compressor inlet cavity.
with compressor unloaded,
check for unloader piston
leakage. Slight leakage is
permissible. Repair or replace
compressor if leakage is
excessive.
e. Check for kinks or restrictions in
line connected to RES port.
Replace damaged line as
necessary.
a. Replace desiccant cartridge.
b. Test operation of valve.
Replace defective valve.
c. Check cartridge for proper
installation. Replace o-ring for
cartridge end cover.

Direct/General Support Troubleshooting - Continued
SYMPTOM PROBABLE CAUSE
2. Excessive water in d. Excessive system leakage.
system (continued).
e. Automatic drain valve in
main supply reservoir
defective.
f. Defective governor
3. Safety valve on air dryer a. Desiccant cartridge plugged.
popping off or exhausting
air.
b. Defective discharge check
valve in air dryer end cover.
c. Safety valve setting lower
than maximum system
pressure.
4. Constant exhaust of air at a. Air dryer purge valve leaking
air dryer purge valve or excessively.
unable to build system
pressure.
b. Defective governor.
c. Defective heater or
thermostat.
5. Air dryer does not purge a. Defective governor.
or exhaust air.
b. Air dryer purge valve stuck
closed.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
d. Check system for leaks and
repair as necessary.
e. Test operation of valve and
repair or replace as necessary.
f. Check governor for proper cut-
in pressure, cut-out pressure,
and excessive leakage in both
positions. Repair or replace
governor as necessary.
a. Check the compressor for
excessive oil passing, correct
as necessary. Rebuild or
replace cartridge.
b. Test valve, refer to Symptom 1.
c. Reduce system air pressure or
install higher setting safety
valve.
a. With compressor loaded, apply
soap solution on purge valve
exhaust to test for excessive
leakage. Repair or replace
purge valve as necessary.
b. Check governor for proper cut-
in pressure, cut-out pressure,
and excessive leakage in both
positions. Repair or replace
governor as necessary.
c. Test heater and thermostat.
repair or replace as necessary.
a. Check governor for proper cut-
in pressure, cut-out pressure,
and excessive leakage in both
positions. Repair or replace
governor as necessary.
b. Test operation of valve and
repair or replace as necessary.
1-5-17
TM 5-3810-307-24-1-1
Direct/General Support Troubleshooting - Continued
SYMPTOM
6. Desiccant material being
expelled from air dryer
purge valve exhaust (may
look like whitish liquid,
paste, or small beads).
7. Constant seepage of air
at air dryer purge valve
exhaust (non-charging
mode).
8. Air dryer purge piston
cycles rapidly with
compressor unloaded
(non-compressing mode).
1. Hard to steer left and
right.
2. Hard to steer either left or
right.
1-5-18
PROBABLE CAUSE
a. Defective cloth covered
perforated plate in air dryer.
b. Desiccant cartridge not
assembled properly to end
cover.
c. Air dryer not securely
mounted.
d. Compressor passing
excessive oil.
a. Inlet of compressor
pressurized by engine
turbocharger.
b. Defective check valve
assembly in air dryer end
cover.
Compressor fails to unload.
STEERING SYSTEM
a. Defective pressure relief
valve.
b. Defective steering control
valve.
c. Defective selector valve.
d. Defective steering pump.
Defective steering cylinder.
CORRECTIVE ACTION
a. Replace desiccant cartridge.
b. Check that cartridge is securely
attached to end cover. Tighten
as necessary.
c. Tighten as necessary.
Vibration should be kept to a
minimum.
d. Check the compressor for
excessive oil passing, correct
as necessary. Rebuild or
replace cartridge.
a. Some leakage of pressure past
metal seat of turbo cut-off
feature of air dryer can be
expected and may be audible.
This slight loss of air will not
affect performance.
b. Test valve, refer to Symptom 1.
Faulty governor installation or air
line from compressor to governor
kinked or restricted. Repair as
necessary.
a. Test pressure relief valve.
Repair or replace as necessary.
b. Test steering control valve.
Repair or replace as necessary.
c. Test selector valve. Repair or
replace as necessary.
d. Test steering pump. Repair or
replace as necessary.
Repair or replace cylinder.

Direct/General Support Troubleshooting - Continued
SYMPTOM
3. Steering is erratic left and
right.
4. Steering pump shaft seal
leaking.
5. Steering pump
overheating.
1. Boom swing operation
erratic in either direction.
PROBABLE CAUSE
a. Defective pressure relief
valve.
b. Defective steering control
valve.
c. Defective selector valve.
d. Defective steering pump.
a. Worn shaft seal.
NOTE
If replacing shaft seal
does not stop leakage,
pump should be dis-
assembled and the
following checked.
b. Broken diaphragm seal or
backup gasket.
c. Bearing out of position.
d. Excessive internal wear.
a. Pump drive shaft
excessively misaligned with
pump driven shaft.
b. Pump drive shaft axially
loaded by driving shaft.
c. System relief valve
bypassing.
SWING SYSTEM
a. Damaged relief valve.
b. Swing brake dragging (not
releasing properly).
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
a. Test pressure relief valve.
Repair or replace as necessary.
b. Test steering control valve.
Repair or replace as necessary.
c. Test selector valve. Repair or
replace as necessary.
d. Test steering pump. Repair or
replace as necessary.
a. Replace shaft seal.
b. Replace seal or gasket.
c. Replace bearing.
d. Replace pump.
a. Check alignment of shafts.
b. Check for clearance at ends of
shafts, shaft misalignment, or
worn driving splines.
c. Check relief valve setting.
Adjust setting or replace valve
as necessary.
a. Replace relief valve.
b. Readjust and/or replace
necessary parts.
1-5-19
TM 5-3810-307-24-1-1
Direct/General Support Troubleshooting - Continued
SYMPTOM
1. Boom swing operation
erratic in either direction
(continued).
2. Boom swing operation
erratic in one direction
only.
3. Boom will not swing in
either direction.
4. Swing operation slow in
either direction.
1-5-20
PROBABLE CAUSE
c. Excessive preload on upper
and lower pinion shaft
bearing.
d. Defective swing box.
e. Worn or damaged pump
section.
f. Damaged pressure reducing
valve.
Damaged swing pinion.
a. Damaged relief valve.
b. Damaged swing motor.
c. Swing brake not releasing
properly.
d. Defective swing box.
e. Worn or damaged pump
section.
f. Inoperative pressure
reducing valve.
a. Damage relief valve.
b. Improperly adjusted swing
brake.
c. Improperly adjusted
pressure reducing valve.
d. Worn or damaged output
shaft bearings.
e. Worn or damaged swing
motor.
CORRECTIVE ACTION
c. Adjust as necessary.
d. Remove and repair swing box
as necessary.
e. Repair or replace damaged
section.
f. Repair or replace valve.
Replace swing pinion.
a. Remove, clean, and repair or
replace relief valve.
b. Repair or replace swing motor.
c. Repair brake as necessary.
d. Remove and repair swing box
as necessary.
e. Repair or replace damaged
section.
f. Replace valve.
a. Remove, clean, and repair or
replace relief valve.
b. Readjust brake.
c. Adjust valve, refer to Chapter 2,
Section 8.
d. Replace bearings.
e. Repair or replace swing motor.
 TM 5-3810-307-24-1-1

Direct/General Support Troubleshooting - Continued

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

4. Swing operation slow in f. Worn or damaged pump f. Repair or replace damaged
either direction section. pump section.
(continued).
g. Improper size hoses and/or g. Check hoses and fittings and
fittings installed. replace as necessary.
5. Swing brake operation a. Brake improperly adjusted. a. Adjust brake.
erratic.
b. Dirty or glazed brake pad b. Clean or replace linings.
linings.
6. Swing brake system will Internal damage to swing brake Repair or replace damaged parts.
not operate. assembly.
7. Swing motor continues to Control valve spool sticking or Repair or replace valve.
operate when swing valve damaged.
control is in neutral
position.
8. Swing motor noisy. Motor defective. Repair or replace motor.
TELESCOPE SYSTEM

1. Boom extends erratically. a. Damaged relief valve(s). a. Repair or replace damaged

relief valve(s).

b. Distorted boom section. b. Replace distorted boom

section.
c. Damaged telescope
cylinder. c. Repair or replace cylinder.

d. Damaged control valve. d. Repair or replace control valve.

2. Boom retracts erratically. a. Damaged relief valve(s). a. Repair or replace damaged
relief valve(s).

b. Check valve malfunctioning. b. Repair or replace check valve.

c. Bent cylinder rod. c. Replace cylinder rod and all

cylinder seals.

d. Scored cylinder barrel. d. Repair or replace cylinder

barrel.

e. Damaged piston seals. e. Replace all cylinder seals

f. Loose or damaged piston. f. Replace all seals and retorque

or replace piston.

g. Distorted boom section. g. Replace distorted boom

section.

1-5-21
TM 5-3810-307-24-1-1
Direct/General Support Troubleshooting - Continued
SYMPTOM
3. Telescope cylinder will
not extend.
4. Telescope cylinder will
not retract.
1. Boom raises erratically.
1-5-22
PROBABLE CAUSE
a. Relief valve malfunctioning.
b. Broken valve linkage.
c. Broken valve spool.
d. Damaged piston seals.
e. Damaged piston.
f. Bent boom section.
g. Broken hydraulic pump
coupling.
h. Worn or damaged hydraulic
pump section.
a. Relief valve malfunctioning.
b. Inoperative check valve.
c. Broken valve linkage.
d. Broken valve spool.
e. Damaged piston seals.
f. Damaged piston.
g. Bent boom section.
h. Broken hydraulic pump
coupling.
i. Broken hydraulic pump
shaft.
j. Worn or damaged hydraulic
pump section.
LIFT CIRCUIT
a. Main relief valve damaged.
b. Bent boom pivot shaft.
CORRECTIVE ACTION
a. Repair or replace relief valve.
b. Repair or replace linkage.
c. Replace valve.
d. Replace all cylinder seals.
e. Replace piston and all cylinder
seals.
f. Replace damaged boom
section.
g. Replace broken hydraulic pump
coupling.
h. Repair or replace pump section.
a. Repair or replace relief valve.
b. Repair or replace check valve.
c. Repair or replace linkage.
d. Replace valve section.
e. Replace all cylinder seals.
f. Replace piston and all cylinder
seals.
g. Replace damaged boom
section.
h. Replace broken hydraulic pump
coupling.
i. Replace pump shaft.
j. Repair or replace pump section.
a. Repair or replace relief valve.
b. Replace pivot shaft.

Direct/General Support Troubleshooting - Continued
SYMPTOM
2. Boom lowers erratically.
3. Boom raises slowly.
4. Boom lowers slowly.
5. Boom will not raise.
PROBABLE CAUSE
a. Circuit and/or main relief
valve inoperative.
b. Control valve linkage out of
adjustment.
c. Damaged hydraulic pump
section.
a. Damaged relief valve.
b. Improper hose or fittings
installed.
c. Control valve linkage out of
adjustment.
d. Cylinder piston seals
leaking.
e. Scored cylinder barrel.
f. Worn hydraulic pump
section.
a. Damaged relief valve.
b. Improper hose or fittings
installed.
c. Control valve linkage out of
adjustment.
d. Cylinder piston seals
leaking.
e. Scored cylinder barrel.
f. Piston rod broken (loose
from piston).
g. Worn hydraulic pump
section.
a. Main and/or circuit relief
valve damaged.
b. Improperly adjusted control
valve linkage.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
a. Repair or replace relief valve.
b. Adjust linkage to obtain full
spool travel.
c. Repair or replace pump section.
a. Repair or replace relief valve.
b. Install proper hose or fittings.
c. Adjust linkage to obtain full
spool travel.
d. Replace all cylinder seals.
e. Hone or replace barrel.
f. Repair or replace pump section.
a. Repair or replace relief valve.
b. Install proper hose or fittings.
c. Adjust linkage to obtain full
spool travel.
d. Replace all cylinder seals.
e. Hone or replace barrel.
f. Replace piston rod and all
cylinder seals.
g. Repair or replace pump section.
a. Repair or replace relief valve.
b. Adjust linkage to obtain full
valve spool travel.
1-5-23
TM 5-3810-307-24-1-1

Direct/General Support Troubleshooting - Continued

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

5. Boom will not raise c. Worn or damaged hydraulic c. Repair or replace pump section.
(continued). pump section.

d. Broken pump shaft. d. Replace pump shaft and seals.

e. Broken pump drive coupling. e. Replace drive coupling.

f. Broken control valve spool. f. Replace control valve.

6. Boom will not lower. a. Main and/or circuit relief a. Repair or replace relief valve.
valve damaged.

b. Improperly adjusted control b. Adjust linkage to obtain full

valve linkage. valve spool travel.

c. Worn or damaged hydraulic c. Repair or replace pump section.

pump section.

d. Broken pump shaft. d. Replace pump shaft and seals.

e. Broken pump drive coupling. e. Replace drive coupling.

f. Broken control valve spool. f. Replace control valve.

OUTRIGGER CIRCUIT

1. Outrigger extension a. Damaged relief valves. a. Remove relief valve and clean
cylinder operation slow or or replace.
erratic.
b. Solenoid valve spool b. Repair or replace spool valve.
sticking.

c. Swivel o-rings damaged. c. Remove swivel and replace 0-

rings.

d. Collector ring dirty or glazed. d. Clean or deglaze collector ring.

e. Weak brush springs on e. Replace brush springs.

collector switch.

f. Extension cylinder damaged f. Remove extension cylinder and

internally. repair as necessary.

g. Bent cylinder rod. g. Replace piston rod and seals.

h. Binding outrigger beam. h. Repair or replace outrigger

beam.

1-5-24
 TM 5-3810-307-24-1-1

Direct/General Support Troubleshooting - Continued

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

1. Outrigger extension i. Damaged outrigger valve. i. Repair or replace valve.
cylinder operation slow or
erratic (continued). j. Damaged valve coil. j. Replace coil.

k. Partially shifted hydraulic k. Disassemble, clean, and polish

selector spool. spool and valve with very fine
emery cloth (water paper).

l. Insufficient voltage for l. Solenoids require a minimum of

operation of solenoid valve. 19 vdc to energize. Check
outrigger wiring and electrical
swivel coupling collector rings.

m. Worn or damaged hydraulic m. Repair or replace pump section.

pump section.

n. Damaged piston seals. n. Replace all cylinder seals.

o. Scored cylinder barrel. o. Repair or replace extension.

p. Cracked or damaged piston. p. Replace piston and all cylinder

seals.

q. Piston loose on piston rod. q. Replace all cylinder seals and

torque piston lockout.
2. Outrigger vertical jack a. Damaged main relief valve. a. Repair or replace valve.
cylinder operation slow or
erratic. b. Damaged holding valve b. Replace holding valve seals.
seals.

c. Bent cylinder rod. c. Replace cylinder rod and all

seals.

d. Bent outrigger housing. d. Repair or replace housing.

e. Damaged o-rings in swivel. e. Replace o-rings.

f. Sticking solenoid valve f. Repair or replace spool valve.

spool.

g. Weak brush springs on g. Replace brush springs.

collector switch.

h. Collector ring dirty or glazed. h. Clean or deglaze collector ring.

i. Worn or damaged hydraulic i. Repair or replace pump section.

pump section.

1-5-25
TM 5-3810-307-24-1-1

Direct/General Support Troubleshooting - Continued

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

3. Jack cylinder retracts a. Damaged piston seals. a. Replace all cylinder seals.
under load.
b. Damaged holding valve b. Replace seals.
seals.

c. Damaged holding valve. c. Replace valve assembly.

d. Scored cylinder barrel. d. Repair or replace cylinder.

e. Cracked or damaged piston. e. Replace piston and all cylinder

seals.
4. Jack cylinder extends a. Damaged piston seals. a. Replace all cylinder seals.
while crane is moving.
b. Scored cylinder barrel. b. Repair or replace cylinder.

c. Cracked or damaged piston. c. Replace piston and all cylinder

seals.

d. Piston loose on cylinder rod. d. Replace seal and retorque

piston.
5. Outrigger system will not a. Damaged relief valve. a. Repair or replace valve.
activate from stowed,
extended, or down b. Damaged control valve. b. Repair or replace valve.
position.
6. Outrigger system a. Damaged solenoid valve. a. Repair or replace valve.
activates, but selected
outrigger will not stow, b. Damaged control switch. b. Replace switch.
extend, or lower.
c. Damaged hydraulic cylinder. c. Repair or replace cylinder.
7. Two outriggers operate Damaged solenoid valves. Repair or replace valves.
from single control
switch.
8. Individual outrigger will a. Damaged piston seals. a. Replace seals.
not set or stow.
b. Damaged check valve. b. Repair or replace valve.

c. Damaged solenoid valve. c. Repair or replace valve.

HOISTS
1. Hoist will not raise load. a. Damaged relief valve. a. Repair or replace valve.

b. Damaged hoist control b. Repair or replace valve.

valve.

1-5-26

Direct/General Support Troubleshooting - Continued
SYMPTOM
1. Hoist will not raise load
(continued).
2. Hoist will not lower.
3. Hoist down operation
slow.
4. Hoist up operation slow.
PROBABLE CAUSE
c. Damaged primary drive
assembly.
d. Damaged overrunning
clutch.
e. Sheared shaft on pump or
damaged pump.
f. Motor control valve out of
adjustment.
a. Damaged relief valve.
b. Damaged hoist control
valve.
c. Damaged primary drive
assembly.
d. Motor control valve out of
adjustment.
a. Damaged circuit relief valve.
b. Damaged hydraulic pump.
a. Damaged circuit relief valve.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
c. Repair or replace primary drive
assembly.
d. Remove brake housing and
associated lines from primary
housing. The clutch assembly
is keyed and bolted to the
center drive shaft of the drum.
The clutch assembly should
turn freely in the counter-
clockwise direction. Repair or
replace as necessary.
e. Install a 0 to 5000 psi (0 to
34,475 kPa) gauge in the inlet
line of the hoist valve bank.
Activate the system. No
pressure or excessively low
pressure indicates a damaged
pump or drive shaft. Repair or
replace as necessary.
f. Contact Grove Worldwide,
Product Support for valve
adjustment.
a. Repair or replace valve.
b. Repair or replace valve.
c. Repair or replace primary drive
assembly.
d. Contact Grove Worldwide,
Product Support for valve
adjustment.
a. Repair or replace valve.
b. Damaged hydraulic pumps
normally build heat. By hand,
carefully check the temperature
of pump in relation to other
hydraulic pumps. Repair or
replace pump as necessary.
a. Repair or replace valve.
1-5-27
TM 5-3810-307-24-1-1
Direct/General Support Troubleshooting - Continued
SYMPTOM PROBABLE CAUSE
4. Hoist up operation slow b. Damaged hydraulic pump
(continued). disconnect.
c. Damaged hydraulic pump.
d. Damaged o-rings in brake
piston.
e. Warped brake piston.
f. Motor control valve out of
adjustment.
5. Hoist up operation erratic. Damaged hoist motor.
6. Hoist down operation a. Damaged circuit relief valve.
erratic.
b. Motor control valve out of
adjustment.
7. Sticking spool in control a. Excessively high oil
valve. temperature.
b. Dirt in oil.
1-5-28
CORRECTIVE ACTION
b. Check speed of other hydraulic
functions under load. If all
operations are slow, repair or
adjust pump disconnect.
c. Damaged hydraulic pumps
normally build heat. By hand,
carefully check the temperature
of pump in relation other
hydraulic pumps. Repair or
replace pump as necessary.
d. Install a 0-5000 psi (0 to 34,475
kPa) pressure gauge in pipe
plug hole in line going to center
of brake housing. The inability
to build or hold pressure at 500
psi (3,447.5 kPa) in this line
indicates defective o-rings.
Replace damaged o-rings.
e. Replace piston.
f. Contact Grove Worldwide,
Product Support for valve
adjustment.
Install a 0-5000 psi (0 to 34,475
kPa) pressure gauge in inlet and
exhaust line of motor. Hoist up in
low speed. Observe meter
readings. If motor has excessively
more or less pressure than normal,
motor is damaged. Repair or
replace motor.
a. Repair or replace valve.
b. Contact Grove Worldwide,
Product Support for valve
adjustment.
a. Eliminate restrictions in pipe
line. Replace joystick pilot
pressure filter.
b. Change oil and flush system.

Direct/General Support Troubleshooting - Continued
SYMPTOM
7. Sticking spool in control
valve (continued).
8. Leaking seals in control
valve.
9. Unable to move control
valve spool in or out.
10. Load drops when
control valve is moved
from neutral.
1. External leakage.
PROBABLE CAUSE
c. Valve warped in mounting.
d. Relief valve not working
properly.
e. Handle or linkage binding.
f. Spacer bent.
g. Return spring damaged.
h. Spring or valve cap binding.
a. Paint on or under seal.
b. Dirt under seal.
c. Scored spool.
d. Loose seal plates.
e. Cut or scored seal.
a. Dirt in valve.
b. Spool cap full of oil.
c. Linkage binding.
a. Dirt in check valve.
b. Scored check valve poppet
or seat.
c. Motor control valve out of
adjustment.
HOIST MOTOR
a. Seal failure.
b. Defective casting.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
c. Loosen valve and check.
d. Check pressure at inlet and at
working ports of control valve.
Repair or replace relief valve as
necessary.
e. Free linkage.
f. Replace valve.
g. Replace faulty parts.
h. Loosen, recenter, and retorque
cap.
a. Remove and clean as
necessary.
b. Remove and clean as
necessary.
c. Replace valve.
d. Clean and tighten plates.
e. Replace damaged seals.
a. Clean and flush out valve
assembly.
b. Replace seals.
c. Free linkage.
a. Disassemble and clean check
valve.
b. Replace poppet or lap poppet
to seat.
c. Contact Grove Worldwide,
Product Support for valve
adjustment.
a. Replace seal.
b. Replace casting.
1-5-29
TM 5-3810-307-24-1-1

Direct/General Support Troubleshooting - Continued

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

2. Leakage at fittings. a. Fitting port burred. a. Stone or file flat.

b. Cracked casting. b. Replace casting.

3. Loss in speed under load. a. Low inlet pressure. a. Check pressure and adjust as
necessary.

b. Excessive back pressure at b. Check line for proper size.

outlet. Replace as necessary

c. Scored port plate or end c. Relap flat to clean up.

cap.
4. Poor speed control. a. Defective pump. a. Repair or replace pump.

b. Worn rotating group. b. Replace rotating group.

5. Motor fails to start a. Insufficient torque. a. Increase relief valve pressure
turning. setting.

b. Excessive motor leakage. b. Check flow from motor outlet. If

excessive, check shuttle valve
in front port plate. Pressure not
loading plate causing plate to
move away from cam ring.
Replace defective parts.

c. Worn port plates. c. Replace port plates.

d. Worn rotating group. d. Replace rotating group.

e. Defective o-ring on OD of e. Replace damaged o-ring.

front port plate.

f. Defective pump. f. Repair or replace pump.

g. Motor defective. g. Repair or replace motor.

6. Shaft play. a. Worn bearings. a. Replace bearings.

b. Hammering coupling on b. Coupling bore should be slip fit

shaft. on shaft. Repair as necessary.

1-5-30

Direct/General Support Troubleshooting - Continued
SYMPTOM
7. Bursting of fluid supply -
inlet or outlet lines.
8. Excessive noise.
1. Heater fails to start -
motor does not run.
2. Heater fails to start -
motor runs.
TM 5-3810-307-24-1-1
PROBABLE CAUSE CORRECTIVE ACTION
Excessive pressure. If high inertia load overruns motor,
relief valve protection is required in
one or possibly both lines between
directional valve and motor. Use
closed center valve with caution.
Relief valve protection probably
required as described above.
Worn or damaged internal parts. Disassemble motor, inspect for
excessive wear, and replace worn
parts. Check condition of faces on
port plate and end cap. Rework
(lap) or replace if scuffed.
DIESEL HEATER
Defective motor. Check motor and replace if
necessary.
a. No spark.
WARNING
Use insulated tools and take
care to prevent contact with
the high tension lead. High
voltage is present which
could cause personal injury.
CAUTION
If the high tension lead is
disconnected from the
igniter for any reason, do
not energize the heater
without first providing a
discharge gap of 0.125 in.
(3.18 mm) or less from the
high tension lead to the
grounded igniter. With a
larger gap, electrical
potential can cause an
insulation breakdown in the
ignition pack or in the high
tension lead. The same is
true if the high tension lead
is attached to the igniter,
with the igniter removed
from the unit. Always
ensure the igniter body is
grounded.
1-5-31
TM 5-3810-307-24-1-1
Direct/General Support Troubleshooting - Continued
SYMPTOM
2. Heater fails to start -
motor runs (continued).
3. Motor runs but there is no
ignition.
1-5-32
PROBABLE CAUSE
a. No spark (continued).
b. Malfunctioning igniter.
a. Inadequate fuel at
carburetor.
b. Malfunctioning HI-LO control
and microswitch.
c. No spark.
d. Malfunctioning igniter.
CORRECTIVE ACTION
a. Check for spark by holding an
insulated handle screwdriver
with the shaft grounded and the
tip approximately 0.125 in. (3.18
mm) away from the high tension
lug of the igniter pack. There
should be a continuous strong
spark. If no spark is produced,
check that there is voltage
applied to the ignition power
supply. If input voltage is
present and no spark or weak
spark is produced, replace
ignition pack.
b. To check igniter, remove and
examine. The electrode should
be centered and not clogged or
shorted with carbon. Visually
check operation with igniter
removed from burner head, but
connected to high tension lead
with body grounded. Shut off
fuel and ground igniter on the
heater case to check for spark.
Replace if defective.
a. Check for fuel at float bowl.
Remove pipe plug at side of
float bowl and gently depress
the float. If fuel is present, it will
show on the object used to
depress float and buoyancy will
be felt.
b. Check HI-LO control and
microswitch adjustment.
c. Check for spark as described in
Symptom 2.
d. Check for spark as described in
Symptom 2.

Direct/General Support Troubleshooting - Continued
SYMPTOM
3. Motor runs but there is no
ignition (continued).
4. Inadequate heat output.
5. Fan fails to go to high
speed during burner
cycle.
PROBABLE CAUSE
e. Malfunctioning tilt switch.
f. Excessive fuel flow.
g. Restricted circulating air
flow.
h. Malfunction in fuel heater
and glow plug circuits.
a. Low voltage.
b. Carbon buildup.
c. Incorrect adjustment of HI-
LO control and microswitch.
a. Malfunctioning relay.
b. Malfunctioning motor.
TM 5-3810-307-24-1-1
CORRECTIVE ACTION
e. Check that tilt switch is secure
in its bracket and in a vertical
position with electrical leads
pointing down. Check leads on
both sides of switch for power.
Replace switch if defective.
f. Check float level, fuel pressure,
and carburetor fuel needle
setting. Excessive fuel flow will
cause rapid buildup of carbon in
heat exchanger. Correct fuel
feed is 1 oz/3.5 minutes (8
cc/minute).
g. Check for restrictions in air
circulating system.
h. Check fuel heater and glow
plug circuits with START-OFF
switch in START position. If
there is power but no heat from
these parts, replace them. If
there is no power, during
preheating, check all electrical
connections, wires, and
thermostat [opens at 85F
(29C) and closes at 70F
(21C)].
a. Check for 22 vdc minimum
voltage to heater.
b. Heat exchanger may have a
heavy coating of carbon
internally. Clean exchanger
and check for excessive fuel
flow, refer to Symptom 3.
c. Check HI-LO control and
microswitch adjustment.
a. Check relay and replace if
defective.
b. With power on, touch orange
motor lead to red motor lead,
fan speed must increase.
Replace motor if defective.
1-5-33
TM 5-3810-307-24-1-1
Direct/General Support Troubleshooting - Continued
SYMPTOM
5. Fan fails to go to high
speed during burner
cycle (continued).
6. Heater remains on burner
cycle after heat demands
are met.
7. Excessive smoke in
exhaust.
1-5-34
PROBABLE CAUSE
c. Malfunctioning HI-LO control
and microswitch.
a. HI-LO control or micro-
switch out of adjustment.
b. Bi-metal blade broken or
linkage out of adjustment.
c. Dirt on fuel solenoid valve
lip.
a. Low voltage.
b. Excessive fuel flow.
c. Mechanical binding in
combustion air blower motor.
d. Incorrect spark.
e. Malfunctioning igniter.
CORRECTIVE ACTION
c. Check HI-LO control and
microswitch adjustment.
a. Check HI-LO control and
microswitch adjustment.
b. Replace bi-metal blade and/or
adjust linkage as necessary.
c. Clean fuel solenoid valve lip.
a. Check for low voltage, refer to
Symptom 4.
b. Check for malfunctioning motor,
refer to Symptom 5.
c. Check for binding and correct
as necessary.
d. Check for spark, refer to
Symptom 2.
e. Check igniter, refer to Symptom
2.
 CHAPTER TWO
DETAILED DESCRIPTION AND MAINTENANCE
 TM 5-3810-307-24-1-1

SECTION 1
CABS

TABLE OF CONTENTS
Page

CABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7
CARRIER CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
SUPERSTRUCTURE CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Seat Belt (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Seat Assembly (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Seat Belt (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Seat Assembly (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Windshield Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17
Skylight Wiper (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Heater (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-24
Heater (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
HI-LO Control and Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-35
Air Conditioner (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-43

2-1-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Air Conditioner (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-60
Tilt Steering Column (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-63
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-63
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-65
Tilt Steering Column and Steering Control Valve (Superstructure Cab) . . . . . . . . . . . . . . . . 2-1-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-66
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-68
Defroster Control (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-69
Heater Control (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-71
Control Assembly, Trailer Air Supply and Parking Brake (Carrier Cab) . . . . . . . . . . . . . . . . 2-1-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-73
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-76
Operating and Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-76
Heater Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-77
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-77
Parking Brake Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-79
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-79
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-79
Operating and Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-79
Throttle Fast/Slow Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Swing Lock Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-83
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-85
Shift Control (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-86
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-86
Shift Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-87
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-87
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-87
Dash Panel (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-89
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-89

2-1-2
 TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Dash Panel (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-91

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-91
Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-94
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-96
Superstructure Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-97
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-97
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-99
Superstructure Heater Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-100
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-100

LIST OF FIGURES
Number Title Page

2-1-1 Seat Assembly and Seat Belt Installation (Carrier Cab) . . . . . . . . . . . . . . . . . . . 2-1-10
2-1-2 Seat Assembly and Seat Belt Installation (Superstructure Cab) . . . . . . . . . . . . . . 2-1-13
2-1-3 Windshield Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-16
2-1-4 Skylight Wiper (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-20
2-1-5 Heater (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-22
2-1-6 Heater Installation (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-28
2-1-7 Air Conditioner (Carrier Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-38
2-1-8 Air Conditioner (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-48
2-1-9 Tilt Steering Column (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-64
2-1-10 Tilt Steering Column (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-67
2-1-11 Defroster Control (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-70
2-1-12 Heater Control (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-72
2-1-13 Trailer Air Supply and Parking Brake Control Assy (Carrier Cab) . . . . . . . . . . . . . 2-1-74
2-1-14 Heater Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-78
2-1-15 Parking Brake Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-80
2-1-16 Throttle Control (Superstructure Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-82
2-1-17 Swing Lock Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-84
2-1-18 Shift Control Assembly (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-86
2-1-19 Shift Control Assembly (Superstructure Cab). . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-88
2-1-20 Dash Panel (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-90
2-1-21 Dash Panel (Superstructure Cab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-93
2-1-22 Carrier Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-95
2-1-23 Superstructure Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-98
2-1-24 Superstructure Cab Heater Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-100

2-1-3 C-1
TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

2-1-21
WARNING
2-1-94
Engine must be cool to the touch prior to working on coolant system
components. Failure to follow could result in scalding or serious burns.

2-1-25
WARNING
2-1-97
Diesel fuel is combustible and an irritant. Skin and eye protection is
required. Good general ventilation is normally adequate. Keep away
from open flame and other ignition sources.

WARNING 2-1-35

Diesel heater produces exhaust gases when operating. Brain damage or

death can result from heavy exposure to exhaust gases. Operate heater
in a well ventilated area or duct exhaust to the outside if operating in an
enclosed area.

2-1-37
WARNING
Fins on evaporator coil are sharp and easily bent. Wear gloves to protect
cuts, and handle evaporator coil with crane to prevent bending fins.
Straighten any bent fins to ensure maximum efficiency.

WARNING 2-1-58
Compressed air used for cleaning can create airborne particles that may
enter the eyes. Wear safety goggles and limit air pressure to 30 psi (207
kpa).

WARNING 2-1-73

There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.

2-1-4
 TM 5-3810-307-24-1-1

WARNING SUMMARY - Continued

Page

WARNING 2-1-73
Be careful to maintain and release pressure slowly when removing
retaining caps. Internal components are assembled with spring tension
and could cause personal injury if allowed to pop free.

WARNING 2-1-83

Apply positive swing lock to ensure turntable does not move during
maintenance.

2-1-5/(2-1-6 Blank)
 TM 5-3810-307-24-1-1

CABS

DESCRIPTION

The crane is equipped with two cabs, a carrier cab
and a superstructure cab. The carrier cab contains
all controls and indicators necessary for crane travel.
The superstructure cab contains all controls and
indicators necessary to perform craning operations.
Both cabs utilize international symbols to label the
various crane controls. A symbol identification decal
is located in each cab.
For a more detailed description of the cabs, refer to
either CARRIER CAB or SUPERSTRUCTURE CAB
in this section.

2-1-7
TM 5-3810-307-24-1-1
CARRIER CAB
DESCRIPTION
The carrier cab contains all of the controls and
indicators necessary for traveling and parking
functions. The cab is all-steel, acoustically treated,
fully enclosed with tinted safety glass windows
throughout. Access to the cab is provided by a
hinged left side door which features a latch handle
and keyed lock. A grab handrail is provided to aid
the operator in getting in and out of the cab. A
suspension seat installed in the cab is adjustable
both vertically and horizontally. The seat is also
equipped with a seat belt.
A 1-A:10-B:C rated, 2.50 lb (1.13 kg) dry type fire
extinguisher is mounted inside the cab, between the
door and the operator's seat.
A single blade windshield wiper is installed to
remove moisture from the windshield. The wiper
arm is driven by an electric motor which is controlled
SUPERSTRUCTURE CAB
DESCRIPTION
The superstructure cab contains all of the controls
and indicators necessary for craning operations and
traveling on the job site. The cab is all-steel,
acoustically-treated, and fully enclosed with tinted
safety glass windows throughout. Access to the cab
is provided by a sliding door which features a latch
handle and keyed lock. Grab handrails are provided
beside the door opening to aid the operator in getting
in and out of the cab.
The cab has a skylight with a tinted safety glass
window. A manually operated skylight wiper is
provided to remove moisture from the skylight.
The cab seat is mounted on a track assembly,
allowing it to be adjusted to a comfortable distance
from the steering wheel and front console. The seat
has a lever at the front of the bottom cushion to
adjust the tilt of the seat back. An armrest on each
side of the seat houses the hydraulic remote controls
used to control the crane functions. The armrests
swing up beside the seat and latch in place to make
it easier for traveling and entering and exiting the
cab.
2-1-8
by a lever on the steering column. A windshield
washer system is also installed to spray a cleaning
solution onto the windshield. It consists of two
nozzles (one on each side of the wiper arm), a
canister, and a pump assembly. The electric pump
draws the solution from the canister and forces it
through a hose to the two nozzles that spray it onto
the windshield.
The carrier cab also features a hot-water heater and
a roof-mounted air conditioning unit. The cab heater
circulates hot engine coolant through a heat
exchanger. Hot air is blown out of the heater into the
cab by a variable speed blower motor. The air
conditioning unit is comprised of a self-contained
evaporator and condenser coil unit, a remote engine-
mounted compressor, and a control panel which
allows the operator to control temperature and fan
speed.
A safety device in the armrests disables the
controllers when the armrests are in the up position.
In addition to the safety device in the armrests, a
tape switch incorporated in the cab seat, deactivates
the controllers when the operator leaves the seat.
A 1-A:10-B:C rated, 2.5 lb (1.13 kg) dry type fire
extinguisher is mounted in the cab under the
operator's seat.
A single blade windshield wiper is installed to
remove moisture from the windshield. The wiper
arm is driven by an electric motor which is controlled
by a two speed switch located on the front console
panel. A windshield washer system is also installed
to spray a cleaning solution onto the windshield. It
consists of two nozzles (one on each side of the
wiper arm), a canister which is located beneath the
cab, and a pump assembly.
Located beneath the cab, is a diesel fuel burning
heater which provides heat to the cab. The heater
tank is located on the right side of the turntable. All
 TM 5-3810-307-24-1-1

heater controls are located within the cab.
Windshield defroster controls and tubing are
provided with the heater.
The superstructure cab also features an air
conditioning unit. The air compressor and a
hydraulic motor are housed behind a cover on the
left side of the boom on the forward side of the
counterweight. The condenser unit is mounted on
the bottom of the counterweight. The air conditioner
controls including the air handler (evaporator) and
blower unit are located in the cab.

MAINTENANCE

SEAT BELT (CARRIER CAB)

Removal

a. Remove nuts (1, Figure 2-1-1) and lockwashers (2) securing anchor belts (14) to cab floor on both sides of
seat.

b. Remove nut (3), lockwasher (4), and capscrew (5) securing inertia reel for shoulder harness (13) to lower
mounting bracket on side wall of cab.

c. Remove nut (6), lockwasher (7), capscrew (8) and bushing (9) securing shoulder harness (13) to upper
mounting bracket on side wall of cab.

d. Remove nuts (10), lockwashers (11), capscrews (12), shoulder harness (13), and anchor belts (14) from
pivot links (21) on both sides of seat.

e. Remove nut (15), lockwasher (16), cap (17), capscrew (18), washers (19), fiber washer (20), pivot link
(21), and latch belt (22) from right side of seat.

Installation

a. Secure latch belt (22, Figure 2-1-1) and pivot link (21) to right side of seat with fiber washer (20), washers
(19), capscrew (18), lockwasher (16), nut (15), and cap (17).

b. Secure shoulder harness (13) and anchor belts (14) to pivot links (21) on both sides of seat with
capscrews (12), lockwashers (11) and nuts (10).

c. Secure shoulder harness (13) to upper mounting bracket on side wall of cab with bushing (9), capscrew
(8), lockwasher (7), and nut (6).

d. Secure inertia reel for shoulder harness (13) to lower mounting bracket on side wall of cab with capscrew
(5), lockwasher (4), and nut (3).

e. Secure anchor belts (14) to floor on both sides of seat with lockwashers (2) and nuts (1).

2-1-9
TM 5-3810-307-24-1-1

LEGEND

1. Nut 10. Nut 19. Washer

2. Lockwasher 11. Lockwasher 20. Fiber washer
3. Nut 12. Capscrew 21. Pivot link
4. Lockwasher 13. Shoulder harness 22. Latch belt
5. Capscrew 14. Anchor belt 23. Locknut
6. Nut 15. Nut 24. Washer
7. Lockwasher 16. Lockwasher 25. Seat assembly
8. Capscrew 17. Cap 26. Cone washer
9. Bushing 18. Capscrew 27. Support plate

Figure 2-1-1. Seat Assembly and Seat Belt Installation (Carrier Cab)
2-1-10
 TM 5-3810-307-24-1-1

SEAT ASSEMBLY (CARRIER CAB)

Removal

a. Remove nuts (10, Figure 2-1-1), lockwashers (11), and capscrews (12) securing anchor belts (14) and
shoulder harness (13) to pivot links (21) on sides of seat (25).

b. Remove locknuts (23), washers (24), seat (25), cone washers (26), and support plates (27) from cab.

c. If necessary, remove nut (15), lockwasher (16), cap (17), capscrew (18), washers (19), fiber washer (20),
pivot link (21), and latch belt (22) from right side of seat.

Installation

a. If removed, secure latch belt (22, Figure 2-1-1) and pivot link (21) to right side of seat with fiber washer
(20), washers (19), capscrew (18), lockwasher (16), nut (15), and cap (17).

b. Position support plates (27) and cone washers (26) on cab floor.

c. Position seat (25) on cone washers (26) and secure with washers (24) and locknuts (23).

d. Secure shoulder harness (13) and anchor belts (14) to pivot links (21) on sides of seat with capscrews
(12), lockwashers (11), and nuts (10).

2-1-11
TM 5-3810-307-24-1-1

SEAT BELT (SUPERSTRUCTURE CAB)

Removal

a. Remove nuts (1, Figure 2-1-2), lockwashers (2), and capscrews (3) securing seat belt halves (4) to
mounting brackets on both sides of seat.

b. Remove seat belt halves (4) from cab.

Installation

a. Position seat belt halves (4, Figure 2-1-2) in cab.

b. Secure seat belt halves (4) to mounting brackets on both sides of seat with capscrews (3), lockwashers
(2), and nuts (1).

2-1-12
 TM 5-3810-307-24-1-1

LEGEND

1. Nut 5. Nut 9. Nut

2. Lockwasher 6. Lockwasher 10. Lockwasher
3. Capscrew 7. Washer 11. Washer
4. Seat belt half 8. Seat assembly 12. Mounting plate assy
13. Switch

Figure 2-1-2. Seat Assembly and Seat Belt Installation (Superstructure Cab)

2-1-13
TM 5-3810-307-24-1-1

SEAT ASSEMBLY (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Tag and disconnect electrical connectors at rear of seat assembly (8, Figure 2-1-2).

NOTE

Be careful that mounting hardware does not drop through heater louvers under
seat.

c. Remove nuts (5), lockwashers (6), washers (7), and seat assembly (8) from mounting plate assembly (12).

d. Remove bottom covers from arm rests, tag and disconnect electrical leads for joysticks and arm switches,
and tag and disconnect hydraulic lines from fittings on joysticks, refer to Joysticks (Superstructure Cab) Removal
procedures.

e. Remove nuts (9), lockwashers (10), washers (11), and mounting plate assembly (12) from cab floor
mounting brackets.

Repair

a. Remove hog rings securing fabric to seat bottom frame at rear and sides of frame and pull fabric forward
off seat bottom.

b. Replace weight sensing safety switch (13, Figure 2-1-2) positioned on seat bottom cushion.

c. Pull fabric back over seat bottom, stretch fabric, and secure fabric to seat frame with hog rings.

Installation

a. Install mounting plate assembly (12, Figure 2-1-2) on cab floor mounting brackets with washers (11),
lockwashers (10), and nuts (9).

b. Connect hydraulic lines to joysticks, connect electrical leads for joysticks and arm switches, remove tags,
and install bottom covers on arm rests, refer to Joysticks (Superstructure Cab) Installation procedures.

c. Install seat assembly (8) on mounting plate assembly (12) with washers (11), lockwashers (10), and nuts
(9).

d. Connect electrical connectors at rear of seat assembly (8) and remove tags.

2-1-14
 TM 5-3810-307-24-1-1

WINDSHIELD WIPER/WASHER

NOTE

Procedures are typical for carrier cab and superstructure cab, except for
location of windshield washer reservoirs. Reservoir for carrier cab is located
on rear wall of cab interior. Reservoir for superstructure cab is located beneath
and outside of cab.

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Remove wiper arm and blade as follows:

(1) Disconnect washer hose (1, Figure 2-1-3) from connector below windshield.

(2) Remove cap nuts (2 and 3), washers (4 and 5), and wiper arm (6) from plate (17) and pivot shaft
(31).

(3) Remove locknut (7), capscrew (8), and wiper blade (9) from wiper arm (6).

c. Remove wiper motor as follows:

(1) Tag and disconnect electrical wires from electrical harness for wiper motor (24).

(2) Remove drive gear (10), rubber boot (11), nut (12), washer (13), and lockwasher (14) securing pivot
shaft (31) in plate (17).

(3) Remove capscrews (15), lockwashers (16), plate (17), seal (18), lockwasher (19), and wiper motor
(24) with bracket (27) from cab.

(4) Remove locknut (20) and washer (21) securing drive arm (29) to shaft of wiper motor (24).

(5) Remove capscrews (22), lockwashers (23), and wiper motor (24) from bracket (27).

d. If necessary, disassemble drive linkage and bracket as follows:

(1) Remove screws (25), lockwashers (26), and drive linkage assembly from bracket (27).

(2) Remove c-clip (28) and drive arm (29) from linking arm (32).

(3) Remove c-clip (30) and pivot shaft (31) from linking arm (32).

(4) Remove nut (33), lockwasher (34), and pin (35) from pivot shaft (31).

e. Remove windshield washer reservoir as follows:

(1) Tag and disconnect electrical connectors for reservoir pump.

(2) Disconnect hose (36) from reservoir pump.

(3) Remove nuts (37), lockwashers (38), washers (39), washer reservoir (40), and spacers (41) from
cab.

2-1-15
TM 5-3810-307-24-1-1

LEGEND

1. Hose 11. Boot 21. Washer 31. Pivot shaft

2. Cap nut 12. Nut 22. Capscrew 32. Linking arm
3. Cap nut 13. Washer 23. Lockwasher 33. Nut
4. Washer 14. Lockwasher 24. Wiper motor 34. Lockwasher
5. Washer 15. Capscrew 25. Screw 35. Pin
6. Wiper arm 16. Lockwasher 26. Lockwasher 36. Hose
7. Locknut 17. Plate 27. Bracket 37. Nut
8. Capscrew 18. Seal 28. C-clip 38. Lockwasher
9. Wiper blade 19. Lockwasher 29. Drive arm 39. Washer
10. Drive gear 20. Locknut 30. C-clip 40. Reservoir
41. Spacer
Figure 2-1-3. Windshield Wiper/Washer

2-1-16
 TM 5-3810-307-24-1-1

Repair

Replace all worn, damaged, or defective parts.

Installation

a. Install windshield washer reservoir as follows:

(1) Position spacers (41, Figure 2-1-3) and washer reservoir (40) on mounting studs and secure with
washers (39), lockwashers (38), and nuts (37).

(2) Connect hose (36) and electrical connector to reservoir pump.

b. Assemble drive linkage and bracket as necessary:

(1) Install pin (35) in the top hole of pivot shaft (31) and secure with lockwasher (34) and nut (33).

(2) Install pin (35) of pivot shaft (31) in hole nearest cutout of linking arm (32) and secure with c-clip
(30).

(3) Install drive arm (29) on linking arm (32) with c-clip (28).

(4) Position drive linkage in bracket (27) and secure pivot shaft (31) with lockwashers (26) and screws
(25).

c. Install wiper motor as follows:

(1) Insert shaft of wiper motor (24) into hole of bracket (27) while positioning drive arm (29) on shaft so
that arm is parallel with motor housing. Secure drive arm (29) on motor shaft with washer (21) and
locknut (20). Torque locknut (20) 150-180 lbs-in. (17-20 Nm).

NOTE

Ensure drive arm (29) remains parallel with motor housing when tightening
locknut (20). If arm moves, cycle motor (using 24 vdc) to position arm prior to
further installation.

(2) Secure wiper motor (24) to bracket (27) with lockwashers (23) and capscrews (24). Ensure motor
ground wire is installed under right side capscrew.

(3) Position seal (18) and plate (17) on outside of cab. Insert capscrews (15) with lockwashers (16)
through plate (17), seal (18), and wall of cab.

(4) Position lockwashers (19) on capscrews (15) and secure bracket (27) with wiper motor (24) in cab
by tightening capscrews (15).

(5) Connect electrical wires for wiper motor and remove tags.

(6) Install lockwasher (14), washer (13), and nut (12) on pivot shaft (31), and then position boot (11) and
drive gear (10) on pivot shaft.

2-1-17
TM 5-3810-307-24-1-1

d. Install wiper blade and arm as follows:

(1) Install wiper blade (9) on wiper arm (6) with capscrew (8) and locknut (7).

(2) Install wiper arm (6) on pivot shaft (31) and plate (17) with washers (4 and 5) and cap nuts (2 and 3).

(3) Connect hose (1) to connector below windshield.

2-1-18
 TM 5-3810-307-24-1-1

SKYLIGHT WIPER (SUPERSTRUCTURE CAB)

Removal

a. Remove wiper arm and blade as follows:

(1) Remove cap nuts (1 and 2, Figure 2-1-4), washers (3 and 4), and wiper arm (5) from plate (16) and
pivot shaft assembly (18).

(2) Remove locknut (6), capscrew (7), and wiper blade (8) from wiper arm (5).

b. Remove wiper operating linkage as follows:

(1) Remove drive gear (9), boot (10), nut (11), washer (12), and lockwasher (13) securing pivot shaft
assembly (18) in plate (16).

(2) Remove capscrews (14), lockwashers (15), plate (16), seal (17), and pivot shaft assembly (18) from
cab.

Repair

Replace all worn, damaged, or defective parts.

Installation

a. Install wiper operating linkage as follows:

(1) Position seal (17, Figure 2-1-4) and plate (16) on outside of cab roof. Insert capscrews (14) with
lockwashers (15) through plate (16), seal (17), and roof of cab.

(2) Align pivot shaft assembly (18) mounting bar holes to capscrews (14) and secure pivot shaft
assembly to cab roof by tightening capscrews (14).

(3) Install lockwasher (13), washer (12), and nut (11) on pivot shaft assembly (18), then position boot
(10) and drive gear (9) on pivot shaft.

b. Install wiper blade and arm as follows:

(1) Install wiper blade (8) on wiper arm (5) with capscrew (7) and locknut (6).

(2) Install wiper arm (5) on pivot shaft assembly (18) and plate (16) with washers (3 and 4) and cap nuts
(1 and 2).

2-1-19
TM 5-3810-307-24-1-1

LEGEND

1. Cap nut 5. Wiper arm 9. Drive gear 14. Capscrew

2. Cap nut 6. Locknut 10. Boot 15. Lockwasher
3. Washer 7. Capscrew 11. Nut 16. Plate
4. Washer 8. Wiper blade 12. Washer 17. Seal
13. Lockwasher 18. Pivot shaft assy

Figure 2-1-4. Skylight Wiper (Superstructure Cab)

2-1-20
 TM 5-3810-307-24-1-1

HEATER (CARRIER CAB)

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Remove capscrews (1, Figure 2-1-5) and heater vent (2) from inside of cab.

c. Disconnect electrical connector for heater motor.

d. Remove screw (3) and clamp (4) securing outer casing of defroster control cable to bottom of heater
plenum.

e. Disconnect defroster control cable from heater flap lever at bottom of heater plenum.

f. Remove screw (5) and clamp (6) securing outer casing of heat control cable, and disconnect heat control
cable from shutoff valve (17).

g. Loosen clamp (7) and disconnect defroster duct (8) from side of heater plenum.
WARNING
Engine must be cool to the touch prior to working on coolant system components.
Failure to comply could result in scalding or serious burns.

h. Place suitable container under heater hoses to catch residual coolant, loosen clamps (9), and remove
heater hoses (10 and 11) from elbows on side of heater (14).

i. Remove capscrews (12), star washers (13), and heater (14) from bottom of cab.

j. If necessary, loosen clamps (15) and remove shutoff valve (17) from hoses (11 and 16).

Repair

a. Disassemble heater (14, Figure 2-1-5) as necessary to replace damaged or defective parts.

(1) Remove screws (18), star washers (19), and lift cover (20) with coil (21) from case (26).

(2) Remove coil (21) with grommet (22) from cover (20), and grommet (21) from tubes of coil (21).

(3) Remove screws (23), star washers (24), and blower housing (25) from case (26).

(4) Remove screws (27), star washers (28), and motor (29) from blower housing (25).

(5) Loosen setscrew in retainer (30), and remove retainer and fan wheel (31) from shaft of motor (29).

b. Assemble heater (14, Figure 2-1-5) as necessary.

(1) Install fan wheel (31) on shaft of motor (29) with retainer (30).

(2) Install motor (29) on blower housing (25) with star washers (28) and screws (27).

(3) Install blower housing (25) on case (26) with star washers (24) and screws (23).

(4) Install grommet (22) on tubes of coil (21), and coil (21) with grommet (22) on cover (20).

2-1-21
TM 5-3810-307-24-1-1

LEGEND

1. Capscrew 9. Hose clamp 17. Shutoff valve 25. Blower housing

2. Heater vent 10. Heater hose 18. Screw 26. Case
3. Screw 11. Heater hose 19. Star washer 27. Screw
4. Clamp 12. Capscrew 20. Cover 28. Star washer
5. Screw 13. Star washer 21. Coil 29. Motor
6. Clamp 14. Heater 22. Grommet 30. Retainer
7. Hose clamp 15. Hose clamp 23. Screw 31. Fan wheel
8. Defroster duct 16. Heater hose 24. Star washer

Figure 2-1-5. Heater (Carrier Cab) (Sheet 1 of 2)

2-1-22
 TM 5-3810-307-24-1-1

Figure 2-1-5. Heater (Carrier Cab) (Sheet 2 of 2)

2-1-23
TM 5-3810-307-24-1-1

(5) Install cover (20) with coil (21) on case (26) with star washers (19) and screws (18).

Installation

a. If removed, install shutoff valve (17, Figure 2-1-5) between hoses (11 and 16) and secure with clamps
(15).

b. Position heater (14) under carrier cab and secure in place with capscrews (12) and star washers (13).

c. Connect hoses (10 and 11) to elbows on side of heater (14) and secure with clamps (9).

d. Connect defroster duct (8) to side of heater plenum and secure with clamp (7).

e. Ensure defroster control cable knob on dash panel is pushed in and flap lever on bottom of heater plenum
is positioned as far toward left side of carrier as possible, then connect defroster control cable to flap lever on
bottom of heater plenum and secure outer casing of cable to plenum with clamp (4) and screw (3).

f. Ensure heater control cable knob on dash panel is pushed in and shutoff lever is closed, then connect
heater control cable to shutoff valve (17) and secure outer casing of cable with clamp (6) and screw (5).

g. Install heater vent (2) with capscrews (1).

h. Start engine, pull heater control knob, and check for coolant leaks at heater hoses.

i. Shut down engine and service radiator overflow bottle as necessary.

2-1-24
 TM 5-3810-307-24-1-1

HEATER (SUPERSTRUCTURE CAB)

Removal

NOTE

Repositioning of superstructure may aid in accessing heater for removal.

a. Ensure battery disconnect switch is in the OFF position.

b. Remove exterior rear access panel from cab.

c. Disconnect electrical power plug from front of heater (18, Figure 2-1-6).

d. Remove screw (2) and clamp (4), disconnect control cable (1) from control lever (107) at front of heater
(18), and remove control cable from heater.

e. Disconnect plug for fuel pump from rear of heater (18).

f. Remove nut (5) and ground wire from rear of heater (18).

g. Remove nut (6), lockwasher (7), clamp (8), and electrical lead from bottom of heater (18). Reinstall
lockwasher (7) and nut (6).
WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.

h. Place suitable container under fuel line (9) to catch any residual fuel that may be present, and disconnect
fuel line (9) from elbow (22) at rear of heater (18).

i. Loosen clamp (10) and disconnect heater duct (11) from side of heater (18).

j. Remove nuts (12), washers (13), and clamp (14) securing exhaust pipe (21) to superstructure frame.

k. Remove nuts (15), lockwashers (16), washers (17), and heater (18) from bottom of cab.

l. If necessary, remove nuts (6), lockwashers (7), capscrews (19), and mounting straps (20) from heater
(18).

m. If necessary, remove exhaust pipe (21) from bottom of heater (18).

n. If necessary, remove elbow (22) from rear of heater (18).

o. If necessary, remove intake duct (23) from rear of heater (18), and outlet duct (24) from front of heater
(ducts secured with captured clips on case).

Repair

a. Disassemble heater assembly (18, Figure 2-1-6) as necessary to replace worn, damaged, or defective
components:

(1) Remove screws (25), cross bar (26), cover (27), and cover (28) from heater (18).

2-1-25 C-1
TM 5-3810-307-24-1-1

(2) Remove fuel line (29) and fittings (32) at carburetor assembly (31) and rear wall of case (89).

(3) Tag and disconnect electrical leads for carburetor assembly (31).

(4) Remove screws (30) and carburetor assembly (31) from burner head (37).

(5) Loosen clamps (33), and remove air hose (34) from burner head (37) and blower housing (62).

(6) Tag and disconnect electrical leads from igniter (39) and glow plug (41).

(7) Remove screws (35), pressure pads (36), burner head (37), and gasket (38) from heat exchanger
(84).

(8) Remove igniter (39), gasket (40), glow plug (41), and hose (42) from burner head (37).

(9) Remove screws (43), star washers (44), and ignition pack (45) from bracket on bottom of case (89).

(10) Loosen clamps (46), and remove air hose (47) from blower cover (52) and bottom of case (89).

(11) Tag and disconnect electrical leads for motor (50).

(12) Remove screws (48), washers (49), and motor (50) with blower assembly attached from mount plate
(72).

NOTE

Manufacturer recommends replacing motor and blower as an assembly. If

replacement of internal components is desired, perform steps (13) thru (19). If
replacement as an assembly is desired perform steps (18) and (19) only.

(13) Loosen clamp (51), and remove blower cover (52) and clamp (51) from blower housing (62).

(14) Release tension on captured spring clip (part of fan wheel hub), and remove fan wheel (53) and
spacer (54) from shaft of motor (50).

(15) Remove screws (55) and stationary wheel (56) from blower housing (62).

(16) Release tension on captured spring clip (part of fan wheel hub), and remove fan wheel (57) from
shaft of motor (50).

(17) Remove nuts (58), lockwashers (59), washers (60), washer (61), blower housing (62), washer (63),
and gasket (64) from motor (50).

(18) Mark position of bracket (67) on motor (50), and remove screw (65), washer (66), and bracket (67)
from motor (50).

(19) Mark position of fan (69) on shaft of motor (50), and remove setscrews (68) and fan (69) from shaft
of motor (50).

(20) Remove screws (70), star washers (71), and mount plate (72) from bracket (88).

(21) Tag and disconnect electrical lead for overheat switch (83) from terminal board (111).

(22) Remove screws (73), star washers (74), and cover (75) with baffle (78) from bracket (88).

2-1-26
 TM 5-3810-307-24-1-1

(23) Disconnect electrical lead from overheat switch (83), and remove screws (76), star washers (77),
and cover (75) from baffle (78).

(24) Remove electrical lead (79) and grommet (80) from cover (75).

(25) Remove screws (81), star washers (82), and overheat switch (83) from baffle (78).

(26) Remove heat exchanger (84) from bracket (88).

(27) Remove locknut (85) and disconnect lever of bracket assembly (96) from pivot arm (108).

(28) Tag and disconnect electrical leads for microswitch (91) and flame switch (102) from terminal board
(111).

(29) Remove screws (86), star washers (87), and bracket (88) from case (89).

(30) Remove screws (90), microswitch (91), and insulator (92) from bracket assembly (96).

(31) Remove grommet (93), screws (94), heat shield (95), and bracket assembly (96) from bracket (88).

(32) Mark position of actuator stop (98) on actuating rod (99), loosen setscrews (97), and remove stop
(98), rod (99), and bi-metal blade (100) from bracket assembly (96).

(33) Remove nuts (101), flame switch (102), and spacers (103) from bracket assembly (96).

(34) Remove nut (104) and collar (105), loosen setscrew (106), and remove control lever (107) and pivot
arm (108) from case (89).

(35) Tag and disconnect electrical leads for harness (109) from terminal board (111) and receptacle
(116), and remove harness (109) from case (89).

(36) Remove screws (110), terminal board (111), spacers (112), and star washer (113) from case (89).

(37) Remove screws (114), star washers (115), and receptacle (116) from case (89).

(38) Remove nut (117), fuel line connector (118), terminal connector (119), screws (120), lockwashers
(121), exhaust connector (122), gasket (123), and washer (124) from case (89).

b. Assemble heater assembly (18, Figure 2-1-6) as necessary.

(1) Install washer (124), gasket (123), and exhaust connector (122) on case (89) with lockwashers
(121) and screws (120).

(2) Install terminal connector (119) and fuel line connector (118) with nut (117) in case (89).

(3) Install receptacle (116) in case (89) with star washers (115) and screws (114).

(4) Install terminal board (111) on case (89) with star washers (113), spacers (112), and screws (110).

(5) Position harness (109) in case (89), connect electrical leads to receptacle (116) and terminal board
(111), and remove tags.

(6) Position pivot arm (108) and control lever (107) in case (89), tighten set screw (106), and install
collar (105) and nut (104) on control lever (107).

2-1-27
TM 5-3810-307-24-1-1

Figure 2-1-6. Heater Installation (Superstructure Cab) (Sheet 1 of 4)

2-1-28
 TM 5-3810-307-24-1-1

Figure 2-1-6. Heater Installation (Superstructure Cab) (Sheet 2 of 4)

2-1-29
TM 5-3810-307-24-1-1

Figure 2-1-6. Heater Installation (Superstructure Cab) (Sheet 3 of 4)

2-1-30
 TM 5-3810-307-24-1-1

Figure 2-1-6. Heater Installation (Superstructure Cab) (Sheet 4 of 4)

2-1-31
TM 5-3810-307-24-1-1

LEGEND For Figure 2-1-6

1. Control cable 32. Fitting 63. Washer 94. Screw

2. Screw 33. Clamp 64. Gasket 95. Heat shield
3. Not Used 34. Air hose 65. Screw 96. Bracket assy.
4. Clamp 35. Screw 66. Washer 97. Setscrew
5. Nut 36. Pressure pad 67. Bracket 98. Actuator stop
6. Nut 37. Burner head 68. Setscrew 99. Actuator rod
7. Lockwasher 38. Gasket 69. Fan 100. Bi-metal blade
8. Clamp 39. Igniter 70. Screw 101. Nut
9. Fuel Line 40. Gasket 71. Star washer 102. Flame switch
10. Clamp 41. Glow plug 72. Mount plate 103. Spacer
11. Heater duct 42. Hose 73. Screw 104. Nut
12. Nut 43. Screw 74. Star washer 105. Collar
13. Washer 44. Star washer 75. Cover 106. Setscrew
14. Clamp 45. Ignition pack 76. Screw 107. Control lever
15. Nut 46. Clamp 77. Star washer 108. Pivot arm
16. Lockwasher 47. Air hose 78. Baffle 109. Harness
17. Washer 48. Screw 79. Elec. lead 110. Screw
18. Heater 49. Washer 80. Grommet 111. Terminal board
19. Capscrew 50. Motor 81. Screw 112. Spacer
20. Mounting strap 51. Clamp 82. Star washer 113. Star washer
21. Exhaust pipe 52. Blower cover 83. Overheat switch 114. Screw
22. Elbow 53. Fan wheel 84. Heat exchanger 115. Star washer
23. Intake duct 54. Spacer 85. Locknut 116. Receptacle
24. Outlet duct 55. Screw 86. Screw 117. Nut
25. Screw 56. Stationary wheel 87. Star washer 118. Connector
26. Cross bar 57. Fan wheel 88. Bracket 119. Trml. connector
27. Cover 58. Nut 89. Case 120. Screw
28. Cover 59. Lockwasher 90. Screw 121. Lockwasher
29. Fuel line 60. Washer 91. Microswitch 122. Exh. connector
30. Screw 61. Washer 92. Insulator 123. Gasket
31. Carburetor assy. 62. Blower housing 93. Grommet 124. Washer
125. Adjust knob

(7) Install flame switch (102) on bracket assembly (96) with spacers (103) and nuts (101).

(8) Install actuating rod (99) and bi-metal blade (100) on bracket assembly (96), position actuator stop
(98) on rod (99) as marked during removal, and secure stop (98) with setscrews (97).

(9) Position bracket assembly (96) and heat shield (95) in bracket (88) with lever of bracket assembly
(96), mounting area for microswitch (91), and wires for flame switch protruding through appropriate
holes in bracket (88). Secure bracket assembly (96) and heat shield (95) to bracket (88) with
screws (94).

(10) Install insulator (92) and microswitch (91) on bracket assembly (96) with screws (90).

(11) Install bracket (88) in case (89) with star washers (87) and screws (86).

(12) Install grommet (93) over wires for flame switch (102) and into bracket (88). Route and connect
wires for flame switch (102) and microswitch (91) to terminal board (111). Remove tags.

(13) Install heat exchanger (84) in bracket (88) ensuring flame switch (102) contacts heat exchanger.
Reposition flame switch as necessary to achieve contact.

2-1-32 C-1
 TM 5-3810-307-24-1-1

(14) Connect lever of bracket assembly (96) to pivot arm (108) with nut (85).

(15) Install overheat switch (83) in baffle (78) with star washers (82) and screws (81).

(16) Install electrical lead (79) and grommet (80) in cover (75).

(17) Position baffle (78) under cover (75), connect electrical lead to overheat switch (83), and secure
baffle (78) to cover (75) with star washers (77) and screws (76).

(18) Install cover (75) on bracket (88) with star washers (74) and screws (73). Route and connect
electrical leads for overheat switch (83) to terminal board (111) and remove tags.

(19) Install mount plate (72) on bracket (88) with star washers (71) and screws (70).

(20) Apply thread sealant to threads of setscrews (68), then install fan (69) on shaft of motor (50) as
marked during removal with setscrews (68) ensuring setscrews engage flats on motor shaft.

(21) Install bracket (67) on motor (50) as marked during removal with washer (66) and screw (65).

NOTE

If replacing motor and blower as an assembly skip to step (27), otherwise

continue with next step.

(22) Install gasket (64), washer (63), and blower housing (62) on motor (50) with washer (61), washers
(60), lockwashers (59), and nuts (58).

(23) Install fan wheel (57) on shaft of motor (50) and secure with spring clip (part of fan wheel hub).

(24) Install stationary wheel (56) on blower housing (62) with screws (55).

(25) Install spacer (54) and fan wheel (53) on shaft of motor (50). Secure fan wheel (53) with spring clip
(part of fan wheel hub).

(26) Install blower cover (52) on blower housing (62) with clamp (51).

(27) Install motor (50) with blower assembly on mount plate (72) with washers (49) and screws (48).

(28) Connect electrical leads for motor (50) and remove tags.

(29) Install air hose (47) to blower cover (52) and bottom of case (89) with clamps (46).

(30) Install ignition pack (45) on bracket at bottom of case (89) with star washers (44) and screws (43).

(31) Install hose (42), glow plug (41), gasket (40), and igniter (39) on burner head (37).

(32) Install gasket (38) and burner head (37) on heat exchanger (84) with pressure pads (36) and screws
(35).

(33) Connect electrical leads to glow plug (41) and igniter (39). Remove tags.

(34) Install air hose (34) on burner head (37) and blower housing (62) with clamps (33).

(35) Install carburetor assembly (31) on burner head (37) with screws (30). Connect electrical leads for
carburetor assembly (31) and remove tags.

2-1-33
TM 5-3810-307-24-1-1

(36) Install fittings (32) and fuel line (29) at carburetor (31) and rear wall of case (89).

(37) Position covers (27 and 28) on heater assembly (18), and install cross bar (26) on heater assembly
with screws (25).

Installation

a. If removed, install intake duct (23, Figure 2-1-6) on rear of heater and outlet duct (24) on front of heater
(ducts snap in place with captured clips on case).

b. If removed, install elbow (22) in rear of heater (18).

c. If removed, install exhaust pipe (21) on bottom of heater (18).

d. If removed, install mounting straps (20) on heater (18) with capscrews (19), lockwashers (7), and nuts (6).

e. Position heater (18) under superstructure cab and secure in place with washers (17), lockwashers (16),
and nuts (15).

f. Connect heater duct (11) on side of heater (18) and secure with clamp (10).

g. Connect fuel line (9) to elbow (22) at rear of heater (18).

h. Connect plug for fuel pump at rear of heater (18) remove nut (6) and lockwasher (7), and secure electrical
lead for fuel pump to heater with clamp (8), lockwasher (7), and nut (6).

i. Connect ground wire to rear of heater (18) with nut (5).

j. Ensure control cable knob on right side console in superstructure cab is pushed all the way in, position
control lever (107) at front of heater to LO, connect control cable (1) to control lever (107), and secure outer
casing of cable to heater with clamp (4) and screw (2).

k. Connect heater power plug to front of heater (18).

l. Secure exhaust pipe (21) to superstructure frame with clamp (14), washers (13), and nuts (12).

m. Install exterior rear access panel on cab.

Adjustment

Carburetor Adjustment.

NOTE

The carburetor is factory adjusted for the proper air/fuel ratio for diesel fuel DF-
2, using sophisticated equipment. After adjustment, the fuel needle adjust
knob is installed with the pointed side of knob pointing to the 6 o'clock position.
This setting should not be changed unless the fuel type is changed or the
adjust knob has been inadvertently moved. If necessary, adjust the carburetor
as follows.

a. Turn fuel needle adjust knob (125, Figure 2-1-6) clockwise until it bottoms, then back adjust knob out one
full turn counterclockwise.

2-1-34 C-1
 TM 5-3810-307-24-1-1

WARNING
Diesel heater produces exhaust gases when operating. Brain damage or
death can result from heavy exposure to exhaust gases. Operate heater in a
well ventilated area or duct exhaust to the outside if operating in an enclosed
area.

b. Start heater and allow heater to run for 5 minutes.

c. Observe that heater is burning evenly and smoothly, and that no smoke is visible in exhaust.

d. Slowly turn adjust knob (125) counterclockwise just to the point that no smoke is visible in exhaust.

e. Shut down heater.

HI-LO Control and Microswitch Adjustment.

a. Remove heater (18, Figure 2-1-6) from bottom of superstructure cab, refer to Removal procedures.

b. Remove covers (27 and 28) from heater (18).

c. Loosen setscrews (97) securing actuator stop (98) to actuator rod (99).

d. Hold actuator rod (99) and move actuator stop (98) toward microswitch (91) to increase the temperature
within the control range. Move stop (98) toward bi-metal blade (100) to decrease the temperature within
the control range.

e. Tighten setscrews (97) to secure actuator stop (98) in place.

NOTE

There must be a minimum gap of .050 in. (1.27 mm) between bi-metal blade
(100) and actuator stop (98) when lever of bracket assembly (96) is in the LO
position [lever is pulled to burner head side of bracket (88)].

f. Install covers (27 and 28) on heater (18).

g. Install heater (18) on bottom of superstructure cab, refer to Installation procedures.

2-1-35
TM 5-3810-307-24-1-1

AIR CONDITIONER (CARRIER CAB)

Test

Refer to Appendix B for testing procedures.

Inspect

Refer to Appendix B for inspection procedures.

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Remove roof mounted air conditioner unit as follows:

(1) Remove nuts (1, Figure 2-1-7), lockwashers (2), washers (3), and hose cover (4) from cab roof.

(2) Remove capscrews (5), washers (6), and cover (7) from air conditioner unit (14).

(3) Discharge/recover system refrigerant, refer to instructions for assigned recovery system and
Appendix B.

(4) Disconnect refrigerant hoses (8 and 9) from air conditioner unit (14).

(5) Remove capscrews (10), release control panel (11), tag and disconnect cab harness electrical leads
from switch assembly (85), and allow control panel to hang from bottom of air conditioner unit (14)
inside cab.

(6) Remove capscrews (12) and washers (13) from interior cab roof securing air conditioner unit (14) to
exterior cab roof.

CAUTION

Use care to ensure control panel (11) does not catch on opening in roof when
removing air conditioner unit (14) from cab. Wiring and thermostat sensor lead
may be damaged.

(7) Remove air conditioner unit (14) with control panel (11) and rubber spacers (15 and 16) from cab
roof.

(8) If necessary, remove seal (17) from exterior cab roof.

c. Remove compressor as follows:

(1) Tag and disconnect electrical lead from engine harness.

(2) Recover system refrigerant, refer to instructions for assigned recovery system and Appendix B.

(3) Disconnect refrigerant hoses (8 and 9, Figure 2-1-7) from compressor (33). Cap hoses to prevent
entry of contaminants.

(4) Remove nut (18), star washer (19), washer (20), capscrew (21), and ground wire (39) from
compressor (33) housing.

2-1-36
 TM 5-3810-307-24-1-1

(5) Loosen nuts (22 and 27), rotate compressor (33) toward engine to relieve tension on drive belt (41),
and remove drive belt (41) from compressor pulley.

(6) Remove nuts (22 and 27), lockwashers (23 and 28), washers (24 and 29), capscrews (25 and 30),
washers (26 and 31), bushing (32) and compressor (33) from bracket (40).

(7) If necessary, remove capscrews (34 and 36), washers (35 and 38), star washer (37), compressor
ground wire (39), and bracket (40) from engine.

(8) If necessary, remove drive belt (41) from engine.

Repair

a. Disassemble air conditioner unit (14, Figure 2-1-7) as necessary to replace worn, damaged, or defective
components:
NOTE

Cut electrical wire ties as necessary to disconnect electrical connectors from

components.

(1) Tag and disconnect electrical connector for condenser fan motor (43).

(2) Remove clamp (42) and condenser fan motor (43) from air conditioner frame (83).

(3) Loosen setscrew and remove retainer (44) and fan (45) from condenser fan motor (43).

(4) Tag and disconnect electrical connector for relay (48), remove nut (46), lockwasher (47), and relay
(48) from air conditioner frame (83).

(5) Tag and remove tube (49) from drier (52) and condenser coil (57).

(6) Tag and remove tube (50) from drier (52) and expansion valve (59).

(7) Tag and disconnect electrical connector for switch (53), remove clamp (51) and drier (52) from air
conditioner frame (83).

(8) Unscrew switch (53) from drier (52).

(9) Remove capscrews (54 and 55), washers (56), and condenser coil (57) from air conditioner frame
(83).

(10) Unhook straps (80) and remove cover (61) from air conditioner frame (83).

(11) Disconnect tubes of evaporator coil (62) from expansion valve (59).

(12) Remove locknuts (58), expansion valve (59), and capscrews (60) from air conditioner frame (83).
WARNING
Fins on evaporator coil are sharp and easily bent. Wear gloves to prevent
cuts, and handle evaporator coil with care to prevent bending fins. Straighten
any bent fins to ensure maximum efficiency.

(13) Pull thermostat sensor lead out of evaporator coil (62) and remove evaporator coil (62) from air
conditioner frame (83).

2-1-37
TM 5-3810-307-24-1-1

Figure 2-1-7. Air Conditioner (Carrier Cab) (Sheet 1 of 3)

2-1-38
 TM 5-3810-307-24-1-1

Figure 2-1-7. Air Conditioner (Carrier Cab) (Sheet 2 of 3)

2-1-39
TM 5-3810-307-24-1-1

Figure 2-1-7. Air Conditioner (Carrier Cab) (Sheet 3 of 3)

2-1-40
 TM 5-3810-307-24-1-1

LEGEND FOR FIGURE 2-1-7

1. Nut 25. Capscrew 49. Tube, refrig. 72. Star washer

2. Lockwasher 26. Washer 50. Tube, refrig. 73. Fan housing
3. Washer 27. Nut 51. Clamp 74. Fan housing
4. Hose cover 28. Lockwasher 52. Drier 75. Motor, evap.
5. Capscrew 29. Washer 53. Switch 76. Capscrew
6. Washer 30. Capscrew 54. Capscrew 77. Resistor
7. Cover 31. Washer 55. Capscrew 78. Locknut
8. Hose, refrig. 32. Spacer 56. Washer 79. Washer
9. Hose, refrig. 33. Compressor 57. Condenser coil 80. Strap
10. Capscrew 34. Capscrew 58. Locknut 81. Gasket
11. Control panel 35. Washer 59. Expansion valve 82. Drain hose
12. Capscrew 36. Capscrew 60. Capscrew 83. Frame, a/c
13. Washer 37. Star washer 61. Cover 84. Screw
14. Air conditioner 38. Washer 62. Evaporator coil 85. Switch assy.
15. Spacer, rubber 39. Ground wire 63. Capscrew 86. Louver
16. Spacer, rubber 40. Bracket 64. Washer 87. Capscrew
17. Seal, roof 41. Drive belt 65. Bracket 88. Drive plate
18. Nut 42. Clamp 66. Capscrew 89. Shim
19. Star washer 43. Motor, cond. 67. Ring 90. Snap ring
20. Washer 44. Retainer 68. Retainer 91. Cover
21. Capscrew 45. Fan 69. Fan wheel 92. Pulley
22. Nut 46. Nut 70. Fan wheel 93. Screw
23. Lockwasher 47. Star washer 71. Nut 94. Coil
24. Washer 48. Relay

(14) Tag and disconnect electrical connectors for motor (75) and resistor (77).

(15) Remove capscrews (63), washers (64), bracket (65), and evaporator fan motor (75) with fans from
air conditioner frame (83).

(16) Remove capscrews (66) and rings (67) from fan housings (73 and 74).

(17) Loosen setscrews, and remove retainers (68) and fan wheels (69 and 70) from shafts of motor (75).

(18) Remove nuts (71), lockwashers (72), and fan housings (73 and 74) from fan motor (75).

(19) Remove capscrews (76) and resistor (77) from fan housing (73).

(20) Remove locknuts (78), washers (79), and straps (80) from air conditioner frame (83).

(21) Remove plenum gasket (81) and drain hoses (82) from air conditioner frame (83).

(22) Remove screws (84) and switch assembly (85) from control panel (11).

(23) Unsnap louvers (86) from control panel (11).

b. Assemble air conditioner unit (14, Figure 2-1-7) as necessary:

NOTE

Replace any o-rings on tube/hose fittings prior to connection.

2-1-41
TM 5-3810-307-24-1-1

(1) Snap louvers (86) into control panel (11).

(2) Install switch assembly (85) on control panel (11) with screws (84) and route electrical wiring and
thermostat sensor lead from switch assembly through bottom of air conditioner frame (83).

(3) Install plenum gasket (81) and drain hoses (82) on air conditioner frame (83).

(4) Install straps (80) on air conditioner frame (83) with washers (79) and locknuts (78).

(5) Install resistor (77) on fan housing (73) with capscrews (76).

(6) Install fan housings (73 and 74) on motor (75) with lockwashers (72) and nuts (71).

(7) Position fan wheels (69 and 70) and retainers (68) on shafts of motor (75) and secure retainers by
tightening setscrews.

(8) Install rings (67) on fan housings (73 and 74) with capscrews (66).

(9) Install evaporator fan motor (75) with fans on air conditioner frame (83) with bracket (65), washers
(64), and capscrews (63).

(10) Connect electrical connectors for motor (75) and resistor (77). Remove tags.

(11) Position evaporator coil (62) in air conditioner frame (83), and insert thermostat sensor lead into coil
fins near middle of coil.

(12) Install expansion valve (59) on air conditioner frame (83) with capscrews (60) and locknuts (58).

(13) Connect tubes of evaporator coil (62) on expansion valve (59).

(14) Position cover (61) on air conditioner frame (83), pull straps (80) over cover and hook straps at rear
of frame to secure cover.

(15) Install condenser coil (57) on air conditioner frame (83) with washers (56) and capscrews (54 and
55).

(16) Screw switch (53) into drier (52), install drier (52) on air conditioner frame (83) with clamp (51),
connect electrical connector for switch (53), and remove tag.

(17) Install tube (50) on drier (52) and expansion valve (59). Remove tag.

(18) Install tube (49) on drier (52) and condenser coil (57). Remove tag.

(19) Install relay (48) on air conditioner frame (83) with lockwasher (47) and nut (46). Connect electrical
connector for relay (48) and remove tag.

(20) Position fan (45) and retainer (44) on shaft of condenser fan motor (43), and secure retainer by
tightening setscrew.

(21) Install condenser fan motor (43) on air conditioner frame (83) with clamp (42).

(22) Connect electrical connector for condenser fan motor (43) and remove tag.

NOTE

Install electrical wire ties as necessary to secure electrical wiring.

2-1-42
 TM 5-3810-307-24-1-1

c. Disassemble compressor (33, Figure 2-1-7) as necessary to replace worn, damaged, or defective
components:

(1) Hold drive plate (88) from turning and remove capscrew (87) from compressor (33).

(2) Using suitable puller, remove drive plate (88) and shim(s) (89) from compressor (33).

(3) Remove snap ring (90) and cover (91) from shaft of compressor (33).

CAUTION

To prevent damage to pulley, ensure claws of bearing puller are hooked into
the top groove of the pulley, not under the grooves.

(4) Using standard gear puller, remove pulley (92) from compressor (33).

(5) Remove electrical lead for coil (94) from holder on compressor (33), then remove screws (93), and
coil (94) from compressor.

d. Assemble compressor (33, Figure 2-1-7) as necessary:

(1) Install coil (94) on compressor (33) with screws (93).

(2) Install electrical lead for coil (94) in holder on compressor (33).

(3) Using hand press, install pulley (92) onto shaft of compressor (33).

(4) Install cover (91) and snap ring (90) on shaft of compressor (33).

NOTE

Ensure chamfered inner edge of snap ring faces outward.

(5) Install shim(s) (89) and drive plate (88) on compressor (33). Press drive plate down as far as
possible by hand, install capscrew (87), and torque to 9 to 10 lbs-ft (12 to 14 Nm).

(6) Measure for drive plate clearance of 0.01 to 0.02 in. (0.3 to 0.6 mm). Adjust thickness of shims (89)
to achieve clearance.

Installation

a. Install compressor as follows:

(1) If removed, install bracket (40, Figure 2-1-7) on engine with washers (38 and 35), one end of ground
wire (39), star washer (37), and capscrews (36 and 34).

(2) Position compressor (33) on bracket (40) and install bushing (32), capscrews (30 and 25), washers
(31, 29, 26, and 24), lockwashers (28 and 23), and nuts (27 and 22). Do not tighten nuts at this
time.

(3) Position drive belt (41) on engine fan drive pulley and outer groove of compressor pulley, rotate
compressor (33) away from engine to tension drive belt until there is approximately 1/2 inch
deflection at midspan, then tighten nuts (22 and 27).

(4) Attach other end of ground wire (39) to compressor (33) housing with capscrew (21), washer (20),
star washer (19), and nut (18).

2-1-43
TM 5-3810-307-24-1-1

(5) Connect compressor electrical lead to engine harness.

NOTE

Replace o-rings on hose fittings prior to connection.

(6) Connect refrigerant hoses (8 and 9) to compressor (33).

(7) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 2.50 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.

b. Install roof mounted air conditioner unit as follows:

(1) If removed, install seal (17, Figure 2-1-7) in cab roof.

(2) Position rubber spacers (15 and 16), equaling 2 inches high in front and 1 inch high in back, over
mounting holes in cab roof.

CAUTION

Guide control panel (11) through opening in cab roof being careful not to
damage wiring and thermostat sensor lead when positioning air conditioner
unit (14) on cab roof.

(3) Position air conditioner unit (14) on rubber spacers (15 and 16). Ensure unit mounting holes are
aligned with spacers and cab roof holes.

(4) Secure air conditioner unit (14) to cab roof with washers (13) and capscrews (12).

(5) Lift control panel (11) into position, connect cab harness electrical leads to switch assembly (85),
remove tags, and secure control panel to interior cab roof with capscrews (10).

NOTE

Replace o-rings on hose fittings prior to connection.

(6) Connect refrigerant hoses (8 and 9) to air conditioner unit (14).

(7) If no other air conditioner component is removed, evacuate and charge air conditioner system with
2.50 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned charging
system and Appendix B.

(8) Install cover (7) over air conditioner unit (14) and secure with washers (6) and capscrews (5).

(9) Install hose cover (4) over hoses (8 and 9) and onto cab roof with washers (3), lockwashers (2), and
nuts (1)

2-1-44
 TM 5-3810-307-24-1-1

AIR CONDITIONER (SUPERSTRUCTURE)

Test

Refer to Appendix B for testing procedures.

Inspect

Refer to Appendix B for inspection procedures.

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Remove condenser assembly as follows:

(1) Remove left side turntable access cover.

(2) Remove screws (12, Figure 2-1-8) and access cover (13) from compressor/motor mounting bracket.

(3) Discharge/recover refrigerant from system at service ports at compressor (18), refer to instructions
for assigned recovery system and Appendix B.

(4) Disconnect electrical connector for condenser unit (8).

(5) Open clamps (3 and 4) on left side of condenser mounting bracket and left side of turntable, and
remove refrigerant hoses (1 and 2) from clamps.

(6) Remove nuts (5), lockwashers (6), washers (7), and condenser (8) from mounting brackets, and set
on spare tire.

(7) Remove capscrews (9), lockwashers (10), and cover (11) from condenser assembly (8).

(8) Disconnect refrigerant supply hose (1) from drier (99) and return hose (2) from condenser coil (74).
Cap hoses to prevent entry of contaminants and pull hoses out of condenser assembly (8).

(9) Remove condenser assembly (8) from crane.

c. Remove compressor as follows:

(1) Remove screws (12, Figure 2-1-8) and access cover (13) from compressor/motor mounting bracket.

(2) Loosen capscrews (14), release tension on drive belt (15), and remove belt from compressor pulley.

(3) Disconnect electrical connector and ground wire for compressor (21).

(4) If necessary, discharge/recover refrigerant from system, refer to instructions for assigned recovery
system and Appendix B.

(5) Tag and disconnect refrigerant return hose (2), and supply hose (16) from compressor (21). Cap
hoses to prevent entry of contaminants.

(6) Remove nuts (22), lockwashers (23), washers (24), capscrews (14), lockwashers (25), washers
(26), adjustment capscrew bushing (27), and compressor (21) from bracket (28).

2-1-45
TM 5-3810-307-24-1-1

NOTE

Mark position of bracket (28) on compressor/motor mounting bracket to aid

installation.

(7) If necessary, remove nuts (17), lockwashers (18), washers (19), capscrews (20), and bracket (28)
from compressor/motor mounting bracket.

d. Remove motor as follows:

(1) If necessary, remove screws (12, Figure 2-1-8) and access cover (13) from compressor/motor
mounting bracket.

(2) If necessary, loosen capscrew (14) releasing tension on drive belt (15) and remove belt from motor
pulley.

CAUTION

Cap/cover all hydraulic openings to prevent entry of dirt and contamination of

hydraulic system.

(3) Disconnect hydraulic hoses (29 and 30) from adapter (46) and tee (47) at top of motor (43).

(4) Disconnect hydraulic hose (31) from tee (45) at rear of motor (43).

(5) Remove hydraulic tubes (32 and 33) from elbow (44) and tee (45) at rear of motor (43) and adapters
(53 and 54) at valve (52).

(6) Remove capscrews (34) and lockwashers (35), retainer (36), key (37), and pulley (38) from motor
(43).

(7) Remove nuts (39), lockwashers (40), washers (41), capscrews (42), and motor (43) from
compressor/motor mounting bracket.

(8) If necessary, remove elbow (44), tee (45), adapter (46), and tee (47) from motor (43).

e. Remove flow divider valve as follows:

CAUTION

Cap/cover all hydraulic openings to prevent entry of dirt and contamination of

hydraulic system.

(1) Disconnect hose (30, Figure 2-1-8) from tube (55) at front of flow divider valve (52).

(2) If necessary, remove hydraulic tubes (32 and 33) from elbow (44) and tee (45) at rear of motor (43)
and adapters (53 and 54) at valve (52).

(3) Remove nuts (48), lockwashers (49) washers (50), capscrews (51), and flow divider valve (52) from
bracket (62).

(4) If necessary, remove adapters (53 and 54), tube (55), and relief valve (56) from valve (52).

(5) If necessary, remove nut (57), lockwasher (58), washer (59), capscrew (60), washer (61), and
bracket (62) from compressor/motor mounting bracket.

2-1-46
 TM 5-3810-307-24-1-1

f. Remove evaporator assembly as follows:

(1) If necessary, discharge/recover refrigerant from system, refer to instructions for assigned recovery
system and Appendix B.

(2) Disconnect electrical connector for evaporator assembly (68, Figure 2-1-8).

(3) Disconnect refrigerant hose (1), and refrigerant hose (16) from right side of evaporator assembly
(68).

(4) Remove nuts (63), lockwashers (64), washers (65), capscrews (66), washers (67), and evaporator
assembly (68) from brackets on rear interior wall of cab.

Repair

a. Disassemble condenser assembly (8, Figure 2-1-8) as necessary to replace worn, damaged, or defective
components:

(1) Disconnect refrigerant hose (69) from coil (74).

(2) Remove capscrews (70 and 72), lockwashers (71 and 73), and lift coil (74) out of case (103).

(3) Tag and disconnect electrical connectors for fan motors (94).

(4) Remove relay (75) from socket (77), then remove screw (76) and socket (77) from mount bracket
(80).

(5) Remove capscrews (78), lockwashers (79), and mount bracket (80) with fan motors (94) from case
(103).

NOTE

Both fan motors are disassembled the same. Steps (6) thru (9) apply to either
motor.

(6) Remove capscrews (81), lockwashers (82), and brackets (83 and 84) with fan motor (94) from
mount bracket (80).

(7) Remove cotter pin (85), retainer (86), and fan (87) from shaft of fan motor (94).

(8) Remove nuts (88), star washers (89), and bracket (84) from fan motor (94).

(9) Remove nuts (90), star washers (91), capscrews (92), clamp halves (93), and brackets (83) from fan
motor (94).

(10) Tag and disconnect electrical leads from switch (100).

(11) Remove nuts (95), star washers (96), capscrews (97), clamp halves (98), and drier (99) from
bracket in case (103).

(12) If necessary, remove refrigerant hose (69) and switch (100) from drier (99).

(13) If necessary, remove grommet (101) and electrical harness (102) from case (103).

2-1-47
TM 5-3810-307-24-1-1

Figure 2-1-8. Air Conditioner (Superstructure Cab) (Sheet 1 of 7)

2-1-48
 TM 5-3810-307-24-1-1

Figure 2-1-8. Air Conditioner (Superstructure Cab) (Sheet 2 of 7)

2-1-49
TM 5-3810-307-24-1-1

Figure 2-1-8. Air Conditioner (Superstructure Cab) (Sheet 3 of 7)

2-1-50
 TM 5-3810-307-24-1-1

Figure 2-1-8. Air Conditioner (Superstructure Cab) (Sheet 4 of 7)

2-1-51
TM 5-3810-307-24-1-1

Figure 2-1-8. Air Conditioner (Superstructure Cab) (Sheet 5 of 7)

2-1-52
 TM 5-3810-307-24-1-1

Figure 2-1-8. Air Conditioner (Superstructure Cab) (Sheet 6 of 7)

2-1-53
TM 5-3810-307-24-1-1

Figure 2-1-8. Air Conditioner (Superstructure Cab) (Sheet 7 of 7)

2-1-54
 TM 5-3810-307-24-1-1

LEGEND for Figure 2-1-8

1. Refrigerant hose 41. Washer 81. Capscrew 121. Check valve

2. Refrigerant hose 42. Capscrew 82. Lockwasher 122. Gasket
3. Clamp 43. Motor 83. Bracket 123. Thrust plate
4. Clamp 44. Elbow 84. Bracket 124. Pocket seal
5. Nut 45. Tee 85. Cotter pin 125. Thrust plate
6. Lockwasher 46. Adapter 86. Retainer 126. Pocket seal
7. Washer 47. Tee 87. Fan 127. Bearing
8. Condenser 48. Nut 88. Nut 128. Seal ring
9. Capscrew 49. Lockwasher 89. Star washer 129. Snap ring
10. Lockwasher 50. Washer 90. Nut 130. Bearing
11. Cover 51. Capscrew 91. Star washer 131. Retainer
12. Screw 52. Flow divider valve 92. Capscrew 132. Seal
13. Cover 53. Adapter 93. Clamp half 133. Capscrew
14. Capscrew 54. Adapter 94. Fan motor 134. Cover
15. Drive belt 55. Tube 95. Nut 135. Capscrew
16. Refrigerant hose 56. Relief valve 96. Star washer 136. Retainer bar
17. Nut 57. Nut 97. Capscrew 137. Mount bracket
18. Lockwasher 58. Lockwasher 98. Clamp half 138. Screw
19. Washer 59. Washer 99. Drier 139. Retainer plate
20. Capscrew 60. Capscrew 100. Switch 140. Clip
21. Compressor 61. Washer 101. Grommet 141. Fan wheel
22. Nut 62. Bracket 102. Electrical harness 142. Capscrew
23. Lockwasher 63. Nut 103. Case 143. Resistor
24. Washer 64. Lockwasher 104. Capscrew 144. Nut
25. Lockwasher 65. Washer 105. Drive plate 145. Star washer
26. Washer 66. Capscrew 106. Shim 146. Capscrew
27. Bushing 67. Washer 107. Snap ring 147. Clamp half
28. Bracket 68. Evaporator assy. 108. Cover 148. Fan motor
29. Hydraulic hose 69. Refrigerant hose 109. Pulley 149. Capscrew
30. Hydraulic hose 70. Capscrew 110. Screw 150. Thermostat
31. Hydraulic hose 71. Lockwasher 111. Coil 151. Capscrew
32. Hydraulic tube 72. Capscrew 112. Capscrew 152. Side cover
33. Hydraulic tube 73. Lockwasher 113. Washer 153. Coil
34. Capscrew 74. Coil 114. Cover 154. Nut
35. Lockwasher 75. Relay 115. Gear housing 155. Star washer
36. Retainer 76. Screw 116. Bearing 156. Capscrew
37. Key 77. Socket 117. Seal ring 157. Connection block
38. Sheave 78. Capscrew 118. Cover 158. Grommet
39. Nut 79. Lockwasher 119. Gear 159. Electrical harness
40. Lockwasher 80. Mount bracket 120. Shaft 160. Case

b. Assemble condenser assembly (8, Figure 2-1-8) as necessary:

(1) If removed, route electrical harness (102) through hole in case (103), and install grommet (101) over
electrical harness (102) and into hole of case (103).

(2) If removed, install switch (100) in drier (99).

(3) Install drier (99) on bracket in case (103) with clamp halves (98), capscrews (97), star washers (96),
and nuts (95).

(4) Connect electrical leads to switch (100) and remove tags.

2-1-55
TM 5-3810-307-24-1-1

NOTE

Both fan motors are assembled the same. Steps (5) thru (8) apply to either
motor.

(5) Install brackets (83) and clamp halves (93) on motor (94) with capscrews (92), star washers (91),
and nuts (90).

(6) Install bracket (84) on fan motor (94) with star washers (89) and nuts (88).

CAUTION

Fan blades bend easily. Handle fan with care to prevent bending fan blades.

(7) Install fan (87) on shaft of fan motor (94) with retainer (86) and new cotter pin (85).

(8) Install brackets (83 and 84) with motor (94) on mount bracket (80) with lockwashers (82) and
capscrews (81). Ensure ground wire for fan motor (94) is installed under head of one capscrew
(81).

(9) Install mount bracket (80) with fan motors (94) in case (103) with lockwashers (79) and capscrews
(78).

(10) Install relay socket (77) on mount bracket (80) with screw (76) and plug in relay (75).

(11) Connect electrical connectors for fan motors (94). Remove tags.

(12) Install coil (74) in case (103) with lockwashers (71 and 73) and capscrews (70 and 72).

(13) Install refrigerant hose (69) between coil (74) and drier (99).

c. Disassemble compressor (21, Figure 2-1-8) as necessary to replace worn, damaged, or defective
components:

(1) Hold drive plate (105) from turning and remove capscrew (104) from compressor (21).

(2) Using suitable puller, remove drive plate (105) and shim(s) (106) from compressor (21).

(3) Remove snap ring (107) and cover (108) from shaft of compressor (21).

CAUTION

To prevent damage to pulley, ensure claws of bearing puller are hooked into
the top groove of the pulley, not under the grooves.

(4) Using standard gear puller, remove pulley (109) from compressor (21).

(5) Remove grommet and electrical lead for coil (111) from holder on compressor (21), then remove
screws (110), and coil (111) from compressor.

d. Assemble compressor (21, Figure 2-1-8) as necessary:

(1) Install coil (111) on compressor (21) with screws (110).

(2) Install grommet and electrical lead for coil (111) in holder on compressor (21).

2-1-56
 TM 5-3810-307-24-1-1

(3) Using hand press, install pulley (109) onto shaft of compressor (21).

(4) Install cover (108) and snap ring (107) on shaft of compressor (21).

NOTE

Ensure chamfered inner edge of snap ring faces outward.

(5) Install shim(s) (106) and drive plate (105) on compressor (21). Press drive plate down as far as
possible by hand, install capscrew (104), and torque to 9 to 10 lbs-ft (12 to 14 Nm).

(6) Measure for drive plate clearance of 0.01 to 0.02 in. (0.3 to 0.6 mm). Adjust thickness of shims
(106) to achieve clearance.

e. Disassemble motor (43, Figure 2-1-8) as necessary to replace worn, damaged, or defective components:

(1) Mount motor (43) in a vise with shaft end pointed down and match mark all sections.

(2) Remove capscrews (112) and washers (113) securing sections together.

CAUTION

If necessary to pry sections apart, be careful not to mar or damage machined

surfaces.

(3) Remove cover (114) from gear housing (115). If necessary pry loose with two large flat tip
screwdrivers.

(4) Using standard bearing puller, remove bearings (116) from cover (114).

(5) Using standard seal removal tool, remove seal ring (117) from cover (114). Discard seal ring.

(6) Remove gear housing (115) from gear (119), shaft (120), and cover (118).

(7) Carefully remove gear (119) and shaft (120) from cover (118).

NOTE

Gear (119) and shaft (120) are a matched set and must be replaced as a set.
Mark gear (119) to ensure it is installed in the same direction as removed
during assembly.

(8) Only if necessary, use drill bit of the same diameter as check valve (121) to drill out peened material
from hole for check valve (121), and unscrew check valve (121) from cover (118).

(9) Remove gaskets (122), thrust plate (123), and pocket seals (124) from gear housing (115). Remove
pocket seal from thrust plate (123) and discard all pocket seals and gaskets.

(10) Being careful not to distort thrust plate (125) or damage machined surface of cover (118), pry thrust
plate (125) from cover (118).

(11) Remove pocket seals (126) from cover (118) and thrust plate (125). Discard all pocket seals.

(12) Using standard bearing puller, remove bearings (127) from cover (118).

2-1-57
TM 5-3810-307-24-1-1

(13) Using standard seal removal tool, remove seal ring (128) from cover (118). Discard seal ring.

(14) Remove snap ring (129), and using a standard bearing puller, remove bearing (130) from cover
(118).

(15) Using standard seal removal tool, remove retainer (131) and seal (132) from cover (118). Discard
retainer and seal.

f. Assemble motor (43, Figure 2-1-8) as necessary:

WARNING
Compressed air used for cleaning can create airborne particles that may enter
the eyes. Wear safety goggles and limit air pressure to 30 psi (207 kPa).

(1) Stone off all machined surfaces with a medium grit carborundum stone, deburr bearing bores, rinse
parts in solvent, dry parts with compressed air, and wipe with a clean, lint-free cloth.

(2) Coat outer edge of new seal (132) and its recess with Form-a-Gasket No. 3 non-hardening sealant,
and press seal (132) into cover (118) until seal is flush with face of recess. Wipe off extra sealant.

(3) Press new retainer (131) and bearing (130) into cover (118), then install snap ring (129).

(4) If removed, install check valve (121) in cover (118) and peen edge of hole with a 1 in. (3.8 cm)
steel ball.

(5) Press new seal ring (128) into shaft bearing hole of cover (118) ensuring notch in ring will be next to
bearing (127).

(6) Press bearings (127) into cover (118).

(7) Cut two pocket seals (126) 7/32 in. (5.5 mm) long, grease seals well with multi-purpose grease, and
install them in the middle slots on the reverse side of thrust plate (125).

(8) With pocket seals (126) facing down, position thrust plate (125) over bearings (127), and tap thrust
plate down to approximately 1/32 in. (0.8 mm) from machined surface of cover (118).

(9) Cut four pocket seals (126) 1/4 in. (6.4 mm) long and insert one pocket seal into each slot in thrust
plate (125). Press pocket seals down until they touch bearings (127), tap thrust plate down firmly
against machined surface of cover (118), and trim pocket seals flush with top of thrust plate.

(10) Tape splined end of shaft (120), lightly grease tape and shaft, and insert shaft into cover (118) with a
twisting motion until gear of shaft rests against thrust plate (125). Remove tape.

(11) Insert gear (119), as marked during disassembly, into cover (118) meshing gears with gears on
shaft (120).

(12) Apply multipurpose grease to new gaskets (122) and install gaskets in grooves on both sides of gear
housing (115).

(13) Carefully install gear housing (115) over shaft (120) and gear (119), line up match marks on cover
(118) with marks on gear housing (115), and gently tap gear housing with a plastic hammer until
seated against cover (118). Squirt oil over gears to provide initial lubrication for pump.

2-1-58
 TM 5-3810-307-24-1-1

(14) Cut two pocket seals (124) 7/32 in. (5.5 mm) long, grease seals well with multi-purpose grease, and
install them in the middle slots on the reverse side of thrust plate (123).

(15) With pocket seals (124) facing down, position thrust plate (123) over shaft (120) and gear (119), and
tap thrust plate down to approximately 1/32 in. (0.8 mm) from machined surface of gear housing
(115).
(16) Cut four pocket seals (124) 1/4 in. (6.4 mm) long and insert one pocket seal into each slot in thrust
plate (123). Press pocket seals down until they touch gears, tap thrust plate down firmly against
machined surface of gear housing (115), and trim pocket seals flush with top of thrust plate.

(17) Press new seal ring (117) into shaft bearing hole in cover (114) ensuring notch in ring will be next to
bearing (116).

(18) Press bearings (116) into cover (114).

(19) Carefully install cover (114) over drive shaft (120) and gear shaft (119), line up match marks on
cover (114) with marks on gear housing (115), and gently tap cover with a plastic hammer until
seated against gear housing (115).

(20) Install washers (113) and capscrews (112), and cross-tighten capscrews.

(21) Rotate drive shaft (120) to ensure there is no binding in motor.

g. Disassemble evaporator assembly (68, Figure 2-1-8) as necessary to replace worn, damaged, or defective
components:

(1) Remove capscrews (133) and cover (134) from case (160).

(2) Remove capscrews (135) and retainer bar (136) securing mount bracket (137) from case (160).

(3) Tag and disconnect electrical connectors (159) for fan motor (148) and resistor (143), then lift mount
bracket (137) with fan motor (148) from case (160).

(4) Remove screws (138) and retainer plates (139) from mount bracket (137).

(5) Remove clips (140) and fan wheels (141) from shafts of motor (148).

(6) Remove capscrews (142) and resistor (143) from right side of mount bracket (137).

(7) Remove nuts (144), star washers (145), capscrews (146), clamp halves (147), and fan motor (148)
from mount bracket (137).

(8) Tag and disconnect electrical leads for thermostat (150).

(9) Pull thermostat sensor lead from coil (153), remove capscrews (149) and thermostat (150) from
case (160).

(10) Remove capscrews (151) and side cover (152) from case (160).

(11) Disconnect refrigerant tubes for coil (153) from connection block (157), and lift coil (153) out of case
(160).

(12) Remove nuts (154), star washers (155), capscrews (156), and connection block (157) from case
(160).

(13) Remove grommet (158) and electrical harness (159) from case (160).

2-1-59
TM 5-3810-307-24-1-1

h. Assemble evaporator assembly (68, Figure 2-1-8) as necessary:

(1) Insert electrical harness (159) through side of case (160), and install grommet (158) over harness
and into hole of case.

(2) Install connection block (157) on side of case (160) with capscrews (156), star washers (155), and
nuts (154).

(3) Position coil (153) in case (160), and connect refrigerant tubes for coil to connection block (157).

(4) Install side cover (152) on case (160) with capscrews (151).

(5) Install thermostat (150) on side wall of case (160) with capscrews (149), and insert thermostat
sensor lead into center of coil (153).

(6) Connect electrical leads to thermostat (150) and remove tags.

(7) Install fan motor (148) on mount bracket (137) with clamp halves (147), capscrews (146), star
washers (145), and nuts (144).

(8) Install resistor (143) in right side of mount bracket (137) with capscrews (142).

(9) Install fan wheels (141) on shafts of fan motor (148) with clips (140).

(10) Install retainer plates (139) on mount bracket (137) with screws (138).

(11) Position mount bracket (137) with fan motor (148) in case (160), connect electrical connectors for
fan motor (148) and resistor (143), and remove tags.

(12) Secure mount bracket (137) in case (160) with retainer bar (136) and capscrews (135).

(13) Install cover (134) on case (160) with capscrews (133).

Installation

a. Install condenser assembly as follows:

(1) Place condenser assembly (8, Figure 2-1-8, Sheet 1) on carrier spare tire.

(2) Insert refrigerant hoses (1 and 2) through side of condenser assembly (8), connect refrigerant
supply hose (1) to drier (99) and return hose (2) to condenser coil (74).

(3) Install cover (11) on condenser assembly (8) with lockwashers (10) and capscrews (9).

(4) Install condenser assembly (8) in mounting brackets with washers (7), lockwashers (6), and nuts (5).

(5) Position refrigerant hoses (1 and 2) in clamps (3 and 4), close, and secure clamps.

(6) Connect electrical connector for condenser (8).

(7) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 3.5 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.

(8) Install access cover (13) on compressor/motor mounting bracket with screws (12).

2-1-60
 TM 5-3810-307-24-1-1

(9) Install left side turntable access panel.

b. Install compressor as follows:

(1) If removed, install bracket (28, Figure 2-1-8, Sheet 2) on compressor/motor mounting bracket as
marked during removal, with capscrews (20), washers (19), lockwashers (18), and nuts (17).

(2) Install compressor (21) on bracket (28) with adjustment capscrew bushing (27), washers (26),
lockwashers (25), capscrews (14), washers (24) lockwashers (23), and nuts (22). Do not tighten
mounting hardware at this time.

(3) Connect refrigerant supply hose (16) and refrigerant return hose (2) to compressor (18). Remove
tags.

(4) Connect electrical connector and ground wire for compressor (21).

(5) Position drive belt (15) on inner pulley groove of compressor (21), adjust belt tension by pressing
down on compressor until there is approximately 1/2 inch deflection in belt at mid span, and tighten
capscrews (14) securing compressor to mount (28).

(6) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 3.5 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.

(7) Install access cover (13) on compressor/motor mounting bracket with screws (12).

c. Install motor as follows:

(1) If removed, install tee (47, Figure 2-1-8, Sheet 2), adapter (46), tee (45), and elbow (44) on motor
(43).

(2) Install motor (43) on compressor/motor mounting bracket with capscrews (42), washers (41),
lockwashers (40), and nuts (39).

(3) Install sheave (38) on motor (43) with key (37), retainer (36), lockwashers (35), and capscrews (34).

(4) Install hydraulic tubes (32 and 33) on adapters (53 and 54) at valve (52) and tee (45) and elbow (44)
at rear of motor (43).

(5) Connect hydraulic hose (31) to tee (45) at rear of motor (43).

(6) Connect hydraulic hoses (29 and 30) to tee (47) and adapter (46) at top of motor (43).

(7) Position drive belt on pulley of motor (43), and if compressor (21) is not removed, adjust belt tension
by pressing down on compressor until there is approximately 1/2 inch deflection in belt at mid span,
and tighten capscrews (14) securing compressor to mount (28).

(8) If compressor is not removed, install cover (13) on compressor/motor mounting bracket with screws
(12).

d. Install flow divider valve as follows:

(1) If removed, install bracket (62, Figure 2-1-8, Sheet 2) on compressor/motor mounting bracket with
washer (61), capscrew (60), washer (59), lockwasher (58), and nut (57).

(2) If removed, install relief valve (56), tube (55), and adapters (54 and 53) on flow divider valve (52).

2-1-61
TM 5-3810-307-24-1-1

(3) Install flow divider valve (52) on bracket (62) with capscrews (51), washers (50), lockwashers (49),
and nuts (48).

(4) If motor is not removed, install hydraulic tubes (32 and 33) on adapters (53 and 54) at valve (52) and
tee (45) and elbow (44) at rear of motor (43).

(5) Connect hose (30) to tube (55) at front of valve (52).

e. Install evaporator as follows:

(1) Position evaporator assembly (68, Figure 2-1-8, Sheet 3) to brackets on rear interior wall of cab and
secure with washers (67), capscrews (66), washers (65), lockwashers (64), and nuts (63).

(2) Connect refrigerant hoses (1 and 16) to right side of evaporator (68).

(3) Connect electrical lead for evaporator (68).

(4) If no other air conditioner components are removed, evacuate and charge air conditioner system
with 3.5 lbs of R-134a refrigerant and 5 oz. of refrigeration oil, refer to instructions for assigned
charging system and Appendix B.

2-1-62
 TM 5-3810-307-24-1-1

TILT STEERING COLUMN (CARRIER CAB)

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Disconnect electrical connector for tilt steering column (17, Figure 2-1-9).

c. Remove capscrews (1), lockwashers (2 and 5), washers (3 and 6), nuts (4), bracket (7), filler plate (8), and
clamp (9) securing tilt steering column (17) to cab weldment (18) and dash panel.

NOTE

Prior to disconnecting tilt steering column from steering shaft, position steering
wheel so spokes are horizontal.

d. Remove nut (10) and capscrew (11) securing tilt steering column (17) to steering shaft (12).

e. Remove nuts (13), lockwashers (14), washers (15), and tilt steering column (17) from cab weldment (18).

Repair

a. Replace steering wheel and/or horn as follows (may be accomplished with steering column installed):

(1) Ensure battery disconnect switch is in OFF position.

(2) Remove horn cover (19, Figure 2-1-9) from steering wheel (22).

(3) Disconnect electrical lead from horn button (20) and remove horn button from steering wheel (22).

(4) Remove nut (21) and using wheel puller, remove steering wheel (22) from steering column.

(5) Slide collar (23) off steering column and remove horn spring and plate assembly (24).

(6) Replace all worn, damaged, or defective parts.

(7) Position horn spring and plate assembly (24) on steering column and slide collar (23) onto column
maintaining downward pressure to hold parts in place.

(8) Install steering wheel (22) on steering column with nut (21) ensuring electrical lead for horn button
(20) is inserted through hole provided in steering wheel hub. Torque nut (21) to 110 lbs-ft (149 Nm).

(9) Connect electrical lead to horn button (20) and install cover (19).

b. Replace turn signal/hazard switch as follows (may be accomplished with steering column and steering
wheel installed):

(1) Ensure battery disconnect switch is in OFF position.

(2) Remove upper cover (25, Figure 2-1-9) and lower cover (26) from steering column.

(3) Tag and disconnect electrical leads to turn signal/hazard switch (29).

(4) Remove screws (27), lockwashers (28), and turn signal/hazard switch (29) from steering column.

2-1-63
TM 5-3810-307-24-1-1

LEGEND

1. Capscrew 10. Nut 20. Horn button

2. Lockwasher 11. Capscrew 21. Nut
3. Washer 12. Steering shaft 22. Steering wheel
4. Nut 13. Nut 23. Collar
5. Lockwasher 14. Lockwasher 24. Spring and plate assy
6. Washer 15. Washer 25. Upper cover
7. Bracket 16. Capscrew 26. Lower cover
8. Filler plate 17. Steering column 27. Screw
9. Clamp 18. Cab weldment 28. Lockwasher
19. Horn cover 29. Turn sig/hazard switch

Figure 2-1-9. Tilt Steering Column (Carrier Cab)

2-1-64
 TM 5-3810-307-24-1-1

(5) Install new turn signal/hazard switch (29) on steering column with lockwashers (28) and screws (27).

(6) Connect electrical leads to turn signal/hazard switch (29), remove tags, and install upper cover (25)
and lower cover (26) on steering column. Ensure covers are secure by snapping slots in covers
onto studs on steering column.

Installation

a. Insert tilt steering column (17, Figure 2-1-9) through cab weldment (18) and secure to weldment with
capscrews (16), lockwashers (15), washers (14), and nuts (13).

NOTE

Prior to sliding splines of steering shaft onto tilt steering column, position
steering wheel so spokes are horizontal.

b. Slide splines of steering shaft (12) onto tilt steering column (17) and secure with capscrew (11) and nut
(10).

c. Position clamp (9), filler plate (8), and bracket (7) to cab weldment (18) and dash panel ensuring clamp
ends extend through bracket (7).

d. Secure bracket (7), filler plate (8) and clamp (9) with washers (3 and 6), lockwashers (2 and 5), nuts (4)
and capscrews (1).

e. Connect electrical connector for tilt steering column (17).

2-1-65
TM 5-3810-307-24-1-1

TILT STEERING COLUMN AND STEERING CONTROL VALVE (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Disconnect electrical connector for tilt steering column (15, Figure 2-1-10).

c. Remove capscrews (1), lockwashers (2 and 5), washers (3 and 6), nuts (4), bracket (7), filler plate (8), and
clamp (9) securing tilt steering column (15) to cab weldment (16) and dash panel.

d. Tag, disconnect, and cap hydraulic lines (10) from steering valve (11).

e. Support steering valve (11), remove capscrews (12), lockwashers (13), washers (14), tilt steering column
(15), and steering valve (11) from cab weldment (16).

Repair

a. Replace steering wheel and/or horn as follows (may be accomplished with steering column installed):

(1) Ensure battery disconnect switch is in OFF position.

(2) Remove horn cover (19, Figure 2-1-10) from steering wheel (22).

(3) Disconnect electrical lead from horn button (20) and remove horn button from steering wheel (22).

(4) Remove nut (21) and using wheel puller, remove steering wheel (22) from steering column.

(5) Slide collar (23) off steering column and remove horn spring and plate assembly (24).

(6) Replace all worn, damaged, or defective parts.

(7) Position horn spring and plate assembly (24) on steering column and slide collar (23) onto column
maintaining downward pressure to hold parts in place.

(8) Install steering wheel (22) on steering column with nut (21) ensuring electrical lead for horn button
(20) is inserted through hole provided in steering wheel hub. Torque nut (21) to 110 lbs-ft (149 Nm).

(9) Connect electrical lead to horn button (20) and install cover (19).

b. Replace turn signal/hazard switch as follows (may be accomplished with steering column and steering
wheel installed):

(1) Ensure battery disconnect switch is in OFF position.

(2) Remove upper cover (25, Figure 2-1-10) and lower cover (26) from steering column.

(3) Tag and disconnect electrical leads to turn signal/hazard switch (29).

(4) Remove screws (27), lockwashers (28), and turn signal/hazard switch (29) from steering column.

2-1-66
 TM 5-3810-307-24-1-1

LEGEND

1. Capscrew 10. Hydraulic line 19. Nut

2. Lockwasher 11. Steering valve 20. Steering wheel
3. Washer 12. Capscrew 21. Collar
4. Nut 13. Lockwasher 22. Spring and plate assy
5. Lockwasher 14. Washer 23. Upper cover
6. Washer 15. Steering column 24. Lower cover
7. Bracket 16. Cab weldment 25. Screw
8. Filler plate 17. Horn cover 26. Lockwasher
9. Clamp 18. Horn button 27. Turn sig/hazard switch

Figure 2-1-10. Tilt Steering Column (Superstructure Cab)

2-1-67
TM 5-3810-307-24-1-1

(5) Install new turn signal/hazard switch (29) on steering column with lockwashers (28) and screws (27).

(6) Connect electrical leads to turn signal/hazard switch (29), remove tags, and install upper cover (25)
and lower cover (26) on steering column. Ensure covers are secure by snapping slots in covers
onto studs on steering column.

Installation

a. Position steering valve (11, Figure 2-1-10) below cab weldment (16), insert tilt steering column (15)
through cab weldment (16), and into splines of steering valve (11).

b. Secure tilt steering column (15) and steering valve (11) to cab weldment (16) with capscrews (12),
lockwashers (13), and washers (14).

c. Remove caps and connect hydraulic lines (10) to steering valve (11).

d. Position clamp (9), filler plate (8), and bracket (7) to cab weldment (16) and dash panel ensuring clamp
ends extend through bracket (7).

e. Secure bracket (7), filler plate (8) and clamp (9) with washers (3 and 6), lockwashers (2 and 5), nuts (4)
and capscrews (1).

f. Connect electrical connector for tilt steering column (15).

2-1-68
 TM 5-3810-307-24-1-1

DEFROSTER CONTROL (CARRIER CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Loosen clamp securing defroster control cable (1, Figure 2-1-11) to bottom of heater and remove cable
from clamp.

c. Disconnect defroster control cable (1) from lever at bottom of heater (under cab).

d. Unscrew knob (2) from defroster control cable (1).

e. Remove nuts (3 and 4), and push defroster control cable (1) out of dash panel.

f. Remove washer (5) from defroster control cable (1), so it does not fall off cable and get lost.

g. Remove all cable ties/clamps securing defroster control cable (1) to carrier, and remove cable from carrier.

Installation

a. Position defroster control cable (1, Figure 2-1-11) in carrier, and secure with all cable ties/clamps removed
during removal procedures.

b. Place washer (5) on defroster control cable (1) and insert cable through hole in dash panel.

c. Secure defroster control cable (1) to dash panel with nuts (4 and 6).

d. Install knob (2) on defroster control cable (1) and tighten nut (3) to knob.

e. Insert defroster control cable (1) through clamp at bottom of heater and connect cable to lever.

NOTE

Ensure control cable knob is pushed all the way in and lever on bottom of
heater is positioned as far as possible toward left side of vehicle before
tightening clamp.

f. Pull slack from cable and tighten clamp at heater to secure defroster control cable to heater.

2-1-69
TM 5-3810-307-24-1-1

LEGEND

1. Defroster control cable 4. Retaining nut

2. Knob, cable 5. Washer
3. Jam nut 6. Jam nut

Figure 2-1-11. Defroster Control (Carrier Cab)

2-1-70
 TM 5-3810-307-24-1-1

HEATER CONTROL (CARRIER CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Loosen clamp and disconnect heater control cable (1, Figure 2-1-12) from lever on heater shutoff valve at
left side of heater.

c. Unscrew knob (2) from heater control cable (1).

d. Remove nuts (3 and 4), and push heater control cable (1) out of dash panel.

e. Remove washer (5) from heater control cable (1), so it does not fall off and get lost.

f. Remove all cable ties/clamps securing heater control cable (1) to carrier, and remove cable from carrier.

Installation

a. Position heater control cable (1, Figure 2-1-12) in carrier, and secure with all cable ties/clamps removed
during removal procedures.

b. Place washer (5) on heater control cable (1) and insert cable through hole in dash panel.

c. Secure heater control cable (1) to dash panel with nuts (4 and 6).

d. Install knob (2) on heater control cable (1) and tighten nut (3) to knob.

NOTE

Ensure control cable knob is pushed all the way in and lever on shutoff valve is
positioned as far as possible toward rear of vehicle before tightening clamp.

e. Connect heater control cable (1) to lever on heater shutoff valve, pull slack from cable, and tighten clamp.

2-1-71
TM 5-3810-307-24-1-1

LEGEND

1. Heater control cable 4. Retaining nut

2. Knob, cable 5. Washer
3. Jam nut 6. Jam nut

Figure 2-1-12. Heater Control (Carrier Cab)

2-1-72
 TM 5-3810-307-24-1-1

CONTROL ASSEMBLY, TRAILER AIR SUPPLY AND PARKING BRAKE (CARRIER CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Relieve system air pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are drained.
Wear eye protection when disconnecting air lines to prevent injury.

c. Tag and disconnect air lines (1, 2, and 3, Figure 2-1-13) from connectors (8, 9, and 10).

d. Unscrew TRAILER AIR SUPPLY knob (4) and PARKING BRAKE knob (5) from control assembly (7).

e. Support control assembly (7), remove screws (6) and control assembly (7) from dash panel.

f. If necessary, remove connectors (8, 9, and 10) from control assembly (7).

Repair
WARNING
Be careful to maintain and release pressure slowly when removing retaining
caps. Internal components are assembled with spring tension and could cause
personal injury if allowed to pop free.

a. Remove retaining caps (11, Figure 2-1-13) from control body (33).

b. Remove holders (12), spools (13), seals (14), and springs (15) from control body (33). Discard seals and
springs.

c. Remove o-rings (16 and 17) from holders (12). Discard o-rings.

d. Remove o-rings (18, 19, and 20) from spools (13). Discard o-rings.

NOTE

If spools show excessive wear or damage, do not proceed with remaining

steps. Control assembly (7) must be replaced.

WARNING
Be careful to maintain and release pressure slowly when removing retaining
plug. Internal components are assembled with spring tension and could cause
personal injury if allowed to pop free.

e. Remove retaining plug (21) from control body (33).

2-1-73
TM 5-3810-307-24-1-1

LEGEND

1. Air line 12. Holder 23. Spring

2. Air line 13. Spool 24. Spring
3. Air line 14. Seal 25. Check valve
4. Knob, trailer air 15. Spring 26. O-ring
5. Knob, parking brake 16. O-ring 27. O-ring
6. Machine screw 17. O-ring 28. Retaining ring
7. Control assembly 18. O-ring 29. Shuttle valve
8. Connector 19. O-ring 30. O-ring
9. Connector 20. O-ring 31. O-ring
10. Connector 21. Retaining plug 32. O-ring
11. Retaining cap 22. Sleeve 33. Control body

Figure 2-1-13. Trailer Air Supply and Parking Brake Control Assy (Carrier Cab) (Sheet 1 of 2)

2-1-74
 TM 5-3810-307-24-1-1

Figure 2-1-13. Trailer Air Supply and Parking Brake Control Assy (Carrier Cab) (Sheet 2 of 2)

2-1-75
TM 5-3810-307-24-1-1

f. Remove sleeve (22), springs (23 and 24), and check valve (25) from control body (33). Discard springs
and check valve.

g. Remove o-ring (26) from plug (21) and o-ring (27) from sleeve (22). Discard o-rings.

h. Remove retaining ring (28) and shuttle valve (29) from control body (33). Discard shuttle valve and
retaining ring.

i. Install new o-rings (30, 31, and 32) on new shuttle valve (29).

j. Install shuttle valve (29) in control body (33) and secure with retaining ring (28).

k. Install new o-ring (27) on sleeve (22) and new o-ring (26) on retaining plug (21).

l. Insert new check valve (25), new springs (24 and 23), and sleeve (22) in control body (33). Secure
components in control body with retaining plug (21).

m. Install new o-rings (18, 19, and 20) on spools (13).

n. Install new o-rings (16 and 17) on holders (12).

o. Insert new springs (15), new seals (14), spools (13), and holders (12) in control body (33). Secure
components in control body with retaining caps (11).

Installation

a. If removed, install connectors (8, 9, and 10, Figure 2-1-13) in control assembly (7).

b. Position control assembly (7) in dash panel, and secure with screws (6).

c. Install PARKING BRAKE knob (5) and TRAILER AIR SUPPLY knob (4) on control assembly (7). Tighten
knobs until fully seated, then position so text is upright.

d. Connect air lines (1, 2, and 3) to connectors (8, 9, and 10).

e. Close air reservoir drain valves (petcocks).

Operating and Leakage Check

NOTE

If the park brake control valve does not operate as described, or leakage is
excessive, it is recommended that it be replaced.

a. Chock the wheels and fully charge the air system.

b. With the PARK BRAKE control pulled out (exhaust position), coat the exhaust port and plunger stem with a
soap solution. A 1 in. (254 cm) bubble in five seconds is permitted. There should be no leakage between the
upper and lower body.

c. Push the PARK BRAKE control in (applied position). A 1 in. (254 cm) bubble in three seconds is
permitted.

d. Reduce system air pressure and observe the PARK BRAKE control. It should pop out when the air
pressure drops to approximately 40 psi (275 kPa), exhausting the delivery line and engaging the park brakes.

2-1-76
 TM 5-3810-307-24-1-1

HEATER CONTROL (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Unplug heater power cord plug from receptacle at front of heater (under cab).

c. Loosen clamp (4, Figure 2-1-6) securing heater control cable (7, Figure 2-1-14) to front of heater and
remove cable from clamp.

d. Disconnect heater control cable (7) from lever at front of heater.

e. Remove two clamps securing heater control cable to bottom of cab.

f. Unscrew knob (4) from heater control cable (7).

g. Remove nuts (5 and 6), and push heater control cable (7) out of cab.

h. Remove screws (1), pull heater control panel (2) from cab wall, and disconnect electrical connector for
control.

i. Remove heater control panel (2) with cord and shims (3) from cab.

Installation

a. Position shims (3, Figure 2-1-14) and heater control panel (2) with power cord on cab wall.

b. Connect electrical connector for heater control panel (2) and secure heater control panel (2) and shims (3)
to cab wall with screws (1).

c. Insert heater control cable (7) through hole in cab mounting bracket and secure with nuts (5, 6, and 8).

d. Install knob (4) on heater control cable (7). Ensure knob (4) is pushed all the way in.

e. Insert heater control cable (7) through clamp (4, Figure 2-1-6) and connect cable to heater lever (under
cab). Ensure lever is positioned as far to the left as possible.

f. Pull slack from control cable (7, Figure 2-1-14) between heater lever and clamp (4, Figure 2-1-6), then
tighten clamp (4) to secure heater control cable (7, Figure 2-1-14) to heater.

g. Plug heater power cord plug into receptacle at front of heater (under cab).

h. Secure heater control cable (7) to bottom of cab with the two clamps removed during removal procedures.

2-1-77
TM 5-3810-307-24-1-1

LEGEND

1. Screw, self-tapping 5. Jam nut

2. Heater control panel 6. Retaining nut
3. Shim 7. Heater control cable
4. Knob, heater cable 8. Retaining nut

Figure 2-1-14. Heater Control (Superstructure Cab)

2-1-78
 TM 5-3810-307-24-1-1

PARKING BRAKE CONTROL (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.

c. Loosen setscrews (3, Figure 2-1-15) and remove knob (4) from control assembly (7).

d. Remove retaining nut (5), shim washer (6) and push control assembly (7) from dash panel.

e. Tag and disconnect air lines (1 and 2) from elbows (8 and 9).

f. If necessary, remove elbows (8 and 9) from control assembly (7).

Installation

a. If removed, install elbows (8 and 9, Figure 2-1-15) in control assembly (7).

b. Connect air lines (1 and 2) on elbows (8 and 9) and remove tags.

c. Position control assembly (7) in dash panel and secure with retaining nut (5) and shim washer (6).

d. Install knob (4) on control assembly (7) and tighten setscrews (3).

e. Close drain valves on air reservoirs.

Operating and Leakage Check

NOTE

If the park brake control valve does not operate as described, or leakage is
excessive, it is recommended that it be replaced.

a. Chock the wheels and fully charge the air system.

b. With the PARK BRAKE control pulled out (exhaust position), coat the exhaust port and plunger stem with a
soap solution. A 1 in. (254 cm) bubble in five seconds is permitted. There should be no leakage between the
upper and lower body.

c. Push the PARK BRAKE control in (applied position). A 1 in. (254 cm) bubble in three seconds is
permitted.

d. Reduce system air pressure and observe the PARK BRAKE control. It should pop out when the air
pressure drops to approximately 40 psi (275 kPa), exhausting the delivery line and engaging the park brakes.

2-1-79
TM 5-3810-307-24-1-1

LEGEND

1. Air line 4. Knob 7. Control assembly

2. Air line 5. Retaining nut 8. Elbow, 900
3. Setscrew 6. Shim Washer 9. Elbow, 900

Figure 2-1-15. Parking Brake Control (Superstructure Cab)

2-1-80
 TM 5-3810-307-24-1-1

THROTTLE FAST/SLOW CONTROL (SUPERSTRUCTURE CAB)

Removal

a. Remove screws (1, Figure 2-1-16), washers (2) and clamp (3) securing throttle cable (8) to cab weldment.

b. Remove clip (10) and pin (11). Then loosen nut (4) and remove clevis (12) from cable (8).

c. Remove nut (5), washer (6), lockwasher (7), and throttle cable (8) from dash panel.

d. Remove clip (14) and pin (13). Then disconnect cable (15) from bracket (24).

e. Remove clip (16), pin (17), and roller (18) from clevis (20).

f. If necessary, loosen nut (19) and remove clevis (20) and nut (19) from stud in cab floor.

g. If necessary, remove nuts (21), lockwashers (22), screws (23), and bracket (24) from air throttle pedal.

Repair

Replace all worn, damaged, defective parts.

Installation

a. If removed, install bracket (24, Figure 2-1-16) on air throttle pedal with screws (23), lockwashers (22), and
nuts (21).

b. If removed, install nut (19) and clevis (20) on stud in cab floor. Do not tighten nut (19) at this time.

c. Attach cable (15) to bracket (24) with pin (13) and clip (14).

d. Install throttle cable (8) in dash panel with lockwasher (7), washer (6), nut (5), and nut (9). Then install nut
(4) and clevis (12) on end of throttle cable (8).

e. Route cable (15) through clevis (20), and install roller (18) in clevis (20) with pin (17) and clip (16).

f. Attach clevis (12) to cable (15) with pin (11) and clip (10).

Adjustment

a. Ensure knob of throttle cable (8, Figure 2-1-16) is pushed all the way in until all slack is out of cables
without moving throttle pedal. If necessary, remove clip (10) and pin (11) and reposition clevis (12). Then install
pin (11) and clip (10) and recheck throttle cable travel. Tighten nut (4).

b. Ensure clevis (20) is positioned so cable (15) runs smoothly on roller (18) when knob is moved in and out,
then tighten nut (19).

c. Secure throttle cable (8) to cab weldment with clamp (3), washers (2), and screws (1).

2-1-81
TM 5-3810-307-24-1-1

LEGEND

1. Screw 9. Nut 17. Pin

2. Washer 10. Clip 18. Roller
3. Clamp 11. Pin 19. Nut
4. Nut 12. Clevis 20. Clevis
5. Nut 13. Pin 21. Nut
6. Washer 14. Clip 22. Lockwasher
7. Lockwasher 15. Cable 23. Screw
8. Throttle cable 16. Clip 24. Bracket

Figure 2-1-16. Throttle Control (Superstructure Cab)

2-1-82
 TM 5-3810-307-24-1-1

SWING LOCK CONTROL (SUPERSTRUCTURE CAB)

Removal

a. Rotate boom over the left side to allow access to swing lock pin from under the superstructure cab. Shut
down diesel engine and position battery disconnect switch to OFF.
WARNING
Engage positive swing lock, using the positive swing lock handle, to ensure
turntable does not move during maintenance. Refer to Operator's Manual, TM
5-3810-307-10 for definition and operation of positive swing lock and positive
swing lock handle.

b. Remove clip (14, Figure 2-1-16), pin (13), clip (16), pin (17), roller (18), and move cable (15) aside.

c. Remove capscrews (1, Figure 2-1-17), lockwashers (2), mounting plate (3), and clamp (4) securing cable
(5) to side wall of cab.

d. Move handle of swing lock control (13) to the LOCKED position so clevis (6) is accessible under
superstructure cab.

e. Loosen nut (7), remove clevis (6) with chain assembly (23) and swing lock pin (24), and nut (7) from cable
(5).

f. Remove screws (8), collars (9), nut (10), lockwasher (11), washer (12), and swing lock control (13) with
bracket (16) and cable (5) from dash panel.

NOTE

It may be necessary to remove mounting hardware for shift control to gain

access to upper mounting hardware for swing lock control, refer to Shift Control
Assembly (Superstructure Cab) Removal procedures.

g. Remove nuts (14), screws (15), and bracket (16) from swing lock control (13).

h. If necessary, remove clamp (17) and boot (18) from cab floor, and clamp (19) and guide (20) from boot
(18).

i. If necessary, remove clip (21), pin (22), and clevis (6) from chain assembly (23).

j. If necessary, remove swing lock pin (24) from chain assembly (23).

Repair

Replace all worn, damaged, and defective parts.

2-1-83
TM 5-3810-307-24-1-1

LEGEND

1. Screw, allen head 9. Collar 17. Clamp

2. Lockwasher 10. Nut 18. Boot
3. Plate, mounting 11. Lockwasher 19. Clamp
4. Clamp 12. Washer 20. Guide
5. Cable 13. Swing lock control 21. Clip
6. Clevis 14. Nut 22. Pin
7. Nut 15. Screw 23. Chain assembly
8. Screw 16. Bracket 24. Swing lock pin

Figure 2-1-17. Swing Lock Control (Superstructure Cab)

2-1-84
 TM 5-3810-307-24-1-1

Installation

a. If removed, apply LOCTITE 272 to threads of chain assembly (23, Figure 2-1-17), and install chain
assembly (23) in swing lock pin (24).

b. If removed, install clevis (6) on chain assembly (23) with pin (22) and clip (21).

c. If removed, install guide (20) in top of boot (18) with clamp (19), and secure boot (18) to cab floor with
clamp (17).

d. Install bracket (16) on swing lock control (13) with screws (15) and nuts (14).

e. Insert cable (5) through dash panel and route cable through boot (18) so cable extends through floor of
cab.

f. Secure swing lock control (13) with bracket (16) to dash panel with collars (9), screws (8), washer (12),
lockwasher (11), and nut (10).

NOTE

If mounting hardware for shift control was removed, secure shift control to dash
panel, refer to Shift Control Assembly (Superstructure Cab) Installation
procedures.

g. Install nut (7) and clevis (6) with chain assembly (23) and swing lock pin (24) on cable (5). Screw clevis
(6) onto cable (5) until approximately 1/2 in. of cable threads extend through clevis, then tighten nut (7) onto
clevis (6).

h. Place handle of swing lock control (13) in the UNLOCKED position, and install clamp (4) over cable (5)
and onto side wall of cab with mounting plate (3), lockwashers (2), and capscrews (1). Do not tighten capscrews
(1).

i. Pull up on cable (5) until swing lock pin (24) bottoms out in the up position, and tighten capscrews (1).

j. Install cable (15, Figure 2-1-16) with pin (13) and clip (14), and roller (18) with pin (17) and clip (16).

k. Disengage positive swing lock, using positive swing lock handle, start engine and carefully rotate boom
over front of carrier ensuring swing lock pin clears carrier.

l. Operate swing lock control several time to ensure proper operation and shut down engine.

2-1-85
TM 5-3810-307-24-1-1

SHIFT CONTROL ASSEMBLY (CARRIER CAB)

Removal

a. Ensure battery disconnect is in OFF position.

b. Remove screws (1, Figure 2-1-18) and lockwashers (2) securing shift control assembly (3) in side console.

c. Lift shift control assembly (3), disconnect electrical connector, and remove shift control assembly from side
console.

Installation

a. Position shift control assembly (3, Figure 2-1-18) near side console and connect electrical connector.

b. Lower shift control assembly (3) into side console and secure with lockwashers (2) and screws (1).

LEGEND

1. Screw
2. Lockwasher
3. Shift control assembly

Figure 2-1-18. Shift Control Assembly (Carrier Cab)

2-1-86
 TM 5-3810-307-24-1-1

SHIFT CONTROL ASSEMBLY (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect is in OFF position.

b. Remove knob (1, Figure 2-1-19) from lever of shift control switch (3).

c. Remove screws (2) and remove shift control switch (3) from rear of housing (4).

d. Tag and disconnect electrical leads for shift control switch (3).

NOTE

It may be necessary to remove mounting hardware for swing lock control

bracket and move bracket aside to remove hardware for shift control housing.

e. If necessary, remove nuts (4), lockwashers (5), screws (6), and shift control housing (7) from dash panel.

Installation

a. If removed, install shift control housing (7, Figure 2-1-19) on dash panel with screws (6), lockwashers (5),
and nuts (4).

b. Connect electrical leads for shift control switch (3) and remove tags.

c. Insert shift control switch (3) into housing (7) from rear of dash panel, and secure to housing with screws
(2).

NOTE

If swing lock control bracket was moved, secure in dash panel with mounting
hardware.

d. Install knob (1) on lever of shift control switch (3).

2-1-87
TM 5-3810-307-24-1-1

LEGEND

1. Knob 5. Lockwasher
2. Screw 6. Screw
3. Shift control switch 7. Housing
4. Nut

Figure 2-1-19. Shift Control Assembly (Superstructure Cab)

2-1-88
 TM 5-3810-307-24-1-1

DASH PANEL (CARRIER CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove top dash panel (3, Figure 2-1-20) as follows:

(1) Remove heater control from dash panel only, refer to Heater Control (Carrier Cab) Removal
procedures, steps a. thru c.

(2) Remove defroster control from dash panel only, refer to Defroster Control (Carrier Cab) Removal
procedures, steps a. thru d.

(3) Tag and disconnect air lines from trailer air supply/parking brake control assembly, refer to Control
Assembly, Trailer Air Supply and Parking Brake (Carrier Cab) Removal procedures.

(4) Remove screws (1, Figure 2-1-20) and collars (2) securing dash panel (3) to front console.

(5) Tilt dash panel (3) to lay against steering column, tag and disconnect all electrical leads from
gauges, switches, and indicator lights, and remove dash panel from cab.

c. Remove left or right dash panel (6 or 7, Figure 2-1-20) as follows:

(1) Remove screws (4) and collars (5) securing dash panel (6 or 7) to front console.

(2) Tilt dash panel (6 or 7) back, tag and disconnect all electrical leads from switches, and remove dash
panel from cab.

Installation

a. Install top dash panel (3, Figure 2-1-20) as follows:

(1) Position dash panel (3) on steering column, connect all electrical leads to gauges, switches, and
indicator lights, and remove tags.

(2) Position dash panel (3) on front console and secure with collars (2) and screws (3).

(3) Mount heater control in dash panel, refer to Heater Control (Carrier Cab) Installation procedures.

(4) Mount defroster control in dash panel, refer to Defroster Control (Carrier Cab) Installation
procedures.

(5) Connect air lines to trailer air supply/parking brake control assembly, refer to Control Assembly,
Trailer Air Supply and Parking Brake (Carrier Cab) Installation procedures.

b. Install left or right dash panel (6 or 7, Figure 2-1-20) as follows:

(1) Position dash panel (6 or 7) near front console, connect all electrical leads to switches, and remove
tags.

(2) Position dash panel (6 or 7) on front console and secure with collars (5) and screws (4).

2-1-89
TM 5-3810-307-24-1-1

LEGEND

1. Screw 4. Screw
2. Collar 5. Collar
3. Top dash panel 6. Left dash panel
7. Right dash panel

Figure 2-1-20. Dash Panel (Carrier Cab)

2-1-90
 TM 5-3810-307-24-1-1

DASH PANEL (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove top dash panel (3, Figure 2-1-21) as follows:

(1) Disconnect swing lock control cable, refer to Swing Lock Control (Superstructure Cab) Removal
procedures, steps a. thru e.

(2) Tag and disconnect air lines from parking brake control, refer to Parking Brake Control
(Superstructure Cab) Removal procedures.

(3) Remove screws (1, Figure 2-1-21) and collars (2) securing dash panel (3) to front console.

(4) Tilt dash panel (3) to lay against steering column, tag and disconnect all electrical leads from
gauges, switches, and indicator lights, and remove dash panel from cab.

c. Remove right dash panel (6, Figure 2-1-21) as follows:

(1) Remove clip (10, Figure 2-1-16) and pin (11) to disconnect throttle control cable (8) and clevis (12).
Then remove clamp (3), refer to Throttle Fast/Slow Control (Superstructure Cab) Removal
procedures.

(2) Remove screws (4, Figure 2-1-21) and collars (5) securing dash panel (6) to front console.

(3) Tilt dash panel (6) back, tag and disconnect all electrical leads from switches, and remove dash
panel from cab.

d. Remove left dash panel (9, Figure 2-1-21) as follows:

(1) Remove screws (7) and collars (8) securing dash panel (9) to front console.

(2) Tilt dash panel (9) back, tag and disconnect all electrical leads from switches, and remove dash
panel from cab.

Installation

a. Install top dash panel (3, Figure 2-1-21) as follows:

(1) Position dash panel (3) on steering column, connect all electrical leads to gauges, switches, and
indicator lights, and remove tags.

(2) Position dash panel (3) on front console and secure with collars (2) and screws (3).

(3) Connect air lines to parking brake control, refer to Parking Brake Control (Superstructure Cab)
Installation procedures.

(4) Connect swing lock cable, refer to Swing Lock Control (Superstructure Cab) Installation procedures.

2-1-91
TM 5-3810-307-24-1-1

b. Install right dash panel (6, Figure 2-1-21) as follows:

(1) Position dash panel (6) near front console, connect all electrical leads to switches, and remove tags.

(2) Position dash panel (6) on front console and secure with collars (5) and screws (4).

(3) Connect throttle control cable, refer to Throttle Fast/Slow Control (Superstructure Cab) Installation
procedures.

c. Install left dash panel (9, Figure 2-1-21) as follows:

(1) Position dash panel (9) near front console, connect all electrical leads to switches, and remove tags.

(2) Position dash panel (9) on front console and secure with collars (8) and screws (7).

2-1-92
 TM 5-3810-307-24-1-1

LEGEND

1. Screw 4. Screw 7. Screw

2. Collar 5. Collar 8. Collar
3. Top dash panel 6. Right dash panel 9. Left dash panel

Figure 2-1-21. Dash Panel (Superstructure Cab)

2-1-93
TM 5-3810-307-24-1-1

CARRIER CAB

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove hydraulic pump disconnect cable from cab side console.

c. Disconnect throttle cable from accelerator pedal.

d. Discharge air conditioner system (refer to instructions for assigned recovery system and Appendix B),
disconnect air conditioner hoses from roof-mounted air conditioner, and remove hose guards and hoses from
exterior of cab.

e. Match mark yokes and disconnect steering shaft from upper connection of 900 angle gearbox.
WARNING
Engine must be cool to the touch prior to working on coolant system
components. Failure to comply could result in scalding or serious burns.

f. Tag and disconnect coolant system hoses from heater, and heater control cable from shutoff valve.

g. Tag and disconnect air lines from air brake valve under cab.

h. Tag and disconnect three trailer/parking brake air lines from unions under cab.

i. Tag and disconnect three large round electrical connectors and one square electrical cable from chassis
wiring harness under cab.

j. Tag and disconnect four cab wiring harness ground wires from chassis under cab.

k. Tag and disconnect electrical lead from horn.

l. Disconnect cab ground cable from chassis near heater.

m. Install lifting eyes (manufacture per Detail A, Figure 2-1-22) at upper corners of cab using existing
hardware, and attach suitable lifting device to lifting eyes.

n. Remove locknuts (1, Figure 2-1-22), washers (2), capscrews (3), and washers (4) securing cab assembly
to carrier at four mounting points.

o. Slowly lift cab assembly from carrier frame ensuring all disconnected lines, cables, etc. are clear and free
of carrier.

NOTE

Mark location and number of washers (5) removed from each shock mount.

p. Remove washers (5) from shock mounts (9).

q. If necessary, remove locknuts (6), washers (7), capscrews (8), and shock mounts (9) from carrier
mounting brackets.

2-1-94
 TM 5-3810-307-24-1-1

LEGEND

1. Locknut 4. Washer 7. Washer

2. Washer 5. Washer 8. Capscrew
3. Capscrew 6. Locknut 9. Shock mount

Figure 2-1-22. Carrier Cab Installation

2-1-95
TM 5-3810-307-24-1-1

Installation

a. If removed, install shock mounts (9, Figure 2-1-22) on carrier mounting brackets with capscrews (8),
washers (7), and locknuts (6).

b. Using suitable lifting device, lift cab assembly, position washers (5), as marked, on shock mounts (9),
lower cab onto mounts while positioning lines, cables, etc. for further routing, and align cab mounting holes with
mounts.

c. Secure cab assembly to carrier with capscrews (3), washers (2 and 4), and locknuts (1).

d. Remove lifting eyes from upper corners of cab, apply RTV to threads of bolts and install bolts in holes at
upper corners of cab.

e. Connect cab ground cable to chassis near heater.

f. Connect electrical lead to horn and remove tag.

g. Connect four cab wiring harness ground wires to chassis and remove tags.

h. Connect three large round electrical connectors and one square electrical connector to chassis wiring
harness and remove tags.

i. Connect three trailer/parking brake air lines at unions under cab, and remove tags.

j. Connect coolant system hoses to heater, heater control cable to shutoff valve, and remove tags.

k. Connect steering shaft, aligning match marks, to upper connection of 900 angle gearbox.

l. Route and connect air conditioner hoses to roof-mounted air conditioner, and install hose guards. Charge
air conditioner system, refer to instructions for assigned charging system, Lubrication Chart, and Appendix B.

m. Route and connect throttle cable to accelerator pedal.

n. Route and install main hydraulic pump disconnect cable on side console.

2-1-96
 TM 5-3810-307-24-1-1

SUPERSTRUCTURE CAB

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove exterior rear access cover from cab.

c. Remove side access cover from left turntable side plate.

d. Tag and disconnect six air lines exiting right side of cab from swivel.

e. Tag and disconnect four electrical connectors from superstructure wiring harness at bracket on right side
of cab.

f. Remove superstructure wiring harness bracket and three cab wiring harness ground wires from right side
of cab.

g. Tag and disconnect seven hydraulic hoses exiting right side of cab at nearest connection point.

h. Disconnect positive swing lock cable from positive swing lock mechanism at turntable gear.

i. Disconnect swing lock pin cable, refer to Swing Lock Control (Superstructure Cab) Removal procedures,
steps a. thru e.

j. Discharge air conditioner system (refer to instructions for assigned recovery system and Appendix B), and
disconnect air conditioner hoses from right side of evaporator. Pull hoses from cab.

WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.

k. Place suitable container under heater to catch fuel, then disconnect fuel line, ground wire, and fuel pump
electrical lead from heater under cab. Cap fuel line and wipe up any spilled fuel.

l. Disconnect heater exhaust pipe from 450 elbow under cab.

m. Tag and disconnect superstructure wiring harness electrical leads from low air pressure switches, horn,
and windshield washer reservoir pump.

n. Tag and disconnect twelve hydraulic hoses exiting bottom rear of cab at nearest connection point.

o. Tag and disconnect hydraulic hoses from auxiliary hoist control valve under cab.

p. Disconnect cab ground strap from superstructure frame near left rear cab mount.

q. Install lifting eyes (manufacture per Detail A, Figure 2-1-22) at upper corners of cab using existing
hardware, and attach suitable lifting device to lifting eyes.

r. Remove locknuts (1, Figure 2-1-23) and washers (2) securing cab to superstructure at four mounting
points.

2-1-97
TM 5-3810-307-24-1-1

LEGEND

1. Locknut 4. Washer 7. Shock mount

2. Washer 5. Capscrew 8. Washer
3. Locknut 6. Washer 9. Washer
10. Shock mount

Figure 2-1-23. Superstructure Cab Installation

2-1-98
 TM 5-3810-307-24-1-1

NOTE

Count number of washers (8) removed from turntable mounting point and
retain for installation.

s. Remove locknut (3), washer (4), capscrew (5), washer (6), shock mount (7), and washer(s) (8) securing
cab to side of turntable.

t. Slowly lift cab assembly from superstructure ensuring all disconnected lines, cables, etc. are clear and free
of superstructure.

NOTE

Mark position and number of washers (9) removed from each shock mount and
retain for installation.

u. Remove washers (9) and shock mounts (10) from four superstructure mounting points.

NOTE

If replacing cab, ensure new acoustics/insulation material is ordered.

Installation

a. Install shock mounts (10, Figure 2-1-23) in four superstructure mounting points and position washers (9),
as marked during removal, on shock mounts.

b. Using suitable lifting device, lift cab assembly above mounts, then lower cab onto mounts while positioning
lines, cables, etc. for further routing, and align cab mounting studs with mounts.

c. Secure cab assembly to four superstructure mounting points with washers (2) and locknuts (1).

d. Secure cab assembly to side of turntable with washer(s) (8), as noted during removal, shock mount (7),
washer (6), capscrew (5), washer (4), and locknut (3).

e. Remove lifting eyes from upper corners of cab, apply RTV to threads of bolts and install bolts in holes at
upper corners of cab.

f. Connect cab ground strap to frame near left rear cab mount.

g. Connect hydraulic hoses to auxiliary hoist control valve under cab and remove tags.

h. Route and connect twelve hydraulic lines exiting bottom rear of cab and remove tags.

i. Connect superstructure wiring harness electrical leads to windshield washer reservoir pump, horn, and low
air pressure switches. Remove tags.

j. Connect heater exhaust pipe to 450 elbow under cab.

k. Connect fuel pump electrical lead, ground wire, and fuel line to heater.

l. Insert air conditioner hoses into cab and connect hoses to right side of evaporator. Charge air conditioner
system, refer to instructions for assigned charging system, Lubrication Chart, and Appendix B.

m. Connect swing lock pin cable, refer to Swing Lock Control (Superstructure Cab) Installation procedures.

2-1-99
TM 5-3810-307-24-1-1

n. Connect positive swing lock cable to positive swing lock mechanism at turntable gear.

o. Route and connect seven hydraulic hoses exiting right side of cab and remove tags.

p. Install superstructure wiring harness bracket and three cab wiring harness ground wires to right side of
cab.

q. Connect four electrical connectors to superstructure wiring harness at bracket on right side of cab and
remove tags.

r. Route and connect six air lines exiting right side of cab to swivel and remove tags.

s. Install access cover on left turntable side plate.

t. Install exterior rear access cover on cab

2-1-100
 TM 5-3810-307-24-1-1

SUPERSTRUCTURE CAB HEATER FUEL PUMP

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove exterior rear access panel from cab.

WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.

c. Place suitable container under heater tank drain plug to catch fuel, then drain the fuel tank. Capacity
approximately 2 gallons (3.8 liters). Reinstall the drain plug.

d. Disconnect heater pump power wire at heater board.

e. Disconnect two fuel lines (1 and 2, Figure 2-1-24) at heater fuel pump (3).

f. Remove two nuts (4), lockwashers (5), and flat washers (6) securing heater fuel pump (3) and bracket (9).

g. Remove sediment bowl (7) with nipple from heater fuel pump (3). Clean sediment bowl with clean cloth
and retain for installation on new heater fuel pump.

h. Remove nuts (12), lockwashers (11), and capscrews (10). Separate bracket (9) and heater fuel pump (3).

i. Remove elbow fitting (8) and retain for installation on new heater fuel pump.

Installation

a. Install sediment bowl (7, Figure 2-1-24) on new heater fuel pump (3).

b. Install elbow fitting (8) on new heater fuel pump (3).

c. Assemble heater fuel pump (3) to bracket (9) with two capscrews (10), new lockwashers (11), and nuts
(12).

d. Using existing mounting studs, install bracket (9) with nuts (4), new lockwashers (5), and flat washers (6).

e. Connect two fuel lines (1 and 2).

f. Attach EMI filter (13) to boom superstructure with a single -inch screw (14).

g. Connect heater fuel pump power lead to heater board in superstructure cab.

h. Install exterior rear access panel on superstructure cab.

i. Service the superstructure cab heater fuel tank. Refer to TM 5-3810-307-10.

j. Turn battery disconnect switch to the on position and check superstructure cab heater for proper
operation. If necessary, troubleshoot superstructure cab heater. Refer to TM 5-3810-307-24-1-2.

2-1-101 C-1
TM 5-3810-307-24-1-1

Legend:

1. Fuel Line 6. Flat Washer 11. Lockwasher

2. Fuel Line 7. Sediment Bowl 12. Nut
3. Heater Fuel Pump 8. Elbow Fitting 13 EMI Filter
4. Nut 9. Bracket 14. Screw, inch
5. Lockwasher 10. Capscrew

Figure 2-1-24. Superstructure Cab Heater Fuel Pump

2-1-102 C-1
 TM 5-3810-307-24-1-1

SECTION 2
ENGINE

TABLE OF CONTENTS
Page

ENGINE
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Engine and Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9
Engine Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Throttle Air Cylinder and Throttle Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-17
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Heated Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Heated Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26
Cold Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-30
WATER COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Radiator and Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-35

2-2-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38
Muffler and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-39

LIST OF FIGURES
Number Title Page

2-2-1 Engine and Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8

2-2-2 Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14
2-2-3 Throttle Air Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-16
2-2-4 Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-21
2-2-5 Heated Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-24
2-2-6 Cold Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-28
2-2-7 Radiator and Air Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-34
2-2-8 Radiator Hose Sealant Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-36
2-2-9 Muffler and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-40

2-2-2
 TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-2-7

The engine and transmission assembly weighs approximately 2500 lbs (1134 kg).
Use a suitable lifting device to remove the engine and transmission assembly.
Using too small of a device may result in personal injury.

WARNING 2-2-9

The engine and transmission assembly weighs approximately 2500 lbs (1134 kg).
Use a suitable lifting device to install the engine and transmission assembly.
Using too small of a device may result in personal injury.

WARNING 2-2-15

There may be residual pressure in air lines after air reservoirs are drained. Wear
eye protection when disconnecting air lines to prevent injury.

WARNING 2-2-20
2-2-22
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame and
other ignition sources.

WARNING 2-2-26

The starting fluid used in the cold start system contains ethyl ether and is
extremely flammable and toxic. Do not smoke and make sure you are in a well-
ventilated area away from heat, open flames, or sparks when installing,
maintaining, testing, or troubleshooting the cold start system.

Wear goggles and make sure openings are pointed away from you when
activating system with lines or fittings disconnected to avoid eye injury. If fluid
enters the eyes or fumes irritate the eyes, they should be flushed with large
quantities of clean water for 15 minutes. A physician should be contacted.

Starting fluid can be harmful or fatal if swallowed. If swallowed, do not induce

vomiting. Call a physician immediately.

Contents of cylinder are under pressure. Store in a cool dry place. Do not
incinerate, puncture, or attempt to remove cores from cylinder.

2-2-3
TM 5-3810-307-24-1-1

WARNING SUMMARY - Continued

Page

WARNING 2-2-32

Engine must be cool to the touch prior to working on coolant system components.
Failure to comply could result in scalding or serious burns.

WARNING 2-2-38

Exhaust components must be cool to the touch prior to working on exhaust

system. Failure to comply could result in serious burns.

WARNING 2-2-39

Exhaust system components can get very hot. Use care to avoid serious burns.

2-2-4
 TM 5-3810-307-24-1-1

ENGINE

DESCRIPTION

The AT422T crane is equipped with the Cummins
B5.9-190 diesel engine. This manual does not
include detailed information on the engine itself. A
separate manual, TM 5-3810-307-24-2, prepared in
detail by the engine manufacturer, is supplied with
the crane. However, a short description and
maintenance of certain engine-related components
are provided in this section.
The cylinder is connected by linkage to the engine
fuel injection pump throttle lever.
The engine and its components are enclosed in a
hood assembly with a grill in the front and rear of the
hood for adequate air circulation. Access to the
engine is gained through side doors in the hood
assembly.

Engine speed is controlled mechanically from the
carrier cab by a throttle cable connected to a foot
pedal in the cab and the engine fuel injection pump
throttle lever. From the superstructure cab, engine
speed is controlled pneumatically from a foot
operated throttle valve in the cab to a throttle air
cylinder on the engine.
To aid in starting the engine in cold weather, a cold
start system is provided. The system consists of a
temperature switch, solenoid valve, starting fluid in a
pressurized container, atomizer, and connecting
tubing.

MAINTENANCE

ENGINE AND TRANSMISSION ASSEMBLY

Removal

a. Start crane, set outriggers, and position boom to left side of carrier so hardware for deck plate over
transmission is accessible.

b. Shutdown crane and position battery disconnect switch to OFF position.

c. Disconnect drive lines from transmission, refer to Drive Lines Removal procedures.

d. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.

e. Drain hydraulic tank.

f. Drain transmission case.

g. Remove engine hood, refer to Engine Hood Removal procedures.

h. Remove deck plate over transmission.

i. Remove radiator and air cooler, refer to Radiator and Air Cooler Removal procedures.

j. Disconnect engine/transmission electrical harness connector and four ground wires (located at front left
side of engine on carrier frame crossmember).

k. Disconnect throttle cable (49, Figure 2-2-3) from bracket (57) and clamp (40) at air compressor.
2-2-5
TM 5-3810-307-24-1-1

l. Disconnect hydraulic pump disconnect cable from lever at top front left side of transmission.

m. Disconnect cold start tube (5, Figure 2-2-6) from atomizer (13).

n. Remove carrier cab air conditioner compressor, refer to Air Conditioner (Carrier Cab) Removal procedures,
steps c. (4) thru (6).

o. Tag and disconnect heater supply hose from rear of engine cylinder head and heater return line from right
side of engine.

p. Tag and disconnect fuel line to fuel filter/water separator from fuel heater at right engine well wall.

q. Tag and disconnect fuel return line from fuel injection pump.

r. Tag and disconnect air line from rear of throttle air cylinder, refer to Throttle Air Cylinder and Throttle
Linkage Removal procedures.

s. Tag and disconnect hydraulic hoses for main hydraulic pump from tubes below pump.

t. Tag and disconnect transmission oil lines to lockup modulator valve from bottom of transmission sump and
right side of transmission just forward of dipstick.

u. Tag and disconnect two transmission oil lines to lockup solenoid valve (right side transmission well wall)
from right side of torque converter and two oil lines from solenoid valve.

v. Tag and disconnect hydraulic hoses from steering pump.

w. Remove emergency steering pump from transmission and allow to hang from oil lines, refer to Emergency
(Standby) Steering Valve and Pump Removal procedures, step c. (3).

x. Tag and disconnect transmission and engine oil hoses from oil filters under battery box.

y. Tag and disconnect electrical cables to batteries and battery disconnect switch from alternator and starter
motor.

z. Tag and disconnect engine ground cable from carrier frame at right side engine well wall.

aa. Tag and disconnect air line to air dryer from air compressor.

bb. Tag and disconnect air line to air compressor unloader valve from air governor.

cc. Tag and disconnect hydraulic hoses to main hydraulic pump from hydraulic tank.

dd. Tag and disconnect oil hoses to transmission oil cooler from front left side of transmission.

ee. Tag and disconnect electrical connector for cold start valve (9, Figure 2-2-6).

ff. Tag and disconnect electrical leads from lockup switch and ground wire from lockup solenoid valve at right
transmission well wall.

gg. Tag and disconnect electrical connector to lockup modulator valve from engine/transmission wiring harness
(rear of transmission).

2-2-6
 TM 5-3810-307-24-1-1

WARNING
The engine and transmission assembly weighs approximately 2500 lbs (1134
kg). Use a suitable lifting device to remove the engine and transmission
assembly. Using too small of a device may result in personal injury.

hh. Attach suitable lifting device to engine lifting eyes and overhead hoist. Take up slack.

ii. Remove locknuts (1, Figure 2-2-1), washers (2), capscrews (3), and washers (4) securing engine mount to
carrier frame.

jj. Remove locknuts (5), washers (6), capscrews (11), and washers (12) securing transmission mount brackets
(13) to transmission and carrier frame.

kk. Slowly lift engine and transmission assembly from carrier ensuring that all components, wiring, and hoses
are free and do not catch on carrier.

ll. Lower engine and transmission assembly onto suitable work stand.

mm. Remove spacer (9) from engine mount on carrier frame.

nn. Remove capscrews (7), washers (8), transmission mount brackets (13), and shock mounts (10) from
transmission mounts on carrier frame.

NOTE

Left and right transmission mount brackets are not symmetrical. Mark brackets
as necessary to ensure proper installation.

oo. Remove transmission from engine as follows:

(1) Tag and disconnect wiring harness electrical leads from transmission components.

(2) Remove capscrews (14), lockwashers (15), and flywheel access cover (16) from left side of flywheel
housing.

(3) Bar engine to align flywheel to transmission flex plate mounting hardware with access hole, and
remove capscrews (17) and lockwashers (18).

(4) Attach suitable lifting device to support transmission.

(5) Mark mounting location of main hydraulic pump disconnect lever bracket (21), and remove nuts (19),
washers (20), and bracket (21) from flywheel housing studs.

(6) Carefully separate transmission from engine.

pp. If replacing engine, set new engine beside old engine, and build-up new engine from components removed
from old engine. Refer to individual component removal and installation procedures.

qq. If replacing transmission, set new transmission beside old transmission, and build-up new transmission
from components removed from old transmission. Refer to individual component removal and installation
procedures.

2-2-7
TM 5-3810-307-24-1-1

LEGEND

1. Locknut 8. Washer 15. Lockwasher

2. Washer 9. Spacer 16. Access cover
3. Capscrew 10. Shock mount 17. Capscrew
4. Washer 11. Capscrew 18. Lockwasher
5. Locknut 12. Washer 19. Nut
6. Washer 13. Mount bracket 20. Washer
7. Capscrew 14. Capscrew 21. Bracket

Figure 2-2-1. Engine and Transmission Installation

2-2-8
 TM 5-3810-307-24-1-1

Installation

a. Install transmission on engine as follows:

(1) Apply zinc chromate paste on transmission mating surface with flywheel housing, and anti-seize
compound on flex plate and flywheel mating surfaces

(2) Using suitable lifting device, carefully position transmission and main hydraulic pump disconnect lever
bracket (21, Figure 2-2-1) on flywheel housing studs.

(3) Secure transmission and bracket (21) to engine with washers (20) and nuts (19), and remove lifting
device from transmission.

(4) Bar engine and turn transmission drive line coupling as necessary to align flywheel holes and
transmission flex plate holes with each other and access hole on flywheel housing.

(5) Apply anti-seize compound to shanks of capscrews (17), and secure flywheel to transmission flex
plate with lockwashers (18) and capscrews (17). Torque capscrews 25 to 30 lbs-ft (34 to 41 Nm).

(6) Install access cover (16) on left side of flywheel housing with capscrews (14) and lockwashers (15).

(7) Connect wiring harness electrical leads to transmission components and remove tags.

b. Position shock mounts (10) and transmission mount brackets (13), as marked during removal, on
transmission mounting brackets on carrier frame, and install washers (8), capscrews (7), washers (6), and nuts
(5). Do not tighten nuts (5).

c. Position spacer (9) on engine mounting bracket on carrier frame.

WARNING
The engine and transmission assembly weighs approximately 2500 lbs (1134
kg). Use a suitable lifting device to install the engine and transmission
assembly. Using too small of a device may result in personal injury.

d. Attach suitable lifting device to engine lifting eyes and overhead hoist. Lift engine and transmission
assembly from work stand.

e. Slowly lower engine and transmission assembly into carrier ensuring that all components, wiring, and hoses
do not catch on carrier or other components.

f. Align transmission to mount brackets (13), and install washers (12) and capscrews (11) through
transmission mount brackets (13) into transmission mounting holes. Do not tighten capscrews (11).

g. Align engine mount to mounting bracket on carrier frame, and install washers (4) and capscrews (3) through
engine mount.

h. Tighten capscrews (11) to 260 lbs-ft (353 Nm) securing transmission mount brackets (13) to transmission,
completely lower engine and transmission assembly onto frame mounting brackets, and remove lifting device.

i. Secure transmission to carrier frame mounts by tightening locknuts (5).

j. Secure engine to carrier frame mount with washers (2) and locknuts (1).

2-2-9
TM 5-3810-307-24-1-1

k. Connect electrical connector to engine/transmission wiring harness for lockup modulator valve and remove
tag.

l. Connect electrical leads to lockup switch and ground wire to lockup solenoid valve at right transmission well
wall. Remove tags.

m. Connect electrical connector for cold start valve (9, Figure 2-2-6) and remove tag.

n. Connect oil hoses from transmission oil cooler to front left side of transmission and remove tags.

o. Connect hydraulic hoses from main hydraulic pump to hydraulic tank and remove tags.

p. Connect air line from air compressor unloader valve to air governor and remove tag.

q. Connect air line from air dryer to air compressor and remove tag.

r. Connect engine ground cable to carrier frame at right side engine well wall and remove tag.

s. Connect electrical leads from batteries and battery disconnect switch to starter and alternator. Remove
tags.

t. Connect engine and transmission oil hoses to oil filters under battery box and remove tags.

u. Install emergency steering pump on transmission, refer to Emergency (Standby) Steering Valve and Pump
Installation procedures.

v. Connect hydraulic hoses to steering pump and remove tags.

w. Connect two oil lines from lockup solenoid valve to right side of transmission and remove tags.

x. Connect two oil lines to lockup solenoid valve and remove tags.

y. Connect oil lines from lockup modulator valve to bottom of transmission sump and to right side of
transmission just forward of dipstick.

z. Connect hoses for main hydraulic pump to tubes below pump and remove tags.

aa. Connect air line to rear of throttle air cylinder and remove tag.

bb. Connect fuel return line to fuel injection pump and remove tag.

cc. Connect fuel filter/water separator inlet fuel line to fuel heater and remove tag.

dd. Connect heater supply hose to rear of engine cylinder head and heater return hose to right side of engine
and remove tags.

ee. Install carrier cab air conditioner compressor on engine bracket, refer to Air Conditioner (Carrier Cab)
Installation procedures.

ff. Connect cold start tube (5, Figure 2-2-6) to atomizer (13).

gg. Connect main hydraulic pump disconnect cable to lever at top front left side of transmission.

hh. Connect throttle cable (49, Figure 2-2-3) to bracket (57) and to air compressor with clamp (40).

2-2-10
 TM 5-3810-307-24-1-1

ii. Connect engine/transmission electrical harness connector and four ground wires at front left side of engine
on carrier frame crossmember.

jj. Install radiator, refer to Radiator and Air Cooler Installation procedures.

kk. Service hydraulic tank, refer to Lubrication Chart.

ll. Service transmission, refer to Lubrication Chart.

mm. Close drain valves on secondary and auxiliary air tanks.

nn. Connect drive lines to transmission, refer to Drive Lines Installation procedures.

oo. Start crane and check for leaks and proper operation.

pp. Shutdown crane and service oil levels as necessary.

qq. Install engine hood, refer to Engine Hood Installation procedures.

rr. Install deck plate over transmission.

ss. Start crane, position boom back onto boom rest, and shutdown crane.

2-2-11
TM 5-3810-307-24-1-1

ENGINE HOOD

Removal

a. Remove front cowl as follows:

(1) Remove capscrews (1, Figure 2-2-2), washers (2) and grill (3) from front cowl (10).

(2) Remove capscrews (5), lockwashers (4), and washers (6) securing front cowl (10) to bracket on
boom rest.

(3) Remove nut (7), lockwasher (8), washer (9), and front cowl (10) from crane.

b. Remove center cowl as follows:

(1) Remove top engine panel and door assembly (17), refer to step c.

(2) Remove coolant recovery tank (do not disconnect hoses) from center cowl (13) and set aside, refer to
Radiator and Air Cooler Removal procedures.

(3) Remove exhaust tube and adapter between turbocharger and flexible exhaust tube, refer to Exhaust
System Removal procedures.

(4) Remove locknuts (11), washers (12), nylon washers (14), and center cowl (13) from crane.

c. Remove engine top panel and door assembly as follows:

(1) Remove clips (15), pins (16), and top panel and door assembly (17) from crane.

(2) If necessary, remove doors from top panel, and handles, latch brackets, and support rods from doors.

d. Remove rear cowl as follows:

(1) Remove top engine panel and door assembly (17), refer to step c.

(2) Remove air intake tubing between air cleaner and turbocharger.

(3) Remove locknuts (18), washers (19), nylon washers (21), and rear cowl (20) from crane.

(4) If necessary, remove grill from rear cowl by removing capscrews and washers.

Installation

a. Install front cowl as follows:

(1) Position front cowl (10, Figure 2-2-2) on crane and secure left side to stud on boom rest with washer
(9), lockwasher (8), and nut (7).

(2) Secure right side of front cowl (10) to bracket on boom rest with capscrews (5), lockwashers (4), and
washers (6).

(3) Apply LOCTITE 242 to threads of capscrews (1), and install grill (3) on front cowl (10) with capscrews
(1) and washers (2).

2-2-12
 TM 5-3810-307-24-1-1

b. Install center cowl as follows:

(1) Position center cowl (13) over studs on crane and secure with nylon washers (14), washers (12) and
locknuts (11).

(2) Install coolant recovery tank on center cowl (10), refer to Radiator and Air Cooler Installation
procedures.

(3) Install exhaust tube and adapter between turbocharger and flexible exhaust tube, refer to Exhaust
System Installation procedures.

(4) Install engine top panel and door assembly (17), refer to step c.

c. Install engine top panel and door assembly as follows:

(1) If removed, install support rods, handles, and latch brackets on doors, and doors on top panel.

(2) Install engine top panel and door assembly (17) on crane with pins (16) and clips (15).

d. Install rear cowl as follows:

(1) If removed, install grill on rear cowl (20) with washers and capscrews.

(2) Position rear cowl (20) over studs on crane and secure with nylon washers (21), washers (19) and
locknuts (18).

(3) Install engine top panel and door assembly (17), refer to step c.

2-2-13
TM 5-3810-307-24-1-1

LEGEND

1. Capscrew 8. Lockwasher 15. Clip

2. Washer 9. Washer 16. Pin
3. Grill 10. Front cowl 17. Top panel and door assy
4. Lockwasher 11. Locknut 18. Locknut
5. Capscrew 12. Washer 19. Washer
6. Washer 13. Center cowl 20. Rear cowl
7. Nut 14. Nylon washer 21. Nylon washer

Figure 2-2-2. Engine Hood

2-2-14
 TM 5-3810-307-24-1-1

THROTTLE AIR CYLINDER AND THROTTLE LINKAGE

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.

c. Remove engine top panel and door assembly, and rear cowl, refer to Engine Hood Removal procedures.

d. Disconnect electrical leads at idle switch (20, Figure 2-2-3) and electrical connector at throttle position
switch (35).

WARNING
There may be residual pressure in air lines after air reservoirs are drained.
Wear eye protection when disconnecting air lines to prevent injury.

d. Disconnect air line from fitting (24) at rear of throttle air cylinder (15).

e. Remove nut (1), lockwasher (2), capscrew (3), and aft end of throttle rod (4) from lever (28).

f. Remove springs (5) from eye bolts (23) and bracket (52).

g. Remove nuts (6), lockwashers (7), capscrews (8), washers (9), oil pressure sender and switch bracket
assembly (10), throttle position switch (35) with attached brackets, and throttle air cylinder (15) with attached
components from engine mounting bracket.

h. Remove nuts (11), lockwashers (12), washers (13), capscrews (14), and separate throttle air cylinder (15)
from lever (27) and bracket (28).

i. Remove screws (16) and bracket (17) from throttle air cylinder (15). These screws are part of the cylinder
and should be reinstalled at this time.

j. Remove nut (18), washer (19), and idle switch (20) from bracket (17).

k. If necessary, remove nuts (21), washers (22), and eye bolts (23) from bracket (17).

l. Remove fitting (24) from throttle air cylinder (15).

m. Remove cotter pin (25), washer (26), and separate lever (27) and bracket (28).

n. If necessary, remove nut (29) and carriage bolt (30) from bracket (28).

o. Remove nuts (31), lockwashers (32), screws (33), washers (34), and throttle position switch (35) from
adjusting bar (39) and bracket (43).

p. If necessary, remove capscrew (36), washers (37), nuts (38), and adjusting bar (39) from bracket (43).

q. If necessary, remove capscrews (40), lockwashers (41), washers (42), and bracket (43) from bracket (44).

2-2-15
TM 5-3810-307-24-1-1

Figure 2-2-3. Throttle Air Cylinder Installation

2-2-16
 TM 5-3810-307-24-1-1

LEGEND for Figure 2-2-3

1. Nut 19. Washer 38. Nut

2. Lockwasher 20. Idle switch 39. Adjusting bar
3. Capscrew 21. Nut 40. Capscrew
4. Throttle rod 22. Washer 41. Lockwasher
5. Spring 23. Eye bolt 42. Washer
6. Nut 24. Fitting 43. Bracket
7. Lockwasher 25. Cotter pin 44. Bracket
8. Capscrew 26. Washer 45. Capscrew
9. Washer 27. Lever 46. Washer
10. Oil press. sender and 28. Bracket 47. Nut
switch bracket 29. Nut 48. Clamp
assembly 30. Carriage bolt 49. Throttle cable
11. Nut 31. Nut 50. Capscrew
12. Lockwasher 32. Lockwasher 51. Washer
13. Washer 33. Screw 52. Bracket
14. Capscrew 34. Washer 53. Spacer
15. Throttle air cylinder 35. Throttle position 54. Spacer
16. Screw switch 55. Washer
17. Bracket 36. Capscrew 56. Nut
18. Nut 37. Washer 57. Bracket

r. Remove capscrew (45), washer (46), and throttle cable (49) from bracket (57).

s. Remove nuts (47), clamp (48), and throttle cable (49) from bracket on air compressor.

t. Remove capscrews (50), washers (51), bracket (52), spacers (53 and 54), washer (55), throttle rod (4), nut
(56), and bracket (57) from fuel injection pump lever.

Installation

a. Install washer (51, Figure 2-2-3) on upper capscrew (50) and insert through upper hole in bracket (52).

b. Install bushing (54), washer (55), throttle rod (4), and nut (56) on upper capscrew (50). Tighten nut (56)
until assembled parts are secured tightly together.

c. Position bracket (52) on bracket (57) with upper capscrew (50) through upper hole of bracket (57).

d. Install bracket (57) on fuel injection pump lever with assembled hardware in upper hole and lower capscrew
(50), washer (51), and spacer (53) in lower hole.

e. Connect throttle cable (49) to bracket (57) with capscrew (45) and washer (46).

f. Ensure throttle cable (49) is fully extended and fuel injection pump lever is in its most rearward position,
then secure throttle cable (49) to bracket on air compressor with clamp (48) and nuts (47) ensuring there is no
slack in cable.

g. If removed, install bracket (43) on bracket (44) with capscrews (40), lockwashers (41), and washers (42).
Do not fully tighten capscrews (40).

h. If removed, install adjusting bar (39) on bracket (43) with capscrew (36), washers (37), and nuts (38). Do
not fully tighten nuts (38).

2-2-17
TM 5-3810-307-24-1-1

i. Install throttle position switch (35) on adjusting bar (39) and bracket (43) with capscrews (33), washers (34),
lockwashers (32), and nuts (31). Do not fully tighten nuts (31).

j. If removed, install carriage bolt (30) on bracket (28) with nut (29).

k. Install lever (27) on bracket (28) with washer (26) and cotter pin (25).

l. If removed, install eye bolts (23) on bracket (17) with washers (22) and nuts (21). Distance from front of
bracket (17) to center of eyes of eye bolts (23) should be 1-1/2 in. (3.8 cm).

m. Install idle switch (20) on bracket (17) with washer (19) and nut (18).

n. Install bracket (17) on throttle air cylinder (15) with screws (16) which are part of the throttle cylinder (15).

o. Install lever (27) with bracket (28) on throttle air cylinder (15) with capscrews (14), washers (13),
lockwashers (12), and nuts (11).

p. Adjust carriage bolt (30) so that button on idle switch (20) is fully depressed when throttle air cylinder lever
is fully rearward, then tighten nut (29).

q. Position throttle air cylinder (15), bracket (44), and oil sender and switch bracket assembly (10) to engine
mounting bracket, then secure components with capscrews (8), washers (9), lockwashers (7), and nuts (6).

r. Place lever of throttle air cylinder (15) in mid-stroke position (straight up and down), then adjust capscrew
(36) and throttle position switch (35) until roller of throttle position switch just contacts front of lever (28), see
Detail A. Tighten nuts (38), capscrews (40), and nuts (31) to secure throttle position switch in position.

s. Place fuel injection pump lever and lever of throttle air cylinder (15) fully rearward, adjust throttle rod (4) as
necessary, and connect throttle rod (4) to bracket (28) with capscrew (3), lockwasher (2), and nut (1).

t. Connect springs (5) to eye bolts (23) and bracket (52).

u. Install fitting (24) in rear of throttle air cylinder (15), and connect air line to fitting.

v. Connect electrical leads at idle switch (20) and electrical connector at throttle position switch (35).

w. Close drain valves on air reservoirs.

x. Perform test procedures for APC 100 to ensure shift points are correct, refer to Chapter Two, Section 3.

y. Install engine rear cowl, and top panel and door assembly, refer to Engine Hood Installation procedures.

Operating Test

With normal air pressure in the system, actuate the foot throttle to various positions and observe that the throttle
cylinder responds quickly, smoothly, and proportionately.

Leakage Test

1. With foot throttle fully depressed and air pressure at cylinder port, there should be no noticeable leakage at
port connector, cylinder cover, control cylinder boot, or exhaust port of the throttle valve.

2. Leakage of not more than a 1 in. (2.54 cm) soap bubble in one second is permissible in above test. If
excessive leakage is present, repair or replacement of cylinder and valve is recommended.

2-2-18

FUEL SYSTEM
DESCRIPTION
The fuel system consists of a fuel tank, fuel filter/
water separator, fuel pump, engine fuel filter, and fuel
injectors. All components except the fuel tank and
heated fuel filter/water separator come installed on
the engine.
FUEL TANK.
The fuel tank is a steel tank located on the right side
of the machine. The fuel tank has a capacity of 44
gallons (166.6 liters). The fuel line connected to the
top of the tank provides the fuel supply to the engine
and the fuel line connected to the bottom front side of
the tank carries the return surplus fuel from the
engine. The tank is equipped with a screw-type filler
cap and a fuel level sender unit which provides a
signal to a fuel gauge on the instrument panels in the
cabs.
FUEL PUMP.
The Cummins engine has a positive displacement
gear-type metering fuel pump driven by an engine
power take-off through a coupling to one of the
accessories. The pump supplies fuel at low pressure
through the engine fuel filter to the fuel injection pump
which distributes the fuel to the injectors.
The fuel is finely atomized by the injector as it is
injected into the cylinder and ignited by the heat of
the compression. It is also metered before injection,
to meet the load requirements imposed upon the
engine.
TM 5-3810-307-24-1-1
Surplus fuel, returning from the injectors, is bypassed
back to the fuel tank. The continuous flow of fuel
through the injectors helps to cool the injectors and to
remove air from the system.
FUEL FILTER.
The engine fuel filter, which comes as a component
of the engine, incorporates a
replaceable-element-type filter to remove impurities
from the fuel. The filter is mounted on the engine
between the fuel pump and fuel injection pump.
HEATED FUEL FILTER/WATER SEPARATOR.
The heated fuel filter/water separator removes water
from the fuel before it reaches the engine. It is
mounted on the top left rear of the engine. As fuel
passes through the outer wrap of the first stage of the
filter paper, large droplets of water are formed as it is
stripped from the fuel. The water falls out into the
void between the two paper elements and goes to a
reservoir in the bottom of the housing where it can be
drained through a drain valve at the bottom of the
housing. This filter is installed in the system between
the fuel tank and pump and operates under suction.
The fuel filter/water separator also incorporates an
electrically operated heater which is actuated by a
temperature switch to warm the fuel whenever the
temperature of the fuel falls below 30 F (-1 C).
2-2-19
TM 5-3810-307-24-1-1

MAINTENANCE

FUEL TANK ASSEMBLY

WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Tag and disconnect electrical connectors for fuel level sender (8, Figure 2-2-4).

c. Open drain cock (1) and drain fuel into a suitable container [capacity 44 gals (166.6 L)]. Close drain cock
(1).

d. Loosen clamp (15) and disconnect fuel return hose from fitting (12).

e. Disconnect fuel supply hose from elbow (14).

f. Support step assembly (5). Remove nuts (2) and washers (3) from straps (4) at bottom of mounting
brackets.

g. Remove step assembly (5), and fuel tank (6) from carrier frame brackets.

h. If necessary, remove screws (7) and fuel level sender (8) from fuel tank (6).

i. If necessary, remove clamp (9) and vent hose (10) from elbow (11), and elbow (11) from fuel tank (6).

j. If necessary, remove fitting (12), elbows (13 and 14), and drain cock (1) from fuel tank (6).

Installation

a. If removed, install drain cock (1, Figure 2-2-4), elbows (13 and 14), and fitting (12) in fuel tank (6).

b. If removed, install elbow (11) in fuel tank (6) and vent hose (10) to elbow (11) with clamp (9).

c. If removed, install fuel level sender (8) in fuel tank (6) with screws (7).

d. Position fuel tank (6) and step assembly (5) on mounting brackets.

e. Secure fuel tank (6) and step assembly (5) on mounting brackets with straps (4), washers (3), and nuts (2).

f. Connect fuel return hose to fitting (12), tighten clamp (15), and connect fuel supply hose to elbow (14).

g. Connect electrical connectors for fuel level sender (8) and remove tags.

h. Service fuel tank.

2-2-20
 TM 5-3810-307-24-1-1

LEGEND

1. Plug, drain 6. Fuel tank 11. Elbow

2. Nut 7. Screw 12. Fitting
3. Washer 8. Sender, fuel level 13. Elbow
4. Strap 9. Clamp 14. Elbow
5. Step assembly 10. Hose, vent 15. Clamp

Figure 2-2-4. Fuel Tank Installation

2-2-21
TM 5-3810-307-24-1-1

HEATED FUEL FILTER/WATER SEPARATOR

WARNING
Diesel fuel is combustible and an irritant. Skin and eye protection is required.
Good general ventilation is normally adequate. Keep away from open flame
and other ignition sources.

Removal

a. Remove filter element as follows:

(1) Ensure battery disconnect switch is in the OFF position.

(2) Disconnect electrical connector for heater unit (3, Figure 2-2-5).

(3) Loosen clamp (1) and disconnect drain tube (2) from heater unit (3).

(4) Unscrew heater unit (3) and remove gasket (4) from filter element (5). Discard gasket.

(5) Unscrew filter element (5) and remove gasket (6) from filter head (13). Pour fuel from element into a
suitable container and discard element and gasket.

b. Remove filter head as follows:

(1) Disconnect fuel inlet hose (7) from elbow (14) and fuel outlet hose (8) from elbow (15).

(2) Remove nuts (9), lockwashers (10), capscrews (11), washers (12) and filter head (13) from engine
mounting bracket.

(3) If necessary, remove elbows (14 and 15) from filter head (13).

Installation

a. Install filter head as follows:

(1) If removed, install elbows (14 and 15, Figure 2-2-5) in filter head (13).

(2) Install filter head (13) on engine mounting bracket with capscrews (11), washers (12), lockwashers
(10), and nuts (9).

(3) Connect fuel outlet hose (8) to elbow (15) and fuel inlet hose (7) to elbow (14).

b. Install filter element as follows:

(1) Fill new filter element (5) with clean diesel fuel and install new gasket (6) and filter element (5) on filter
head (13). Tighten filter element hand tight and an additional 1/2 turn.

(2) Install heater unit (3) with new gasket (4) on filter element (5). Tighten heater unit hand tight and an
additional 1/2 turn.

(3) Connect drain hose (2) on heater unit (3) and tighten clamp (1).

(4) Connect electrical connector for heater unit (3).

2-2-22
 TM 5-3810-307-24-1-1

(5) Prime fuel filter/water separator, refer to step c.

c. Prime fuel filter/water separator as follows:

(1) Loosen vent plug.

(2) Activate hand pump until fuel begins to flow from around vent plug with no air bubbles.

(3) Close vent plug.

d. Start engine and check for leaks.

2-2-23
TM 5-3810-307-24-1-1

LEGEND

1. Clamp 6. Gasket 11. Capscrew

2. Drain hose 7. Inlet hose 12. Washer
3. Heater unit 8. Outlet hose 13. Filter head
4. Gasket 9. Nut 14. Elbow, 45
5. Filter element 10. Lockwasher 15. Elbow, 90

Figure 2-2-5. Heated Fuel Filter/Water Separator Installation

2-2-24
 TM 5-3810-307-24-1-1

AIR INTAKE SYSTEM

DESCRIPTION

The engine air intake system consists of an air
cleaner and associated piping for channeling the air
from the atmosphere to the engine intake manifold.
The intake pipe also provides the necessary
connection for starting fluid to be injected into the air
intake for cold starts and a restriction indicator to
indicate a dirty air cleaner.
The air cleaner is the dry-type with a replaceable
element. It is located on the front right wheel fender
beside the engine hood. A restriction indicator,
designed to display red when servicing is required, is
used on this system.
The cold weather starting system consists of a
temperature switch, valve assembly, starting fluid
bottle (customer supplied), and an atomizer. The
cold start system is used during cold weather
operations to facilitate engine starting. The system
operates automatically whenever the ambient
temperature is below 30 F (-1 C) and the ignition
switch is in the start (2) position. The temperature
switch actuates the valve assembly, passing starting
fluid from the bottle through the atomizer into the air
intake manifold where it mixes with the intake air to
facilitate engine combustion.

2-2-25
TM 5-3810-307-24-1-1

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

COLD START SYSTEM

WARNING
The starting fluid used in the cold start system contains ethyl ether and is
extremely flammable and toxic. Do not smoke and make sure you are in a
well-ventilated area away from heat, open flames, or sparks when installing,
maintaining, testing, or troubleshooting the cold start system.

Wear goggles and make sure openings are pointed away from you when
activating system with lines or fittings disconnected to avoid eye injury. If fluid
enters the eyes or fumes irritate the eyes, they should be flushed with large
quantities of clean water for 15 minutes. A physician should be contacted.

Starting fluid can be harmful or fatal if swallowed. If swallowed, DO NOT

INDUCE VOMITING. Call a physician immediately.

Contents of cylinder are under pressure. Store in a cool dry place. Do not
incinerate, puncture, or attempt to remove cores from cylinder.

Inspection

a. Remove fluid cylinder (3, Figure 2-2-6), refer to Removal procedures, and weigh cylinder to determine
remaining fluid as follows:

(1) 21 oz cylinder:
Full - weighs 37 oz (1049 gr)
Empty - weighs 16 oz (454 gr)

(2) Present weight minus empty weight = remaining weight. To convert to liquid volume, one oz of weight
= 39 ml of liquid (one gr = 1.4 ml). Example:
Present weight = 26 oz (733 gr)
Empty weight = 16 oz (454 gr)
Remaining weight = 10 oz (279 gr)
Liquid volume = 10 oz (279 gr) X 39 ml (1.4 ml) = 390 ml or cylinder approximately 1/2 full

b. Inspect all system tubing for damage and cleanliness (obstructions). Clean or replace as necessary.

c. Remove atomizer (13), refer to Removal procedures, and inspect for damage and cleanliness. Clean or
replace as necessary.

d. Inspect system electrical wiring for security and damaged connectors or insulation. Tighten or replace as
necessary.

2-2-26
 TM 5-3810-307-24-1-1

NOTE

The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (9) has left-hand threads.

e. Remove metered orifice elbow (10) and filter (11) from bottom port of valve (9), refer to Removal
procedures, and inspect for damage and cleanliness. Clean or replace as necessary.

f. Inspect valve assembly (9) for damage and security of mounting. Tighten or replace as necessary.

NOTE

The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (9) has left-hand threads.

g. Install fluid cylinder (3), filter (11), metered orifice elbow (10), and atomizer (13), refer to Installation
procedures.

Test

a. Test cold start temperature switch (14, Figure 2-2-6) as follows:

(1) Drain radiator.

(2) Remove cold start temperature switch, refer to Removal procedures.

(3) Connect multimeter, set for ohms, across terminals of switch connector. Multimeter should indicate
switch is open (no continuity).

(4) Suspend temperature switch in water chilled to below 45 F (7 C). Multimeter should indicate closed
circuit (continuity).

(5) If indications are other than above, switch is defective and must be replaced.

(6) Apply thread sealant to threads of temperature switch (14) and install temperature switch, refer to
Installation procedures.

(7) Service radiator, refer to Lubrication Chart.

b. Test operation of cold start valve assembly (9) as follows:

(1) Remove fluid cylinder (3) from valve assembly (9).

(2) Disconnect electrical connector for fuel shutoff solenoid (refer to TM 5-3810-307-24-2-1, page A-33),
position battery disconnect switch to on position, and actuate cold start valve by positioning ignition
switch to START.

2-2-27 C-1
TM 5-3810-307-24-1-1

LEGEND

1. Cover 6. Capscrew 11. Filter

2. Clamp 7. Lockwasher 12. O-ring
3. Fluid cylinder 8. Washer 13. Atomizer
4. Gasket 9. Valve assembly 14. Temperature Switch
5. Plastic tube 10. Metered orifice elbow

Figure 2-2-6. Cold Start System

2-2-28
 TM 5-3810-307-24-1-1

NOTE

If ambient temperature is above 45F (7C) it will be necessary to "hot-wire"

the system in order to actuate the valve. This is accomplished by
disconnecting the cold start temperature switch from the engine harness and
connecting a jumper wire across terminals of the engine harness connector,
refer to Detail A. When finished, be sure to remove jumper wire and connect
temperature switch.

(3) Valve plunger should move up and remain up until ignition switch is released from START position.

(4) If valve plunger does not move up, apply 24 vdc directly to valve electrical connector. If plunger still
does not move up, valve is defective and must be replaced. If plunger moves up, electrical wiring is
faulty.

(5) Position ignition switch to OFF, place battery disconnect switch to off position, and connect fuel
shutoff solenoid electrical connector.

(6) If jumper wire was used, remove jumper wire and connect electrical connector for temperature switch.

(7) Install fluid cylinder (3) on valve assembly (9), refer to Installation procedures.

Removal

a. Ensure battery disconnect switch is in off position.

b. Disconnect electrical connector for cold start valve assembly (9, Figure 2-2-6) from engine harness.

c. Remove cover (1) from valve assembly (9).

d. Loosen clamp (2), unscrew fluid cylinder (3) from valve assembly (9), then remove gasket (4) from inside of
valve.

e. Disconnect tube (5) from metered orifice elbow (10).

f. Remove capscrews (6), lockwashers (7), washers (8), and valve assembly (9) from crane.

NOTE

The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (8) has left-hand threads.

g. Remove metered orifice elbow (10) from valve assembly (9) and filter (11) and o-ring (12) from elbow (10).

h. Disconnect tube (5) from atomizer (13) and remove tube (5) from crane.

i. Remove atomizer (13) from engine air inlet tube.

j. Drain radiator.

k. Disconnect electrical connector for cold start temperature switch (14) and unscrew switch from tee at top
front center of cylinder head.

2-2-29
TM 5-3810-307-24-1-1

Installation

a. Apply thread sealant to threads of cold start temperature switch (14, Figure 2-2-6), and install cold start
temperature switch (14) in tee at top front center of cylinder head.

b. Install atomizer (13) in engine air inlet tube. Ensure atomizer port is directed toward incoming air (red dot
on fitting indicates position of port).

c. Connect tube (5) to atomizer (13) and route tube (5) to cold start valve assembly (9) mounting area.

d. Install valve assembly (9) with washers (8), lockwashers (7), and capscrews (6).

CAUTION

Always replace gasket (4) when installing a new fluid cylinder (3). Gasket
comes with cylinder.

e. Spread a light film of clean engine oil on gasket (4) and threads of cylinder (3).

f. Position gasket (4) in valve (9) and screw cylinder (3) into valve until o-ring on cylinder contacts valve.
Then tighten cylinder 1-1/2 additional turns.

g. Tighten clamp (1) and connect valve electrical connector to engine harness.

CAUTION

Allow contents of cylinder to settle for approximately 15 to 20 minutes before

testing or activating cold start system. Failure to allow contents to settle may
cause premature clogging of system necessitating cleaning or replacement of
filter at valve outlet port.

h. Disconnect electrical connector for fuel shutoff solenoid (refer to TM 5-3810-307-24-2-1, page A-33),
position battery disconnect switch to on position, and actuate cold start valve by positioning ignition switch to
START. This will purge any debris that did not settle from valve.

NOTE

If ambient temperature is above 45F (7C) it will be necessary to "hot-wire"

the system in order to actuate the valve. This is accomplished by
disconnecting the cold start temperature switch from the engine harness and
connecting a jumper wire across terminals of the engine harness connector,
refer to Detail A. Remember to remove jumper wire and connect temperature
switch when finished.

i. Position ignition switch to OFF, place battery disconnect switch to off position, and connect fuel shutoff
solenoid electrical connector.

j. If jumper wire was used, remove jumper wire and connect electrical connector for temperature switch.

NOTE

The metered orifice elbow (10) fitting that threads into the bottom of valve
assembly (9) has left-hand threads.

k. Position o-ring (12) and filter (11) in metered orifice elbow (10) and install elbow (10) in valve assembly (9).

2-2-30 C-1
 TM 5-3810-307-24-1-1

l. Connect tube (5) to elbow (10).

m. Install cover (1) on cold start valve assembly (9).

n. Service radiator, refer to Lubrication Chart.

2-2-31
TM 5-3810-307-24-1-1

WATER COOLING SYSTEM

DESCRIPTION

The cooling system consists of the radiator, engine
cooling circuit, and the connecting hoses. The
temperature is controlled by a 180 degree F (82
degrees C) thermostat located between the top of the
engine and the top of the radiator. Attached to the
radiator as part of the assembly, is an air cooler
(aftercooler) which cools the intake air prior to
entering the air intake manifold.
At all times, the coolant should be properly inhibited
against corrosion. Ensure that the proper antifreeze,
in the proper proportion is used, to ensure adequate
protection in reference to cooling system capacity.
Only the antifreeze listed in the Lubrication Chart
should be used.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

RADIATOR AND AIR COOLER

WARNING
Engine must be cool to the touch prior to working on coolant system
components. Failure to comply could result in scalding or serious burns.

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Place appropriate container under radiator (34, Figure 2-2-7), open drain valve (49) and drain coolant from
radiator [capacity - 10.5 gals. (39.7 L)]. Close drain valve (49).

c. Remove engine top panel and side access doors, refer to Engine Hood Removal procedures.

d. Remove nut (1), lockwasher (2), washer (3), clamp (4), and drain hose (5) from carrier frame.

e. Loosen clamp (6) and disconnect recovery coolant hose (7), from radiator (34) filler neck.

f. Remove capscrews (8) and clamps (9) securing recovery tank overflow hose (10) to radiator shroud (44).

g. Remove exhaust tube and adapter between turbocharger and flexible tubing, refer to Muffler and Piping
Removal procedures.

h. Remove engine hood center cowl, refer to Engine Hood Removal procedures.

i. Loosen clamps (11) and disconnect air cooler tubes from flexible hoses (12).

j. Loosen clamps (13) and disconnect top radiator hose (14) from radiator (34), and bottom radiator hose (15)
from engine.

2-2-32
 TM 5-3810-307-24-1-1

k. Loosen clamp (16) and disconnect aeration hose (17) from adapter (52).

l. Remove capscrews (18), lockwashers (19), large washers (20), fan guard (21), and spacers (22) from
shroud (44).

m. Remove capscrews (62), lockwashers (63), washers (64), and plate (60) from shroud (44) to access cooling
fan (25) attaching hardware.

n. Remove capscrews (23), washers (24), cooling fan (25), and three-piece adapter (26) from engine.

o. Remove nut (27), lockwasher (28), and disconnect support rod (29) from bottom of radiator (34).

p. Remove locknuts (30), washers (31), capscrews (32), and washers (33) securing radiator (34) to frame
mounting brackets.

CAUTION

Ensure radiator and air cooler components do not catch on carrier baffling or
other components resulting in equipment damage when lifting assembly from
carrier.

q. Attach lifting device to radiator (34), lift radiator (34) and air cooler (39) from carrier as an assembly, then
remove rubber mounts (35) from frame mounting brackets.

r. Remove the following as necessary:

(1) Remove capscrews (36), lockwashers (37), washers (38), air cooler (39), and baffle (40) from radiator
(34).

(2) Remove capscrews (41), lockwashers (42), washers (43), and shroud (44) from radiator (34).

(3) Remove capscrews (45), lockwashers (46), and radiator mount brackets (47) from radiator (34).

(4) Loosen clamp (48) and remove drain valve (49) from radiator drain hose (5).

(5) Loosen clamp (50) and remove hose (5) from adapter (51) and adapters (51 and 52) from radiator
(34).

(6) Remove nuts (53), lockwashers (54), washers (55), capscrews (56), and coolant recovery tank (57)
from engine hood center cowl.

(7) Remove clamps (58) and hoses (7 and 10) from recovery tank (57).

(8) Remove clamp (59) and lower radiator hose (15) from radiator (34).

2-2-33
TM 5-3810-307-24-1-1

Figure 2-2-7. Radiator and Air Cooler Installation

2-2-34
 TM 5-3810-307-24-1-1

LEGEND for Figure 2-2-7

1. Nut 17. Hose 33. Washer 49. Drain valve

2. Lockwasher 18. Capscrew 34. Radiator 50. Clamp
3. Washer 19. Lockwasher 35. Mount 51. Adapter
4. Clamp 20. Large washer 36. Capscrew 52. Adapter
5. Hose 21. Fan guard 37. Lockwasher 53. Nut
6. Clamp 22. Spacer 38. Washer 54. Lockwasher
7. Hose 23. Capscrew 39. Air cooler 55. Washer
8. Capscrew 24. Washer 40. Baffle 56. Capscrew
9. Clamp 25. Cooling fan 41. Capscrew 57. Recovery tank
10. Hose 26. Adapter 42. Lockwasher 58. Clamp
11. Clamp 27. Nut 43. Washer 59. Clamp
12. Flexible hose 28. Lockwasher 44. Shroud 60. Plate
13. Clamp 29. Support rod 45. Capscrew 61. Retaining nut
14. Hose 30. Locknut 46. Lockwasher 62. Capscrew
15. Hose 31. Washer 47. Mount bracket 63. Lockwasher
16. Clamp 32. Capscrew 48. Clamp 64. Washer

Installation

a. Install the following as necessary:

CAUTION

Do not apply sealant to inside of radiator hose and push it onto male adapter.
This can result in excess sealant being pushed ahead of male adapter and
into hose exposing sealant to engine coolant. The coolant can then carry the
excess sealant into the radiator cores and engine water jackets, plug the
coolant passages, and result in premature engine failure.

(1) Apply LOCTITE #518 sealant on male hose adapter, and install lower radiator hose (15, Figure 2-2-7)
on radiator (34) with clamp (59).

(2) Install hoses (7 and 10) on coolant recovery tank (57) with clamps (58).

(3) Install recovery tank (57) on engine hood center cowl with capscrews (56), washers (55), lockwashers
(54), and nuts (53).

(4) Install adapters (52 and 51) in radiator (34) and drain hose (5) on adapter (51) with clamp (50).

(5) Install drain valve (49) in hose (5) with clamp (48).

(6) Install radiator mount brackets (47) on radiator (34) with lockwashers (46) and capscrews (45).

(7) Install shroud (44) on radiator (34) with washers (43), lockwashers (42), and capscrews (41).

(8) Install baffle (40) and air cooler (39) on radiator (34) with washers (38), lockwashers (37), and
capscrews (36).

CAUTION

Ensure radiator and air cooler components do not catch on carrier baffling or
other components resulting in equipment damage when lowering assembly
into carrier.

2-2-35
TM 5-3810-307-24-1-1

b. Attach lifting device to radiator (34), place rubber mounts (35) on frame mounting brackets, and lower
radiator (34) and air cooler (39) into carrier while aligning holes for rubber mounts and mounting brackets.

c. Secure radiator (34) to frame mounting brackets with washers (33), capscrews (32), washers (31), and
locknuts (30).

d. Apply LOCTITE 242 to threads of capscrews (23), position and align three-piece adapter (26) and cooling
fan (25) to engine, and secure with washers (24) and capscrews (23). Torque capscrews (23) to 32 lbs-ft (43.4
Nm).

e. Install plate (60) over opening in shroud (44) and secure with capscrews (62), lockwashers (63), and
washers (64).

f. Install fan guard (21) on shroud (44) with spacers (22), large washers (20), lockwashers (19), and
capscrews (18).

g. Connect aeration hose (17) to adapter (52) with clamp (16).

CAUTION

Do not apply sealant to inside of radiator hose and push it onto male adapter.
This can result in excess sealant being pushed ahead of male adapter and
into hose exposing sealant to engine coolant. The coolant can then carry the
excess sealant into the radiator cores and engine water jackets, plug the
coolant passages, and result in premature engine failure.

h. Apply LOCTITE #518 sealant to male hose adapters, and connect lower radiator hose (15) to engine, and
upper radiator hose (14) to radiator (34) and tighten clamps (13).

Figure 2-2-8. Radiator Hose Sealant Application

2-2-36
 TM 5-3810-307-24-1-1

i. Connect air cooler tubes to flexible hoses (12) and tighten clamps (11). Torque "Breeze" clamps 50-60 lbs-
in. (5.6-6.7 Nm) or "R. G. Ray" clamps 60-75 lbs-in. (6.7-8.5 Nm).

j. Install engine hood center cowl, refer to Engine Hood Installation procedures.

k. Install exhaust tube and adapter between turbocharger and flexible tubing, refer to Muffler and Piping
Installation procedures.

l. Secure recovery tank overflow hose (10) to shroud (44) with clamps (9) and capscrews (8).

m. Connect recovery tank coolant hose (7) to radiator (34) filler neck and tighten clamp (6).

n. Connect support rod (29) to bottom of radiator (34) with lockwasher (28) and nut (27).

o. Secure drain hose (5) to carrier frame with clamp (4), washer (3), lockwasher (2), and nut (1).

p. Install engine top panel and side access doors, refer to Engine Hood Installation Procedures.

q. Ensure drain valve (49) is closed and service radiator.

r. Using static coolant system pressure tester, perform static check of coolant system.

s. Start engine and check for leaks. Shut down engine after 15 minutes of operation. Allow system to cool.

t. Check coolant level in recovery tank and service if necessary.

2-2-37
TM 5-3810-307-24-1-1

EXHAUST SYSTEM

DESCRIPTION

The exhaust system consists of the muffler and the
tubing connecting the muffler to the exhaust side of
the engine turbocharger.
The muffler is mounted vertically to direct exhaust
gases up and away from personnel operating the
crane or working in the immediate vicinity. The
muffler includes a weather cap which is installed on
the top of the exhaust stack to keep rain water from
entering the muffler when the engine is not running.
A muffler guard is installed around the portion of the
muffler exposed above the crane deck to help protect
personnel from the potential of burns.

MAINTENANCE

MUFFLER AND PIPING

WARNING
Exhaust components must be cool to the touch prior to working on exhaust
system. Failure to comply could result in serious burns.

Removal

a. Open right side engine access door.

b. Remove capscrews (1, Figure 2-2-9), lockwashers (2), washers (3), and cover (4) from underside of right
front fender.

c. Remove nuts (5), lockwashers (6), capscrews (7), washers (8), and cover (9) from top of right front fender.

d. Remove screws (10), lockwashers (11), washers (12), and cover (13) from underside of deck plate just
forward of right front fender.

e. Remove clamp (14), locknuts (15), clamp (16), locknuts (17), capscrews (18), both clamps (19), and
exhaust tube (20) from turbocharger. Then remove adapter (21) from flexible exhaust tube (25).

f. Remove locknuts (22), capscrews (23), clamp (24), and flexible exhaust tube (25) from exhaust pipe (28).

g. Remove locknuts (26), clamps (27) and exhaust pipe (28) from muffler (41).

h. Remove capscrews (29), lockwashers (30), washers (31), large washers (32), muffler guard (33), and cover
(34) from muffler mount bracket (50).

i. Remove weather cap (35), locknuts (36), capscrews (37), clamp (38), and exhaust stack (39) from muffler
(41).

j. Loosen screws in mounting bands (40), spread mounting bands apart, and remove muffler (41) from crane.

k. If necessary, remove nuts (42), lockwashers (43), capscrews (44), washers (45), and mounting bands (40)
from muffler mount bracket (50).

2-2-38
 TM 5-3810-307-24-1-1

l. If necessary, remove nuts (46), lockwashers (47), capscrews (48), washers (49), and muffler mount bracket
(50) from crane.

Installation

a. If removed, install muffler mount bracket (50, Figure 2-2-9) on crane with washers (49), capscrews (48),
lockwashers (47), and nuts (46).

b. If removed, install mounting bands (40) on muffler mount bracket (50) with washers (45), capscrews (44),
lockwashers (43), and nuts (42).

c. Slide muffler (41) up through mounting bands (40) and place bottom of muffler onto bracket on frame.
Tighten mounting bands (40).

d. Install exhaust stack (39) with weather cap (35) on muffler (41) with clamp (38), capscrews (37), and
locknuts (36).

e. Install cover (34) and muffler guard (33) on muffler mount bracket (50) with large washers (32), washers
(31), lockwashers (30), and capscrews (29).

f. Install exhaust pipe (28) on muffler (41) and frame bracket with clamps (27) and locknuts (26).

g. Install flexible exhaust tube (25) on exhaust pipe (28) with clamp (24), capscrews (25), and locknuts (22).

h. Install adapter (21) on flexible exhaust tube (25) and exhaust tube (20) on adapter (21) with clamps (19),
capscrews (18), and locknuts (17).

i. Install exhaust tube (20) on turbocharger with clamp (14), and secure exhaust tube (20) to engine bracket
with clamp (16) and locknuts (15).
WARNING
Exhaust system components can be very hot. Use care to avoid serious
burns.

j. Start diesel engine and check exhaust system for evidence of exhaust leaks. Shutdown diesel engine,
allow exhaust system components to cool, and tighten any clamps as necessary.

k. Install cover (13) on underside of deck plate forward of right front fender with washers (12), lockwashers
(11), and screws (10).

l. Install cover (9) on top of right front fender with washers (8), capscrews (7), lockwashers (6), and nuts (5).

m. Install cover (4) on underside of right front fender with washers (3), lockwashers (2), and capscrews (1).

n. Close right side engine access door.

2-2-39
TM 5-3810-307-24-1-1

LEGEND

1. Capscrew 18. Capscrew 35. Weather cap

2. Lockwasher 19. Clamp 36. Locknut
3. Washer 20. Exhaust tube 37. Capscrew
4. Cover 21. Adapter 38. Clamp
5. Nut 22. Locknut 39. Exhaust stack
6. Lockwasher 23. Capscrew 40. Mounting band
7. Capscrew 24. Clamp 41. Muffler
8. Washer 25. Flexible exhaust tube 42. Nut
9. Cover 26. Locknut 43. Lockwasher
10. Screw 27. Clamp 44. Capscrew
11. Lockwasher 28. Exhaust pipe 45. Washer
12. Washer 29. Capscrew 46. Nut
13. Cover 30. Lockwasher 47. Lockwasher
14. Clamp 31. Washer 48. Capscrew
15. Locknut 32. Large washer 49. Washer
16. Clamp 33. Muffler guard 50. Muffler mount bracket
17. Locknut 34. Cover

Figure 2-2-9. Muffler and Piping (Sheet 1 of 2)

2-2-40
 TM 5-3810-307-24-1-1

Figure 2-2-9. Muffler and Piping (Sheet 2 of 2)

2-2-41/(2-2-42 Blank)
 TM 5-3810-307-24-1-1

SECTION 3
DRIVE TRAIN

TABLE OF CONTENTS
Page

DRIVE TRAIN
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Drive Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
TRANSMISSION/TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Converter Lockup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Operation of Powershift Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9
Transmission Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
TRANSMISSION OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
AUTOMATIC POWERSHIFT CONTROL (APC 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Direct Engagement Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Downshift Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Low Clutch Pressure Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Override System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic/Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Throttle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Lockup Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Turbine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Two Wheel Drive Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Lockup Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Overspeed and Low Clutch Pressure Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Checkout Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-18

2-3-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

Page

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
Test Procedures with Checkout Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
Installation of Checkout Kit and Start-up Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
Input and Output Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
APC 100 Checkout Kit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-25
Replacement of Checkout Kit EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-26
Test Procedures Without Checkout Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-27
Transmission RPM/Pressure Indicator Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-27
Shifting Problem Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-27
Manual/Automatic Shared System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-28
APC 100 Control Box Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-29
Throttle Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-31
Gear Selector Input Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-32
Speed Sender Input Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-33
Torque Converter Lockup Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-33
4WD Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-34

LIST OF FIGURES

Number Title Page

2-3-1 Drive Lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6

2-3-2 Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-12
2-3-3 APC 100 and Related Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-14
2-3-4 Block Diagram of APC 100 Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-15
2-3-5 APC 100 Mode Control Fuse and Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-16
2-3-6 Diagnostic LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
2-3-7 Checkout Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-18
2-3-8 Transmission Harness Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-21
2-3-9 Checkout Kit Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-25
2-3-10 Checkout Kit Input Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-25
2-3-11 Checkout Kit Output Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-25
2-3-12 Checkout Kit Center PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-26
2-3-13 Transmission Solenoid Connector (Transmission Valve Body). . . . . . . . . . . . . . . . . . . . 2-3-28
2-3-14 Transmission Solenoid Connector (Engine Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-28
2-3-15 APC 100 Input Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-30
2-3-16 APC 100 Output Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-30
2-3-17 APC 100 EPROM Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-31

2-3-2
 TM 5-3810-307-24-1-1

LIST OF TABLES

Number Title Page

2-3-1 Checkout Kit LEDs for Transmission Shift Control Inputs . . . . . . . . . . . . . . . . . . . . 2-3-20
2-3-2 Harness Tester LEDs for Transmission Shift Control Outputs to Solenoids. . . . . . . . . 2-3-22
2-3-3 Checkout Kit LEDs for APC 100 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-23
2-3-4 Four Wheel Drive Control System and Checkout Kit Conditions . . . . . . . . . . . . . . . . 2-3-23
2-3-5 Gear Selection Circuit Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-29
2-3-6 Gear Selector Input Signals (Voltages) to APC 100 . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-32
2-3-7 Lockup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-34
2-3-8 2WD/4WD Output Circuit Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-35

2-3-3/(2-3-4 Blank)
 TM 5-3810-307-24-1-1

DRIVE TRAIN

DESCRIPTION

The drive train consists of the transmission/torque
converter assembly and two drive shafts.
The transmission/torque converter is a Clark 13.9
LFHR 24658 assembly w/APC 100 auto shift, and is
mounted on, and driven by the engine. The torque
converter assembly also provides for mounting and
driving the hydraulic pump. The transmission is a
powershift (six speed forward and three reverse)
transmission. The transmission is controlled by a
shift control lever located on the right side console of
the carrier cab and the right side of the front console
in the superstructure cab.

2-3-5
TM 5-3810-307-24-1-1

MAINTENANCE

DRIVE LINES

Removal

CAUTION

Mark the universal(s) so they can be installed as removed, otherwise severe

drive line vibration may occur.

a. Scribe a match mark across drive shaft universal bearings and component drive flanges (Figure 2-3-1).

b. Support drive shaft and remove capscrews and lockwashers securing drive shaft universal bearings to
component drive flanges.

c. Remove drive shaft from crane.

d. If necessary, remove capscrews, lockwashers, and universal bearings from drive shaft.

Installation

a. If removed, install universal bearings (Figure 2-3-1) on drive shaft with lockwashers and capscrews.
Torque capscrews to 90-110 lbs-ft (122-149 Nm).

b. Position drive shaft to component drive flange aligning match marks made during removal.

c. Secure drive shaft with lockwashers and capscrews. Torque capscrews to 90-110 lbs-ft (122-149 Nm).

Lubrication

Lubricate the universal joints in accordance with Lubrication Chart, Chapter One, Section 4.

Figure 2-3-1. Drive Lines Installation

2-3-6
 TM 5-3810-307-24-1-1

TRANSMISSION/TORQUE CONVERTER

DESCRIPTION

The function of the transmission/torque converter is made are shown on the following chart:
to control/convert power developed by the engine
and supply power to drive the hydraulic pumps, and Shift Points at MPH/KPH
motive power to the axles. The transmission/torque
converter is a single assembly mounted directly onto Gear Up-Shift Speed Gear Down-Shift
the engine. It provides six sequential, power shifted MPH ! KPH
speeds. Torque from the transmission/torque 1st to 2nd 5 8 2nd to 1st
converter is transferred as driving power for the
axles via drive shafts connected between them. 2nd to 3rd 7 11 3rd to 2nd

3rd to 4th 12 19 4th to 3rd

CONVERTER LOCKUP 4th to 5th 17 28 5th to 4th

5th to 6th 36 57 6th to 5th

The torque converter is equipped with automatic
lock-up capabilities and activates at a predetermined
rpm and torque level.
This capability allows the crane to operate more
effic-iently when driven and is useful on downhill
grades and during deceleration where the additional
braking effect from the engine is advantageous.
OPERATION OF POWERSHIFT TRANSMISSION
Stepping of changes should be progressive. No
attempt should be made to down or up-shift 2 gears
or more at any one time.
It is not always necessary to start crane in 1st gear.
Up to 3rd gear may be used when starting on
reasonably level terrain.

To avoid hard shifting, when operating in the manual

mode, the road speeds at which a shift should be

THEORY OF OPERATION

The transmission and torque converter function spool works against the spring until a port is exposed
together and operate through a common hydraulic along the side of the bore. This sequence maintains
system. Therefore, it is necessary to consider both the pressure needed for control and assures proper
units in discussing operation. system operation.

With the engine running, the converter charging
pump draws oil from the transmission sump through
the removable oil suction screen and directs it
through the pressure regulating valve and oil filter.
The pressure regulating valve maintains the
pressure used to actuate the directional and speed
clutches which control the transmission. This
requires a small portion of the total volume of oil
used in the system. The remaining volume of oil is
directed through the torque converter circuit to the oil
cooler, then returned to the transmission. The
regulator valve consists of a hardened valve spool
operating in a closely fitted bore. The valve spool is
spring loaded to hold the valve in a closed position.
When the specified pressure is achieved, the valve
After entering the converter housing, the oil is
directed through the reaction member support, to the
converter blade cavity, then exits in the passage
between the turbine shaft and reaction member
support. The oil then flows out of the converter to
the oil cooler. After leaving the cooler, the oil is
returned to a fitting on the transmission, and directed
through a series of tubes and passages where it
lubricates the transmission bearings and clutches,
then gravity drains to the transmission sump.
2-3-7
TM 5-3810-307-24-1-1
The torque converter consists of three basic
elements and their related parts which multiply
engine torque. The engine power is transmitted from
the engine flywheel to the impeller element through
the impeller cover. This element is the pump portion
of the hydraulic torque converter, and is the primary
component which starts the oil flowing to the other
components to obtain the desired torque
multiplication. The impeller can be compared to a
centrifugal pump in that it picks up fluid at its center
and discharges at its outer diameter.
The torque converter turbine is mounted opposite the
impeller and is connected to the output shaft of the
torque converter. This element receives fluid at its
outer diameter and discharges at its center. Fluid
directed by the impeller out into the particular design
of blading in the turbine and reaction member,
provides the coupling by which the hydraulic torque
converter multiplies torque.
The reaction member of the torque converter is
located between and at the center of inner diameters
of the impeller and turbine elements. Its function is
to capture the fluid which is exhausting from the
inner portion of the turbine and change its direction
to allow correct entry for recirculation into the
impeller element.
The torque converter will multiply engine torque to its
designed maximum multiplication ratio when the
output shaft is at zero rpm. Therefore, as the output
shaft is decreasing in speed, the torque multiplication
is increasing.
The torque converter is equipped with automatic
lockup capabilities. This feature allows the torque
converter to change from a fluid coupling to a direct
mechanical link between the engine and
transmission at a predetermined rpm level. The
lockup function is controlled by the lockup solenoid
located on the right wall of the transmission well.
Torque converter slippage is eliminated when in the
lockup mode, allowing the engine to run at a lower
rpm to maintain vehicle speed. It also provides the
advantage of using engine compression as a brake
in downgrade conditions.
The shift control valve assembly consists of a valve
body with selector valve spools. A detent ball and
2-3-8
spring in the selector spool provides one position for
each speed range. A detent ball and spring in the
direction spool provides three positions, one each for
forward, neutral, and reverse.
With the engine running and the directional control
lever in the neutral position, oil pressure from the
regulating valve is blocked at the control valve, and
the transmission is in neutral. Movement of the
forward and reverse spool will direct oil under
pressure, to either the forward or reverse direction
clutch as desired. When either directional clutch is
selected, the opposite clutch is relieved of pressure
and vents back through the direction selector spool.
The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a
drum with internal splines and a bore to receive a
hydraulically actuated piston. Sealing rings make
the piston oil tight. A steel disc with external splines
is inserted into the drum and rests against the piston.
Next a friction disc with splines at the inner diameter
is inserted. Discs are alternated until the required
total is achieved. A heavy back-up plate is then
inserted and secured with a snap ring. A hub with
OD splines is inserted into the splines of discs with
teeth on the inner diameter. The discs and hub are
free to increase in speed, or rotate in the opposite
direction as long as no pressure is present in that
specific clutch.
To engage the clutch, the control valve is placed in
the desired position. This allows oil under pressure
to flow from the control valve, through a tube, to a
chosen clutch shaft. This shaft has a drilled
passageway for oil under pressure to enter the shaft.
Pressure sealing rings located on the clutch shaft,
direct oil under pressure to the desired clutch.
Pressure of the oil forces the piston and discs
against the heavy back-up plate. The discs, with
teeth on the outer diameter, clamping against discs
with teeth on the inner diameter, cause the hub and
clutch shaft to be locked together and force them to
drive as a unit.
There are bleed balls in the clutch piston which allow
quick escape for oil when the pressure to the piston
is released.
 TM 5-3810-307-24-1-1

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

TRANSMISSION REMOVAL AND INSTALLATION.

Refer to Section 2 - Engine and Transmission Assembly.

2-3-9
TM 5-3810-307-24-1-1

TRANSMISSION CONTROL VALVE

DESCRIPTION

The transmission control valve is mounted directly electrically controlled and functions to direct oil under
onto the side of the transmission. The valve is pressure to the desired directional and speed clutch.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

2-3-10
 TM 5-3810-307-24-1-1

TRANSMISSION OIL COOLER

DESCRIPTION

The transmission oil cooler is located at the rear of
the crane carrier and is mounted on brackets
between the frame rails. The oil cooler consists of a
radiator core and an electric motor with fan. The oil
cooler is used to dissipate heat from the oil in the
transmission system. The fan motor is controlled by
a temperature switch and a relay. The temperature
switch is threaded into the oil cooler and has
normally open contacts. When the oil temperature
reaches approximately 165 degrees F (73.8 degrees
C) the switchs contacts close. This allows the oil
cooler relay to energize and activate the oil cooler
fan motor.

MAINTENANCE

REMOVAL. INSTALLATION.

1. Tag and disconnect the wires for the tempera- 1. Position the oil cooler onto the mounting brack-
ture switch and the oil cooler fan motor, refer to ets and secure in place with the bolts, nuts, and
Figure 2-3-2. washers, refer to Figure 2-3-2.

2. Disconnect the transmission oil lines from the 2. Connect the transmission oil lines to the oil
oil cooler. cooler.

3. Remove the bolts, nuts, and washers securing 3. Connect the wires for the temperature switch
the oil cooler to the mounting brackets and remove and oil cooler fan motor as tagged during
the oil cooler. REMOVAL.

2-3-11
TM 5-3810-307-24-1-1

Figure 2-3-2. Transmission Oil Cooler

2-3-12

AUTOMATIC POWERSHIFT CONTROL (APC 100)
DESCRIPTION
GENERAL
NOTE
The automatic powershift control is only
applicable to the carrier cab.
Transmission control from the super-
structure cab is manual.
The automatic powershift control (APC 100), located
behind the operator's seat, is a small computer
dedicated to transmission control. Information such
as engine speed, turbine speed, gear selection, and
throttle position is used by the computer to determine
the proper time to shift the transmission. The APC
100 prevents a dangerous shift if an improper gear is
selected with the shift control. Torque converter
lockup is also controlled by the APC 100.
NOTE
Removing carrier cab seat will provide
easier access to the APC 100 and the
fuse and relay box.
DIRECT ENGAGEMENT PROTECTION
From neutral, a forward or reverse gear cannot be
selected if the engine speed is above 1000 rpm.
When changing direction, the engine speed must be
less than 1000 rpm and the vehicle speed must be
less than one mph, or the transmission will shift into
neutral.
If the crane is moving, drive can only be engaged
when the engine speed is less than 1200 rpm in 1st
or 2nd, 1400 rpm in 3rd or 4th, and 1600 rpm in 5th
or 6th (both forward and reverse).
DOWNSHIFT PROTECTION
Downshifting is only allowed if there is no risk of
overspeeding the transmission. If a gear is selected
that would result in an overspeeding condition, the
computer will select the lowest gear that will not
cause overspeeding and the TRANS RPM/PRESS
indicator on the front console will be lit (steady). This
condition will remain until the vehicle has slowed
enough to make the shift into the selected gear.
TM 5-3810-307-24-1-1
LOW CLUTCH PRESSURE WARNING
The APC 100 monitors transmission clutch pressure.
If clutch pressure becomes critically low, the APC
100 will cause the TRANS RPM/PRESS indicator to
light as a blinking warning, until normal clutch
pressure returns.
OVERRIDE SYSTEM
The override system allows the transmission to be
shifted manually. The override (automatic/manual)
switch is mounted on top of the APC 100 mode
control fuse and relay box and energizes relays that
disconnect the shift solenoids from the computer and
connects them to the cab shift control. This allows a
vehicle disabled due to electronic shift failure to be
driven to the nearest maintenance point. Each time
the ignition switch is turned off and then back on, the
override switch must be reset. The safety
parameters set by the computer are not active in
system override.
INPUTS
Automatic/Manual
The automatic/manual mode (override) switch is on
top of the APC 100 mode control fuse and relay box.
An open switch indicates automatic mode and a
closed switch indicates manual mode. A closed
switch inputs battery voltage. The manual mode
must be reactivated each time the ignition switch is
turned off then back on.
Clutch Pressure
Clutch pressure is monitored by a clutch pressure
switch that closes if the clutch pressure becomes
critically low. A closed switch inputs battery voltage.
Engine Speed
The engine speed input is obtained from a variable
reluctance speed sensor mounted in the converter
housing. The teeth of a ferrous target wheel pass by
the pole of the sensor which produces a pulsed
signal. The APC 100 measures the time between
the pulses to calculate the engine rpm.
2-3-13
TM 5-3810-307-24-1-1

Figure 2-3-3. APC 100 and Related Components Installation

2-3-14
 TM 5-3810-307-24-1-1

Figure 2-3-4. Block Diagram of APC 100 Inputs and Outputs

2-3-15
TM 5-3810-307-24-1-1

Figure 2-3-5. APC 100 Mode Control Fuse and Relay Box

2-3-16

Four Wheel Drive
The DRIVE AXLE selector switch on the front
console is used to select two or four wheel drive.
When two wheel drive is selected, there is no input.
When four wheel drive is selected, battery voltage is
input indicating four wheel drive selection.
Throttle Position
An idle switch inputs battery voltage when the throttle
is in the idle position (switch closed). When the
throttle is moved from the idle position the idle switch
opens and the full throttle position switch closes
inputting battery voltage to indicate throttle position.
Gear Selection
A switch matrix of five wires decodes the gear
selector position. The five wires are switched
between open and battery voltage.
Lockup Request
The lockup switch closes and inputs battery voltage
to enable converter lockup when conditions permit.
An open switch disables lockup.
Turbine Speed
The turbine speed is monitored by a pulsed signal
that is generated by a speed sensor in the same
manner as the engine speed sensor.
OUTPUTS
Diagnostic LEDs
Figure 2-3-6. Diagnostic LEDs
There are three diagnostic LEDs (Light Emitting
Diodes), under a cover, on the top of the APC 100
control box. These lights can be used by
TM 5-3810-307-24-1-1
maintenance personnel to help troubleshoot the
system. During initial power-up, the unit will self test
and the LEDs will light for about one second. After
that they will light to reflect the following faults:
RED LED - Illuminates if there is a problem
internal to the APC 100 control unit. In this
case the APC 100 enters the fail-safe mode
and all outputs are switched off.
YELLOW LED - Illuminates when engine or
turbine speed reads zero. This LED will
remain lit until the engine is started.
GREEN LED - Illuminates when an improper
gear selection pattern is input by the shift
selector.
Two Wheel Drive Solenoid
If four wheel drive input voltage is present, the APC
100 will automatically switch to two wheel drive when
the transmission reaches F4 or R5. The four wheel
drive voltage opens the 2WD interlock relay allowing
the 2WD load out relay to close and battery voltage
is output to switch the vehicle to two wheel drive.
Lockup Solenoid
The torque converter lockup output switches
between battery voltage and zero depending on the
engine and turbine speed input ratio. The output is
connected to a solenoid and is energized when
lockup is engaged.
Overspeed and Low Clutch Pressure Indicator
This output lights a LED on the front console. The
LED will illuminate (steady) if a gear is selected that
would cause an overspeed condition and will go out
when rpm drops to a speed allowing the selection.
The LED will blink rapidly should a turbine failure
occur. The APC must be reset to clear this
condition. The LED will blink slowly if low clutch
pressure is detected for more than five seconds.
LED will go out when sufficient pressure returns.
Shift Solenoids
The shift solenoids output switch between battery
voltage and zero as associated shift speeds are
reached. The output energizes the appropriate shift
solenoid when the output is switched on.
2-3-17
TM 5-3810-307-24-1-1

CHECKOUT KIT
Description
The checkout kit is an APC 100 with a LCD display,
input/output signal LEDs, and diagnostic software to
help determine system and/or wiring faults. Refer to
Figure 2-3-7 for identification of the parts to the
checkout kit.
The input LEDs will be either dark (off state) or
yellow/orange (on state). The output LEDs will light
various colors depending on the condition of the
output circuit:
dark = off
green = good
yellow = open circuit or shorted to +24v
red = shorted to ground.

Figure 2-3-7. Checkout Kit

2-3-18
 TM 5-3810-307-24-1-1

MAINTENANCE

TEST PROCEDURES WITH CHECKOUT KIT e. Press and release the hold button. This
will activate the "checkout" mode and will
Installation of Checkout Kit and Start-up Screens show the checkout screen:

1. Ensure ignition switch is off (O) and

transmission shift control is in neutral (N). T = Turbine RPM
E = Engine RPM
2. Disconnect 37 pin connector from APC 100 H = "Hold" Screen - no new data being
and connect to checkout kit. shown
R = Speed Ratio - ratio of turbine speed
NOTE to engine speed
C = Controller Position - gear selected
With checkout kit installed and ignition via transmission shift control as
switch on, TRANS RPM/PRESS interpreted by checkout kit
indicator will flicker dimly. G = Gear that checkout kit is outputting
to transmission
3. Position ignition switch to 1 (run). Display will
quickly flash through three start-up screens. Use the Input/Output Checks
hold button to freeze the screens. Release the hold
button to move to the next screens: 1. Transmission Shift Control (Controller) Inputs
(01,02,20,21,22).
a. Screen #1 will show:
a. Move the shift control lever to each gear
CLARK-HURTH Comp position. As this done observe the
CHECKOUT KIT 1.3 following:

Also all input LEDs should be (1) The "C:xx" display should match
yellow/orange and all output LEDs the position selected.
should be green. (2) The "G:xx" display will show only
F1 or R1 while vehicle is
b. Screen #2 will show: motionless.
(3) The indicator LEDs should
13.9FLHR24658 illuminate yellow/orange as
AT400MILCRANE shown in Table 2-3-1.

Also all input LEDs should be NOTE

yellow/orange and all output LEDs
should be red. The input to #01 (forward) is turned off if
the shift control is in positions F3-F6 with
c. Screen #3 will show: rear axle steering unpinned.

(4) If inputs are incorrect, check shift

APC100 4204409
control, wiring to and from shift
V1.0 05.11.95
control, and APC 100 mode
control fuse and relay box for
This is the program number of the faulty connections and/or
EPROM which is installed in the components.
checkout kit. Be sure it is #4204409.

d. Screen should go blank. If checkout kit

does not function as shown above, refer
to checkout kit troubleshooting.

2-3-19
TM 5-3810-307-24-1-1

Table 2-3-1. Checkout Kit LEDs for Transmission Shift Control Inputs

LED# INPUT NAME TRANSMISSION SHIFT CONTROL POSITION

F1 F2 F3 F4 F5 F6 N R3 R2 R1
01 Forward X X X X X X
20 Reverse X X X
02 1st Range X X X
21 2nd Range X X X X X X
22 Splitter X X X

2. Throttle Inputs (08,23) and Adjustments. d. Gradually increase engine speed.

a. Make sure transmission is in neutral (N) (1) LED #23 should turn off at 890-
and main hydraulic pump is disengaged. 940 engine rpm.

b. Start engine and run at idle. The "E:xxx"
display should be approximately 840-
860.
(1) If reading is zero or erratic, check
speed sensor, harnesses, and
APC 100 fuse and relay box.
(2) If reading is greater than the
range, check and adjust throttle
cable and linkage as necessary,
refer to Section 2 - THROTTLE
AIR CYLINDER AND
THROTTLE LINKAGE.
(3) If still out of range, adjust fuel
injection pump idle setscrew.
Setscrew is located between
pump control lever and pump
body. Turn screw counter-
clockwise to increase and
clockwise to decrease.
c. Check LEDs.
(1) LED #23 (idle switch) and LED
#08 (throttle position switch)
should be illuminated
yellow/orange.
(2) If not illuminated, check
harnesses and APC 100 fuse
and relay box for faulty
connections/components. Check
appropriate throttle switch for
proper adjustment, refer to
Section 2, THROTTLE AIR
CYLINDER AND THROTTLE
LINKAGE.
(2) If necessary, adjust carriage bolt
(30, Figure 2-2-3) closer to idle
switch to increase rpm setting
and farther away from switch to
decrease setting.
e. Increase engine speed farther.
(1) LED #08 should turn off at 2250-
2350 engine rpm.
(2) If necessary, loosen mounting
hardware slightly for adjusting bar
(39, Figure 2-2-3) and adjust
capscrew (36) clockwise to
decrease setting and counter-
clockwise to increase setting.
NOTE
A slight reduction in the setting speed
usually occurs as the mounting hardware
is tightened. Therefore adjust toward the
upper end of range.
f. Increase engine speed to full throttle.
(1) "E:xxx" display should be 2500-
2781.
(2) If out of range, check and adjust
throttle cable and linkage as
necessary, refer to Section 2 -
THROTTLE AIR CYLINDER
AND THROTTLE LINKAGE.

2-3-20
 TM 5-3810-307-24-1-1

3. Transmission Clutch Pressure Input (07). (3) If clutch pressure is inadequate,

check and correct hose routing to
a. Position ignition switch to 1 (run); do not four wheel drive (FWD) solenoid
start engine. valve and to lockup modulator
valve as necessary.
(1) LED #07 should be illuminated
yellow/orange (no pressure). 4. Outputs to Transmission Shift Solenoids
(12,13,14,15,19).
(2) If not illuminated, check
harnesses and pressure switch a. Check transmission harness.
for continuity.
(1) Install transmission harness
b. Start engine. tester as shown in Figure 2-3-8.

(1) LED #07 should go out (adequate (2) Position ignition switch to 1 (run);
pressure). do not start engine.

(2) If not out, check transmission
clutch pressure. Clutch pressure
should be 240-280 psi (1655-
1931 kPa) with oil at 180-2500 F
(82-1210 C), engine at idle, and
transmission in N (neutral).
(3) Place APC 100 override switch in
manual position.
(4) Move the transmission shift
control lever to each position and
check that LEDs in left and right
columns of harness tester
illuminate green as shown in
Table 2-3-2.

Figure 2-3-8. Transmission Harness Tester

2-3-21
TM 5-3810-307-24-1-1

Table 2-3-2. Harness Tester LEDs for Transmission Shift Control Outputs to Solenoids

SOLENOID NAME TRANSMISSION SHIFT CONTROL POSITION

F1 F2 F3 F4 F5 F6 N R3 R2 R1
FWD HI X X X
FWD LO X X X X X X
2ND X X X X X X
1ST X X X
REV X X X

(a) If different than shown in (3) Place transmission control lever

Table 2-3-2, check harness
circuit.
(b) If neither the red nor green
LEDs light when expected, check
harnesses and APC 100 fuse
and relay box for faulty
connections/ components. If fuse
is blown in fuse and relay box
check for ground in carrier
harness.
(c) If LED in right column lights
but LED in left column does not,
check fuse in harness tester. If
fuse is blown, check that solenoid
for reversed wiring at 12 pin
connector.
NOTE
The order of the transmission solenoids
from top to bottom and the harness tester
LEDs from top to bottom is the same.
(d) If a red LED lights, the leads for
that solenoid are reversed in the
harness. Correct and recheck.
(e) If both the red and green LEDs
light, check the ground circuit in
the harness for an open or poor
connection. Correct and
recheck.
b. Check APC 100 fuse and relay box
outputs.
in F6. The checkout kit readout
should show T:0000, E:840-860,
C:F6, and G:F1.
(4) Release the brakes (parking
brake also).
(a) Turbine rpm (T:) should be
slightly less engine rpm (E:).
(b) If turbine rpm is considerably
greater (more than 100 rpm) than
engine rpm or if either value
varies erratically, check the
speed sensors and cables for
incorrect or faulty connections.
(c) Check that LEDs 12, 14 and
15 for gear F1 are green as
shown in Table 2-3-3. If not,
recheck for correct inputs as
shown in Table 2-3-1.
(d) Have an assistant check the
transmission harness tester
LEDs. These should match
Table 2-3-2. If not, check the
APC 100 fuse and relay box for
incorrect wiring.
(5) Accelerate engine enough for
transmission to shift to F2 and
verify LEDs illuminate on
checkout kit as shown in Table 2-
3-3 and on harness tester as
shown in Table 2-3-2.

(1) Place crane on outriggers. (6) Repeat steps (4) and (5) for each
of the remaining gears.
(2) Restart engine from carrier cab
and apply brakes.

2-3-22
 TM 5-3810-307-24-1-1

Table 2-3-3. Checkout Kit LEDs for APC 100 Outputs

LED# OUTPUT NAME TRANSMISSION SHIFT CONTROL POSITION

F1 F2 F3 F4 F5 F6 N R3 R2 R1
12 Forward X X X X X X
13 Reverse X X X
14 1st Range X X X
15 2nd Range X X X X X X
19 Splitter X X X

NOTE (2) With transmission shift control

lever in N (neutral), check
The APC 100 program defines gears by conditions of four wheel drive
their ratios, therefore the reverse gears control system components and
will appear as follows: checkout kit LEDs as shown in
Table 2-3-4.
Shift Lever Position Checkout Kit Display (G:)
R3 R5 (a) If the input LED functions
R2 R3 improperly, check the DRIVE
R1 R1 AXLE selector switch, cab
harnesses, and APC 100 fuse
and relay box for faulty
5. Lockup Request Input (25). connections/components.

a. Position ignition switch to 1 (run); do not (b) If input LED functions

start engine. properly, but output LED is not
green or yellow at appropriate
b. LED #25 should be illuminated. If not times, see output LED color
illuminated, check APC 100 fuse and definitions in CHECKOUT KIT -
relay box for faulty Definition, and repair accordingly.
connections/components.
(c) If the input and output LEDs
6. Four Wheel Drive Input (04) and Output (35). function properly, but the
pressure at the 4WD disconnect
a. Static Check. is not correct, check hoses for
proper routing.
(1) Start engine.
(d) If everything functions
properly, but 4WD does not
engage, transmission is
defective.

Table 2-3-4. Four Wheel Drive Control System and Checkout Kit Conditions

DRIVE AXLE INPUT LED OUTPUT LED SOLENOID PRESSURE AT 4WD

SELECTOR STATE STATE ENERGIZED 4WD ENGAGED
SWITCH POSITION DISCONNECT*
2WD OFF GREEN YES YES NO
4WD YELLOW YELLOW NO NO YES

* With engine running

2-3-23
TM 5-3810-307-24-1-1
b. Running check.
(1) Place crane on outriggers.
(2) Restart engine from carrier cab,
apply brakes, and position shift
control lever to F6.
(3) Position DRIVE AXLE selector
switch to 4WD, release brakes,
and accelerate through gears.
(a) Front wheels should turn until
4WD automatically disengages
when transmission shifts into F4
or R5.
CAUTION
4WD will re-engage when transmission
reenters f2 or r3. This should not be
allowed to occur if front wheels are not
turning at same speed as rear wheels.
Otherwise, damage to transmission
could occur.
(b) Position DRIVE AXLE
selector switch to 2WD to prevent
transmission from re-entering
4WD automatically when
transmission reaches F2 or R3
during deceleration (front wheels
will be turning at different speed).
(c) Release throttle and apply
brakes.
(d) If 4WD does not function as
stated, recheck conditions in step
6.a. above.
7. Converter Lockup Output
NOTE
This LED lights when program is
attempting to achieve torque converter
lockup. Lockup is only allowed in F4 thru
F6 when certain engine speed and
turbine speed criteria dependent on
throttle position are met [i.e., conditions
indicate vehicle is cruising (not
accelerating or pulling hard)].
2-3-24
a. Place crane on outriggers.
b. Restart engine from carrier cab and
position shift control lever in F4.
c. Release brakes and run transmission up
to F4.
(1) As turbine speed (T:) approaches
engine speed (E:), lockup should
occur and LED #37 should
illuminate green.
(2) Once lockup occurs, engine
speed and turbine speed should
be equal.
d. Maintaining engine speed at 2100-2200
rpm, move transmission shift control
lever to F5.
(1) Lockup should disengage when
turbine speed reaches
approximately 2000 rpm.
(2) Immediately following unlock
(LED #37 should go out),
transmission should upshift and
lockup should re-occur again
when turbine speed approaches
engine speed (LED #37 should
illuminate green).
e. If behavior is different than above, check
the following:
(1) If LED #37 is a color other than
green, see output LED color
definitions in CHECKOUT KIT -
Definition, and repair accordingly.
(2) If LED #37 is green but the
turbine and engine speeds are
not equal during lockup, check
pressure at lockup port on right
side of transmission.
(a) Pressure should equal
transmission clutch pressure
[240-280 psi (1655-1931 kPa).
(b) If pressure is incorrect, check
hose routing to and from
modulator valve.
(c) If pressure is good,
transmission is defective.
 TM 5-3810-307-24-1-1

APC 100 CHECKOUT KIT TROUBLESHOOTING

1. If checkout kit is suspected of being faulty,

connect to crane and diagnose as follows:

a. Position ignition switch to 1 (run) and

observe the screens and LEDs as stated
in INSTALLATION AND START-UP
SCREENS. Also observe the three
diagnostic LEDs on the top cover.

(1) If no LEDs light, the checkout kit

is not getting power. Figure 2-3-10. Checkout Kit Input Fuse

(a) Check the red and black tests
points for +24 volts, refer to
Figure 2-3-9.
(b) Repair harness if no power is
present.
(3) If input LEDs and displays are
normal, but all output LEDs
remain red, remove front cover
(cover with display), remove
screws retaining bottom cover,
slide pc boards out, and check
output fuse. Replace with very
fast acting (FF) 10 A fuse if
necessary, refer to Figure 2-3-11.

Figure 2-3-9. Checkout Kit Bottom Cover

(2) If diagnostic LEDs are only

glowing faintly, remove top cover
of checkout kit (cover with LEDs)
and check input fuse. Replace
with very fast acting (FF) 800 mA
fuse if necessary, refer to Figure
2-3-10.
Figure 2-3-11. Checkout Kit Output Fuse
(4) If some of the LEDs do not light
when powering up, checkout kit is
defective.

2-3-25
TM 5-3810-307-24-1-1

REPLACEMENT OF CHECKOUT KIT EPROM.
1. Remove front cover, screws retaining bottom
cover, and slide pc boards completely out of
housing, refer to Figure 2-3-11.
2. Carefully separate top pc board from center pc
board.
3. Unplug EPROM from center pc board, refer to
Figure 2-3-12 for location of EPROM.
4. Plug in new EPROM ensuring all 28 pins are
inserted straight into socket.
CAUTION
Do not force any component. All pieces
reassemble with very minor effort.
Check for cause of difficulty and correct
before forcing.
5. Install top pc board on center pc board.

CAUTION 6. Slide pc boards into housing and secure

bottom cover.
Be sure to install the EPROM chip with
the notched end toward the center of the 7. Install front cover.
board. Installing chip backwards will
destroy it.

Figure 2-3-12. Checkout Kit Center PC Board

2-3-26
 TM 5-3810-307-24-1-1

TEST PROCEDURES WITHOUT CHECKOUT KIT

TRANSMISSION RPM/PRESSURE INDICATOR (1) Check transmission system for

DIAGNOSIS adequate clutch (regulated
system) pressure (240-280 psi
This indicator, located on the carrier cab dash panel, with oil at 180-2500F, engine at
is used to convey warning signals when in idle, and transmission in N.
AUTOMATIC shift mode. The signals and Remove pressure switch (at 4WD
associated errors are: solenoid) and replace with
pressure gauge to measure
1. On - Transmission Overspeed: pressure.

a. Vehicle must slow down to extinguish. (2) If pressure is low, check for
improperly routed transmission
b. If slowing vehicle does not extinguish hoses to 4WD solenoid valve and
indicator, proceed to Speed Sensor lockup modulator valve (located
Inputs. on right wall of transmission well),
refer to FO-2, Hydraulic
2. Fast Blink - Turbine failure: The computer has Schematic for proper routing.
lost turbine speed input signal, refer to Speed Reroute hoses as necessary.
Sensor Inputs.
(3) If pressure is correct, check
3. Slow Blink - Low clutch pressure for more than pressure switch for proper
5 seconds. This condition will exist with ignition operation. Switch should be
switch on until adequate pressure is developed open with system pressure.
within transmission circuits. Replace as necessary.

a. If indicator does not blink with ignition SHIFTING PROBLEM DIAGNOSIS

switch on and engine stopped:
1. Operate vehicle in both AUTOMATIC and
(1) Check that clutch pressure switch MANUAL shift modes.
is closed with no pressure.
Replace as necessary. a. If symptom only occurs in AUTOMATIC
mode, proceed to APC 100 CONTROL
(2) Check for 24 vDC power at BOX DIAGNOSTICS.
pressure switch wire 44 (at 4WD
solenoid) and continuity from wire b. If symptom occurs in both modes,
920 to socket #7 of relay box proceed to step 2.
harness connector (rectangular
connector. Correct as necessary. 2. Check if rear steering is unlocked. The
electrical system limits the transmission to F1, F2,
(3) Check indicator for proper and R1 when rear steering is unlocked.
operation. Correct or replace as
necessary. a. If rear steering is unlocked, lock it and
recheck operation.
(4) Proceed to APC 100 CONTROL
BOX DIAGNOSTICS. b. If rear steering is locked and symptom
persists, proceed to MANUAL/
b. If indicator stays lit with engine running: AUTOMATIC SHARED SYSTEM
DIAGNOSTICS.

2-3-27
TM 5-3810-307-24-1-1

MANUAL/AUTOMATIC SHARED SYSTEM

DIAGNOSTICS

If shifting problems occur in both manual and

automatic shift modes, proceed as follows:

1. Disconnect harness at transmission solenoid

connector.

2. Ensure wires for transmission solenoid

connector at transmission valve body are properly
connected. Wires should lay in parallel layers from
the solenoids to the connector with all green wires
connected to pins 1 thru 5 and all black wires
connected to pins 7 thru 12, refer to Figure 2-3-13.

3. Measure resistance through each transmission
solenoid coil. The readings should be 39-42 ohms.
If a reading is 0 ohms, solenoid must be replaced
and a fuse in the fuse and relay box is probably
blown requiring replacement.
Figure 2-3-14. Transmission Solenoid Connector
(Engine Harness)
5. Position ignition switch to 1 (run) and
AUTOMATIC/MANUAL switch to MANUAL.

4. Check engine harness side of transmission 6. Place the transmission shift lever into each
solenoid connector for proper wire connection, refer position and check voltage reading at every socket of
to Figure 2-3-14. engine harness transmission solenoid connector.
The readings should match those in Table 2-3-5.

a. If voltage readings are correct and wires

on solenoid side connector are properly
connected, transmission is faulty.

b. If voltage readings are correct but

another problem was corrected,
symptom may be eliminated. Check
vehicle operation.

c. If voltage readings are incorrect,

proceed to step 7.

7. Disconnect cab harness (round connector)

from fuse and relay box.

8. With ignition switch positioned to 1 (run), place

transmission shift lever in each position and check
input voltage readings at sockets L, C, J, G, and E of
cab harness. Readings should match those in Table
2-3-5.

Figure 2-3-13. Transmission Solenoid Connector a. If voltage readings are correct, proceed
(Transmission Valve Body) to step 9.

2-3-28
 TM 5-3810-307-24-1-1

Table 2-3-5. Gear Selection Circuit Voltages

INPUT OUTPUT SOCKET SOCKET TRANS TRANSMISSION SHIFT LEVER POSITION

SOCKET CIRCUIT ID (CAB ID (ENGINE SOLENOID
ID # HARNESS) HARNESS) NAME

F1 F2 F3 F4 F5 F6 N R3 R2 R1

L 789 K 1 Forward HI 24 24 24

C 788 B 2 Forward LO 24 24 24 24 24 24

J 598 H 3 2nd Range 24 24 24 24 24 24

G 597 F 4 1st Range 24 24 24

E 609 D 5 Reverse 24 24 24

b. If voltage readings are not correct, gear APC 100 CONTROL BOX DIAGNOSTICS
selector or cab harness is faulty.
Correct as necessary and check vehicle 1. Remove blackout cover from APC 100 control
operation. box to expose the three diagnostic LEDs.

9. Ensure there is continuity in each output
circuit, refer to Table 2-3-5. Ensure that there is no
continuity between any two circuits and no continuity
between any circuit and ground.
a. If continuity is as stated, proceed to step
10.
b. If continuity is not as stated, check the
harnesses and circuits in main junction
box (exterior, back side of cab) for
cause. Correct any fault(s) and check
vehicle operation.
NOTE
Since solenoids require less than 1 amp
of current to operate, even a small strand
of wire may cause undesirable continuity
between circuits.
10. Remove cover from fuse and relay box and
check for loose connections, blown fuses, and bad
relays. Correct any fault(s) and check vehicle
operation.
NOTE
The cab harness needs to be
reconnected and manual mode
reactivated for the relays to be in their
manual mode position.
2. With transmission selector lever in N and
ignition switch positioned to 1 (run), observe the
three diagnostic LEDs and the TRANSmission RPM/
PRESSure indicator (LED) on dash panel. All four
should light for 2 seconds, then the TRANSmission
RPM/PRESSure indicator should begin to blink
slowly and the red diagnostic LED should turn off.
The yellow and green LEDs should remain on.
a. If no LEDs light, check for 24 vDC power
and ground at the rectangular connector
for the APC 100 control box harness.
(1) If no power is indicated, check
harness circuit #718. Power
should be available at sockets
17, 18, and 25 of APC relay box
harness. Correct any fault(s) and
recheck LEDs.
(2) If no ground is indicated, check
harness circuit #51. Ground
should be available at socket 11
of APC 100 relay box harness.
Correct any fault(s) and recheck
LEDs.
(3) If power and ground are present,
check input fuse under top cover
of APC 100 control box, refer to
Figure 2-3-15. If blown, replace
only with a 5 x 20 mm very fast
acting (FF) 315 mA fuse.
Recheck LEDs.

2-3-29
TM 5-3810-307-24-1-1

Figure 2-3-15. APC 100 Input Fuse

(4) If power, ground, and input fuse

are all good, APC 100 control box
must be replaced.
b. If any one of the APC 100 LEDs does
not light, APC 100 may still function, but
should be replaced as soon as possible.
c. If the three APC 100 LEDs perform
correctly, but the TRANSmission RPM/
PRESSure indicator does not light, the
APC 100 has power but no output.
Check the output fuse in the APC 100
control box.
(1) Remove control box from fuse
and relay box.
(2) Remove screws retaining bottom
cover and slide pc boards
halfway out of box, refer to Figure
2-3-16. If blown, replace only
with 5 x 20 mm very fast acting
(FF) 10 A fuse.
(3) Reassemble and install box.
Recheck indicator.
d. If the red diagnostic LED remains on,
there is an internal failure in the APC
100 control box.
(1) Remove control box from fuse
and relay box.
Figure 2-3-16. APC 100 Output Fuse
(2) Remove screws from connector
end of box and slide pc boards
halfway out of box.
(3) Ensure correct EPROM is
installed, refer to Figure 2-3-17.
The correct EPROM is Clark
#4500828V1.0 or V1.1.
CAUTION
The glue that retains the EPROM chip is
very tough and the pc boards are very
fragile. Extreme care must be taken
when replacing EPROM chip. When
installing EPROM chip, be sure that
notch in EPROM matches notch in pc
board. Reverse installation will destroy
EPROM. Do not force any component!
All pieces assemble with very minor
effort. Look for cause of the difficulty and
correct before forcing.
(4) Ensure EPROM is installed
correctly. Reinstall if necessary
and recheck LED.
(5) If nothing appears wrong with the
existing EPROM, replace with a
new one and recheck LED.

2-3-30

Figure 2-3-17. APC 100 EPROM Location
(6) If no problems with the EPROM
can be found, the APC 100
control box must be replaced.
e. If all LEDs perform correctly, proceed to
Throttle Tests.
Throttle Tests
1. With main hydraulic pump disengaged and
transmission shift lever in N, start engine and verify
idle speed is 840 50 rpm. If needed, adjust as
follows. Otherwise proceed to step 2.
a. If reading is greater than the range,
check throttle cable and throttle
assembly for proper installation, refer to
THROTTLE AIR CYLINDER AND
THROTTLE LINKAGE Installation
procedures, Section 2.
b. If reading is still out of range, adjust fuel
injection pump idle set screw located
between injection pump control lever
and injection pump body. Turn screw
counter-clockwise to increase idle speed
and clockwise to decrease idle speed.
2. Gradually increase engine speed while
observing green diagnostic LED on top of APC 100
control box. It should be on at idle, turn off at
TM 5-3810-307-24-1-1
890-940 rpm, and come back on again at 2250-2350
rpm.
a. If correct, the engine idle switch and full
throttle switch are properly set and their
circuits are good. Proceed to Gear
Selection Diagnostics.
b. If LED operation is not correct:
(1) Disconnect relay box harness
from APC 100 control box.
(2) Check socket 23 for 24 vDC
signal at idle and drops out when
engine reaches 890-940 rpm.
(a) If signal is not present or
does not drop out, check idle
switch. Idle switch should be
closed until rpm setting is
reached. Correct and
recheck operation.
(b) If signal drops out at wrong
rpm setting, adjust idle switch
carriage bolt (30, Figure 2-2-
3) closer to idle switch to
increase rpm setting and
farther from switch to
decrease setting. Correct
and recheck operation.
2-3-31
TM 5-3810-307-24-1-1

(c) If signal is correct, proceed to a. If correct, proceed to Gear Selector Input

step (3). Diagnostics.

(3) Check that socket 8 (full throttle
switch input) has 24 vDC signal
at idle and drops out when
engine reaches 2250-2350 rpm.
(a) If signal is not present or
does not drop out, check full
throttle switch. Switch should
be closed until rpm setting is
reached. Correct and
recheck operation.
(b) If signal drops out at wrong
rpm setting, adjust full throttle
switch by slightly loosening
the mounting screws (33,
Figure 2-2-3) and turning
screw (36) clockwise to
decrease rpm setting and
counterclockwise to increase
setting. Correct and recheck
operation.
NOTE
A slight reduction in rpm setting usually
occurs as mounting screws are
tightened. Therefore, adjust toward
upper end of rpm range.
3. Check maximum engine RPM by increasing
engine speed to full throttle (2500-2800 rpm).
b. If rpm is less than range, check throttle
cable and throttle assembly for proper
installation, Refer to THROTTLE AIR
CYLINDER AND THROTTLE LINKAGE
Installation procedures, Section 2.
Gear Selector Input Diagnostics
1. Disconnect relay box harness (rectangular
connector) from APC 100 control box.
2. Position ignition switch to 1 (run).
3. Place transmission shift lever in each position
and check input signals (voltages) at sockets 1, 2,
20, 21, and 22 for 24 vDC or 0 v. Readings should
match those in Table 2-3-6.
a. If all input signals are correct, proceed to
Speed Sender Input Diagnostics.
b. If input signals are incorrect, check the
APC fuse and relay box for faults
between the manual mode relays and
APC 100 harness connector. Faults in
the rest of the relay box would create
symptoms during manual mode
operation and would be detected during
that diagnosis. Correct any fault(s) and
recheck operation.

Table 2-3-6. Gear Selector Input Signals (Voltages) to APC 100

SOCKET ID (RELAY TRANSMISSION TRANSMISSION SHIFT LEVER POSITION

BOX HARNESS) SOLENOID NAME
F1 F2 F3 F4 F5 F6 N R3 R2 R1
22 Splitter 24 24 24
1 Forward 24 24 24 24 24 24
21 2nd Range 24 24 24 24 24 24
2 1st Range 24 24 24
20 Reverse 24 24 24

2-3-32

Speed Sender Input Diagnostics
1. Disconnect relay box harness (rectangular
connector) from APC 100 control box.
2. Position ignition switch to 1 (run).
3. Check resistance between sockets 28 and 29,
and sockets 30 and 31 of relay box harness
connector. Resistance should be 1000-1200 ohms.
a. If resistance readings are as stated,
proceed to step 4.
b. If resistance readings are not
acceptable, check appropriate circuit.
Correct any fault(s) and recheck
resistance.
4. Place crane on outriggers, start engine from
carrier cab, place transmission shift lever in F1, and
run at idle.
5. Measure AC voltage between sockets 28 and
29, and sockets 30 and 31 (turbine speed). Voltage
should be 5-10 vAC. If voltage reading is less than 3
vAC, check speed sender for damage. Replace
sender if damaged and recheck voltage.
NOTE
Clearance is preset by bushings installed
in transmission and should not be a
problem.
Torque Converter Lockup Diagnosis
NOTE
For proper lockup operation, APC 100,
throttle switch inputs, gear selector
inputs, and speed sender inputs must be
functioning properly, refer to appropriate
procedures and check functions prior to
diagnosing lockup problems.
1. Lockup is allowed in gears F4 thru F6 and also
in F3 when the throttle is less than mid-throttle. The
crane will feel sluggish, fuel economy will suffer, and
top speed will be difficult to achieve if lockup is not
functioning. The operator can usually feel lockup
engaging (feels like a smooth prolonged shift to a
higher gear) about 3 seconds after TORQUE
CONVERter UNLOCKED indicator turns off.
TM 5-3810-307-24-1-1
2. The TORQUE CONVERter UNLOCKED
indicator should illuminate when ignition switch is
turned on. If it does not light, check electrical circuit
and indicator. Correct any fault(s) and proceed to
step 3.
3. Disconnect relay box harness (rectangular
connector from APC 100 control box and place
ignition switch to 1 (run).
4. Check socket 25 (lockup request input) of
harness connector for 24 vDC.
a. If voltage is absent, check fuse and relay
box for faulty wiring or loose connection.
Correct any fault(s) and recheck
voltage.
b. If voltage is present, proceed to step 5.
5. Measure resistance between socket 37
(lockup output) and socket 11 (ground). Resistance
should be 30-60 ohms.
a. If reading is not as stated, check
harness, fuse and relay box fuse FU8
and connections, and solenoid for faults.
Correct any fault(s) and recheck
resistance.
b. If reading is acceptable, reconnect APC
100 relay box harness and proceed to
step 6.
6. Attach a voltmeter to wire 448 at lockup
solenoid modulator valve. Use a jumper wire if
necessary and secure wires away from driveshaft to
allow taking reading safely with driveshaft rotating.
7. Place crane on outriggers, with tires off the
ground, and start engine from carrier cab.
8. Position transmission shift lever to F4, release
brakes, run engine at 2200 rpm, and allow
transmission to enter F4 gear. Lockup may occur in
F3 since engine speed is below full throttle switch
setting.
9. As turbine speed (torque converter output)
surpasses minimum speed (refer to Table 2-3-7) and
approaches engine speed, TORQUE CONVERter
UNLOCKED indicator should turn off, the voltage
reading at lockup solenoid should change from 0 to
24 vDC, and lockup should occur.
2-3-33
TM 5-3810-307-24-1-1

Table 2-3-7. Lockup Parameters

THROTTLE TRANSMISSION TURBINE TURBINE TURBINE

MODE GEAR ACTIVE ENGAGEMENT DISENGAGEMENT DISENGAGEMENT
SPEED SPEED SPEED
(MINIMUM) (DUE TO LOAD) (FOR UPSHIFT)
Half Throttle 3 thru 6 1400 1200 2350
Full Throttle 4 1500 1400 2350
Full Throttle 5 or 6 1900 1800 2350
Braking 1 thru 6 1200 1000 (For downshift) 2350 (Only if overspeed)

a. If voltage does not change as stated, NOTE

there is a fault in the EPROM or the APC
100 control box, see APC 100
CONTROL BOX DIAGNOSTICS and
correct any fault(s).
NOTE
This again assumes that all inputs and
drivetrain loading are proper.
b. If transmission reacts as stated, proceed
to step 12.

This assumes drivetrain is not inducing a
load which would cause turbine speed to
stay well below the engine speed. The
engine will be laboring if this is the case.
The converter will normally achieve
lockup very easily with crane on
outriggers.
b. If voltage does change, but lockup
engagement is not noticed, check the
hydraulic circuit related to lockup for
faults. If transmission lockup port is
receiving pressure, transmission is
defective.
c. If voltage changed and lockup occurred
properly, proceed to step 10.
10. Increase engine speed to 2400-2500 rpm and
move transmission shift lever to F5.
11. Lockup should disengage. Immediately
following unlock, the transmission should upshift and
lockup should re-occur when the turbine speed again
approaches engine speed.
a. If transmission does not upshift, there is
a fault in the EPROM or APC 100 control
box, see APC 100 CONTROL BOX
DIAGNOSTICS and correct any fault(s).
12. Keeping throttle at one position, apply brakes
to reduce turbine speed to the loaded
disengagement speed, refer to Table 2-3-7. While
doing this, watch the voltage at lockup solenoid. The
voltage should drop to 0 vDC and lockup should
disengage at the specified speed.
a. If voltage does not drop, there is a fault
in the EPROM or the APC 100 control
box, see APC 100 CONTROL BOX
DIAGNOSTICS and correct any fault(s).
b. If voltage drops but lockup does not
disengage, check lockup hydraulic circuit
and transmission for faults.
c. If lockup disengages, converter lockup
circuit is functioning properly.
d. Disconnect voltmeter and/or jumper wire
from wire 448.
4WD Diagnosis
1. Place machine on outriggers, with tires off the
ground, and start engine from carrier cab.
2. Position DRIVE AXLE selector switch to 2WD,
position transmission shift lever to F2, release the
brakes, and accelerate slightly. The rear wheels
should turn and the front wheels should remain
relatively still.

2-3-34
 TM 5-3810-307-24-1-1

a. If wheels turn as stated, proceed to step a. If 4WD operates as stated, 4WD is

3. functioning properly. No further steps
are necessary.
b. If front wheels turn with rear wheels,
check wire 935 for 24 vDC at 4WD b. If front wheels do not turn at all, check
solenoid valve. wire 935 for 24 vDC at 4WD solenoid.

(1) If 24 vDC is present, problem is in (1) If 24 vDC is not present, solenoid,

solenoid, solenoid valve, 4WD solenoid valve, 4WD hydraulic
hydraulic circuit, or transmission. circuit, or transmission is faulty.
Check and correct any fault(s) as Check and correct any fault(s) as
necessary and recheck necessary and recheck
operation. operation.

(2) If 24 vDC is not present, check
2WD/4WD electrical circuit.
Correct any fault(s) and recheck
operation.
3. Idle engine and apply brakes. When wheels
are stopped, place DRIVE AXLE selector switch in
4WD position, position transmission shift lever to F4,
release brakes, and accelerate so transmission will
shift up to F4 gear. The front wheels should turn with
the rear wheels until transmission shifts from F3 to
F4. When this occurs, 4WD should disengage and
front wheels should begin to slow.
CAUTION
Be sure to position drive axle selector
switch to 2WD before decelerating. If
selector switch is left in 4WD position,
4WD re-engagement will occur when
transmission shifts into F2. Damage
may occur if 4WD is allowed to engage
while wheels are turning at different
speeds.
(2) If 24 vDC is present, stop crane
and proceed to step 4.
c. If front wheels turn but do not disengage
after entering F4, stop crane, and
proceed to step 4.
4. Remove APC 100 fuse and relay box from cab
wall mounting, and remove cover from fuse and relay
box leaving APC 100 control box connected to relay
box harness (rectangular connector).
5. Position ignition switch to 1 (run), place
transmission shift lever in F1, and check 4WD output
circuits for voltage during the various modes as
shown in Table 2-3-8.
a. Correct any faults in circuits that do not
function as stated in table and recheck
circuit outputs.
b. If the voltage in wire 35 is not correct,
there is a fault in the EPROM or the APC
100 control box, see APC 100
CONTROL BOX DIAGNOSTICS,
correct any fault(s), and recheck circuit
output.

Table 2-3-8. 2WD/4WD Output Circuit Voltages

DRIVE AXLE SELECTOR CIRCUIT VOLTAGES

RELAY BOX MODE SWITCH POSITION
WIRE WIRE WIRE WIRE WIRE
914 35 70 50 935
Automatic 2WD 24 24 24 24 0
Automatic 4WD 0 0 0 0 24
Automatic 4WD 24 24 24 24 24
Manual 2WD 0 0 0 24 0
Manual 4WD 0 0 0 0 24

2-3-35/(2-3-36 Blank)
 TM 5-3810-307-24-1-1

SECTION 4
AXLES AND BRAKE SYSTEM

TABLE OF CONTENTS
Page

AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-6
Wheel Alignment and Lock Cylinder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-7
Boom Rest Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
Hydraulic Power Bleeding and Adjustment (Front Axle) . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
Rear Axle Alignment and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-12
AXLE PROXIMITY SENSOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-17
REAR AXLE STEERING UNLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Operation Check/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Mounting Wheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Initial Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Operational Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Actuator (Expander Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
BRAKE CHAMBER (FRONT WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-29
BRAKE CHAMBER (REAR WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-34

2-4-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

Page

AIR VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-36

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-36

LIST OF FIGURES
Number Title Page

2-4-1 Torque Rod Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-6

2-4-2 Axle and Suspension Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-9
2-4-3 Axle Proximity Sensor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-15
2-4-4 Rear Axle Unlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-21
2-4-5 Lug Nut Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
2-4-6 Brake Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-26
2-4-7 Front Brake Chamber Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-30
2-4-8 Rear Brake Chamber Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-35

2-4-2
 TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-4-5

Ensure any lifting device used is capable of supporting the weight of the
axle.

WARNING 2-4-6

Do not allow the axle to twist or tilt when removing the mounting
hardware.

WARNING 2-4-22

Do not attempt to demount or mount tires without proper training. The

high pressures involved can cause tire and rim parts and tools to fly with
explosive force, if proper procedures are not used, causing severe injury
or death to personnel and damage to the crane and surrounding area.

WARNING
2-4-25

These parts are under spring tension and must be held, or caged when
snap ring is removed.

WARNING
2-4-27
There may be residual pressure in air lines after air reservoirs are 2-4-33
drained. Wear eye protection when disconnecting air lines to prevent
injury.

2-4-3
TM 5-3810-307-24-1-1

WARNING SUMMARY (Continued)

Page

WARNING 2-4-27
2-4-27
2-4-33
2-4-33

Brake chamber assembly is adjusted to have spring tension. Personal

injury may occur if tension is not released prior to removing clamp and
separating cover from cylinder.

WARNING 2-4-28

Brake chamber assembly is assembled with spring tension. Maintain

pressure on cover and cylinder, and slowly release spring tension when
removing clamp and separating cover from cylinder. Failure to observe
this warning could result in personal injury.

2-4-4
 TM 5-3810-307-24-1-1

AXLES

DESCRIPTION

The crane is equipped with two axles, one on the either the carrier or superstructure cab. The axles
front of the carrier and one on the rear of the carrier. are mounted to the carrier frame by means of an
To provide maximum maneuverability, both axles oscillation lockout cylinder and leaf spring located at
are drive and steer axles and can be controlled from each end of each axle.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

REMOVAL. NOTE

NOTE Wheel and axle alignment will be easier

if the tie rods are not removed from the
The axles do not have to be removed axle.
from the crane to remove the planetary
wheel ends or the drive units. NOTE

1. Fully extend and set the outriggers. Install
blocking under the frame at the outboard ends of the
outrigger boxes.
2. Deplete the air pressure in the brake system.
NOTE
Each tire and wheel assembly weighs
approximately 540 pounds (245 kg).
Step 6 applies only to the front axle.
Mark position of washers removed from
torque rod to ensure proper positioning
during installation.
6. Remove the cotter pin and hex nut securing
the drag link to the steering arm and the hex nut,
washer(s), and capscrew securing the torque rod to
the axle assembly. Disconnect the drag link and
torque rod from the axle.

3. Remove the tire and wheel assemblies from 7. Tag and disconnect the air lines to the brake
the axle to be removed. chambers. Cap or plug all lines and openings.

4. Remove the drive lines. Refer to DRIVE 8. Tag and disconnect the hydraulic lines to the
LINES in Section 3 - DRIVE TRAIN. steer cylinders. Cap or plug all lines and openings.

NOTE
WARNING
Each axle weighs approximately 1600 Ensure any lifting device used is capable
lbs (726 kg). of supporting the weight of the axle.

5. Place adequate blocking beneath the axle(s) to

be removed.

2-4-5
TM 5-3810-307-24-1-1

6. Install the air lines to the brakes as tagged

WARNING during removal.
Do not allow the axle to twist or tilt when
removing the mounting hardware. 7. If applicable, install the hydraulic lines to the
steer cylinders as tagged during removal. Bleed the
steering system if necessary.
NOTE
8. Install the tire and wheel assemblies, refer to
Each axle assembly weighs MOUNTING WHEEL ASSEMBLIES.
approximately 1600 pounds (726 kg).
9. Build up pressure in the air system.

9. With an adequate lifting/supporting device 10. Refer to LUBRICATION CHART (Chapter 1,

supporting the weight of the axle, remove the nuts,
washers, bolts, and cotter pins securing the
oscillation lockout cylinder lower retaining pins and
remove the retaining pins.
10. Remove the bolts and washers securing the
axle to the leaf springs.
11. Remove the axle and move it to a clean work
area.
INSTALLATION.
1. Using an adequate lifting/supporting device,
position the axle under the crane.
Section 4) and service the axle.
11. Remove the blocking.
12. Retract and stow the outriggers.
13. With full weight of crane on tires, boom in
boom rest, and oscillation cylinders unlocked, check
gap between torque rod and axle mount. Gap must
be less than one washer thickness. Ensure torque
rod is perpendicular to the axle center line. Add
washers as shown in Figure 2-4-1 to achieve stated
conditions. Torque nuts securing torque rod to axle
mount 567 to 615 pounds-foot (769 to 834 Nm).

2. Apply Loctite #271 to the bolt threads and

install the bolts and washers securing the axle to the
leaf springs.

3. Install the oscillation lockout cylinder lower

retaining pins and secure in place with the cotter
pins, bolts, washers, and nuts. Torque the bolts to
75 pounds- foot (102 Nm).

NOTE

Step 4 applies only to the front axle.

4. Secure the drag link to the steering arm with

the hex nut and cotter pin. Torque the nut to 215
pounds-foot (291 Nm) then back the nut off to the
nearest cotter pin hole and install the cotter pin.
Secure the torque rod to the axle assembly with
capscrews, washers (as marked during removal),
and hex nuts. Do not torque nuts at this time.

5. Install the drive lines. Refer to DRIVE LINES

in Section 3 - DRIVE TRAIN.

Figure 2-4-1. Torque Rod Adjustment

2-4-6

WHEEL ALIGNMENT AND LOCK CYLINDER
ADJUSTMENT.
NOTE
The following procedures are referenced
to Figure 2-4-2.
1. Ensure the steering relay shafts are properly
aligned. Refer to RELAY SHAFT ALIGNMENT in
Section 5 - STEERING SYSTEMS.
2. Ensure the steering gear is centered properly.
Refer to CENTERING THE STEERING GEAR in
Section 5 - STEERING SYSTEMS.
3. Adjust drag link as follows:
a. Using alignment equipment or other
accurate method, set left hand wheel to
straight ahead position.
NOTE
Left hand wheel must remain straight
until drag link adjustment is completed.
b. Loosen clamp bolts on both ends of drag
link and turn tube until index marks on
steering gear are aligned per View C-C.
c. Check position of drop arm. Position
must be with in 30 of the position shown.
(1) If not, check that index marks on
steering gear and drop arm are
aligned. If the marks are not
aligned, remove the drag link
from the drop arm and the drop
arm from the steering gear.
(2) Reinstall the drop arm on the
steering gear by aligning the
index marks.
(3) Check that index marks in View
C-C are still aligned and that drop
arm is parallel to axis of steering
gear. Torque drop arm retaining
nut to 295 pounds-foot (400 Nm)
then back off nut to nearest cotter
pin hole and install cotter pin.
d. Adjust the drag link to fit between the
axle and the drop arm.
TM 5-3810-307-24-1-1
NOTE
The end of the drag link that attaches to
the drop arm must not be allowed to
rotate while turning the tube.
e. Install drag link on the drop arm and
torque nut to 215 pounds-foot (290 Nm).
f. Check that drag link ends are within
limits specified in Detail B, then torque
drag link clamp bolts to 55 pounds-foot
(75 Nm).
4. Adjust toe-in for both axles as follows:
a. Using alignment equipment, set toe-in to
+.00 in. to -.06 in. (+.00 mm to -1.52
mm).
NOTE
Toe-in for both axles is to be measured
on the side of the axle towards the front
of the crane. In order to set toe-in for
rear axle, the rear steering lock must be
disengaged.
b. Tighten all tie rod clamp bolts to 36
pounds-foot (49 Nm).
c. Adjust sensors for front axle proximity
sensor assembly, refer to AXLE
PROXIMITY SENSOR ASSEMBLIES,
Adjustment.
d. Perform step 7 in HYDRAULIC POWER
BLEEDING AND ADJUSTMENT (FRONT
AXLE) procedures.
e. Check that front axle wheel ends are
contacting the axle stops. If not, perform
steps 8 and 9 in HYDRAULIC POWER
BLEEDING AND ADJUSTMENT (FRONT
AXLE) procedures.
NOTE
Wheel ends must contact axle stops!
5. Adjust rear steer lock cylinder as follows:
a. Loosen bolts that secure rear steer lock
cylinder to axle mounting bracket, refer
to Detail A.
2-4-7
TM 5-3810-307-24-1-1

b. Adjust the lock cylinder so that the rear Check that steer cylinders have a minimum of 0.25 in
wheels remain straight when the (6.35 mm) or a maximum of 0.28 in. (7.11 mm) with
steering lock cylinder is engaged the tie-rod(s) and/or steering arm(s). Check that
(pinned). there is a minimum of 0.50 in. (12.7 mm) clearance
between brake chambers and axle. Adjust axle
c. Torque mounting bolts to 165 pounds- stops as necessary to achieve clearances.
foot (224 Nm).
CAUTION
d. Check that rear axle toe-in was not
affected. Both wheel ends must firmly contact axle
stops. Failure to adjust steering gear
e. Perform step 6 in REAR AXLE limiters can result in damage to the steering
ALIGNMENT AND BLEEDING gear box.
procedures.
8. Turn steering wheel full left and verify that
BOOM REST SWITCH ADJUSTMENT. wheel end pushes firmly against left side axle stop
and that all clearances are taken up by the pressure.
Adjust the boom rest switch so that switch activates If wheel end is not contacting stop:
when the boom is 0.5 inches (12.7 mm) from the
boom rest. Assure the axle lockout valves open a. Shut down engine.
when the carrier ignition switch is positioned to 1
(run) and the boom is in the boom rest. Refer to b. Remove plug from upper end of steering
Figure 2-4-2. gear.

HYDRAULIC POWER BLEEDING AND c. Turn adjusting ring in direction shown to

ADJUSTMENT (FRONT AXLE). reduce gap between wheel end and axle
stop, refer to Detail D-D.
NOTE
d. Install plug and torque to 52 pounds-foot
The following procedures are referenced (71 Nm).
to Figure 2-4-2.
e. Restart engine and repeat step 8 as
1. Engage the hydraulic pump. Start the engine necessary until left wheel pushes firmly
from the superstructure. against axle stop and all clearances are
taken up.
2. Extend the outrigger beams and jack cylinders
to lift the crane off the ground. Shut off the engine in 9. Turn steering wheel full right and verify that
the superstructure and start the engine up again wheel end pushes firmly against right wheel axle
from the carrier. stop and that all clearances are taken up by the
pressure. If wheel end is not contacting stop:
3. Loosen steer cylinder ball end clamps and
rotate steer cylinders so that fittings are vertical. a. Shut down engine.

4. Open bleed fittings on each steer cylinder, turn b. Remove plug from lower end of steering
steering wheel from lock to lock, and bleed each gear.
cylinder until no air appears (Hydraulic fluid should
flow from the bleed port in a steady stream). Close c. Turn adjusting ring in direction shown to
all bleed fittings. reduce gap between wheel end and axle
stop, refer to Detail D-D.
5. Open air/bleed fittings on front side of steering
gear, turn steering wheel from lock to lock, and bleed d. Install plug and torque to 52 pounds-foot
steering gear until no air appears. Close air/bleed (71 Nm).
fittings.
e. Restart engine and repeat step 9 as
6. Rotate steer cylinders back to correct installed necessary until right wheel end pushes
position and tighten ball end clamps. firmly against axle stop and all
clearances are taken up.
7. Turn steering wheel fully in both directions.
2-4-8
 TM 5-3810-307-24-1-1

Figure 2-4-2. Axle and Suspension Installation (Sheet 1 of 3)

2-4-9
TM 5-3810-307-24-1-1

Figure 2-4-2. Axle and Suspension Installation (Sheet 2 of 3)

2-4-10
 TM 5-3810-307-24-1-1

Figure 2-4-2. Axle and Suspension Installation (Sheet 3 of 3)

2-4-11
TM 5-3810-307-24-1-1
REAR AXLE ALIGNMENT AND BLEEDING.
NOTE
The following procedures are referenced
to Figure 2-4-2.
1. Pull the steering mode control handle at the
side of the hydraulic tank and engage the lock. This
will transfer the steering from the carrier to the
superstructure. Assure the CARRIER STEER
DISENGAGED indicator on carrier dash panel
illuminates when carrier cab ignition switch is in 1
(run) position.
2. Loosen steer cylinder ball end clamps and
rotate cylinders so that fittings are vertical.
3. Start the engine from the superstructure.
Position REAR AXLE STEERING LOCK switch to
UNLOCKED. The red steering lock light (to right of
switch) will go out.
2-4-12
4. Crack the bleed fittings on each steer cylinder
and turn the steering wheel lock to lock, bleeding the
cylinders until no air appears. Tighten the fittings.
5. Rotate steer cylinders back to correct installed
position and tighten ball end clamps.
6. Turn steering wheel fully in both directions.
Check that steer cylinders have a minimum of 0.25 in
(6.35 mm) or a maximum of 0.28 in. (7.11 mm) with
the tie-rod(s) and/or steering arm(s). Check that
there is a minimum of 0.50 in. (12.7 mm) clearance
between brake chambers and axle. Adjust axle
stops as necessary to achieve clearances.
7. Adjust sensors for rear axle proximity sensor
assembly, refer to AXLE PROXIMITY SENSOR
ASSEMBLIES, Adjustment.
 TM 5-3810-307-24-1-1

AXLE PROXIMITY SENSOR ASSEMBLIES

Description

There are two axle proximity sensor assemblies installed on the crane, one on each axle. The proximity sensor
assembly on the front axle is connected to the indicator lights for the FRONT AXLE STEERING control in the
superstructure cab. The assembly on the rear axle is connected to the indicator lights for the REAR AXLE
STEERING control in the carrier cab. The assemblies are comprised of proximity sensors connected to a wiring
harness. The assembly on the rear axle also includes a sensor which is connected to the rear axle steering lock
indicator lights in both cabs.

The purpose of the axle proximity sensor assemblies is to indicate to the operator that the wheels, for the axle
being steered with the steering control toggle switch, are turned from center. When the wheels are centered, the
center indicator light on the dash is lit. When the wheels are moved from center using the steering control toggle
switch, the right or left indicator light will be lit indicating the direction in which the crane will turn, except when
crabbing (crane will crab in opposite direction of indicator lit). When the rear axle is being steered from the
carrier cab, the center indicator light also means that the rear steering cylinder locking pin is near alignment and
can be activated. When the rear steering lock pin engages, the sensor is then close enough to the pin to
complete the circuit and light the rear axle steering lock indicator light.

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Remove front axle proximity sensor assembly (12, Figure 2-4-3) as follows:

(1) Disconnect electrical connector for proximity sensor assembly (12) from carrier electrical harness.

(2) Remove nuts (1), lockwashers (2), washers (3), and clamps (4) securing proximity sensor assembly
(12) electrical wires to studs on axle.

(3) Loosen nuts (5), and remove screws (6), nuts (5), and ground wires for EMI shields (8) from
adjustment brackets (10).

(4) Remove clamps (7) securing EMI shields (8) to sensors of proximity sensor assembly (12).

(5) Remove nuts (9), adjustment brackets (10), proximity sensor assembly (12), and washers (13) from
axle bracket.

c. Remove rear axle proximity sensor assembly (25, Figure 2-4-3) as follows:

(1) Disconnect electrical connector for proximity sensor assembly (25) from carrier electrical harness.

(2) Remove nuts (14), lockwashers (15), washers (16), and clamps (17) securing proximity sensor
assembly (25) electrical wires to studs on axle.

(3) Loosen nuts (18), and remove screws (19), nuts (18), and ground wires for EMI shields (21) from
adjustment brackets (23).

(4) Remove clamps (20) securing EMI shields (21) to sensors of proximity sensor assembly (25).

(5) Remove nuts (22), adjustment brackets (23), proximity sensor assembly (25), and washers (26)
from axle brackets.

2-4-13
TM 5-3810-307-24-1-1

Installation

a. Install front axle proximity sensor assembly (12, Figure 2-4-3) as follows:

(1) Install adjustment brackets (10), washers (13), and sensors for proximity sensor assembly (12) on
axle bracket with nuts (9). Ensure sensor marked "CTR" is installed in the right (outboard) hole of
the axle bracket and the sensor marked "LT" is installed in the left (inboard) hole. Do not fully
tighten nuts (9) at this time, so adjustment bracket (10) can be moved.

NOTE

To identify the sensors of the axle proximity sensor assembly, the wires
are marked with an ID tag near the electrical connector.

(2) Insert screws (6) through holes in adjustment brackets (10), install ground wires for EMI shields (8)
and nuts (5) on screws (6), and turn screws (6) into axle bracket as far as possible. Do not tighten
nuts (5) at this time.

(3) Route wires of proximity sensor assembly (12) over axle and secure to axle studs with clamps (4),
washers (3), lockwashers (2), and nuts (1).

(4) Connect electrical connector for proximity sensor assembly (12) to carrier electrical harness.

(5) Adjust sensors for front axle proximity sensor assembly (12), refer to Adjustment procedures below.

b. Install rear axle proximity sensor assembly (25, Figure 2-4-3) as follows:

(1) Install adjustment brackets (23), washers (26), and sensors for proximity sensor assembly (25) on
axle brackets with nuts (22). Ensure sensor marked "CTR" is installed in the right (outboard) hole of
the right axle bracket, the sensor marked "LT" is installed in the left (inboard) hole, and the sensor
marked "LK" is installed in the right axle bracket. Adjust nuts (24 and 22) until a clearance of 0.25 in.
(6.4 mm) min. is obtained between the bottom of sensors marked "CTR" and "LT", and the steering
arm. Do not fully tighten nuts (22) at this time, so adjustment bracket (23) can be moved.

NOTE

To identify the sensors of the axle proximity sensor assembly, the wires
are marked with an ID tag near the electrical connector.

(2) Insert screws (19) through holes in adjustment brackets (23), install ground wires for EMI shields
(21) and nuts (18) on screws (19), and turn screws (19) into axle bracket as far as possible. Do not
tighten nuts (18) at this time.

(3) Route wires of proximity sensor assembly (25) over axle and secure to axle studs with clamps (17),
washers (16), lockwashers (15), and nuts (14).

(4) Connect electrical connector for proximity sensor assembly (25) to carrier electrical harness.

(5) Adjust sensors for rear axle proximity sensor assembly (25), refer to Adjustment procedures below.

2-4-14
 TM 5-3810-307-24-1-1

LEGEND

1. Nut 10. Adjustment bracket 19. Screw

2. Lockwasher 11. Nut 20. Clamp
3. Washer 12. Proximity sensor assy. 21. EMI shield
4. Clamp 13. Washer 22. Nut
5. Nut 14. Nut 23. Adjustment bracket
6. Screw 15. Lockwasher 24. Nut
7. Clamp 16. Washer 25. Proximity sensor assy.
8. EMI shield 17. Clamp 26. Washer
9. Nut 18. Nut

Figure 2-4-3. Axle Proximity Sensor Assemblies (Sheet 1 of 2)

2-4-15
TM 5-3810-307-24-1-1

Figure 2-4-3. Axle Proximity Sensor Assemblies (Sheet 2 of 2)

2-4-16
 TM 5-3810-307-24-1-1

Adjustment

a. Adjust sensors for front axle proximity sensor assembly (12, Figure 2-4-3) as follows:

(1) Using alignment equipment, center front wheels.

(2) Install steering wheel lock on carrier cab steering wheel.

(3) Ensure carrier cab ignition switch is in OFF position, and place superstructure cab ignition switch is
in ACC position, so FRONT AXLE STEERING indicator lights on superstructure dash panel can be
monitored.

(4) Turn screw (6) of sensor marked "CTR" out until sensor is over solid portion of the steering arm and
not over the hole in the arm.

(5) If CENTER indicator light on dash panel is off, loosen nuts (11 and 9) and adjust "CTR" sensor up
(away from steering arm) until light comes on. If CENTER indicator light is on, continue with next
step.

(6) Slowly adjust the "CTR" sensor down (toward steering arm) until CENTER indicator light goes out,
then adjust the sensor down an additional 1/4 turn.

(7) Turn screw (6) of sensor marked "CTR" in until the CENTER indicator light comes on, and mark
position of the leading edge of adjustment bracket (10) on axle bracket.

(8) Continue turning screw (6) of sensor marked "CTR" in until the CENTER indicator light goes off, and
mark position of the leading edge of adjustment bracket (10) on axle bracket.

(9) Turn screw (6) of sensor marked "CTR" out until the leading edge of adjustment bracket (10) is
positioned half way between the two marks. Check that CENTER indicator light is on.

(10) Adjust the "CTR" sensor down until the CENTER indicator light goes out.

(11) Adjust the "CTR" sensor up until the CENTER indicator light comes on, then turn sensor an
additional 1/4 turn up.

(12) Apply LOCTITE 242 to threads of screw (6), hold head of screw (6), and tighten nut (5) to secure
adjustment bracket (10) in place.

(13) Apply LOCTITE 242 to threads of "CTR" sensor, and tighten nuts (9 and 11) to hold sensor in place.

(14) With wheels centered, slide a metal object [1 3/4 in. (4.5 cm) square X 1/8 in. (.318 cm) thick]
between "CTR" sensor and steering arm to cover hole. CENTER indicator light should go out. If
CENTER indicator light stays lit, increase thickness of metal object and recheck light.

(15) Turn screw (6) of sensor marked "LT" out until sensor is over solid portion of the steering arm.

(16) If LEFT indicator light on dash panel is on, loosen nuts (11 and 9) and adjust "LT" sensor up (away
from steering arm) until light goes off. If LEFT indicator light is off, continue with next step.

(17) Slowly adjust the "LT" sensor down (toward steering arm) until LEFT indicator light comes on, then
adjust the sensor down an additional 1 turn.

(18) Turn screw (6) of sensor marked "LT" in until RIGHT indicator light comes on, and mark position of
the leading edge of adjustment bracket (10) on axle bracket.

2-4-17
TM 5-3810-307-24-1-1

(19) Turn screw (6) of sensor marked "LT" out until LEFT indicator light comes on, and mark position of
the leading edge of adjustment bracket (10) on axle bracket.

(20) Turn screw (6) of sensor marked "LT" in until the leading edge of adjustment bracket (10) is half way
between the two marks.

(21) Apply LOCTITE 242 to threads of screw (6), hold head of screw (6), and tighten nut (5) to secure
adjustment bracket (10) in place.

(22) Apply LOCTITE 242 to threads of "LT" sensor, and tighten nuts (9 and 11) to hold sensor in place.

(23) Remove metal object from under "CTR" sensor.

(24) Remove steering wheel lock from carrier cab steering wheel.

(25) Start engine from superstructure cab and position boom over rear of crane. Verify that FRONT
AXLE STEERING CENTER indicator light is lit (front wheels centered). Position FRONT AXLE
STEERING toggle switch to RIGHT, ensure front axle wheels turn in direction shown on pictogram
on right side of switch, CENTER and LEFT indicator lights are out, and RIGHT indicator light comes
on. Position toggle switch to LEFT, ensure front axle wheels turn in direction shown on pictogram on
left side of switch, CENTER and RIGHT indicator lights are out, and LEFT indicator light comes on.

(26) Position EMI shield (8) over sensors and secure in place with clamps (7).

b. Adjust sensors for rear axle proximity sensor assembly (25, Figure 2-4-3) as follows:

(1) Using alignment equipment, center rear wheels.

(2) Place ignition switch in carrier cab to ACC position.

(3) Engage rear steering lock cylinder by placing REAR AXLE STEERING LOCK switch on carrier cab
dash panel to LOCKED position.

(4) Adjust "CTR" and "LT" sensors of rear axle by performing step a.(4) thru a.(23) above, except use
REAR AXLE STEERING indicator lights on carrier cab dash panel.

(5) Loosen nuts (22 and 24) on "LK" sensor and adjust sensor to achieve a clearance of 0.31 0.03 in.
(7.9 0.8 mm) between bottom of "LK" sensor and top of rear steering lock cylinder actuator pin.
Tighten nuts (22 and 24) finger tight.

(6) Disengage rear steering lock cylinder by placing REAR AXLE STEERING LOCK switch to
UNLOCKED position. The REAR STEER LOCK ENGAGED indicator light should go out and the
REAR STEER LOCK DISENGAGED light should come on.

(7) Turn screw (19) in until the REAR STEER LOCK ENGAGED indicator light comes on, and mark
position of the leading edge of adjustment bracket (23) on axle bracket.

(8) Turn screw (19) out until the REAR STEER LOCK ENGAGED indicator light goes out and comes on
again, then mark position of the leading edge of adjustment bracket (23) on axle bracket. If REAR
STEER LOCK ENGAGED indicator light never goes out as screw (19) is turned out, adjust "LK"
sensor up (away from steering arm) 1/4 turn and repeat steps (6) and (7).

(9) Turn screw (19) of sensor marked "LK" in until the leading edge of adjustment bracket (23) is half
way between the two marks.

2-4-18
 TM 5-3810-307-24-1-1

(10) Apply LOCTITE 242 to threads of screw (19), hold head of screw (19), and tighten nut (18) to secure
adjustment bracket (23) in place.

(11) Apply LOCTITE 242 to threads of "LK" sensor, and tighten nuts (22 and 24) to hold sensor in place.

NOTE

After adjustments are made, the REAR STEER LOCK ENGAGED indicator
light should come on only when the axle is centered and the axle lock cylinder
is extended.

(12) Place REAR AXLE STEERING LOCK switch to the LOCKED position and ensure REAR STEER
LOCK ENGAGED indicator light comes on, and goes out when REAR AXLE STEERING LOCK
switch is placed in the UNLOCKED position.

(13) Start engine from carrier cab. Verify that REAR STEER DIRECTION center arrow indicator light is lit
(rear wheels centered). Position REAR AXLE STEERING toggle switch to RIGHT, ensure rear axle
wheels turn in direction shown on pictogram on right side of switch, center and left arrow indicator
lights are out, and right arrow indicator light comes on. Position toggle switch to LEFT, ensure rear
axle wheels turn in direction shown on pictogram on left side of switch, center and right arrow
indicator lights are out, and left arrow indicator light comes on.

(14) Position EMI shields (21) over sensors and secure in place with clamps (20).

2-4-19
TM 5-3810-307-24-1-1

REAR AXLE STEERING UNLOCK SWITCH

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Tag and disconnect electrical leads from rear axle steering unlock switch (1, Figure 2-4-4).

c. Remove rear axle steering unlock switch (1) and washer(s) (2) from rear steer lock cylinder.

Installation

a. Install washer(s) (2, Figure 2-4-4) and rear steering unlock switch (1) in rear steer lock cylinder.

b. Connect electrical leads to switch (1) and remove tags.

c. Perform operation check/adjustment of rear steering unlock switch, refer to Operation Check/ Adjustment
procedures.

Operation Check/Adjustment

a. Position battery disconnect switch to ON and place ignition switch in carrier cab to ACC position.

b. Place REAR AXLE STEERING LOCK switch to UNLOCKED position and ensure REAR STEER LOCK
DISENGAGED indicator light is on.

c. Place REAR AXLE STEERING LOCK switch to LOCKED position and ensure REAR STEER LOCK
DISENGAGED indicator light is off.

d. If REAR STEER LOCK DISENGAGED indicator light stays lit, ensure rear steer lock cylinder pin is fully
engaged in steering arm. Pin must be fully engaged for proper operation of switch.

e. If lock pin is fully engaged, and the light is lit, rear steering unlock switch must be adjusted as follows:

(1) Remove switch (1, Figure 2-4-4) and washer(s) (2) from lock cylinder, refer to Removal procedures.

(2) Install another washer (2) and switch (1) in lock cylinder.

(3) Check to see if REAR STEER LOCK DISENGAGED indicator light is now out. If light is out, remove
switch (1), add one more washer (2), install switch (1), and adjustment is complete. If light is still lit,
repeat steps e.(1) thru (3) until light goes out.

2-4-20
 TM 5-3810-307-24-1-1

LEGEND

1. Rear steer unlock switch

2. Washer

Figure 2-4-4. Rear Axle Unlock Switch

2-4-21
TM 5-3810-307-24-1-1

WHEELS AND TIRES

DESCRIPTION

The size of tires used on this crane are 16.00 x R21.
CAUTION
Do not mix tires and rims of different
manufacturers.
Each wheel assembly (tire and rim) weighs
approximately 540 pounds (245 kg) and is mounted
on the planetary hub with 10 M22 lug nuts.
Off-highway tires are designed to operate with a
certain sidewall deflection or bulge. Correct air
pressure ensures proper deflection which, in turn,
ensures proper traction, flotation, support of load,
and prevents excessive flexing of the tire. Over
inflation increases rim stresses, which results in
lowered rim life.
Refer to and adhere to the inflation pressures on the
Tire Inflation decal on the crane.

NOTE

The tire diameters, widths, and weights may vary slightly depending on
the manufacturer.

MAINTENANCE

3. Torque the lug nuts to 435 pounds-foot (590

WARNING Nm) in the sequence shown in the Lug Nut Torquing
Do not attempt to demount or mount Sequence figure.
tires without proper training. The high
pressures involved can cause tire and
rim parts and tools to fly with explosive
force, if proper procedures are not used,
causing severe injury or death to
personnel and damage to the crane and
surrounding area.

MOUNTING WHEEL ASSEMBLIES.

NOTE

Do not lubricate the wheel studs or lug

nuts.

1. Position the wheel assembly on the mounting

studs. Install the lug nuts and washer and tighten
them until they are just snug, rotating the wheel so
the nut being tightened is in the top position.

2. Ensure the wheel assembly is positioned

properly on the hub.

Figure 2-4-5. Lug Nut Torquing Sequence

2-4-22
 TM 5-3810-307-24-1-1

BRAKE SYSTEM

DESCRIPTION

The brake system is pneumatically controlled and cab), the service brake relay valves (one for each
can be operated from either cab. The components axle), park brake relay valve, spring brake control
which make up the brake system include the brake valve, brake chambers, and service brakes.
valves and park brake valves (one of each for each

THEORY OF OPERATION

Each wheel end has a spring powered brake
chamber. This chamber is spring actuated and must
be released by air pressure. The spring brakes
(parking brakes) are released by the parking brake
push-pull knob in the cabs. Pushing down on the
parking brake causes air pressure to enter the spring
brake chamber on each wheel and compress the
spring, releasing the brakes.
At least 40 psi (275.8 kPa) is required to keep the
parking brake valve engaged. If supply pressure to
the valve drops below 40 psi (275.8 kPa), the valve
will release, applying the brakes.
The service brakes are applied by air pressure.
Depressing the foot brake pedal on the cab floor
causes pressurized air to enter the service brake
chamber on each wheel, applying the brakes. In the
event of a loss of supply pressure to the service
brakes, the spring brake valve will allow the operator
to release or bleed off the air pressure in the spring
brake chamber by depressing the foot brake pedal to
apply the brakes.

2-4-23
TM 5-3810-307-24-1-1
SERVICE BRAKES
DESCRIPTION
The service brakes are the drum and shoe type. The
brakes on the rear axle are single wedge actuated
and the brakes on the front axle are dual wedge
actuated. Each wedge is actuated by an air brake
MAINTENANCE
GENERAL.
To ensure proper operation of service brakes,
perform Preventive Maintenance Checks and
Services when due, refer to Chapter 1, Section 3.
Brakes should be cleaned, inspected, lubricated, and
adjusted each time the hubs are removed.
During a major overhaul, the following parts should
be carefully checked and replaced with genuine
replacement parts as required.
1. Check the backing plates for distortion,
looseness, and sheared rivets.
2. Check the anchor pins for wear or
misalignment.
3. Check the brake shoes for wear at the anchor
pin holes.
4. Shoe return springs should be replaced at the
time of overhaul.
5. Check the brake linings for grease saturation,
wear, and loose rivets or bolts.
6. Check the drums for cracks, scoring, or other
damage.
2-4-24
chamber (power unit) mounted on the brake backing
plate. The brakes have automatically adjusting
plungers that ensure the brakes are properly
adjusted to compensate for brake lining wear.
BRAKE ASSEMBLY.
Initial Adjustment.
The brake actuator (expander unit) is adjusted at the
minimum dimension by the manufacturer. This
dimension varies with respect to the brake diameter.
When changing linings (after turning down the
drums and linings), turn the adjusting screw to obtain
a clearance of 0.006 in. 0.0015 in. ( 0 .152 mm
0.04 mm) between brake shoe and drum. Do not
block the screw. Check the sealing of the boots.
Operational Check.
Slowly operate the brake system using the pedal
operated valve. Look through the holes to see that
the shoes move against the drums. After releasing
the pedal, the brake shoes should return instantly to
the original position.
Brake Linings.
In the event of wear or oil impregnation, always
change the linings on both sides of the axle. Never
replace the linings on one side only.
Brake Drum.
Admissible machining of the brake drum to remove
scoring is 0.06 in. (1.54 mm) radially. Thus, the
maximum allowable inside diameter of the drum after
machining is 16.26 in. (413.08 mm) or .75% of the
nominal diameter of 16.14 in. (410 mm).
 TM 5-3810-307-24-1-1

Brake Actuator (Expander Unit). 4. Remove the plugs, pins, and springs.

Before installation, coat all moving parts with CLEANING AND INSPECTION.
multipurpose grease, MIL-G-10924.
1. Clean all parts with a non-residue type
The brakes will adjust themselves automatically cleaning solvent.
during operation to a certain diameter with respect to
operating condition. 2. Inspect all parts for wear, scoring, cracks, or
other damage.

DISASSEMBLY. 3. Before assembly, grease all moving parts with

Shell 16 grease.
1. Remove the push rod assembly by removing
the snap ring. Remove the cup, springs, cage, and ASSEMBLY.
balls, refer to Figure 2-4-6.
1. Install the spring washer, spacer adjusting ring,
WARNING and piston into the housing, refer to Figure 2-4-6.
These parts are under spring tension
and must be held, or caged when snap 2. Install the brake shoe locator, spring clip, and
ring is removed. clip.

2. Remove the clip, spring clip, and brake shoe 3. Install the cage, balls, cup, and springs. Install
locator. the snap ring and the push rod assembly.

3. Remove the adjuster, adjusting ring, and 4. Install the plugs, pins, and spring.
spacer from the piston. Remove the spring washer.

2-4-25
TM 5-3810-307-24-1-1

LEGEND

1. Spring clip 14. Plug 27. Ball

2. Rubber boot 15. Spring 28. Ball
3. Brake shoe actuator 16. Spring 29. Cage
4. Adjuster 17. Pin 30. Wedge
5. Adjuster ring 18. Piston 31. Washer
6. Spacer 19. Spring washer 32. Spring
7. Clip 20. Spacer 33. Cup
8. Spring washer 21. Adjuster ring 34. Snap ring
9. Piston 22. Adjuster 35. Spring
10. Pin 23. Brake shoe locator 36. Washer
11. Spring 24. Rubber boot 37. Collet
12. Spring 25. Spring clip 38. Plunger assembly
13. Plug 26. Clip

Figure 2-4-6. Brake Actuator

2-4-26
 TM 5-3810-307-24-1-1

BRAKE CHAMBER (FRONT WHEELS)

Removal

a. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.

b. Tag and disconnect air lines from connectors (5, Figure 2-4-7) and tee (9).

c. Back off counter nut (1) and unscrew brake chamber assembly (2) from wheel.

d. Back off counter nut (3) and unscrew brake chamber assembly (4) from wheel.

e. If necessary, remove connectors (5), adapters (6), washers (7), o-rings (8), and counter nut (1) from brake
chamber assembly (2).

f. If necessary, remove tee (9), adapter (10), washer (11), o-ring (12), and counter nut (3) from brake
chamber assembly (4).

Repair

a. Disassemble brake chamber assembly (2, Figure 2-4-7) as necessary to replace damaged, worn, and
defective components.

(1) Loosen clamps (13), and remove hose (14) and clamps (13) from cover (20) and brake chamber
cylinder (19).
WARNING
Brake chamber assembly is adjusted to have spring tension. Personal
injury may occur if tension is not released prior to removing clamp and
separating cover from cylinder.

(2) Release spring tension on brake chamber assembly (2) by backing spring release bolt (15) out of
brake chamber cylinder (19) to a minimum length of 3.08 in. (78 mm) from back of chamber body to
top of bolt head.

(3) Match mark cover (20) to brake chamber cylinder (19), remove nuts (16), capscrews (17), clamp
halves (18), and separate brake chamber cylinder (19) and cover (20).

(4) Remove diaphragm (21) from brake chamber cylinder (19).

(5) Remove piston (22) from cover (20).

(6) Remove snap ring (23) and guide (24) from cover (20).

(7) Remove o-ring (25) from guide (24).

(8) Remove snap ring (26), bushing (27), and collar (28) from cover (20).

2-4-27
TM 5-3810-307-24-1-1

(9) Remove rings (29) from collar (28).

b. Assemble brake chamber assembly (2, Figure 2-4-7) as necessary.

(1) Install rings (29) on collar (28).

(2) Position collar (28) and bushing (27) in cover (20), and secure with snap ring (26).

(3) Install o-ring (25) on guide (24), position guide (24) in cover (20), and secure with snap ring (23).

(4) Install piston (22) in cover (20) so that shaft of piston passes through guide (24) and contacts collar
(28).

(5) Install diaphragm (21) in brake chamber cylinder (19), carefully position cover (20) on brake
chamber cylinder (19) as marked during removal, and secure together with clamp halves (18),
capscrews (17), and nuts (16).

(6) Install hose (14) on brake chamber cylinder (19) and cover (20), and secure both ends with clamps
(13).

c. Disassemble brake chamber assembly (4, Figure 2-4-7) as necessary to replace damaged, worn, and
defective components.
WARNING
Brake chamber assembly is assembled with spring tension. Maintain
pressure on cover and cylinder, and slowly release spring tension when
removing clamp and separating cover from cylinder. Failure to observe
this warning could result in personal injury.

(1) Match mark cover (34) to brake chamber cylinder (33), hold cover (34) and cylinder (33) together,
remove nuts (30), capscrews (31), clamp halves (32), and slowly separate brake chamber cylinder
(33) and cover (34).

(2) Remove diaphragm (37) from brake chamber cylinder (33).

(3) Remove piston (35) and spring (36) from cover (34).

(4) Remove snap ring (38) and guide (39) from cover (34).

(5) Remove o-ring (40) from guide (39).

(6) Remove snap ring (41), bushing (42), and collar (43) from cover (34).

(7) Remove rings (44) from collar (43).

d. Assemble brake chamber assembly (4, Figure 2-4-7) as necessary.

(1) Install rings (44) on collar (43).

(2) Position collar (43) and bushing (42) in cover (34), and secure with snap ring (41).

(3) Install o-ring (40) on guide (39), position guide (39) in cover (34), and secure with snap ring (38).

(4) Position spring (36) and piston (35) in cover (34) so that shaft of piston passes through guide (39).

2-4-28
 TM 5-3810-307-24-1-1

(5) Install diaphragm (37) in brake chamber cylinder (33), carefully position brake chamber cylinder (33)
on piston (35), press brake chamber cylinder (33) and cover (34) together while aligning match
marks, and secure together with clamp halves (32), capscrews (31), and nuts (30).

Installation

a. If removed, install new o-ring (12, Figure 2-4-7), washer (11), adapter (10), and tee (9) in brake chamber
assembly (4).

b. If removed, screw counter nut (3) onto brake chamber assembly (4) with castellations toward brake
chamber body. Screw nut on as far as it will go.

c. Apply LOCTITE 565 to threads of brake chamber assembly (4). Then screw brake chamber assembly (4)
into brake expander housing until it bottoms

d. Back out brake chamber assembly (4) no more than 1 turn to correctly orient air connections as shown in
Figure 2-4-7.

e. Screw counter nut (3) down to brake expander housing and torque nut to 105-135 lbs-ft (142-183 Nm).

f. If removed, install new o-rings (8), washers (7), adapters (6), and connectors (5) in brake chamber
assembly (2).

g. If necessary, cage parking brake spring on brake chamber assembly (2) by backing spring brake release
bolt (15) out of brake chamber cylinder (19) to a minimum length of 3.08 in. (78 mm) as measured from back of
chamber body to top of bolt head.

h. If removed, screw counter nut (1) onto brake chamber assembly (2) with castellations toward brake
chamber body. Screw nut on as far as it will go.

i. Apply LOCTITE 565 to threads of brake chamber assembly (2). The screw brake chamber assembly (2)
into brake expander housing until it bottoms.

j. Back out brake chamber assembly (2) no more than 1 turn to correctly orient air connections as shown in
Figure 2-4-7.

k. Screw counter nut (1) down to brake expander housing and torque nut to 105-135 lbs-ft (142-183 Nm).

l. Tension spring (to set parking brake) in brake chamber assembly (2) by turning spring release bolt (15)
into brake chamber cylinder (19) to a maximum dimension of 1.02 in. (26 mm) from back of chamber body to top
of bolt head.

m. Connect air lines to connectors (5) and tee (9). Remove tags.

2-4-29
TM 5-3810-307-24-1-1

LEGEND

1. Counter nut 16. Nut 31. Capscrew

2. Brake chamber assy. 17. Capscrew 32. Clamp half
3. Counter nut 18. Clamp half 33. Brake chamber cyl.
4. Brake chamber assy. 19. Brake chamber cyl. 34. Cover
5. Connector 20. Cover 35. Piston
6. Adapter 21. Diaphragm 36. Spring
7. Washer 22. Piston 37. Diaphragm
8. O-ring 23. Snap ring 38. Snap ring
9. Tee 24. Guide 39. Guide
10. Adapter 25. O-ring 40. O-ring
11. Washer 26. Snap ring 41. Snap ring
12. O-ring 27. Bushing 42. Bushing
13. Clamp 28. Collar 43. Collar
14. Hose 29. Ring 44. Ring
15. Spring release bolt 30. Nut

Figure 2-4-7. Front Brake Chamber Assembly (Sheet 1 of 3)

2-4-30
 TM 5-3810-307-24-1-1

Figure 2-4-7. Front Brake Chamber Assembly (Sheet 2 of 3)

2-4-31
TM 5-3810-307-24-1-1

Figure 2-4-7. Front Brake Chamber Assembly (Sheet 3 of 3)

2-4-32
 TM 5-3810-307-24-1-1

BRAKE CHAMBER (REAR WHEELS)

Removal

a. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.

b. Tag and disconnect air lines from connectors (3, Figure 2-4-8).

c. Back off counter nut (1) and unscrew brake chamber assembly (2) from wheel.

d. If necessary, remove connectors (3), adapters (4), washers (5), o-rings (6), and counter nut (1) from brake
chamber assembly (2).

Repair

a. Disassemble brake chamber assembly (2, Figure 2-4-8) as necessary to replace damaged, worn, and
defective components.

(1) Loosen clamps (7), and remove hose (8) and clamps (7) from elbow (24) and brake chamber
cylinder (13).
WARNING
Brake chamber assembly is adjusted to have spring tension. Personal
injury may occur if tension is not released prior to removing clamp and
separating cover from cylinder.

(2) Release spring tension on brake chamber assembly (2) by backing spring release bolt (9) out of
brake chamber cylinder (13) to a minimum length of 3.08 in. (78 mm) from back of chamber body to
top of bolt head.

(3) Match mark cover (14) to brake chamber cylinder (13), remove nuts (10), capscrews (11), clamp
halves (12), and separate brake chamber cylinder (13) and cover (14).

(4) Remove diaphragm (15) from brake chamber cylinder (13).

(5) Remove piston (16) from cover (14).

(6) Remove snap ring (17) and guide (18) from cover (14).

(7) Remove o-ring (19) from guide (18).

(8) Remove snap ring (20), bushing (21), and collar (22) from cover (14).

(9) Remove rings (23) from collar (22).

(10) Remove elbow (24) from cover (14).

b. Assemble brake chamber assembly (2, Figure 2-4-8) as necessary.

2-4-33
TM 5-3810-307-24-1-1

(1) Install elbow (24) in cover (14).

(2) Install rings (23) on collar (22).

(3) Position collar (22) and bushing (21) in cover (14), and secure with snap ring (20).

(4) Install o-ring (19) on guide (18), position guide (18) in cover (14), and secure with snap ring (17).

(5) Install piston (16) in cover (14) so that shaft of piston passes through guide (18) and contacts collar
(22).

(6) Install diaphragm (15) in brake chamber cylinder (13), carefully position cover (14) on brake
chamber cylinder (13) as marked during removal, and secure together with clamp halves (12),
capscrews (11), and nuts (10).

(7) Install hose (8) on brake chamber cylinder (13) and elbow (24), ensuring hose passes through hole
in cylinder flange, and secure both ends with clamps (7).

Installation

a. If removed, install new o-rings (6, Figure 2-4-8), washers (5), adapters (4), and connectors (3) in brake
chamber assembly (2).

b. If necessary, cage parking brake spring on brake chamber assembly (2) by backing spring brake release
bolt (9) out of brake chamber cylinder (13) to a minimum length of 3.08 in. (78 mm) as measured from back of
chamber body to top of bolt head.

c. If removed, screw counter nut (1) onto brake chamber assembly (2) with castellations toward brake
chamber body. Screw nut on as far as it will go.

d. Apply LOCTITE 565 to threads of brake chamber assembly (2). The screw brake chamber assembly (2)
into brake expander housing until it bottoms.

e. Back out brake chamber assembly (2) no more than 1 turn to correctly orient air connections as shown in
Figure 2-4-8.

f. Screw counter nut (1) down to brake expander housing and torque nut to 105-135 lbs-ft (142-183 Nm).

g. Tension spring (to set parking brake) in brake chamber assembly (2) by turning spring release bolt (9) into
brake chamber cylinder (13) to a maximum dimension of 1.02 in. (26 mm) from back of chamber body to top of
bolt head.

h. Connect air lines to connectors (3) and remove tags.

2-4-34
 TM 5-3810-307-24-1-1

LEGEND

1. Counter nut 9. Spring release bolt 17. Snap ring

2. Brake chamber assy. 10. Nut 18. Guide
3. Connector 11. Capscrew 19. O-ring
4. Adapter 12. Clamp half 20. Snap ring
5. Washer 13. Brake chamber cyl. 21. Bushing
6. O-ring 14. Cover 22. Collar
7. Clamp 15. Diaphragm 23. Ring
8. Hose 16. Piston 24. Elbow

Figure 2-4-8. Rear Brake Chamber Assembly

2-4-35
TM 5-3810-307-24-1-1

AIR VALVES

DESCRIPTION

The air valves used in the brake system are the control valve. These valves control the application
brake valves, park brake valves, service brake relay and release of the service brakes and parking
valves, park brake relay valve, and the spring brake brakes and are all a part of the cranes air system.

NOTE

For more detailed information concerning the air valves used in the
crane's brake system refer to Section 7 - AIR SYSTEM.

2-4-36
 TM 5-3810-307-24-1-1

SECTION 5
STEERING SYSTEM

TABLE OF CONTENTS
Page

STEERING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Front Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Rear Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Front Axle Steering from the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Rear Axle Steering from the Superstructure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Front Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Rear Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-4
Front Axle Steering from the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-4
Rear Axle Steering from the Superstructure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-4
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-4
Relay Shaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-7
Centering the Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-7
MITER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
SELECTOR VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
INTEGRATED OUTRIGGER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
STEER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17

2-5-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS - Continued

Page

EMERGENCY (STANDBY) STEERING VALVE AND PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Emergency (Standby) Steering Valve and Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-20
STEERING SYSTEM FILTER CHECK VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23

LIST OF FIGURES
Number Title Page

2-5-1 Relay Shaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5

2-5-2 Steering Gear Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-8
2-5-3 Steering Gear Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-9
2-5-4 Miter Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-11
2-5-5 Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-13
2-5-6 Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-15
2-5-7 Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-18
2-5-8 Emergency Steering Valve and Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-21
2-5-9 Steering System Filter Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23

2-5-2 C-1

STEERING SYSTEMS
DESCRIPTION
The crane is equipped with four steering systems,
one for steering the front axle from the carrier, one
for steering the rear axle from the carrier, one for
steering the front axle from the superstructure, and
one for steering the rear axle from the
superstructure.
FRONT AXLE STEERING FROM THE CARRIER.
The system for steering the front axle from the carrier
consists of the steering pump, single selector valve,
double selector valve, miter gear, front steering gear,
and front steer cylinders. This system is primarily
used for roading the crane and is operated by the
steering wheel in the carrier cab.
The steering pump is driven by the engine. The
single selector valve and the double selector valve
are mechanically linked and operate together. The
two valves are controlled by the steering mode
control handle. The handle must be pushed in to
steer the front axle from the carrier. The miter gear
transmits the mechanical force from the steering
column in the cab at a 90 degree angle to the
steering gear which is connected to the wheels
through the drag link and tie rod. The steering gear
also directs hydraulic flow to the applicable side of
the front steer cylinders which provides the power
assistance for steering.
REAR AXLE STEERING FROM THE CARRIER.
The system for steering the rear axle from the carrier
consists of the steering pump, single selector valve,
steering selector valve, steer control valve, and the
rear steer cylinders. The system is used only at low
speed to provide the additional maneuverability
needed when steering the crane into a tight area for
parking or when near a job site. The function is
operated by the REAR AXLE STEERING control
switch on the front console.
THEORY OF OPERATION
FRONT AXLE STEERING FROM THE CARRIER.
The steering mode selector must be in the CARRIER
position (handle pushed in) to enable steering
control.
TM 5-3810-307-24-1-1
FRONT AXLE STEERING FROM THE SUPER-
STRUCTURE.
The system for steering the front axle from the
superstructure consists of the third section of the
hydraulic pump, the integrated outrigger valve,
double selector valve, and front steer cylinders. This
system is primarily used for maneuvering the crane
into tight areas on the job site and is operated by the
FRONT AXLE STEERING control switch on the front
console.
The steering mode control handle must be pulled out
to steer the front axle from the superstructure.
REAR AXLE STEERING FROM THE SUPER-
STRUCTURE.
The system for steering the rear axle from the
superstructure consists of the steering pump, single
selector valve, steering control valve, steer reversing
solenoid, steer selector valve, and the rear steer
cylinders. This system is used for job site travel and
is operated by the steering wheel in the
superstructure cab.
The steering pump feeds the system through the
single selector valve. The steering mode control
handle must be pulled out to steer the rear axle from
the superstructure.
The steer reversing solenoid is located on the
electrical swivel and the steer selector valve is
located in the turntable center section. The purpose
of these components is to reverse the direction of the
hydraulic flow to the steer cylinders in accordance
with the position of the superstructure. This means
that the crane will turn in the direction the steering
wheel is turned whether the superstructure is facing
the front or rear of the carrier.
Hydraulic flow for steering is provided by the steering
pump. Flow from the pump is routed through the
single selector valve to the front steering gear. As
the steering wheel is turned, the miter gear transmits
the mechanical force at a 90 degree angle to the
2-5-3
TM 5-3810-307-24-1-1
front steering gear. The mechanical input to the
steering gear shifts the internal valving within the
gear which routes hydraulic flow from the steering
gear through the double selector valve to the
applicable ends of the front steer cylinders as
determined by the positioning of the steering wheel
in the cab.
REAR AXLE STEERING FROM THE CARRIER.
The steering mode selector must be in the CARRIER
position (handle pushed in) to enable steering
control.
Hydraulic flow for steering is provided by the steering
pump. Flow from the pump is routed through the
single selector valve to the steer control valve, and
steering selector valve to the appropriate ends of the
steer cylinders as selected by the REAR AXLE
STEERING control switch on the console. As the
switch is positioned to the left or right, the
appropriate solenoid on the steer control valve is
energized to actuate steering in the same direction.
A gauge on the console indicates the positioning of
the wheels.
FRONT AXLE STEERING FROM THE SUPER-
STRUCTURE.
For front axle steering from the superstructure the
steering mode control handle must be pulled out.
Hydraulic flow is provided by the third section of the
hydraulic pump. Flow from the pump is routed to the
integrated outrigger valve. As the control switch in
the cab is positioned to the left or right, the
applicable solenoid on the integrated outrigger valve
is energized and hydraulic oil is routed through the
double selector
MAINTENANCE
FUNCTIONAL CHECK.
A normal periodic functional check of the entire
power steering system will generally be adequate to
ensure satisfactory service.
1. Check all fittings for leakage. An accumulation of
moist, black dirt is a good indication of leakage.
2. Actuate the control lever, and turn the steering
wheels through their full range of travel, with the
engine running at idle, and at full throttle, and with
the crane standing still, and moving. Note any speed
2-5-4
valve to the appropriate ends of the front axle steer-
ing cylinders.
REAR AXLE STEERING FROM THE SUPER-
STRUCTURE.
For rear axle steering from the superstructure the
steering mode control handle must be pulled out.
Hydraulic flow for steering is provided by the steering
pump. Flow from the pump is routed through the
single selector valve, through the swivel to the steer-
ing control valve. The steering control valve routes
flow through the steer selector valve, through the
swivel to the appropriate ends of the steer cylinders
as selected by the steering wheel in the cab.
The steer selector valve is actuated by the steer
reversing switch. With the superstructure over the
rear of the crane carrier the valve is de-energized.
Turning the steering wheel to the right will turn the
wheels to the right and turning the wheel to the left
will turn the wheels to the left. This causes the crane
to turn in the direction the steering wheel is turned.
Rotating the superstructure over the front of the
carrier actuates the steer reversing solenoid, which
in turn energizes the solenoid in the steer selector
valve and shifts the valve spool. This reverses the
flow of oil to the steer cylinders on the rear axle thus
turning the steering wheel to the right will turn the
wheels to the left and turning the steering wheel to
the left will turn the wheels to the right. This allows
the crane to turn in the direction the steering wheel is
turned whether the superstructure is facing the front
or the rear of the carrier.
irregularities or sticky sensation. This may indicate
dirt in the fluid.
3. Ensure the system has adequate power. If there
is an indication of ``hard steering'', this can be
caused by either a reduced oil flow to the control
valve or a reduced system relief pressure. Adequate
oil flow under all conditions can best be checked by
timing the full travel of the cylinder with the steered
axle unloaded and loaded. If there is a great
difference at low engine speed and slight difference
at high engine speeds this may indicate a defective
pump drive. Adequate oil pressure can only be

determined by connecting a pressure gauge (5000
psi [34,475 kPa] full scale recommended) at the
pump outlet port or at the IN port of the steering
control valve. With the engine running at a medium
speed, turn the steering wheel to one end of the
travel and hold the cylinders at the travel limit briefly,
just long enough to read the pressure gauge. Never
hold the system at relief pressure for more than a
few seconds at a time. The pressure gauge
readings should be as follows: 2500 psi (17237 kPa)
for the steering pump, 3500 psi (24132 kPa) for the
steering portion of the integrated outrigger valve, and
2175 psi (14996 kPa) for the front steering gear.
Figure 2-5-1. Relay Shaft Alignment
TM 5-3810-307-24-1-1
RELAY SHAFT ALIGNMENT.
NOTE
For proper alignment, the axle must be in
the straight ahead position.
There are two relay shafts used in the steering
system, between the carrier steering column and the
miter gear and between the miter gear and the
steering gear. Ensure the universal joints on the
relay shafts are properly aligned as shown on the
figure titled Relay Shaft Alignment.
2-5-5
TM 5-3810-307-24-1-1

STEERING GEAR

DESCRIPTION

The Z.F. Steering Gear is a semi-integral power
steering unit that directs the steering fluid to the steer
cylinders in response to the movement of the
steering wheel. The steering housing contains the
control valve, a complete mechanical steering gear,
and it is at the same time the operating cylinder of
the piston. The worm and the steering nut are
connected by an endless chain of balls. The balls
are returned via a recirculating tube. The steering
nut is maintained clearance free
against axial thrust by means of two anti-friction
bearings. The control valve is installed across in the
piston. The valve is composed of a valve spool and
two fixed reaction pistons. One finger of the steering
nut fits snugly into the bore of the valve spool. The
piston and the sector shaft are positively connected
by a gearing. Due to a special tooth shape on the
sector shaft, their axial adjustment is possible. This
ensures clearance free operation in the straight
ahead travel range.

THEORY OF OPERATION

In the neutral position of the valve, the oil pressure in
the right and the left cylinder chambers is balanced.
By moving the valve spool from the neutral position,
a pressure difference is produced between the left
and the right cylinder chambers. The piston will
receive more oil pressure on one side, and the
hydraulic power assistance is operative. The valve
is actuated by a rotation of the steering wheel, or by
the forces which coming from the road wheels, act
through the sector shaft and piston on the steering
nut and worm. Any rotation of the worm means an
axial movement of the piston, and a radial movement
of the output shaft. This operation causes the valve
spools to be moved by the finger on the steering nut.
Consequently the oil pressure is now supplied to
only one of the two cylinder chambers. The piston
assists the worm rotation. A compression spring
arranged in the steering nut causes the return of the
steering nut, and also the valve spools, to neutral
position. The return to neutral, is also assisted by a
design function called hydraulic reaction. Two
hydraulic pistons are mounted to float in bores of the
valve spool, and secured against axial movement by
locking plates. The outside faces of the two reaction
pistons are permanently pressurized in the operating
position of the valve. Likewise only one of the two
faces in the bores of the valve spool are pressurized
with oil. This causes a hydraulic reaction force which
is trying to return the valve spool to the neutral
position.

MAINTENANCE

REMOVAL. 3. Remove the nut, bolt, and washer securing the

relay shaft to the steering gear.
1. Tag and disconnect the hydraulic lines to the
steering gear. Cap or plug all lines and openings. 4. Remove the bolts and washers mounting the
steering gear to the mounting bracket on the carrier
2. Disconnect the drop arm from the steering frame. Remove the steering gear.
gear.

2-5-6
 TM 5-3810-307-24-1-1

INSTALLATION. The following procedure is to be used to center the

1. Position the steering gear to the mounting
bracket on the carrier frame and secure in place with
the mounting bolts and washers. Torque the bolts to
144 pounds-foot (195 Nm).
2. Center the steering gear. Refer to
CENTERING THE STEERING GEAR.
3. Connect the drop arm to the steering gear and
secure in place with the castle nut. Torque the nut to
295 pounds-foot (400 Nm) then back off nut to the
nearest cotter pin hole and install the cotter pin.
Refer to the figure titled Steering Gear Service Infor-
mation.
4. Ensure steering wheel is in the straight ahead
position and connect the relay shaft to the steering
gear with the bolt, nut, and washer. Refer to RELAY
SHAFT ALIGNMENT. Torque the bolt to 35 pounds-
foot (47 Nm).
steering gear after installation.
1. Turn the input stub until it bottoms out.
2. Turn the input stub in the opposite direction
and count the number of turns until it bottoms out.
3. Divide the number of turns in half and turn the
input stub that number of turns back to center the
steering gear.
4. Refer to the figure titled Steering Gear Service
Information and check for proper positioning of the
index mark.
NOTE
For procedures concerning centering the
front wheels, refer to Hydraulic Power
Bleeding and Adjustment in Section 4 -
Axles And Brake System.

5. Before applying hydraulic pressure, turn CAUTION

steering wheel fully in both directions. Check that
steering cylinders have a minimum of 0.25 in. (6.35 Do not operate front axle steering from
mm) or a maximum of 0.28 in. (7.11 mm) clearance the super-structure unless the front axle
with the tie-rod(s) and/or steering arm(s). Check that stops are correctly set. Damage to the
there is a minimum of 0.50 in. (12.7 mm) clearance steering gear will result. Refer to
between brake chambers and axles. Adjust axle Hydraulic Power Bleeding And
stops as necessary to achieve clearances. Adjustment in Section 4 - Axles And
Brake System.
CENTERING THE STEERING GEAR.

NOTE

For proper alignment, the axle must be in

the straight ahead position.

2-5-7
TM 5-3810-307-24-1-1

Figure 2-5-2. Steering Gear Installation

2-5-8
 TM 5-3810-307-24-1-1

Figure 2-5-3. Steering Gear Service Information

2-5-9
TM 5-3810-307-24-1-1

MITER GEAR

DESCRIPTION

The miter gear is located at the front of the carrier. It steering column at a 90 degree angle to the steering
is connected to the carrier steering column and the gear. The miter gear is necessary because the
steering gear by relay shafts. The miter gear is used distance and angles between the steering column
to transmit mechanical turning power from the and the steering gear make a direct link impossible.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

REMOVAL. INSTALLATION.

1. Remove the bolt, nut, and washer securing the
steering column relay shaft to the miter gear and
disconnect the shaft.
2. Remove the bolt, nut, and washer securing the
steering gear relay shaft to the miter gear and
disconnect the shaft.
3. Remove the bolt, nuts, and washers securing
the miter gear to the mounting bracket and remove
the miter gear.
1. Position the miter gear on the mounting
bracket and secure in place with the bolts, nuts, and
washers. Torque the bolts to 75 pounds-foot (102
Nm).
2. Connect the relay shafts to the miter gear and
secure in place with the bolts, nuts, and washers.
Refer to RELAY SHAFT ALIGNMENT. Torque the
bolts to 35 pounds-foot (47 Nm).

2-5-10
 TM 5-3810-307-24-1-1

Figure 2-5-4. Miter Gear Installation

2-5-11
TM 5-3810-307-24-1-1

SELECTOR VALVES

DESCRIPTION

The single selector valve and the double selector
valve are located on the inner rail near the center of
the carrier frame. The two valves are mechanically
connected and are used to select the mode of
steering (carrier or superstructure). The mechanical
linkage is connected to a control cable which is
operated by a handle mounted beside the hydraulic
reservoir.
Incorporated in the linkage is a switch that is
actuated when the valve linkage is in the
superstructure steering mode. The switch
illuminates an indicator light in the carrier cab to
signify that the control handle is in the superstructure
mode and the crane cannot be steered from the
carrier.
For more detailed information concerning the valves,
refer to VALVES in Section 8 - HYDRAULIC
SYSTEM.

MAINTENANCE

CABLE ADJUSTMENT.
1. Position the steering selector valve to the
carrier position by pushing in on the control handle.
Turn the handle to the horizontal position to lock the
cable and engage the mechanical lock.
NOTE
Ensure the cable jam nut is adjusted so
the control handle is in the horizontal
position when locked.
2. Remove the bolt from the rod end of the cable
at the steering valve mechanism. Position the
mechanism so the upper and lower steering valve
spools are bottomed out against the snap rings.
3. Adjust the cable rod end so the attach bolt will
just fit. Lengthen the rod end by one full turn and
tighten the jam nut.
4. Adjust the switch so the steering disconnected
light in the carrier cab is out when the valves are in
the carrier steering mode and the light illuminates
when moved from the carrier steering position.

2-5-12
 TM 5-3810-307-24-1-1

Figure 2-5-5. Selector Valves

2-5-13
TM 5-3810-307-24-1-1

STEERING PUMP

DESCRIPTION

The steering pump is mounted on the torque system, and the parking brake. The pump is a gear
converter and driven by the engine. It provides the type pump and provides a priority flow of
hydraulic flow necessary to power the front steer approximately 8 gpm. (30.2 lpm) at 2500 psi
cylinders, the brake system, the axle lockout (17237.5 kPa).

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

REMOVAL. INSTALLATION.

1. Thoroughly clean the area around the steering 1. Install the drive gear, lockwasher, and nut onto
pump. the pump. Torque the nut 121 to 147 pounds-foot
(164 to 199 Nm).
2. Disconnect both hoses from the pump. Cap
the hoses and pump connections. 2. Place the pump and drive gear onto the
mounting pad. Ensure the steel spacer is between
3. Remove the two bolts and lockwashers the two gaskets. Secure the pump in place with the
securing the pump. two bolts and washers. Torque the bolts 70 to 84
pounds-foot (95 to 114 Nm).
4. Remove the pump and drive gear. Cover the
mounting pad. 3. Connect the hydraulic lines to the pump as
tagged during REMOVAL.
5. Remove the nut, lockwasher, and drive gear
from the pump. 4. Function test the pump and check for proper
operation and any leakage.

2-5-14
 TM 5-3810-307-24-1-1

Figure 2-5-6. Steering Pump

2-5-15
TM 5-3810-307-24-1-1

INTEGRATED OUTRIGGER VALVE

DESCRIPTION

The front axle steering from the superstructure circuit control switch in the superstructure cab.
utilizes a working section of the integrated outrigger
valve as a control valve. The valve section is con- For more information on the valve refer to VALVES
trolled electrically by the FRONT AXLE STEERING in Section 8 - HYDRAULIC SYSTEM.

2-5-16
 TM 5-3810-307-24-1-1

STEER CYLINDERS

DESCRIPTION

Four steer cylinders are utilized on the crane, two on
the front axle and two on the rear axle. The steer
cylinders have a 2.76-inch (7.0 cm) cylinder bore
with an extended length of 28.35 inches (72.0 cm)
and a retracted length of 18.5 inches (47.0 cm).
Each set of steering cylinders are connected hydrau-
lically so the rod end of one cylinder is connected to
the barrel end of the other thus providing dual
cylinder action for steering the axle in either
direction.

The steer cylinders weigh approximately 17.60

pounds (8.0 kg).

MAINTENANCE

NOTE

Refer to CYLINDERS in Section 8 for Disassembly and Assembly

procedures.

REMOVAL. INSTALLATION.

1. Tag and disconnect the hydraulic hoses from 1. Position the steer cylinder (Figure 2-5-7) onto
the steer cylinder ports (Figure 2-5-7). Cap or plug the axle and secure in place with the cotter pins and
all openings. castle nuts.
NOTE
2. Connect the hydraulic hoses to the cylinders
Wheel and axle alignment will be easier as tagged during removal.
if the tie rod ends are not unscrewed
from the steer cylinder. 3. Function the cylinders and check for proper
operation and any leakage.
2. Remove the cotter pins and castle nuts
securing the steer cylinders to the axles. Remove
the cylinders.

2-5-17
TM 5-3810-307-24-1-1

Figure 2-5-7. Steer Cylinder

2-5-18
 TM 5-3810-307-24-1-1

EMERGENCY (STANDBY) STEERING VALVE AND PUMP

DESCRIPTION

The steering system incorporates a ground driven
emergency (standby) steering pump which is
mounted on the rear of the transmission. As long as
the transmission is turning (crane moving), the
emergency steering pump will pump hydraulic oil.
The hydraulic flow is controlled by the standby
valve which normally returns the oil to the hydraulic
reservoir. The standby valve is spooled so that in
the event of an engine failure or main steering pump
failure, the hydraulic oil flow produced by the
emergency steering pump is directed to the front
axle steering circuit which will allow the operator to
safely steer the crane while the crane is moving.

MAINTENANCE

EMERGENCY (STANDBY) STEERING VALVE AND PUMP

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove emergency (standby) steering valve as follows:

(1) Tag and disconnect electrical leads from emergency steering valve (4, Figure 2-5-8).

(2) Place a suitable drain pan under emergency steering valve (4) to catch residual oil.

(3) Tag and disconnect hydraulic lines from fittings on emergency steering valve (4). Cover open ends
of lines and fittings.

(4) Remove capscrews (1), washers (2), lockwashers (3), and nuts (5) securing emergency steering
valve (4).

(5) If necessary, remove elbows (6, 8, and 10) and o-rings (7, 9, and 11) from connectors (12, 13, and
14).

(6) If necessary, remove connectors (12, 13, 14, and 15), washers (16, 18, and 19), crush washer (17),
and o-rings (20, 21, and 22) from emergency steering valve (4).

c. Remove emergency (ground driven) steering pump as follows:

(1) Drain oil from hydraulic tank and place suitable drain pan under emergency steering pump (29,
Figure 2-5-8) to catch residual oil.

(2) Remove capscrews (23), flange halves (24), hydraulic hose (25), and o-ring (26) from emergency
steering pump (29).

(3) Tag and disconnect remaining hydraulic hoses from elbows (38 and 40) and adapter (39). Cover
open ends of lines and fittings.

(4) Remove capscrews (27), washers (28), pump (29), and gasket (30) from spacer (32).

(5) Remove splined adapter (41) from shaft of pump (29) or transmission if it did not come out with
pump.
2-5-19
TM 5-3810-307-24-1-1

(6) If necessary, remove socket head screws (31), spacer (32), and gasket (33) from transmission.

(5) If necessary, remove capscrews (34), washers (35), relief valve (36), and flow regulator (37) from
pump (29).

(6) If necessary, remove elbow (38) from relief valve (36), adapter (39) from flow regulator (37), and
elbow (40) from pump (29).

Installation

a. Install emergency (standby) steering valve as follows:

(1) If removed, install new o-rings (20, 21, and 22, Figure 2-5-8), washers (16, 18, and 19), new crush
washer (17), and connectors (12, 13, 14, and 15), on emergency steering valve (4).

(2) If removed, install new o-rings (7, 9, and 11) and elbows (6, 8, and 10) on connectors (12, 13, and
14).

(3) Position emergency steering valve (4) near mount and start hydraulic line, as tagged, on connector
(15). Do not tighten hydraulic line at this time.

(4) Secure emergency steering valve (4) on frame mount with capscrews (1), washers (2), lockwashers
(3), and nuts (5).

(5) Remove covers, connect, and tighten hydraulic lines to fittings on emergency steering valve (4) and
remove tags.

(6) Connect electrical leads to emergency steering valve (4) and remove tags.

b. Install emergency (ground driven) steering pump as follows:

(1) If removed, install elbow (40, Figure 2-5-8) in emergency steering pump (29), adapter (39) in flow
regulator (37), and elbow (38) in relief valve (36).

(2) If removed, install flow regulator (37) and relief valve (36) on pump (29) with washers (35) and
capscrews (34).

(3) If removed, apply LOCTITE 518 to gasket (33), and install gasket (33) and spacer (32) on
transmission with socket head screws (31).

(4) Install splined adapter (41) on shaft of pump (29), apply LOCTITE 518 to gasket (30) and install
gasket (30) and pump (29) on spacer (32) with washers (28) and capscrews (27).

(5) Position o-ring (26) and hydraulic hose (25) on pump (29) and secure in place with flange halves
(24) and capscrews (23).

(6) Connect hydraulic hoses to elbows (38 and 40) and adapter (39). Remove tags.

(7) Service hydraulic tank.

2-5-20
 TM 5-3810-307-24-1-1

LEGEND

1. Capscrew 15. Connector 29. Emerg. steering pump

2. Washer 16. Washer 30. Gasket
3. Lockwasher 17. Crush washer 31. Socket head capscrew
4. Emerg. steering valve 18. Washer 32. Spacer
5. Nut 19. Washer 33. Gasket
6. Elbow, 900 20. O-ring 34. Capscrew
7. O-ring 21. O-ring 35. Washer
8. Elbow, 900 22. O-ring 36. Relief valve
9. O-ring 23. Capscrew 37. Flow regulator
10. Elbow, 900 24. Flange half 38. Elbow, 900
11. O-ring 25. Hydraulic hose 39. Adapter
12. Connector 26. O-ring 40. Elbow, 900
13. Connector 27. Capscrew 41. Splined adapter
14. Connector 28. Washer

Figure 2-5-8. Emergency Steering Valve and Pump Installation (Sheet 1 of 2)

2-5-21
TM 5-3810-307-24-1-1

Figure 2-5-8. Emergency Steering Valve and Pump Installation (Sheet 2 of 2)

2-5-22
 TM 5-3810-307-24-1-1

STEERING SYSTEM FILTER CHECK VALVE

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Use tie wraps to secure hydraulic hoses out of the way to clear a path to the check valve (3,
Figure 2-5-9).
c. Get set to contain any hydraulic fluid contained in the four hydraulic lines connected to manifold
(1). Then tag and disconnect the four hydraulic lines connected to manifold (1).
d. Remove manifold (1) and adapter (2).
e. Remove check valve (3) from straight adapter (4).
Installation
WARNING
Ensure check valve is installed with the arrowhead pointing toward
the filter element as illustrated in Figure 2-5-9 to prevent
catastrophic damage to equipment or injury to personnel.

a. Install new check valve (3, Figure 2-5-9) on straight adapter (4).
b. Install adapter (2) and manifold (1).
c. Connect four hydraulic lines to manifold (1) as tagged. Remove tags.
d. Remove tie wraps securing hydraulic hoses out of the way.

4 3 2

Figure 2-5-9. Steering System Filter Check Valve

2-5-23/(2-5-24 Blank) C-1
 TM 5-3810-307-24-1-1

SECTION 6
AXLE OSCILLATION SYSTEM

TABLE OF CONTENTS
Page

AXLE OSCILLATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
Superstructure Over Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
Superstructure Over Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
LOCKOUT CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
DOUBLE SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6

LIST OF FIGURES
Number Title Page

2-6-1 Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-5

2-6-2 Double Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6

2-6-1/(2-6-2 Blank)
 TM 5-3810-307-24-1-1

AXLE OSCILLATION SYSTEM

DESCRIPTION

The axle oscillation system allows both the front and
rear axles to oscillate under certain conditions. The
system consists of four oscillation lockout cylinders,
two double solenoid valves, an area definition switch,
and a micro switch. An oscillation lockout cylinder is
mounted at each end of both axles. The double
solenoid valves are located at the center of the carrier
frame, one forward of the swivel and one to the rear of
the swivel. The area definition switch is located on the
electrical swivel and the micro switch is mounted on
the boom rest.
The two double solenoid valves control hydraulic oil
flow between the oscillation lockout cylinders. One
valve controls flow between the two front cylinders and
the other valve controls flow between the two rear
cylinders. The double solenoid valves are controlled
by the area definition switch and the micro switch.

THEORY OF OPERATION

SUPERSTRUCTURE OVER FRONT. SUPERSTRUCTURE OVER REAR.

With the superstructure facing the front and the boom
in the boom rest, the micro switch on the boom rest is
closed. When closed, the micro switch activates both
double solenoid valves allowing the front and rear
axles to oscillate. As soon as the boom is raised from
the boom rest, the contacts on the micro switch open,
thus deactivating the solenoid valves and locking both
axles.
With the superstructure facing directly over the rear,
the area definition switch on the electrical swivel
activates the double solenoid valve that controls the
front oscillation lockout cylinders allowing the front axle
to oscillate. As soon as the superstructure rotates
more than 6 degrees in either direction from directly
over the rear, the area definition switch deactivates the
double solenoid valve and causes the front axle to
lock.

2-6-3
TM 5-3810-307-24-1-1
LOCKOUT CYLINDERS
DESCRIPTION
Two 3.5-inch (8.9-cm) hydraulic lockout cylinders are
installed on each axle, one left and one right. The
base end of each cylinder is attached to each side of
the carrier frame and the rod ends are attached to
MAINTENANCE
NOTE
Refer to CYLINDERS in Section 8 for
disassembly and assembly procedures.
REMOVAL.
1. Raise the crane up on outriggers.
2. Raise the boom enough to deactivate the micro
switch on the boom rest and lock out the oscillation
cylinders.
3. Remove the wheel.
4. Tag and disconnect both hydraulic hoses from
the ports on the cylinder (Figure 2-6-1). Cap both
hoses and the ports on the cylinder.
5. At the rod end of the cylinder, remove the bolt,
nut, lockwasher, and cotter pin securing the retaining
pin to the fitting on the axle.
6. Tap out the retaining pin, freeing the rod end
from the cradle fitting.
7. At the barrel end of the cylinder, remove the bolt,
2-6-4
each side of the axle. The lockout cylinders are
connected hydraulically so that hydraulic oil flows from
the left cylinder to the right cylinder and from the right
cylinder to the left cylinder.
nut, lockwasher, and cotter pin securing the barrel end
to the fitting on the frame.
8. Tap out the retaining pin and remove the
cylinder.
INSTALLATION.
1. Position the barrel end of the cylinder in the
frame attach fitting and tap in the shaft (Figure 2-6-1).
2. Install the cotter pin, nut, bolt, and lockwasher.
Torque the bolt to 75 pounds-foot (102 Nm).
3. Align the rod end of the cylinder in the fitting on
the axle and tap in the shaft.
4. Install the cotter pin, lockwasher, bolt, and nut.
Torque the bolt to 75 pounds-foot (102 Nm).
5. Connect the two hydraulic hoses to the
appropriate ports on the cylinder, and bleed cylinder.
Refer to Section 4 - AXLES.
6. Install the wheel and follow the proper tightening
sequence. Refer to Section 4 - AXLES.
7. Grease both ends of the cylinder using the
fittings provided.
 TM 5-3810-307-24-1-1

Figure 2-6-1. Lockout Cylinder

2-6-5
TM 5-3810-307-24-1-1

DOUBLE SOLENOID VALVES

DESCRIPTION

The double solenoid valves are located to the front and an area definition switch. For more detailed
rear of the swing bearing on the center of the carrier information on the double solenoid valve, refer to
frame. The valves are actuated by a micro switch and VALVES in Section 8.

MAINTENANCE

REMOVAL. INSTALLATION.

1. Tag and disconnect the hydraulic hoses from the 1. Position the valve on the mounting bracket and
ports on the solenoid valve (Figure 2-6-2). Cap or plug secure with bolts, lockwashers, and nuts (Figure 2-6-
all openings. 2).

2. Remove the two nuts, lockwashers, and bolts 2. Connect the hydraulic hoses to the appropriate
securing the valve to the mounting bracket and remove ports on the valve.
the valve.

Figure 2-6-2. Double Solenoid Valve

2-6-6
 TM 5-3810-307-24-1-1

SECTION 7
AIR SYSTEM
TABLE OF CONTENTS
Page

AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Air System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-6
AIR SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Preventive Maintenance and Serviceability Checks . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Low Pressure Indicating Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Stop Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18

2-7-1 C-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Automatic Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Preventive Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Pressure Protection Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Double Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Relay Valves (R-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Dual Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Foot Throttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Three Way Air Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Spring Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-31
Pressure Reducing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-31

2-7-2 C-1
 TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Four-way Air Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-34

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-34
Trailer Air Brake System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-36

LIST OF FIGURES
Number Title Page

2-7-1 Air System Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-10

2-7-2 Air Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-13
2-7-3 Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-14
2-7-4 Air Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-16
2-7-5 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-19
2-7-6 Automatic Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-20
2-7-7 Pressure Protection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-22
2-7-8 Double Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-24
2-7-9 Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-25
2-7-10 Dual Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-28
2-7-11 Foot Throttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-29
2-7-12 Spring Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-32
2-7-13 Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-33
2-7-14 Four-way Air Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-35
2-7-15 Trailer Air Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-37

LIST OF TABLES
Title Page

Air Systems Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-8

2-7-3 C-1
TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-7-5
Before removing or disconnecting any component or line of the air
system, ensure that all air pressure in both systems has been depleted.

WARNING 2-7-5

Before attempting to remove any components for leak repair, ensure that
all air pressure in both air systems has been depleted.

WARNING 2-7-11
Before removing any air lines for component maintenance, bleed the air
from the primary and secondary systems.

2-7-17
WARNING
Disconnect the batteries prior to loosening the front console screws.

WARNING

There may be residual pressure in air lines after air reservoirs are 2-7-34
drained. Wear eye protection when disconnecting air lines or components 2-7-36
to prevent injury.

2-7-4 C-1

AIR SYSTEM
DESCRIPTION
The air system provides the air supply to operate the
service brakes, the differential locks, the engine
throttle, and the rear steering lock. The air system
also provides air to the trailer air couplings, the rear
air supply coupling, and the tire inflation couplings.
The air system is pressurized by an air compressor
mounted on the engine. The air pressure generated
by the compressor is stored in three air reservoirs
mounted to the carrier frame. From these reservoirs,
air is provided for operation of the above mentioned
components.
A dual air pressure gauge is provided in each cab to
monitor air pressure in the system. The red arrow
indicates primary air pressure (primary supply
reservoir), while the green arrow indicates secondary
pressure (secondary and auxiliary air reservoirs).
An air dryer is installed beside the primary supply
reservoir, and is connected between the compressor
MAINTENANCE
All connecting lines of the air system are either tubing
or flexible hoses. All tubing in the system is nylon,
except that from the compressor to the air dryer.
WARNING
Before removing or disconnecting any
component or line of the air system,
ensure that all air pressure in both
systems has been depleted.
CAUTION
Do not allow the nylon tubing to be
exposed to flames or excessive heat. If
any white shows through the outside
covering, that section of the line should
be replaced, and action taken to
eliminate the cause of the chafing or
other damage.
TM 5-3810-307-24-1-1
and the primary supply reservoir. When the
governor is on an unload cycle, the air dryer
functions to remove water and oil vapor from the air.
An alcohol evaporator is installed below the primary
supply reservoir and connected between the
secondary and auxiliary air reservoirs. As
compressed air from the secondary air reservoir
passes through the evaporator, alcohol is evaporated
into the air to act as antifreeze to keep any moisture
in the air from freezing and causing air actuated
components in auxiliary air circuit from locking up.
The air system is a split system wherein the primary
and secondary systems are isolated from each other
under normal operation. Therefore, in the event of
the failure of one system, air is retained in the other
and, by means of the pressure protection valves, and
check valves, a reserve of air pressure remains to
operate the brakes through normal use of the brake
pedal. Any unusual loss of pressure should be
investigated immediately and corrected, so as to
restore the full back-up capability of the system.
LEAK DETECTION.
If a leak is suspected in the air system, shut down
the engine and record the pressure readings of the
green and red arrow in the air pressure gauge on the
front console. A loss of 6 psi (41.37 kPa) or less
within a 30 minute time interval is usually considered
acceptable.
If a leak is detected and not obvious, the leaking
valve, fitting, or reservoir may be isolated by wetting
the suspected area with a concentrated liquid soap
solution and observing for bubbles.
WARNING
Before attempting to remove any
components for leak repair, ensure that
all air pressure in both air systems has
been depleted.
2-7-5
TM 5-3810-307-24-1-1
NOTE
Perform the AIR SYSTEM TEST
PROCEDURE as the final step of ANY
maintenance action. Ensure all
functions are restored to full operational
capability before returning the crane to
service.
AIR SYSTEM TEST PROCEDURE
NOTE
Refer to the Air System Components
Location Table, and the Figure titled Air
System Component Locations for
Physical locations.
Perform a test of the complete Air System.
Accomplish all tests in sequence as defined below:
1. Park crane on a firm level surface.
2. Raise crane on outriggers.
3. Turn off engine.
4. Drain entire system by opening drain cocks on
the air reservoirs.
5. If not already on, park brakes will automatically
apply with air pressure drop.
6. Check that brakes are applied on all wheels.
7. Close drain cocks and start engine.
8. Low Air Pressure light and warning buzzer
should operate immediately.
9. Air will fill the main supply reservoir first,
consequently, the red needle on the dual air gauge
will rise first, pressure will increase to approximately
85 psi, at which time the pressure protection valve
will open, allowing air to flow into the secondary air
reservoir and the green needle will then begin to rise.
NOTE
If required, the pressure protection valve
pressure setting can be adjusted by
turning the cap; Clockwise to raise the
pressure - Counterclockwise to lower the
pressure.
2-7-6
10. Warning buzzer and light will operate until both
pressure gauge needles show 60 - 70 psi.
11. Release park brakes.
12. Continue charging air system until air dryer
cycles and compressor shuts off, all system gauges
should read 120 10 psi.
13. Turn off engine.
14. Check that all wheels turn freely.
15. Air pressure should remain constant with no
leaks. Any drop in pressure should be no more than
1 psi per minute.
16. Apply service brakes to full application and
hold.
17. Check that a drop in reservoir pressure
occurred and that after pressure equalization,
pressure loss does not exceed 2 psi per minute.
18. Check that brakes are applied on all wheels,
19. Release the service brake and check that
existing reservoir pressure is maintained.
20. Start engine and recharge air system.
21. With engine running, simulate a full air leak in
the secondary air system by opening the drain cock
on the secondary air reservoir.
22. The low air pressure light and warning buzzer
should come on when the air pressure in the
secondary system drops below 70 5 psi.
23. Air pressure in the primary system should not
drop below 85 5 psi.
24. Drain secondary air system pressure to 0 psi.
25. With park brakes released, check that all
wheels can turn.
26. Apply service brakes and hold.
27. Front service brakes and rear spring brakes
should apply.
28. Assure brake lights on rear of machine come
on when service brakes are applied.
29. Release service brakes.

30. Close drain cock on the secondary reservoir
and recharge the air system.
31. Simulate a full air leak in the primary air
system by depressing needle in center of automatic
drain valve on the main supply reservoir.
32. Low Air Pressure light and warning buzzer will
come on when primary system air pressure drops
below 70 5 psi. Keep needle on automatic drain
valve depressed.
33. Secondary system air pressure should not
drop below 85 5 psi.
34. Check that all wheels can turn freely.
35. Apply service brakes.
TM 5-3810-307-24-1-1
36. Service brakes on rear axles only should
apply.
37. Assure brake lights on rear of crane come on
when service brakes are applied.
38. Release service brakes.
39. Check that all wheels can turn freely.
40. Release needle on automatic drain valve and
recharge primary air system.
41. Retract and stow outriggers.
This completes the Air System Test, if all test results
are acceptable, the crane may be returned to
service.
2-7-7
TM 5-3810-307-24-1-1

AIR SYSTEM COMPONENTS

DESCRIPTION

NOTE

All air system components will be removed and installed in this Section.

NOTE

For more detailed information refer to the applicable SM package.

AIR SYSTEM COMPONENTS LOCATION TABLE

Component Physical Location

Compressor Left side of engine

Air Governor Mounted on left engine deck

Throttle Air Cylinder Mounted on engine

Supply Reservoir Left frame rail forward of hydraulic reservoir

Auto Drain Valve Mounted to supply reservoir

Secondary Reservoir Right frame rail behind fuel tank

Auxiliary Tank Front outrigger box

Air Dryer Beside supply reservoir

Double Check Valve Six places; see diagram; right turntable side plate

Pressure Protection Valve Three places; see diagram

Three-way Air Valve, Pilot Left side inner frame near rear

Three-way Air Valve Two places; see diagram

Relay Valve Three places; see diagram

Spring Brake Control Valve Center of frame rail forward of rear axle

Air Pressure Reducing Valve (47 psi) Left inner frame rail at the rear

Air Pressure Reducing Valve (110 psi) Center of frame rail behind front axle

Latching Valve Right side inner frame near rear

Four-way Air Valve Left side inner frame near rear

2-7-8
 TM 5-3810-307-24-1-1

AIR SYSTEM COMPONENTS LOCATION TABLE (continued)

Component Physical Location

Stop Light Switch Mounted to foot brake valves

Low Pressure Switch Mounted to foot brake valves and park brake relay valve

Safety Valve In line near air dryer

Air Pressure Gauge One on each cab console

Park Brake Valve One on each cab console

Dual Brake Valve One on each cab floor

Foot Throttle One on superstructure cab floor

2-7-9
TM 5-3810-307-24-1-1

1. Supply reservoir 7. Press. protection valve 13. Press. reducing valve

2. Automatic drain valve 8. Double check valve 14. Protection valve
3. Secondary reservoir 9. Relay valve 15. Spring brake valve
4. Drain valve 10. 3-way air valve 16. 3-way air valve, pilot
5. Auxiliary reservoir 11. Latching valve 17. Press. reducing valve
6. Air dryer 12. 4-way air valve

Figure 2-7-1. Air System Components Location

2-7-10
 TM 5-3810-307-24-1-1

MAINTENANCE

AIR GOVERNOR
WARNING
Before removing any air lines for Description
component maintenance, bleed the air
from the primary and secondary The governor, operating in conjunction with the
systems. compressor unloading mechanism, automatically
controls the air pressure in the system between the
NOTE desired, predetermined maximum and minimum
pressures. The compressor runs continually while
Perform the AIR SYSTEM TEST PRO- the engine runs, but the actual compression of air is
CEDURE as the final step of ANY controlled by the governor which stops or starts
maintenance action. Ensure all compression when the maximum or minimum
functions are restored to full operational reservoir pressures are reached. The governor has
capability before returning the crane to a piston upon which air pressure acts to overcome
service. the pressure setting spring and control the inlet and
exhaust valve to either admit or exhaust air to or
from the compressor unloading mechanism.
AIR COMPRESSOR
Removal
NOTE
1. Chock the wheels.
For more detailed information refer to the
applicable SM package. 2. Deplete all pressure in both systems.

Removal 3. Disconnect the air lines from the governor.

1. Chock the wheels. 4. Remove the governor mounting bolts and

remove the governor.
2. Deplete the air pressure in both air systems.
Installation
3. Open the engine compartment to gain access
to the compressor. 1. Position the governor and secure it with the
mounting bolts.
4. Drain the engine cooling system and the
cylinder head of the compressor. 2. Connect the air lines to the governor ports.

5. Tag and disconnect all air, water, and oil lines Service Checks
going to and from the compressor.
Operating Test
6. Remove the two mounting nuts and remove
the compressor from the engine. 1. Start the vehicle engine and build up air
pressure in the system. Check the pressure
Installation registered by the dash gauge or a test gauge at the
time the governor cuts-out, stopping the
1. Position the compressor on the engine and compression of air by the compressor.
secure it with the two mounting bolts.

2. Connect all air, water, and oil lines to the

proper fittings on the compressor.

3. Refill the engine cooling system.

2-7-11 C-1
TM 5-3810-307-24-1-1
2. With the engine still running, perform a series
of brake applications to reduce the air pressure and
observe the pressure when the governor cuts-in the
compressor. The cut-in pressure is 105 psi (7239
kPa) Never adjust the governor pressure settings
unless they are checked with a gauge that is known
to be accurate If it has been determined that the
pressure settings of the governor must be changed,
the procedure is as follows:
a. Unscrew the cover at the top of the
governor.
b. Loosen the adjusting screw locknut.
c. Turn the adjusting screw counter-
clockwise to raise the pressure settings and
clockwise to lower the pressure setting.
d. Tighten the adjusting screw locknut to
lock the adjustment.
3. Repeat Step 2 as necessary.
Leakage Test
1. Leakage checks on the governor are made at
its exhaust port in both the cut-in and cut-out
positions. In the cut-in position, check the exhaust
port for inlet valve leakage by applying a soap
solution at the port. Leakage could also be through
the bottom piston grommet. In the cut-out position,
check the exhaust port to determine leakage at the
exhaust valve seat or stem grommet. In this
position, leakage could also be through the upper
piston grommet.
2 If the governor does not function as described,
or if leakage is excessive, it is recommended that it
be repaired or replaced. Refer to the Parts Manual.
AIR DRYER
Description
The function of the air dryer is to collect and
remove air system contaminates in solid, liquid, and
vapor form before they enter the brake system. It
provides clean, dry air to the components of the
brake system which increases the life of the system
and reduces maintenance costs.
2-7-12 C-1
The air dryer consists of a desiccant cartridge and
a die cast aluminum end cover secured to a
cylindrical steel outer shell with eight capscrews
and nuts. The end cover contains a check valve
assembly, a safety valve, three threaded air
connections and the purge valve housing
assembly. The removable purge valve housing
assembly incorporates a purge valve mechanism
and a turbo charger cutoff feature that is designed
to prevent loss of engine turbo boost pressure
during the purge cycle of the air dryer. For ease of
serviceability, the desiccant cartridge and
discharge check valve assembly are screw-in type.
The purge valve housing assembly, which includes
the heater and thermostat assembly, and the
discharge check valve assembly, is serviceable
from the exterior of the air dryer, while servicing the
screw-in desiccant cartridge requires removal of
the air dryer assembly from the crane.
Removal
1. Chock the wheels.
2. Deplete the pressure in both air systems.
3. Ensure the ignition switch is in the OFF
position.
4. Tag and disconnect the air lines from the
dryer.
5. Disconnect the electrical lead from the bottom
of the dryer.
6. Remove four bolts, lockwashers, and nuts
attaching the dryer to the chassis frame and remove
the dryer.
7. If the dryer is to be replaced with a new one,
remove the fittings from the dryer ports.
NOTE
The dryer does not have to be removed
to disassemble it.
Installation
1. Install the fittings in the dryer ports.
2. Position the air dryer on the mounting bracket
and secure it with the four bolts, lockwashers, and
nuts.
3. Connect the electrical lead to the connection
on the bottom of the dryer.
 TM 5-3810-307-24-1-1

Figure 2-7-2. Air Governor

2-7-13
TM 5-3810-307-24-1-1

Figure 2-7-3. Air Dryer

2-7-14

4. Connect the air lines to the dryer as tagged
during removal.
5. Test the air dryer as outlined under Preventive
Maintenance and Serviceability Checks.
Preventive Maintenance and Serviceability
Checks
1. Check for moisture in the air system by
opening the reservoir's drain cock or automatic drain
valve. In areas where more than approximately a 30
degree range of temperature is common, small
amounts of water can accumulate in the air system
due to condensation. The presence of small
amounts of water due to condensation is normal and
should not be considered as an indication that the
dryer is not performing properly.
2. The desiccant cartridge should be replaced or
rebuilt when the desiccant is contaminated and does
not have adequate water absorption capacity.
However, the following checks should be made
before replacing the desiccant cartridge to ensure
the water accumulation is not related to the items
listed below:
a. An outside air source has been used to
charge the system. This air did not pass
through the drying bed.
b. Air usage is exceptionally high and not
normal for a highway vehicle. This may be
due to accessory air demands or some
unusual air requirement that does not allow the
compressor to load and unload (compressing
and non-compressing cycle) in a normal
fashion. Check for high air system leakage.
c. The air dryer has been installed in a
system that has been previously used without
an air dryer. This type system will be saturated
with moisture and several weeks of operation
may be required to dry it out.
d. Location of the air dryer is too close (less
than 6 feet [1.83 m]) to the air compressor.
3. Check the mounting bolts for tightness. Check
the electrical connection to the dryer.
4. Check the operation of the integral single
check valve. Build air system pressure to governor
cut-out and observe the test air gauge installed in the
No. 1 reservoir. A rapid loss of pressure could
indicate a failed check valve. This can be confirmed
by checking at the purge valve exhaust.
TM 5-3810-307-24-1-1
NOTE
The purge valve will be open when the
governor cut-out pressure is reached.
Allow two minutes for the purge cycle
before testing the check valve.
5. Check for excessive leakage at the purge
valve by coating the exhaust with a soap solution
while the compressor is loaded (compressing air).
6. Check the operation of the safety valve by
pulling the exposed stem while the compressor is
loaded (compressing air). There must be an exhaust
of air while the stem is held and the valve should
reseat when the stem is released.
7. Check all lines and fittings leading to and from
the air dryer for leakage and integrity.
8. Check the operation of the heater and
thermostat during cold weather operation. This can
be done by allowing the end cover assembly to cool
below 50 degrees F (10 degrees C) and feeling the
end cover. When the ignition is turned ON, the end
cover should be warm to the touch within a few
moments. Warming should cease at about 85
degrees F (294 degrees C).
RESERVOIRS
NOTE
For more detailed information refer to the
applicable SM package.
Removal
1. Chock the wheels.
2. Deplete all pressure in both air systems.
3. Disconnect and tag all air lines from the
reservoir to be removed.
4. Remove the bolts, lockwashers, and nuts
attaching the reservoir bracket to supporting
framework.
5. Remove the reservoir with the brackets from
the framework.
6. If a new reservoir is to be installed, remove the
brackets, fittings, and components from the
reservoir.
2-7-15
TM 5-3810-307-24-1-1

Figure 2-7-4. Air Reservoir

2-7-16
 TM 5-3810-307-24-1-1

Installation STOP LIGHT SWITCH

1. If a new reservoir is being installed, install the NOTE

brackets and all fitting and components on the
reservoir. For more detailed information refer to the
applicable SM package.
2. Position the reservoir on the supporting
framework and secure the brackets to the frame with Removal
the bolts, lockwashers and nuts.
1. Disconnect the electrical lead from the switch.
3. Connect all air lines to the reservoir as tagged
during removal. 2. Using a wrench on the hex portion of the
switch, unscrew the switch from the dual brake
LOW PRESSURE INDICATING SWITCHES valve.

NOTE Installation

For more detailed information refer to the 1. Screw the switch into the fitting on the dual
applicable SM package. brake valve. Using a wrench on the hex portion of
the switch, tighten the switch securely.
Removal
2. Connect the electrical lead to the switch.
1. Chock the vehicle wheels.
Service Checks
2. Deplete all pressure in both air systems.
Operating Test
3. Disconnect the electrical lead from the
indicator switch. 1. Install an accurate air gauge in the service
brake line.
4. Unscrew the indicator switch from the fitting.
2. Depress brake pedal and observe that stop
Installation lights illuminate at 6 psi (41 kPa) or less.

1. Screw the indicator switch into the appropriate 3. Release the brake valve and observe that the
valve fitting. stop lights go out.

2. Connect the electrical lead to the switch. Leakage Test

Operating and Leakage Checks
1. With the engine shut down and the ignition
switch ON, slowly reduce pressure in the system.
2. The switch should actuate at approximately 75
psi (517 kPa) as indicated by sounding of the buzzer
and illumination of the LOW AIR indicator. This
pressure may be read on the dual pressure gauge in
the cab.
1. With pressure applied, coat the switch with a
soap solution. No leakage is permitted.
If the switch does not function as described or if
leakage is found, replace the switch with a new one.
Refer to the Parts Manual.
AIR PRESSURE GAUGE
Removal

3. With air pressure present at the port, coat the 1. Chock the vehicle wheels.
indicator switch with a soap solution. No leakage is
permitted. 2. Deplete all air pressure in both air systems.
WARNING
Disconnect the batteries prior to
loosening the front console screws.

2-7-17
TM 5-3810-307-24-1-1
3. Loosen and remove the four screws securing
the left front console to the dash.
4. Pull out the left front console enough to gain
access to the rear of the air pressure gauge. Loosen
the two fittings and tag and remove the nylon tubes
from the rear of the gauge
5. Remove the hardware securing the gauge to
the front console and remove the gauge.
Installation
1. Install the air pressure gauge into the front
console using the attaching hardware.
2. Install the two nylon tubes to the fittings in the
rear of the gauge as tagged during removal.
3. Secure the front console to the dash using the
four screws.
4. Connect the batteries as tagged previously.
Functional Check
Start the engine and observe the air pressure gauge.
The green arrow on the gauge (primary) should rise
first until a pressure reading of approximately 95 psi
(655 kPa) at which time the red arrow (secondary)
should begin to climb. Both arrows should level off
at approximately 110 psi (7584 kPa).
SAFETY VALVE
Description
A safety valve is installed in the top of the supply
reservoir to protect the air system against
excessive air pressure buildup. The valve consists
of a spring loaded ball valve subjected to reservoir
pressure which permits air to exhaust from the
reservoir to the atmosphere if the pressure rises
above 150 psi (1034.3 kPa/1 0.3 bar). This
pressure setting is nonadjustable and is determined
by the force of the spring.
Removal
1. Chock the vehicle wheels.
2. Deplete the pressure in both air systems.
3. Using the wrench flat, closest to the reservoir,
unscrew the valve from the fitting on the reservoir.
2-7-18 C-1
Installation
1. Using the wrench flat closest to the threaded
end, screw the valve into the fitting.
Operating and Leakage Checks
With air pressure in the system, pull the exposed end
of the valve stem removing the spring load from the
ball check valve. Air should exhaust from the valve's
exhaust port. Release the stem, and the air flow
should stop. Failure of the valve to pass the
operating test would indicate the valve should be
repaired or replaced.
Coat the exhaust port with a soap solution. A
leakage of a one inch bubble in five seconds is
permitted. Excessive leakage indicates dirt in the
valve or a faulty ball valve or seat. If excessive
leakage is indicated, the valve should be repaired or
replaced.
AUTOMATIC DRAIN VALVE
Description
The automatic drain valve is designed to eject
moisture and contaminates from the air system
reservoir upon a slight reduction in reservoir
pressure. It operates automatically from ascending
and descending reservoir pressures, has only one
moving part, and requires no manual assistance of
control lines from other sources. The valve has a
die cast aluminum body and cover.
Removal
1. Chock the vehicle wheels.
2. Deplete all pressure in both air systems.
3. Remove the drain valve from the bottom port
of the reservoir.
Installation
1. To prevent early plugging of the drain valve
filter, thoroughly flush and clean the reservoir before
installing the drain valve.
2. Aerate the reservoir thoroughly if any solvents
have been used to clean the reservoir.
3. Install the drain valve in the bottom port of the
reservoir and tighten.
 TM 5-3810-307-24-1-1

Figure 2-7-5. Safety Valve

2-7-19
TM 5-3810-307-24-1-1

Figure 2-7-6. Automatic Drain Valve

2-7-20
 TM 5-3810-307-24-1-1

Preventive Maintenance Procedures Removal

1. Remove, disassemble, clean, and lubricate the 1. Chock the wheels.

drain valve.
2. Deplete all pressure in both air systems.
2. Parts showing signs of wear or deterioration
should be replaced. 3. Disconnect the two air lines from the pressure
protection valve.
3. Special attention should be given to the filter
when the maintenance check is made. 4. Remove the two mounting bolts, if used, and
remove the valve.
4. The filter must be clean and should be cleaned
or replaced if clogged or damaged. Installation

5. Under no conditions should the valve be 1. Position the valve, and if used, install the
installed without a filter installed in the adapter. mounting bolts.

Service Checks 2. Connect the two air lines to the proper ports of
the valve.
Operating Test
3. Perform the procedures under Operating and
With the air system pressurized, make several foot Leakage Checks.
valve applications and note that each time an
application is made an exhaust of air occurs at the Service Checks
exhaust port of the drain valve. If no air comes out,
push the wire stem. If no air comes out, the filter is Operating Test
plugged and the valve should be removed and
cleaned.
NOTE
NOTE If the pressure protection valve does not
operate as described or leakage is
Because the automatic drain valve
excessive, it is recommended that it be
functions as reservoir pressure is
replaced.
reduced, excessive leakage in the
system could cause constant exhausting
1. Provide a pressure gauge and drain valve at
of the valve.
the supply side and delivery side of the pressure
protection valve being checked.
Leakage Test
2. Build up the air system to full pressure and
With the system pressurized and pressure stabilized
shut off the engine.
in the system, there should be no leaks at the drain
valve exhaust. A constant slight exhaust of air at the
3. While watching the gauges on the supply and
drain valve exhaust could be caused by excessive
delivery sides of the valve, slowly begin to exhaust
leakage in the air system.
pressure from the delivery side. Note that both
gauges will show pressure loss until the closing
If the valve does not function as described or if
pressure of the pressure protection valve is reached.
leakage is excessive, it is recommended that the
The pressure protection valve should close at
valve be replaced or rebuilt. Refer to the Parts
approximately 85 5 psi (586 344 kPa). The gauge
Manual.
on the delivery side of the valve should continue to
show loss of pressure while the gauge on the supply
side should stop at the same pressure as the setting
PRESSURE PROTECTION VALVES of the valve.
NOTE

For more detailed information refer to the

applicable SM package.
2-7-21 C-1
TM 5-3810-307-24-1-1

Figure 2-7-7. Pressure Protection Valve

2-7-22

Leakage Test
1. Build up the air system to full pressure and
shut off the engine.
2. Apply a soap solution around the cap of the
pressure protection valve. A 1 in. (254 cm) bubble in
three seconds or longer is acceptable.
3. Drain the air pressure from the delivery side
of the pressure protection valve and disconnect air
line to it.
4. Apply a soap solution to the delivery port. A 1
in. (254 cm) bubble in five seconds or more is
acceptable.
DOUBLE CHECK VALVES
Description
The double check valve is used in the air system
when a single function or component must be
controlled by either of two sources of pressure. The
double check valve transmits the higher of the two
pressure sources to the outlet port.
Removal
1. Chock the wheels.
2. Deplete the pressure in both air systems.
3. Disconnect and tag the air lines from the
double check valve and remove the valve.
Installation
1. Install the fittings and air lines to the double
check valve as tagged during removal.
Service Checks
Operating Test
If the double check valve is to be bench tested or
tested on the vehicle, two separately controlled air
supplies must be connected to the inlet ports.
1. Install an accurate test gauge in the outlet port
or in a line from the outlet port.
2. Apply and release air to one inlet port and note
the gauge registers application and release.
3. Repeat by applying and releasing air to the
other inlet port.
TM 5-3810-307-24-1-1
Leakage Test
The leakage check should be performed at the inlet
ports of the valve in the following manner.
1. Disconnect the line from the inlet port.
2. Apply air to the other inlet port and coat the
opposite inlet port with a soap solution. Permissible
leakage is a 1 in. (254 cm) bubble in five seconds.
3. Repeat step b. applying air to the other inlet
port while checking the opposite inlet port for
leakage. If the double check valve does not function
as described or if leakage is excessive, it is
recommended that the valve be replaced.
RELAY VALVES (R-12)
NOTE
For more detailed information refer to the
applicable SM package.
Removal
NOTE
The inlet and exhaust valve assembly,
generally referred to as the insert, can be
easily removed and replaced. Just
remove the snap ring and exhaust cover
assembly, then pull the insert out.
Normally the insert can be removed
without disturbing the valve mounting or
connecting line.
CAUTION
Deplete all reservoirs before attempting
to remove the insert.
1. Chock the wheels.
2. Deplete all pressure in both air systems.
3. Identify, mark, and disconnect all air lines from
the relay valve.
4. Remove the bolt, lockwashers, and nuts that
secure the valve and remove the valve.
2-7-23 C-1
TM 5-3810-307-24-1-1

Figure 2-7-8. Double Check Valve

2-7-24
 TM 5-3810-307-24-1-1

Figure 2-7-9. Relay Valve

2-7-25
TM 5-3810-307-24-1-1
Installation
1. Prior to installing the valve on the crane, all
connecting air lines should be inspected for kinks,
cuts, chafing, and deterioration. Lines displaying any
of these deficiencies should be replaced.
2. Position the valve on the mounting and secure
it with the bolts, lockwashers, and nuts provided.
3. Connect the air lines to the proper port on the
valve in accordance with identification marks made
during removal.
4. Perform the procedures under Operating and
Leakage Checks.
Service Checks
Operating Test
1. Chock the wheels and fully charge the air
system. Adjust the brakes.
2. Apply and release the brakes several times
and check for prompt response of the brakes at all
wheels.
Leakage Test
1. With the dual brake valve in the brake released
position, coat the exhaust port with a soap solution to
check for inlet valve and O-ring leakage. A 1 in. (254
cm) bubble in five seconds is permitted.
2. Place the dual brake valve in the brake applied
position and again check at the exhaust port for
leakage of the exhaust valve. Apply a soap solution
around the valve where the cover joins the body to
check for seal ring leakage. A 1 in. (254 cm) bubble
in three seconds is permitted.
3. With the dual brake valve still in the brake
applied position, apply the soap solution to the quick
release exhaust port on the R-12 valve to check the
diaphragm exhaust seat, and to the valve body in the
area where the cover joins the body on the R-12
valve, to check for cover O-ring leakage. No leakage
is permitted.
If the valve does not function as described above, or
if leakage is excessive, it is recommended that the
valve be repaired or replaced.
2-7-26 C-1
DUAL BRAKE VALVE
Description
The dual brake valve is mounted to the cab floor. It
is a treadle-operated type brake valve with two
separate supply and delivery circuits. The valve
provides the driver with a graduated control for
applying and releasing the vehicle brakes.
The circuits in the dual brake valve are identified as
follows. The No. 1 circuit portion is that portion of
the valve between the spring seat which contacts
the plunger and the relay piston. The No. 2 circuit
portion is that portion between the relay piston and
the exhaust cavity.
The No. 1 circuit portion of the valve is similar in
operation to a standard single-circuit air brake
valve and under normal operating conditions the
No. 2 circuit portion is similar in operation to a relay
valve.
Both the No. 1 and No. 2 circuit portions of the dual
brake valve use a common exhaust protected by an
exhaust diaphragm.
Removal
1. Chock the wheels.
2. Deplete all pressure in both air systems.
3. Identify, mark, and disconnect all air lines from
the brake valve.
4. Remove the three bolts, lockwasher, and nuts
securing the brake valve and treadle assembly to the
cab floor. Remove the brake valve and treadle
assembly as a unit.
NOTE
The basic brake valve alone can be
removed by removing the three
capscrews on the inner bolt circle.
Installation
1. Position the brake valve and treadle assembly
in the cab floor opening and secure it with the three
bolts, lockwashers, and nuts.
2. Connect the air lines to the proper ports on the
valve in accordance with the identification marks
made during removal.

Service Checks
Operating Test
CAUTION
A change in vehicle braking
characteristics or a low pressure warning
may indicate a malfunction in one or the
other brake circuit, and although the
vehicle air brake system may continue to
function, the vehicle should not be
operated until the necessary repairs
have been made and both braking
circuits, including the pneumatic and
mechanical devices are operating
normally. Always check the vehicle
brakes after performing brake work and
before returning the vehicle to service.
1. Check the delivery pressure of both No. 1
and No. 2 circuits using a test gauge known to be
accurate. Depress the treadle to several positions
between the fully released and fully applied
positions, and check the delivered pressure on the
test gauges to see that it varies equally and
proportionately with the movement of the brake
pedal.
2. After a full application is released, the reading
on the test gauges should fall off to zero promptly.
It should be noted that the No. 1 circuit delivery
pressure will be about 2 psi (138 kPa) greater than
the No. 2 circuit delivery pressure with both supply
reservoirs at the same pressure. This is normal for
this valve.
Leakage Test
1. Make and hold a high pressure (80 psi [5516
kPa]) application.
2. Coat the exhaust port and body of the brake
valve with a soap solution.
3. Leakage of a 1 in. (2.54 cm) bubble in three
seconds is permitted.
TM 5-3810-307-24-1-1
FOOT THROTTLE VALVE
Description
The foot throttle valve is a treadle operated air valve
mounted on the superstructure cab floor. The valve
controls the air pressure to the air cylinder mounted
on the engine, which in turn controls the engine rpm.
Removal
1. Chock the wheels.
2. Deplete the pressure in both air systems.
3. Disconnect the air lines from the foot throttle
valve.
4. Lift the rubber material on the pedal and
remove the two screws, lockwashers, and nuts
securing the throttle bracket to the pedal. Leave the
bracket connected to the cable.
5. Remove the three bolts, lockwashers, and nuts
securing the throttle valve and pedal assembly to the
cab floor. Remove throttle valve and pedal assembly
from the hole in the cab floor.
Installation
1. If installing a new pedal assembly, it will be
necessary to drill two 0.281-inch (7.14 mm)
diameter holes in the upper end of the pedal using
the throttle bracket as a template. Lift the rubber
material from the pedal. Do not drill through the
rubber.
2. Position the throttle valve and pedal
assembly through the hole in the cab floor and
secure it with the three bolts, lockwashers, and
nuts.
3. Lift the rubber material on the pedal, position
the throttle bracket on the pedal and secure it with
the two screws, lockwashers, and nuts.
4. Connect the air lines to the foot throttle valve.
2-7-27 C-1
TM 5-3810-307-24-1-1

Figure 2-7-10. Dual Brake Valve

2-7-28
 TM 5-3810-307-24-1-1

Figure 2-7-11. Foot Throttle Valve

2-7-29
TM 5-3810-307-24-1-1

THREE WAY AIR SOLENOID VALVE SPRING BRAKE CONTROL VALVE

Removal Description

1. Chock the wheels. The function of the spring brake control valve is to
supply a specific, limited hold-off pressure to the
2. Deplete all pressure in both air systems. spring brakes, and in the event of loss of service
pressure, to modulate the spring brakes through
3. Identify, mark, and disconnect the air lines the use of the dual brake valve.
from the three-way air solenoid valve.
The valve has four air connection ports and a
4. Tag and disconnect the electrical leads to the diaphragm protected exhaust port. Each air
solenoid. connection port is labeled with embossed letters to
identify the ports.
5. Remove the bolts, lockwashers, and nuts
securing the valve to the mounting bracket and NOTE
remove the valve.
For proper internal drainage, the spring
6. If a new valve is to be installed, remove the brake control valve should be mounted
mufflers from the two exhaust ports and remove all with the exhaust port down.
fittings.
Removal
Installation
1. Chock the wheels.
1. If a new valve is being installed, install fittings
in the ports and a muffler on each exhaust port. 2. Deplete all pressures in both air systems.

2. Position the valve on the mounting bracket and 3. Tag and disconnect all air lines from the valve.
secure with the bolts, lockwashers, and nuts.
4. Remove the two nuts and lockwashers
3. Connect the electrical leads as tagged at attaching the valve and remove the valve.
removal.
Installation
4. Connect the air lines to the appropriate ports
on the valve in accordance with the identification 1. Position the spring brake control valve on the
marks made during removal. mounting studs and secure it with the nuts and
lockwashers.

2. Connect the air lines to the proper ports on the

valve in accordance with the identification marks
made during removal.

2-7-30 C-1
 TM 5-3810-307-24-1-1

Operating and Leakage Checks
1. Chock the vehicle wheels.
2. Charge the air systems to the governor cut-out
pressure.
3. Place the parking control valve in the park
position. Observe the spring brake actuators apply
promptly. In the delivery port of the valve, install a
test gauge known to be accurate. Place the parking
control valve in the release position. Observe the
spring brake actuators release fully.
7. With the air system fully charged and the
parking control valve in the release position, coat the
exhaust port and the area around the valve corner
with a soap solution. Slight leakage is permitted.
8. If the spring brake control valve does not
function as described above, or leakage is
excessive, it is recommended that it be repaired or
replaced Refer to the Parts Manual for repair parts.
PRESSURE REDUCING VALVES
Removal

4. With the parking control valve in the release 1. Chock the wheels.
position, note the gauge pressure reading. It should
be approximately 45 psi (310 kPa). If the pressure 2. Deplete the pressure in both air systems.
reading is incorrect, the valve must be repaired or
replaced. 3. Disconnect and tag the air lines from the valve
and remove the valve.
5. Place the parking control valve in the park
position The gauge reading should drop to zero Installation
promptly A slow release of pressure could indicate
faulty operation of the single check valve (within the 1. Install the fittings and air lines to the valve as
modulating valve). tagged during removal.

6. Place the parking control valve in the release

position. Locate the No 1 service reservoir and drain
it completely. Then, apply the foot brake valve
several times and note that the pressure reading on
the gauge decreases each time the foot brake valve
is applied. After the foot brake valve has been
applied several times, pressure on the gauge will
drop to the point where release of the spring brake
actuators will no longer occur.

2-7-31 C-1
TM 5-3810-307-24-1-1

Figure 2-7-12. Spring Brake Control Valve

2-7-32 C-1
 TM 5-3810-307-24-1-1

Figure 2-7-13. Pressure Reducing Valve

2-7-33 C-1
TM 5-3810-307-24-1-1

FOUR-WAY AIR SOLENOID VALVE

Description

The four-way air solenoid valve installed in the air system allows the operator to engage or release the parking
brake from either cab regardless of the position of the PARK BRAKE control in the other cab. The air valve has
two solenoids, one connected into the circuitry of each cab to activate the valve. This means that only one
solenoid is powered at a time depending on which cab has electrical control (ignition switch on), thus giving that
cab and only that cab control of the parking brake.

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Relieve air system pressure by draining supply (depress pin in center of automatic drain valve), secondary,
and auxiliary air reservoirs.

c. Disconnect electrical connector for four-way air solenoid valve (8, Figure 2-7-14).

WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines to prevent
injury.

d. Loosen clamps (1), tag, and disconnect air hoses (2) from air fittings on four-way air solenoid valve (8).

e. Tag and disconnect air lines from elbows (9 thru 13).

f. Remove nuts (5), lockwashers (6), washers (7), and four-way air solenoid valve (8) from mounting studs.
Note that ground wires are installed under one nut (5).

g. If necessary, note position of 45 elbows (11 and 13) and remove elbows (9 thru 13) from valve.

Installation

a. If removed, install elbows (9 thru 13, Figure 2-7-14) in four-way air solenoid valve (8). Ensure 45 elbows
(11 and 13) are installed in ports noted during removal.

b. Position four-way air solenoid valve (8) on mounting studs and secure with washers (7), lockwashers (6),
and nuts (5). Secure ground wires on right side mounting stud under one nut (5) as removed.

c. Connect air lines to elbows (9 thru 13) and remove tags.

d. Install air hoses (2) on valve air fittings and tighten clamps (1). Remove tags.

e. Connect four-way air solenoid valve (8) electrical connector.

f. Close air tank drain valves.

2-7-34 C-1
 TM 5-3810-307-24-1-1

LEGEND

1. Clamp 5. Nut 9. Elbow, 90

2. Air hose 6. Lockwasher 10. Elbow, 90
3. Not Used 7. Washer 11. Elbow, 45
4. Not Used 8. Solenoid valve 12. Elbow, 90
13. Elbow, 45

Figure 2-7-14. Four-Way Air Solenoid Valve

2-7-35 C-1
TM 5-3810-307-24-1-1

TRAILER AIR BRAKE SYSTEM COMPONENTS

Removal

a. Remove gladhand as follows (typical):

(1) Relieve system air pressure by draining supply (depress pin in center of automatic drain valve),
secondary, and auxiliary air reservoirs.
WARNING
There may be residual pressure in air lines after air reservoirs are
drained. Wear eye protection when disconnecting air lines or
components to prevent injury.

(2) Unscrew gladhand (1, Figure 2-7-15) from nipple (7).

(3) If necessary, remove air line (2) from elbow (3), and elbow (3) from connector (6).

(4) If necessary, remove nut (4), lockwasher (5), and connector (6) from vehicle frame.

(5) If necessary, remove nipple (7) from connector (6).

b. Remove tractor protection valve as follows:

(1) Relieve system air pressure.

(2) Tag and disconnect air lines (8 and 9, Figure 2-7-15) from elbows (16 and 17).

(3) Tag and disconnect air lines (10 and 11) from elbows (18 and 19).

(4) Remove nuts (12), lockwashers (13), tractor protection valve (14), and washers (15) from mounting
studs.

(5) If necessary, remove elbows (16, 17, 18, and 19) from valve (14).

Installation

a. Install tractor protection valve as follows:

(1) If removed, install elbows (16, 17, 18, and 19, Figure 2-7-15) on tractor protection valve (14).

(2) Position washers (15) on mounting studs, and install tractor protection valve (14) on studs with
lockwashers (13) and nuts (12).

(3) Connect air lines (10 and 11) to elbows (18 and 19).

(4) Connect air lines (8 and 9) to elbows (16 and 17).

b. Install gladhand as follows:

(1) If removed, install nipple (7, Figure 2-7-15) in connector (6).

(2) If removed, install connector (6) in vehicle frame with lockwasher (5) and nut (4).

(3) If removed, install elbow (3) in connector (6) and connect air line (2) to elbow (3).

(4) Install gladhand (1) on nipple (7).

2-7-36 C-1
 TM 5-3810-307-24-1-1

LEGEND

1. Gladhand 6. Connector 11. Air line 16. Elbow, 45

2. Air line 7. Nipple reducer 12. Nut 17. Elbow, 45
3. Elbow, 45 8. Air line 13. Lockwasher 18. Elbow, 90
4. Nut 9. Air line 14. Protection valve 19. Elbow, 90
5. Lockwasher 10. Air line 15. Washer

Figure 2-7-15. Trailer Air Brake Components

2-7-37/(2-7-38 blank) C-1

 TM 5-3810-307-24-1-1

SECTION 8
HYDRAULIC SYSTEM
TABLE OF CONTENTS
Page

HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-9

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-11
Hydraulic Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-11
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-11
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-12
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Binding Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
SUPPLY PRESSURE AND RETURN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Pump Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Section One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Section Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Section Three . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-18a
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-18a
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-18a
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19
HYDRAULIC PUMP DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Main Relief Valve Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Single Section Valve Bank (Swing Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Five Section Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27

2-8-1 C-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Circuit Relief Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27

Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Telescope - Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-28
Lift - Retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-28
Front or Rear Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-28
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
Controllers (Joysticks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-31
Hydraulic Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Joystick Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-33
Telescope/Clamshell Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Hoist Control Valve (HO-15 Hoist) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Double Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43

2-8-2
 TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Single Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Integrated Outrigger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Outrigger Solenoid Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Pilot-Operated Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Cylinder-Mounted Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Frame Mounted Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Cylinder-Mounted Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Frame-Mounted Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-54
CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-57
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-57
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-57
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-57
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-59
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-59
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61

2-8-3
TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-64

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-64
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-64
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-64
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-65
Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-68
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-68
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-68
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-68
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-70
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-70
Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-72
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-72
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-72
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-72
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-74
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-74
Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-75
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-75
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-75
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-75
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-77
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-77

2-8-4
 TM 5-3810-307-24-1-1

LIST OF FIGURES
Number Title Page

2-8-1 Hydraulic Test Panel Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-9

2-8-2 A.N.S.I. Graphical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-10
2-8-3 Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-15
2-8-4 Reservoir Connection Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-16
2-8-5 Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-18
2-8-6 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-20
2-8-7 Hydraulic Pump Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-22
2-8-8 Valve Locations (Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-24
2-8-9 Valve Locations (Superstructure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-25
2-8-10 Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-31
2-8-11 Joystick Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-34
2-8-12 Telescope/Clamshell Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-36
2-8-13 Hoist Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-38
2-8-14 Hydraulic Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-40
2-8-15 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-42
2-8-16 Double Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-44
2-8-17 Single Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-46
2-8-18 Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-48
2-8-19 Integrated Outrigger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-50
2-8-20 Outrigger Solenoid Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-52
2-8-21 Pilot-Operated Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-55
2-8-22 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-58
2-8-23 Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-59
2-8-24 Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-60
2-8-25 Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-63
2-8-26 Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-66
2-8-27 Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-67
2-8-28 Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-67
2-8-29 Oscillation Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-69
2-8-30 Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-70
2-8-31 Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-70
2-8-32 Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-73
2-8-33 Outrigger Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-76
2-8-34 Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-77
2-8-35 Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-78

LIST OF TABLES
Title Page

Valve Usage Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23

Main Relief Settings Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
Circuit Relief Settings Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Head Wear Ring Gap Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56

2-8-5
TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-8-12

Extreme care must be used when removing any plugs or restrictions from
a hydraulic system suspected to have entrapped air that may be
pressurized.

WARNING 2-8-13

Do not attempt to loosen fittings in pressurized lines or while the hydraulic

pumps are in operation.

WARNING 2-8-17
Ensure that all hydraulic systems are shut down and the pressure is
relieved.

WARNING 2-8-27
Do not attempt to loosen fittings in pressurized lines or while the hydraulic
pumps are in operation.

WARNING 2-8-57
2-8-64
Do not use air pressure to remove the cylinder rod assembly. Use only a 2-8-68
source of controlled hydraulic oil pressure if the rod assembly is hard to 2-8-72
remove. 2-8-75

2-8-6
 TM 5-3810-307-24-1-1

WARNING SUMMARY (continued)

Page

2-8-60
WARNING
2-8-62
Do not use air pressure to cycle or pressurize the cylinder. Use only a 2-8-67
source of controlled hydraulic pressure. 2-8-71
2-8-74
2-8-78

2-8-7/(2-8-8 Blank)
 TM 5-3810-307-24-1-1

HYDRAULIC SYSTEM

DESCRIPTION

This Section describes the supply pressure and
return hydraulic circuit, pumps, and disconnect, all
hydraulic valves, and all hydraulic cylinders.
Description and operation of individual hydraulic
circuits are discussed in their individual Sections.
A hydraulic test panel for checking relief valve
settings is located at the rear left side of the
turntable,
refer to Figure 2-8-1. The test panel contains five
fittings. By removing the fittings and connecting a
pressure gauge, the pressure setting of the relief
valves can be checked.
A complete hydraulic system schematic showing all
options is at the back of this Manual and an A.N.S.I.
Graphical Symbols chart is provided in this Section,
refer to Figure 2-8-2.

Figure 2-8-1. Hydraulic Test Panel Decal

2-8-9
TM 5-3810-307-24-1-1
2-8-10

MAINTENANCE
HYDRAULIC OIL RECOMMENDATIONS.
For the hydraulic oil specifications, refer to Chapter
1, Section 4 - LUBRICATION.
DRAINING AND FLUSHING.
If a component has been changed because of a
failure that might allow metal or abrasive particles to
enter the system, all systems must be thoroughly
checked, drained, and flushed.
1. Remove the reservoir drain plug. Allow
approximately three minutes, after oil stops flowing
from the drain port, for the side walls to drain.
2. Clean and install the reservoir plug and fill the
reservoir with a 50-50 mixture of fuel oil and clean
hydraulic oil.
3. Cycle the crane through all functions several
times; then return the crane to its stowed position
and turn the front and rear wheels to the extreme left.
Shut down the engine.
4. Remove the reservoir drain plug and drain the
reservoir. Clean and install the drain plug and fill the
reservoir with clean oil.
CAUTION
Oil supply lines must be connected to
the cylinders when flushing the system.
NOTE
Draining the various components will be
facilitated by connecting a drain line in
place of the disconnected return line.
5. Disconnect the return line from the lift cylinder
and raise the boom to maximum elevation.
6. Connect the cylinder return line and lower the
boom to its stowed position. Replenish the reservoir
oil level as required.
7. Disconnect the return line from an outrigger
extension cylinder and fully extend the outrigger.
TM 5-3810-307-24-1-1
8. Connect the outrigger return line and retract
the outrigger. Replenish the reservoir oil level as
necessary.
9. Repeats steps 7 and 8 for the remaining
outriggers.
CAUTION
When draining the jack cylinders, always
operate either both front or both rear
cylinders together to prevent twisting the
crane.
10. Disconnect the return lines from a pair of
outrigger jack cylinders and activate the cylinders to
their maximum down position.
11. Connect the return lines and raise the jack
cylinders to the stowed position. Replenish the oil
level as necessary.
12. Repeat steps 10 and 11 for the remaining two
outrigger jack cylinders.
13. Disconnect the return line from the telescope
cylinder and fully extend the boom.
14. Connect the return line and retract the boom.
Replenish the reservoir oil level as necessary.
15. Disconnect the return lines from both front
steer cylinders and turn the front wheels to the
extreme right.
16. Connect the return lines and turn the front
wheels to the extreme left and then back to center.
Replenish the reservoir oil level as necessary.
17. Repeat steps 15 and 16 for the rear steering
cylinders.
CAUTION
When oils are changed or added, ensure
that oils of different manufacturers are of
the same specifications. However, dis-
coloration (milkiness) may occur.
2-8-11
TM 5-3810-307-24-1-1
When hydraulic oils are changed, recheck the
reservoir oil level after brief system operation and
add oil as required.
Reservoir capacity, at full level, is 64.4 gal. (244 l).
Ensure the crane is in the travel mode of operation
when the oil system is being filled. The system must
be filled with all cylinders retracted and the boom at
rest. Fill the reservoir to the full mark on the
reservoir sight gauge. After the reservoir is filled,
operate all circuits and recheck the reservoir sight
gauge. Add oil as required.
REMOVING AIR FROM THE HYDRAULIC
SYSTEM.
Due to the manner in which the hydraulic system is
designed, air entering the hydraulic oil will normally
be removed automatically by passage of the oil over
the baffles in the hydraulic reservoir. However, if a
component has been replaced, the reservoir level is
too low, or a leak develops in the suction lines to the
pumps, air can enter the system. If air becomes
entrapped in the hydraulic oil, it may be detectable in
pumps and motor-operated components such as the
swing mechanism and hoist(s), because it can cause
these units to become noisy during operation.
Should noisy operation occur, first check the level of
the hydraulic reservoir and replenish as necessary.
Then inspect for leaks in the suction lines leading to
the pumps.
Minute leaks may be difficult to locate. Should you
encounter a leak that is not readily detectable, the
following method may be used when checking for
such leaks. Seal all normal openings in the hydraulic
system and the reservoir. Using a positive means to
control the pressure (i.e. a regulator), pressurize the
hydraulic system to 2 to 4 psi (13.79 to 27.6 kPa)
and inspect all joints and fittings for evidence of
leaks. A soap solution applied to the fittings and
joints may also prove helpful in detecting minute
leaks while the system is pressurized. Remove the
pressure, repair any leaks found, and reopen any
openings (vents, etc.) closed for inspection. Refill
the reservoir after completing any repairs or service.
Operate all hydraulic circuits several times in both
directions. This action should return any entrapped
air to the reservoir where it can be removed from the
oil by the baffle system provided.
2-8-12
NOTE
On cranes with booms that can not be
lowered to below horizontal, the
outriggers may be used to raise the
machine in order to lower the boom nose
below horizontal.
CAUTION
Locate the crane on a firm supporting
surface and position the boom in the
most stable position when extending the
boom at low angles.
On cranes with boom telescope cylinders attached
so the rod (ram) moves while the cylinder barrel
remains stationary, cycling may not remove the air.
Lowering the boom to below horizontal and fully
telescoping the boom in and out several times
should remove entrapped air from the cylinders.
However, if the air is not readily removed, lower the
boom to below horizontal, extend the telescope
cylinders as far as practicable, and allow the boom to
remain in this position overnight. This should allow
entrapped air to find its way to the holding valve
where telescoping the boom IN the next morning
should force the air back to the reservoir.
While allowing the boom to remain in an extended
and lowered position overnight is helpful in removing
entrapped air from the hydraulic cylinder, ensure the
boom is first telescoped IN (not OUT) in the morning.
Telescoping OUT may cause air to be forced back
into a cylinder.
WARNING
Extreme care must be used when
removing any plugs or restrictions from a
hydraulic system suspected to have
entrapped air that may be pressurized.
Entrapped air may be removed from cylinders having
wet rods by cycling. On certain cylinders, a plugged
port is provided on the rod end to bleed-off
entrapped air.

WARNING
Do not attempt to loosen fittings in
pressurized lines or while the hydraulic
pumps are in operation.
In the event that air entrapment should persist,
bleeding of air by loosening various clamp and
screw-type fittings may become necessary. If the
above procedures fail to eliminate air entrapment,
contact Grove Worldwide, Product Support.
PARTS REPLACEMENT.
Parts found damaged or out of tolerance when
maintenance is being performed should be replaced.
Refer to the Parts Manual for proper replacement
parts.
CONTROL VALVES.
The control valves that control the crane functions
are installed on the turntable assembly center
section. The valves are controlled hydraulically
through pilot pressure signals from the hydraulic
remote control valves in the cab.
Inspection.
Inspect the control valves for visible damage, binding
spools, and evidence of leakage. If excessive
internal leakage is suspected during operation with a
spool in its center position, it is possible that the area
between the spool and working section bore of the
valve body is worn beyond serviceable limits. If this
condition exists, the spool and body must be
replaced as an assembly.
Valve Leakage.
Dripping oil indicates some type of external leakage.
The machine should be removed from service for
immediate repairs. External leaks sometimes
develop at fittings and seals. Spool seals are
susceptible since they are subject to wear. Seals
may be damaged by temperatures that are too high,
or by dirt or paint accumulation on the spool.
Damaged seals must be replaced.
A component functioning at reduced efficiency may
indicate that the control valve for that component is
leaking internally. Assuming preliminary check-out
TM 5-3810-307-24-1-1
reveals that adequate volume is being supplied to
the affected valve bank, relief valves are properly
adjusted, and the component is not at fault, check
the valve for scored or worn parts. Scoring is a sign
of the number one problem in hydraulics -
contamination: external contamination by dust or
internal contamination by debris from deteriorating
components or oxidized oil. Scored or severely worn
valve components must be replaced.
Warped mounting surfaces can distort the assembly
and cause leakage and binding. To check for valve
distortion, loosen the mounting bolts slightly. If the
leakage stops when the bolts have been backed off
slightly, distortion was the problem. To correct this
condition, shim the valve assembly to level and
retighten the mounting bolts.
Check valves in the control valves are designed to
permit a flow of oil in one direction only. If a piece of
dirt or rust has worked its way into the check valve
and lodges between the poppet and seat, it will keep
the valve open and allow a return flow of oil. The
remedy is to clean the valve, but it is also a good
idea to follow through and ensure the hydraulic
system filters are still serviceable.
Binding Spools.
Some of the most common causes for stiff spool
movement or jammed spool action are; system
overheating, excessive pressure, contaminated or
deteriorated oil, or warped mountings. When
scorched or deteriorated oil or contamination is the
cause, flushing the system and replenishing with
clean oil may solve the problem. If the spool bores
are badly scored or galled, the valve must be
removed for servicing.
Warping occurs when mounting plates are not level
or they become distorted from machine damage. As
mentioned previously, the valve can be shimmed
level.
Also check the valve for rust. Rust or dirt collecting
on the linkages can prevent free movement of the
spool, and keep it from the true center position.
Excessive system pressure can create both internal
and external leaks in valves that are otherwise
sound. Therefore, it is extremely important that relief
valves be adjusted only by qualified personnel using
the proper equipment.
2-8-13
TM 5-3810-307-24-1-1
SUPPLY PRESSURE AND RETURN CIRCUIT
DESCRIPTION
The supply pressure and return circuit is made up of
three (3) separate circuits which route oil from the
hydraulic pumps to the directional control valves for
the individual operating circuits. The supply
pressure and return circuit consists of the reservoir,
a three section hydraulic pump, pump disconnect, oil
cooler, two oil filters, and a 15 port hydraulic swivel.
The operating circuits description and components
begin with the circuits directional control valve.
HYDRAULIC RESERVOIR AND FILTER.
The hydraulic reservoir is mounted on the left side of
the carrier frame and is held in place by two retaining
straps, refer to Figure 2-8-3. The reservoir is all-
steel and has an internally-mounted full-flow filter
and an integral baffle that helps cool the oil and
prevent foaming. The reservoir has a capacity of
approximately 73 gal. (276 l) total; 64.4 gal. (244 l) to
the full level, with a low level of 60 gal. (227 l).
Oil flows through the two individual tubes at the back
of the reservoir to the hydraulic pump. The majority
of the return flow enters directly into the return filter.
A drain plug located in the bottom of the reservoir is
magnetized to collect metal particles from the oil,
should the oil become contaminated.
A sight level gauge is located on the side of the
reservoir to indicate oil level. A screw-on breather
located on the top of the reservoir allows air to enter
or exhaust from the reservoir. It is most important
that the breather be kept clean to prevent damage to
the reservoir. A filler cap located on the top of the
reservoir is used when hydraulic oil is added to the
reservoir.
The oil filter housing located inside the reservoir,
contains a replaceable 10 micron filter element. To
gain access to the filter element, unbolt the filter
head. Most of the oil returning from the system is
directed to the filter. The oil passes through the filter
element and to the outlet at the bottom of the filter
bowl. Oil returning from the steering circuit is
2-8-14
directed through an external filter located inboard of
the hydraulic reservoir. Both filters incorporate a
bypass feature allowing oil to bypass the filter when
the element is clogged and back pressure exceeds
25 psi (172.3 kPa). Gauges on the front of the filter
heads show the amount of filter restriction present.
OIL COOLER.
An air cooled hydraulic oil cooler is mounted on the
right side of the superstructure. The oil cooler
consists of a hydraulic radiator, and fan-mounted on
an electric motor. The fan draws cool air through the
cooling fins on the radiator.
A temperature switch installed in the return manifold
controls the operation of the fan motor. When the
temperature of the oil reaches 120F (48.8C) the
switch's contacts close and energize the fan motor
relay to actuate the fan motor.
PUMP DISTRIBUTION.
Section One.
Section One of the hydraulic pump supplies the main
hoist circuit. Oil flowing from the valve bank returns
to the return manifold.
Section Two.
Section Two of the hydraulic pump supplies the lift
and telescope directional control valves. Oil flowing
from the valve bank returns to the reservoir.
Section Three.
Section Three of the hydraulic pump supplies the
integrated outrigger valve which controls the
outrigger circuit and the superstructure rear steering
circuit. Bypass flow from the integrated outrigger
valve supplies the pressure reducing valve, which in
turn divides the flow to supply the swing system and
the hydraulic remote controllers.
 TM 5-3810-307-24-1-1
2-8-15

Figure 2-8-3. Hydraulic Reservoir and Filter

2-8-16

TM 5-3810-307-24-1-1
Figure 2-8-4. Reservoir Connection Legend
 TM 5-3810-307-24-1-1

MAINTENANCE

HYDRAULIC FILTER. 5. Remove the filter bowl from the filter head and
remove the element.
Removal and Disassembly.
6. Discard the used element.
WARNING Assembly and Installation.
Ensure that all hydraulic systems are
shut down and the pressure is relieved. 1. Install a new element into the filter bowl and
install the filter bowl into the filter head, refer to
1. Shut down all hydraulic systems. Figure 2-8-5.

2. Thoroughly clean the area around the filter. 2. Using a new gasket, install the filter and gasket
Wipe any dirt from the filter housing and filter head. onto the hydraulic reservoir.

3. Disconnect the hydraulic line from the filter 3. Secure the filter in place with the mounting
head, refer to Figure 2-8-5. bolts.

4. Remove the four bolts securing the filter to the 4. Connect the hydraulic line to the filter head.
reservoir and remove the filter and gasket.
5. Operate the system and check for any
leakage.

2-8-17
TM 5-3810-307-24-1-1

Figure 2-8-5. Hydraulic Filter

2-8-18

HYDRAULIC RESERVOIR.
Removal.
WARNING
Ensure that all hydraulic systems are
shut down and the pressure is relieved.
1. Ensure battery disconnect switch is in OFF
position.
2. Thoroughly clean the reservoir around the
hydraulic hose connections.
3. Drain the hydraulic reservoir. The reservoir
has a capacity of approximately 73 gallons
(276 liters).
4. Tag and disconnect all hydraulic lines on the
reservoir. Refer to Figure 2-8-4. If Espar
coolant heater is installed, also refer to
Appendix J. Plug the hydraulic lines and all
openings.
5. If Espar coolant heater is installed, drain the
engine coolant from the diesel engine. Get
set to catch any engine coolant contained in
the coolant lines. Then tag and disconnect
the engine coolant lines to the hydraliner
heating elements. If necessary, refer to
Appendix J for the component locations and
engine coolant line connections.
6. Remove the locknuts and lockwashers (four
places) securing the two retaining straps (6,
Figure 2-8-3) to the hydraulic reservoir
mounting bracket (7).
WARNING
The empty hydraulic reservoir weighs
approximately 250 lbs (113.5 kg). Use
care when removing it to avoid injury
and/or damage to the equipment.
7. Remove superstructure cab access steps.
8. Use a suitable lifting device to remove the
reservoir from its mounting bracket (7).
9. If replacing the reservoir, remove the
hydraulic oil sampling valve hose connection
(10) and pressure gauge.
10. If replacing the reservoir, remove the return
filter (9), window gauge (4), and the breather
(1).
11. If replacing the reservoir, remove hydraliner
heater elements, if installed.
TM 5-3810-307-24-1-1
Installation.
1. If required, modify the replacement hydraulic
reservoir for the hydraliner heating elements
in accordance with Appendix J.
2. If required, install two hydraliner heating
elements in accordance with Appendix J.
3. If removed, install return filter (9, Figure 2-8-
3), window gauge (4), and breather (1).
4. If removed, install the hydraulic oil sampling
valve hose connection (10).
WARNING
The empty hydraulic reservoir weighs
approximately 250 lbs (113.5 kg). Use
care when installing it to avoid injury
and/or damage to the equipment.
5. Use a suitable lifting device to position the
reservoir on its mounting bracket (7).
6. Connect hydraulic return line to hydraulic
reservoir and hose from connection on
reservoir to hydraulic oil sampling valve.
7. Position superstructure cab access steps and
secure retaining straps (6) with locknuts and
lockwashers (four places).
8. Remove all plugs and ensure that all pre-
formed packings in the disconnected
hydraulic lines are not damaged. Replace
any damaged preformed packing.
9. Install the remaining disconnected hydraulic
lines to the hydraulic reservoir. Refer to
Figure 2-8-4 and/or Appendix J. Remove
tags.
10. If removed, connect engine coolant hoses to
the hydraliner heating elements. Remove tags.
If necessary, refer to Appendix J for component
locations and engine coolant line connections.
11. Remove the breather and fill the hydraulic
reservoir with clean hydraulic oil.
12. If coolant heater installed, refill engine
coolant.
13. Place battery disconnect switch in the ON
position.
14. Start the diesel engine, bleed air from system,
and check all hydraulic functions. Inspect the
hydraulic reservoir hose connections for
evidence of leaks. Refill engine coolant as
necessary.
15. Remove air trapped in the hydraulic system.
2-8-18a/(2-8-18b Blank) C-1
 TM 5-3810-307-24-1-1

HYDRAULIC PUMP

DESCRIPTION

The hydraulic pump is mounted on a drive pad of the
torque converter. The purpose of the pump is to
convert the mechanical energy of the torque
converter into fluid energy for the operation of the
crane's hydraulic components.
The hydraulic pump is a positive displacement, gear-
type pump and consists of three separate sections.
The first section of the pump, the one on the
mounting flange end, has an output of 39 gpm (148
lpm). The second (middle) section has an output of
39 gpm (148 lpm). The third section has an output of
16 gpm (61 lpm).

MAINTENANCE

NOTE

For more detailed information, refer to the applicable SM package.

REMOVAL. 5. Cover the pump mount opening to prevent dirt

from entering the drive unit.
1. Remove the pump cover plate.
6. Remove and discard the gasket between the
2. Tag and disconnect the supply lines from the drive pad and the pump.
pump, refer to Figure 2-8-6. Cap all the lines and
openings. INSTALLATION.

3. Tag and disconnect the pump distribution lines NOTE

from the pump. Cap all the lines and openings.
CAUTION
Keep the pump as level as possible to
avoid damaging the splines.
NOTE
During assembly, assure that a new
gasket is used between the drive pad
and pump.
1. Install pump to torque converter, refer to Figure
2-8-6. Assure that the distribution and supply lines
are properly connected as tagged during removal.

The hydraulic pump and the disconnect
are attached to the torque converter with
the same hardware.
4. Remove the four nuts and washers attaching
the pump to the torque converter drive pad. Remove
the pump.
2. Operate the pump for at least two minutes at
zero pressure and moderate speed (not over 1,500
rpm). If the pump appears to be operating
satisfactorily, increase the rpm intermittently, until the
governed rpm has been attained. Continue this
procedure for approximately five minutes while
checking for proper operation and leakage.

2-8-19
TM 5-3810-307-24-1-1

Figure 2-8-6. Hydraulic Pump

2-8-20
 TM 5-3810-307-24-1-1

HYDRAULIC PUMP DISCONNECT

DESCRIPTION

The hydraulic pump disconnect is mounted between
the hydraulic pump and the drive pad on the torque
converter.
The disconnect assembly is provided for cold
weather starting and consists of a housing, lever,
movable collar, and a sliding splined sleeve. The
housing and pump are bolted to the torque converter
drive pad with the same hardware. The lever
extends up through the cover plate. Moving the lever
actuates the movable collar within the housing which
in turn sides the splined sleeve on the splined pump
shaft to engage the sleeve with the splined shaft of
the torque converter drive. The disconnect housing
is initially filled with one pint of transmission fluid and
during operation, the torque converter will spray
transmission fluid into the housing to lubricate the
disconnect.

MAINTENANCE

(Text Deleted)

REMOVAL. 4. Remove and discard the gasket between the

disconnect and drive pad, and the one between the
1. Remove the pump cover plate. disconnect and pump.

2. Remove the hydraulic pump. Refer to 5. Cover the disconnect mount opening to
HYDRAULIC PUMP - REMOVAL in this Section. prevent dirt from entering the drive unit.

NOTE INSTALLATION.

The hydraulic pump and the disconnect 1. Using a new gasket, position the pump
are attached to the torque converter with disconnect to the torque converter drive pad, refer to
the same hardware. Figure 2-8-7.

3. Remove the pump disconnect from the torque 2. Refer to HYDRAULIC PUMP - INSTALLATION
converter drive pad, refer to Figure 2-8-7. and install the hydraulic pump.

2-8-21 C-1
TM 5-3810-307-24-1-1

Figure 2-8-7. Hydraulic Pump Disconnect

2-8-22
 TM 5-3810-307-24-1-1

VALVES

GENERAL

This sub-section provides descriptive information for
all the hydraulic valves used on this crane. For a
listing of all valves, the circuit they are used in, and
their physical location, refer to the Valve Usage
Table and Figures 2-8-8 and 2-8-9.
The description of the valves given here is for the
valve itself. For information on how the valve
functions in the individual circuits, refer to the
Description and Operation of that circuit.

VALVE USAGE TABLE

Valve Name Circuit Used In Physical Location

Hoist Control Valve Hoist On Hoist
Solenoid Valve Manifold, LMI Controls Turntable Side Plate
Lockout
Hydraulic Remote Control Valve Swing Armrest, Left
(dual function) Telescope/Clamshell (Foot Pedal) Beneath Cab
Main Hoist Armrest, Right
Aux Hoist Armrest, Left
Lift Armrest, Right
Directional Control Valve Swing Turntable Center Section
Telescope Turntable Side Plate
Lift Turntable Side Plate
Clamshell Turntable Side Plate
Main Hoist Turntable Side Plate
Aux Hoist Turntable Side Plate
Pressure Reducing Valve Supply Pressure and Return Turntable Center Section
Solenoid Valves Outrigger On Outrigger Boxes
Axle Lockout On Frame (1-Front, 2-Rear)
Rear Steer Lockout On Frame
Rear Steering On Frame
Front Axle Lockout On Frame
Steer Reversal Turntable Center Section
A/C Idle Boost Turntable Center Section
Control Lockout Turntable Center Section
Swing Brake Release Turntable Center Section
Integrated Outrigger/Steer Valve Outrigger Center of Carrier Frame
Holding Valves Lift Cylinder Port Block
Telescope Cylinder Port Block
Pilot-Operated Check Valve Outrigger Cylinder Port Block and on
Frame (2)
Single Selector Valve Tele/Clamshell Turntable Side Plate
Shuttle Valve Swing-A/C Turntable Center Section
Modulator Valve Torque Converter Lock-up On Frame

2-8-23
2-8-24

TM 5-3810-307-24-1-1
Figure 2-8-8. Valve Locations (Carrier)
 TM 5-3810-307-24-1-1

1. Solenoid Valve, Steer Reversal 5. Solenoid Valve, LMI Lockout 9. Solenoid Valve, Swing Brake
2. Manifold Assembly, Return 6. Directional Valve, Controls 10. Pressure Reducing Valve
3. Directional Valve, Swing 7. Selector Valve, Tele/Clamshell 11. Shuttle Valve, Swing-A/C
4. Solenoid Valve, A/C Idle Boost 8. Pressure Switch, A/C 12. Pressure Switch, Swing Brake Light
13. Solenoid Valve, Controller Lockout

Figure 2-8-9. Valve Locations (Superstructure)

2-8-25
TM 5-3810-307-24-1-1

Relief Valves

DESCRIPTION

Relief valves are used to protect a component, a valves, but some are located in the line between
circuit, or a system from over pressurization. Most of components (e.g., double cross-over relief valve),
the relief valves are located in the directional control while others are part of a component.

MAINTENANCE

GENERAL.
Relief valves are checked and adjusted by causing a
given circuit to reach its prescribed pressure limit
(stall). At this point, the relief valve opens, returning
oil to the reservoir. Hydraulic motor circuits may be
stalled by preventing rotation of the motor shaft prior
to actuating the control valve. Cylinder circuits may
be stalled by extending or retracting a cylinder to its
limit of travel.
By placing a pressure gauge in the proper line or
port, a pressure reading will indicate the point at
which the relief valve opens. The needle on the
meter face will climb until it reaches the relief valve
setting. At that point the needle will stop climbing
and fluctuate, indicating the relief valve is open and
returning oil to the reservoir.
Correct relief valve adjustment is mandatory if any
hydraulic circuit is to function properly. Settings must
be within specified tolerances. Therefore, after the
need for adjustment has been established, it should
be performed only by qualified technicians using the
correct equipment.
The following test tables list Main and Circuit Relief
Valve Settings. If the pressure setting of any relief
valve is not 100 psi ( 689.5 kPa) of that listed in
the tables, adjustment is necessary.
CAUTION
Do not overtighten the adjustment screw
or locknut.
CAUTION
Do not hold the relief valve open for
more than one minute at a time.
NOTE
To adjust a relief valve, turn the
adjustment screw (in to increase or out
to decrease) until the proper setting is
reached.
MAIN RELIEF SETTINGS TABLE
Valve Bank Setting - psi (kPa)

The hydraulic system utilizes two valve banks. A One Section (Swing) . . . . . . . . . . . 1,500 (10,342)
single section valve bank directs oil flow for operation Five Section . . . . . . . . . . . . . . . . 3,500 (24,132)
of the Swing Circuit. The five section valve bank
directs flow for operation of the Telescope, Lift, NOTE
Auxiliary Hoist, Main Hoist, and Clamshell/
Attachments Circuits. Release the control lever after taking
each reading and while making
Each valve bank has one main relief valve limiting adjustments.
maximum operating pressure of the component(s) in
that circuit. In addition, circuit relief valves further
limit operating pressures as required by circuit
design.

2-8-26
 TM 5-3810-307-24-1-1

CIRCUIT RELIEF SETTINGS TABLE

Valve Bank Circuit Relief - psi (kPa) Main Relief - psi (kPa)

Main Hoist . . . . . . . . . . . . . . ................ . . . . . . . . . . . . . . . . . . . . . . . . 3,500 (24,132)

Auxiliary Hoist . . . . . . . . . . . . ................ . . . . . . . . . . . . . . . . . . . . . . . . 3,500 (24,132)
Lift.. . . . . . . . . . . . . . . . . . . 1,900 (13,101) Retract. . . . . . . . . . . . . . . . . . . . . . . . . 3,500 (24,132)
Telescope . . . . . . . . . . . . . . 3,700 (25, 511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,500 (24,132)
Clamshell. . . . . . . . . . . . . . . ................ . . . . . . . . . . . . . . . . . . . . . . . . 3,500 (24,132)
Swing . . . . . . . . . . . . . . . . . ................ . . . . . . . . . . . . . . . . . . . . . . . . 1,500 (10,342)
Outrigger . . . . . . . . . . . . . . . 2,000 (13,790). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
Rear Steer . . . . . . . . . . . . . . 2,500 (17,237). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,500 (24,132)
Front Power Steering . . . . . . . 2,500 (17,237). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
Swing Brake . . . . . . . . . . . . . . 250 (1,724) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
Controllers (Joysticks) . . . . . . . . 450 (3,111) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........

NOTE 3. Move the SWING control and hold

momentarily. Note the maximum reading on the
An accurate 0 to 5,000 psi (0 to 34, 475 pressure gauge. If the reading is not 100 psi (
kPa) pressure gauge should be used 689.5 kPa) of that listed in the Main Relief Settings
when adjusting the relief valves. Table, adjust the pressure setting as necessary.
Pressure test ports are located on the
HYDRAULIC TEST PANEL. These test 4. Shut down the engine. Remove the pressure
ports are connected to the inlet line of gauge and install the pipe plug.
each valve bank.
Five Section Valve Bank.
When the proper pressure setting has been attained,
tighten the adjustment screw locknut and recheck 1. Remove the pipe plug from the
the pressure. It is possible that the setting may TELE/LIFT/CLAMSHELL pressure test port on the
change while tightening the locknut. Hydraulic Test Panel and install the pressure gauge.

PREPARATION. 2. Set the throttle to 2,800 rpm.

1. Start and warm up the engine until the 3. Fully extend the boom lift cylinder and hold
hydraulic oil temperature reaches a minimum of 70F momentarily. Note the maximum reading on the
(21C). pressure gauge. If the reading is not 100 psi (
689.5 kPa) of that listed in the Main Relief Settings
WARNING Table, adjust the pressure setting as necessary.
Do not attempt to loosen fittings in
pressurized lines or while the hydraulic 4. Shut down the engine. Remove the pressure
pumps are in operation. gauge and install the plug.

2. Shut down the engine. CIRCUIT RELIEF VALVE ADJUSTMENT.

MAIN RELIEF VALVE SETTINGS. Outrigger.

Single Section Valve Bank. (Swing Circuit) 1. Disconnect a retract line from any one of the
outrigger jack cylinders and install the pressure
1. Remove the pipe plug from the SWING gauge in this line.
pressure test port on the Hydraulic Test Panel and
install the pressure gauge. 2. Set the throttle to 2,800 rpm.

2. Set the throttle to 2,800 rpm. 3. On the front console position, the outrigger
extension/retraction toggle switch to RETRACT.

2-8-27
TM 5-3810-307-24-1-1
Note the maximum reading on the pressure gauge.
If the reading is not 100 psi ( 689.5 kPa) of that
listed in the Circuit Relief Setting Table, adjust the
pressure setting as necessary.
4. Shut down the engine. Remove the pressure
gauge and reconnect the line to the jack cylinder.
Telescope - Retract.
NOTE
Telescope extend uses the valve bank
main relief valve.
1. Remove the plug from the pressure test port
on the Hydraulic Test Panel and install the pressure
gauge.
2. Set the throttle to 1,000 rpm.
3. Move the TELESCOPE control lever to IN and
hold momentarily. Note the maximum reading on the
pressure gauge. If the reading is not 100 psi (
689.5 kPa) of that listed in the Circuit Relief Setting
table, adjust the pressure setting as necessary.
4. Shut down the engine. Remove the pressure
gauge and install the plug.
Lift - Retract.
NOTE
Lift extend uses the valve bank main
relief valve.
2-8-28
1. Remove the plug from the pressure test port
on the Hydraulic Test Panel and install the pressure
gauge.
2. Set the throttle to 1,000 rpm.
3. Move the boom control lever to down and hold
momentarily. Note the maximum reading on the
pressure gauge. If the reading is not 100 psi (
689.5 kPa) of that listed in the Circuit Relief Setting
Table, adjust the pressure setting as necessary.
4. Shut down the engine. Remove the pressure
gauge and install the pipe plug.
Front or Rear Steer.
1. Disconnect one hose from the applicable steer
cylinder. Install the pressure gauge in this hose.
2. Set the throttle to 1,200 rpm.
3. Turn the steering wheel in the direction that will
pressurize this hose. Continue turning to the end of
its travel and hold it momentarily. Note the maximum
reading on the pressure gauge. If the reading is not
100 psi ( 689.5 kPa) of that listed in the Circuit
Relief Setting Table, adjust the pressure setting as
necessary.
4. Shut down the engine. Remove the pressure
gauge and reconnect the hose to the steer cylinder.
 TM 5-3810-307-24-1-1

Swing Brake. Controllers (Joysticks).

1. Remove the plug from the pressure test port 1. Remove the plug from the pressure test port
on the Hydraulic Test Panel and install the pressure on the Hydraulic Test Panel and install the pressure
gauge. gauge.

2. Set the throttle to 2,800 rpm. 2. Set the throttle to 2,800 rpm.

3. Engage the swing brake and mechanical 3. Lift the armrests in the cab to disable the
swing lock. controllers.

4. If the reading is not 10 psi (68.9 kPa) of that 4. If the reading is not 10 psi (68.9 kPa) of that
listed in the Circuit Relief Settings Table, adjust the listed in the Circuit Relief Settings Table, adjust the
pressure setting as necessary. pressure as necessary.

2-8-29
TM 5-3810-307-24-1-1
Directional Control Valve
DESCRIPTION
The directional control valves are pilot-operated,
four-way, three-position valves with either an open or
closed spool. Whether a valve has an open or
closed spool is determined by whether, with the
spool in the neutral position, the work ports are open
to the reservoir return passage. If the work ports are
open to the reservoir return passage, the valve is
classified as an open spool-type; if they are not, the
valve is a closed spool-type. (Refer to the Valve
Usage Table for circuit applicability by valve type.)
Additionally, the valve spool is spring-loaded to the
neutral position.
The open spool directional control valve is
constructed with a through passage to allow flow to
pass to the next valve(s) in the bank and on to the
reservoir, when the valve spool is in the neutral
position. By positioning the valve spool to a work
position, the through passage is blocked and flow is
diverted o the dead end parallel passage. This
causes flow to be directed to the component's open
supply work port. Return flow is routed from the
return work port to the reservoir return passage by
MAINTENANCE
(Text Deleted)
REMOVAL.
1. Remove the valve cover, if applicable.
2. Tag and disconnect the hydraulic lines running
to the directional control valve bank, refer to Figure
2-8-10. Cap or plug all openings.
3. Tag and disconnect any electrical leads from
the valve bank.
4. Remove the bolts and nuts securing the valve
bank and remove the valve bank.
2-8-30 C-1
the opposite end of the valve spool. This flow
pattern is applicable in either direction the valve may
be positioned. If it is necessary to open more than
one directional control valve in the same valve bank,
it may be required to partially close or feather the
valves that are located in the bank first, in reference
to flow from the pump, in order to provide sufficient
flow to the valves located last in the bank.
The closed spool directional control valve functions
basically the same way as the open spool directional
control valve, in that the through passage of the
valve must be blocked off by the valves' spool to
divert flow to the dead end parallel passage. With
flow diverted to the parallel passage, pressure than
must unseat the load check valve to allow the flow to
reach the open work port. The load check valve is
provided to prevent back sliding of components
which support heavy loads as is evidenced by the
circuits this valve is used in. Return flow from the
component is through the return work port to the
reservoir return passage.
INSTALLATION.
1. Position the valve bank onto the turntable and
secure it in place with the bolts and nuts, Refer to
Figure 2-8-10.
2. Connect the electrical leads to the valve bank
as tagged during removal.
3. Connect the hydraulic lines to the valve bank
as tagged during removal.
 TM 5-3810-307-24-1-1

FUNCTIONAL CHECK. engine speed to the recommended operating rpm.

1. Start the engine with the pump disconnect
disengaged and check the operation at high and low
idle speed with no load applied.
2. Engage the hydraulic pump and set the
3. Operate the control lever(s) of the affected
circuit(s). Check for smooth operation of cylinders
and motors. Check the valve bank(s) and lines for
leakage.

Figure 2-8-10. Directional Control Valve

2-8-31
TM 5-3810-307-24-1-1

Hydraulic Remote Control Valve

DESCRIPTION

There are three hydraulic remote control valves
utilized in the crane cab. One is a pedal operated
dual function valve located under the cab. This valve
is used for control of the telescope cylinder or the
clamshell/grapple cylinder depending on the position
selected on the TELE/CLAMSHELL selector switch
on the right armrest.
The other two hydraulic remote control valves are
dual-function joystick-type valves. One valve is
located in each armrest. The valve in the right
armrest controls the main hoist and boom lift.
Moving the control lever straight forward or back
operates the main hoist function. Pushing the
control lever to either side operates boom lift.
Positioning the lever in a diagonal direction operates
both functions simultaneously. The valve in the left
armrest controls the auxiliary hoist and swing.
Pushing the control lever straight forward or back
controls the auxiliary hoist function. Pushing the
control lever to either side operates swing.
Positioning the lever diagonally operates both
functions simultaneously.

MAINTENANCE

(Text Deleted)

JOYSTICK CONTROL VALVES.

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove screws (1, Figure 2-8-11), lift top cover (2), and slide bottom cover (3) from arm rest.

c. Tag and disconnect electrical leads for joystick assembly (6).

d. Tag and disconnect hydraulic lines from fittings on joystick assembly (6).

e. Remove screws (4), threaded plates (5), and joystick assembly (6) with mount (10) from top cover (2) of
arm rest.

f. If necessary, remove locknut (7), washers (8), screws (9), and mount (10) from joystick assembly (6).

g. If necessary, remove tubes (11) and o-rings (12) from ports A2, B1, B2, and T, elbow (13) from port A1,
and tube (14), o-ring (15), and adapter (16) from port P of joystick assembly (6).

h. If replacing joystick, remove screws and nuts and retain joystick instruction plate.

Installation

a. If removed, install adapter (16, Figure 2-8-11), tube (14), and new o-ring (15) in port P, elbow (13) in port
A1, and o-rings (12) and tubes (11) in ports A2, B1, B2, and T of joystick assembly (6).

2-8-32 C-1
 TM 5-3810-307-24-1-1

b. If removed, install mount (10) on joystick assembly (6) with screws (9), washers (8), and locknuts (7).

c. Install joystick assembly (6) with mount (10) in top cover (2) of arm rest with screws (4) and threaded
plates (5).

d. Connect hydraulic lines to fittings of joystick assembly (6) and remove tags.

e. Connect electrical leads for joystick assembly (6) and remove tags.

f. Slide bottom cover (3) onto arm rest and secure top cover (2) to bottom cover (3) with screws (1).

g. If removed, install joystick instruction plate and secure with screws and nuts.

Functional Check

With engine running at governed rpm, operate both functions controlled by the control valve. Check the valve for
proper operation and leaks.

2-8-33
TM 5-3810-307-24-1-1

LEGEND

1. Screw 7. Locknut 12. O-ring

2. Top cover 8. Washer 13. Elbow, 900
3. Bottom cover 9. Screw 14. Tube
4. Screw 10. Mount 15. O-ring
5. Threaded plate 11. Tube 16. Adapter
6. Joystick assembly

Figure 2-8-11. Joystick Control Valve Installation

2-8-34
 TM 5-3810-307-24-1-1

TELESCOPE/CLAMSHELL CONTROL VALVE. 2. Connect the hydraulic lines to the valve as

tagged during removal.
Removal.
3. Connect the pedal linkage to the control valve.
1. Disconnect the pedal linkage from the control
valve, refer to Figure 2-8-12. Functional Check.

2. Tag and disconnect the hydraulic lines from 1. With the engine running at governed rpm,
the control valve. telescope the boom the whole way out and then the
whole way back in. Check valve for proper operation
3. Remove the bolts, nuts, and washers securing and any leakage.
the control valve to the mounting bracket and
remove the valve. 2. Place TELE/CLAMSHELL selector switch in
CLAMSHELL position, operate pedal in both
Installation. directions, and check for leaks.

1. Position the valve onto the mounting bracket

and secure in place with the bolts, nuts, and
washers, refer to Figure 2-8-12.

2-8-35
TM 5-3810-307-24-1-1

Figure 2-8-12. Telescope/Clamshell Control Valve

2-8-36
 TM 5-3810-307-24-1-1

Hoist Control Valve (H0-15 Hoist)

DESCRIPTION

The hoist control valve is designed to provide an operated poppet off its seat. This allows flow to the
even flow of oil to the hoist motor in both directions. return reservoir through the directional control valve.

To drive the hoist motor in the raise direction, An orifice plug is installed in the pilot pressure port to
hydraulic oil flows through the in port and pushes the restrict back flow when the directional control valve is
free flow poppet off its seat. The oil then flows to the closed. The restriction prevents the pilot-operated
out port and on to the hoist drive motor. poppet from chattering on its seat.

When driving the hoist motor in the lower direction,
oil from the directional control valve enters the out
port. The pilot-operated poppet is held shut by the
adjustment spring until pilot pressure of sufficient
force is sensed at the pilot pressure port to move the
pilot-
A vent is provided that vents the area between the
pilot piston seal and the free flow poppet and pilot-
operated poppet seals to prevent a hydraulic lock
should weepage around the seals occur.

MAINTENANCE

(Text Deleted)

REMOVAL. 2. Connect the hydraulic lines to the valve as

tagged during removal.
1. Tag and disconnect the hydraulic lines running
to the valve, refer to Figure 2-8-13. Cap or plug all FUNCTIONAL CHECK.
openings.
With the engine running at governed rpm, activate
2. Remove the bolts and washers securing the the hoist several turns in both directions. Check for
valve and remove the valve, refer to Figure 2-8-13. proper operation and check the valve for any
leakage.
INSTALLATION.

1. Position the valve and secure in place with the

bolts and washers, refer to Figure 2-8-13.

2-8-37 C-1
TM 5-3810-307-24-1-1

Figure 2-8-13. Hoist Control Valve

2-8-38
 TM 5-3810-307-24-1-1

Pressure Reducing Valve

DESCRIPTION

There is one pressure reducing valve used on the Hydraulic circuits served by the pressure reducing
crane. The purpose of the valve is to take input flow valve include the remote controllers, swing brake
from the supply pressure and return circuit, divide it, and the swing directional control valve bank.
and maintain a regulated flow to two or more
separate circuits. Excess oil returns to the reservoir
via a vent port in the valve.

MAINTENANCE

NOTE

Maintenance to the valve is limited to removing and replacing the valve

cartridges and/or O-rings.

REMOVAL. INSTALLATION.

1. Remove the hoses and fittings from the valve, 1. Position the valve and secure in place with the
refer to Figure 2-8-14. nuts and lockwashers, refer to Figure 2-8-14.

2. Remove the nuts and lockwashers which 2. Install the fittings and attach the hoses.
secure the valve.
FUNCTIONAL CHECK.
3. Remove the valve and plug the ports.
With the engine running at governed rpm, activate
the remote controllers and swing brake several
times. Check for proper operation and check the
valve for any leakage.

2-8-39
TM 5-3810-307-24-1-1

Figure 2-8-14. Hydraulic Pressure Reducing Valve

2-8-40
 TM 5-3810-307-24-1-1

Solenoid Valve

DESCRIPTION

The valve is held in a normally closed position or
normally open position by a spring. When the
solenoid is energized, the plunger assembly forces
the spool to shift, causing the valve to open or close.
De-energizing the solenoid allows spring pressure to
shift the spool back to its normal position.
Single solenoid valves are used in the control
lockout, swing brake release, LMI lockout manifold,
A/C (idle boost), steer reversal, front axle steering,
rear axle steering, axle disconnect, and rear steer
lockout circuits. Double solenoid valves are used in
the axle oscillation lockout circuit.

MAINTENANCE

NOTE

For more detailed information, refer to the applicable SM package.

REMOVAL. 2. Connect the hydraulic lines to the valve as

tagged during removal.
1. Tag and disconnect the hydraulic lines running
to the valve, refer to Figure 2-8-15. Cap or plug all FUNCTIONAL CHECK.
openings.
With the engine running at governed rpm, activate
2. Remove the bolts, nuts, and washers securing the replaced solenoid valve several times. Check for
the valve and remove the valve. proper operation and check the valve for any
leakage.
INSTALLATION.

1. Position the valve and secure in place with the

bolts, nuts, and washers, refer to Figure 2-8-15.

2-8-41
TM 5-3810-307-24-1-1

Figure 2-8-15. Solenoid Valve

2-8-42
 TM 5-3810-307-24-1-1

Double Selector Valve

DESCRIPTION

A manually-operated, two-position double selector
valve is located in the carrier frame center section.
The valve is connected by a control cable to the
steering mode selector handle located at the rear of
the hydraulic reservoir. The selector valve
determines if the front steer cylinders are to be
operated from the carrier cab or from the
superstructure cab. The hydraulic circuit which is to
be operated should be selected before pressure is
applied. The valve spool is of the open crossover-
type. As the spool is moved and one set of outlet
ports start to close, the other set of outlet ports start
to open. With the spool pulled out of the housing
(viewed from the handle end), ports A and D are
connected to each other, and ports B and C are
connected to each other. With the spool pushed into
the housing (viewed from the handle end), ports A
and E are connected to each other, and ports B and
F are connected to each other.
A solenoid operated double check valve is located
on the turntable left side plate. The solenoid,
controlled by the TELE/CLAMSHELL selector switch
positions the valve to direct hydraulic pilot pressure
so that the telescope/clamshell control pedal
operates the boom telescope cylinder or the
clamshell/grapple cylinder. With the selector switch
in the TELE position, ports T and C4, and ports P
and C1 are connected together directing pilot
pressure to the telescope directional control valve
which in turn directs hydraulic flow to operate the
telescope cylinder. With the selector switch in the
CLAMSHELL position, ports T and C3, and ports P
and C2 are connected together directing pilot
pressure to the clamshell directional control valve to
operate the clamshell/grapple cylinder.

MAINTENANCE

(Text Deleted)

REMOVAL. INSTALLATION.

1. Tag and disconnect the six hydraulic hoses 1. Position the selector valve onto the mounting
from the ports on the selector valve, refer to Figure bracket and secure it with bolts and lockwashers,
2-8-16. Cap or plug all openings. refer to Figure 2-8-16.

2. Disconnect the handle linkage or electrical 2. Connect the handle linkage or electrical
connector as applicable. connector onto the valve as applicable.

3. Remove the bolts and lockwashers securing 3. Connect the six hydraulic hoses to the selector
the selector valve to the mounting bracket. Move the valve as tagged prior to removal.
valve to a clean work area.
FUNCTIONAL CHECK.

With the engine running at governed rpm, activate

the replaced selector valve several times. Check for
proper operation and check the valve for any
leakage.

2-8-43 C-1
TM 5-3810-307-24-1-1

Figure 2-8-16. Double Selector Valve

2-8-44
 TM 5-3810-307-24-1-1

Single Selector Valve

DESCRIPTION

The single selector valve is a manually-operated, two
position valve located in the carrier frame center
section. The selector valve is mechanically
connected to the double selector valve and
determines if hydraulic flow for steering control is to
be routed to the carrier steering control or to the
superstructure steering control. Both the single and
double selector valves are operated by a single
control located at the rear of the hydraulic reservoir.
Positioning the control will, by cable, move the
mechanical linkage which shifts the selector valve's
valve spool.

MAINTENANCE

REMOVAL. INSTALLATION.

1. Tag and disconnect the hydraulic hoses from 1. Position the selector valve onto the mounting
the ports on the selector valve, refer to Figure 2-8- bracket and secure it with bolts and lockwashers,
17. Cap or plug all openings. refer to Figure 2-8-17.

2. Disconnect the handle linkage. 2. Connect the handle linkage.

3. Remove the bolts and lockwashers securing 3. Connect the hydraulic hoses to the selector
the selector valve to the mounting bracket. Move the valve as tagged prior to removal.
valve to a clean work area.
FUNCTIONAL CHECK.

With the engine running at governed rpm, activate

the replaced selector valve several times. Check for
proper operation and check the valve for any
leakage.

2-8-45
TM 5-3810-307-24-1-1

Figure 2-8-17. Single Selector Valve

2-8-46

Holding Valves
DESCRIPTION
Two different holding valves are utilized on the
crane, one in the lift cylinder and one in the
telescope cylinder. Both valves are installed in the
port block of their respective cylinder.
The holding valve is ported to allow hydraulic flow
in two directions. To raise a load, the oil must
unseat the free flow poppet valve. In this case, oil
pressure must overcome the main poppet spring.
To do this, the oil flows through the oil ports of the
pilot release poppet valve which applies pressure
to the inside face of the free flow poppet. When the
main poppet unseats, the oil flows past the main
poppet seat to the component to be worked.
When a load is to be lowered, as in retracting the
boom, better control is necessary because of the
weight of the load. For this reason a pilot
pressure
MAINTENANCE
REMOVAL.
1. To remove the holding valve, unscrew it from
the port block, refer to Figure 2-8-18.
INSTALLATION.
1. Check the inside of the port block for any
sharp edges or burrs and remove as necessary with
emery cloth.
2. Install new O-rings onto the holding valve, refer
to Figure 2-8-18.
3. Lubricate the holding valve and O-rings with
clean hydraulic oil.
TM 5-3810-307-24-1-1
is used for positioning the main poppet valve which
is being held against its seat by heavy springs. The
pilot pressure is sensed from the lowering side of
the hydraulic circuit. As the directional control valve
is opened to the lower position, pressure is applied
to the pilot piston. The pilot piston moves against
the pilot release poppet until it unseats the pilot
release poppet valve which ports oil to the return
side of the directional control valve.
The free flow check valve is provided for venting
the pressure side of the pilot piston.
A vent is provided for venting the area between the
pilot piston 0-rings should weepage occur. A
second vent is provided at the adjustment end of
the pilot release poppet valve should weepage
occur past the 0-ring seal into the spring area.
CAUTION
Do not damage the O-rings during
installation of the holding valve. If the
holding valve turns freely then gets hard
to turn, then easy to turn; remove the
holding valve and check the O-rings.
They have probably been damaged by a
sharp edge of a port.
NOTE
The holding valve should turn by hand
until compression of the O-rings begins.
4. Carefully install the holding valve into the port
block until fully seated.
2-8-47 C-1
TM 5-3810-307-24-1-1

Figure 2-8-18. Holding Valve

2-8-48
 TM 5-3810-307-24-1-1

Integrated Outrigger Valve

DESCRIPTION

The integrated outrigger valve is mounted near the
center of the carrier frame and is used for the control
of the outrigger circuit and the rear steer circuit from
the superstructure cab. The valve consists of five
subassemblies; two solenoid valves, and inlet
section, an outlet section, and two working sections.
The solenoid valves are normally closed and are
energized by 24 volts. They are used to control a
pilot pressure that positions the spool within the
working section. When the solenoid valves are de-
energized, the springs maintain the spool in a
centered position, permitting oil to flow to the
pressure beyond circuit.

MAINTENANCE

NOTE

For more detailed information, refer to the applicable SM package.

REMOVAL. 2. Connect the electrical leads and hydraulic lines

to the outrigger valve as tagged prior to removal.
1. Tag and disconnect the electrical leads to the
outrigger valve, refer to Figure 2-8-19. Tape the lead FUNCTIONAL CHECK.
ends.
1. Activate the hydraulic system.
2. Tag and disconnect the hydraulic lines to the
outrigger valve; cap all lines and openings. 2. Extend and retract one outrigger beam.

3. Remove the nuts and lockwashers securing 3. Observe the beam for adequate speed of
the selector valve; remove the valve. extension and retraction and smooth operation.

INSTALLATION. 4. Check the hydraulic connections for evidence

of leakage.
1. Place the outrigger valve in the mounting
position and secure with the attaching nuts and
lockwashers, refer to Figure 2-8-19.

2-8-49
TM 5-3810-307-24-1-1

Figure 2-8-19. Integrated Outrigger Valve

2-8-50
 TM 5-3810-307-24-1-1

Outrigger Solenoid Valve Stack

DESCRIPTION

There are two outrigger solenoid valve stacks utilized Each valve stack consists of four solenoid valve
on the crane, one to control each outrigger box assemblies, two for each outrigger beam.
assembly.

MAINTENANCE

NOTE

For more detailed information, refer to the applicable SM package.

REMOVAL. INSTALLATION.

1. Tag and disconnect the hydraulic lines to the 1. Position the valve assembly on the mounting
solenoid valve bank, refer to Figure 2-8-20. Cap all bolts; secure with the nuts and lockwashers, refer to
lines and openings. Figure 2-8-20.

2. Disconnect the electrical leads; tape the lead 2. Connect the electrical leads to the solenoid.
ends.
3. Connect the hydraulic lines as marked prior to
3. Remove the nuts and lockwashers securing removal.
the valve bank assembly to the frame; remove the
assembly. FUNCTIONAL CHECK.

INSPECTION. Activate the hydraulic system and cycle the affected

cylinder(s) several times. Observe for proper
Visually inspect the valves and hydraulic connections functioning of the affected cylinder(s). Check the
for any evidence of leaks or other damage. Check solenoid valve for leaks and hydraulic connections
security of the electrical connections. Inspect the for security.
wiring for any evidence of cracks or breaks.

2-8-51
TM 5-3810-307-24-1-1

Figure 2-8-20. Outrigger Solenoid Valve Stack

2-8-52

Pilot-Operated Check Valves
DESCRIPTION
There are three types of pilot-operated check valves
utilized on the crane, two being used in the outrigger
circuit, and one in the superstructure cab steering
circuit.
CYLINDER-MOUNTED VALVES.
A valve is located in each outrigger cylinder port
block. The check valve provides two functions; the
first function is a holding valve, the second function
provides a thermal relief of the stabilizer.
FRAME-MOUNTED VALVES.
The valve associated with the outrigger circuit is
located on the center frame rail near the swivel. The
MAINTENANCE
(Text Deleted)
CYLINDER-MOUNTED VALVE.
Removal.
1. To remove the check valve, unscrew the check
valve from the stabilizer port block, refer to Figure 2-
8-21.
Installation.
1. Check the inside of the port block for any
sharp edges or burrs and remove as necessary with
emery cloth.
2. Install new O-rings onto the check valve, refer
to Figure 2-8-21.
3. Lubricate the check valve and O-rings with
clean hydraulic oil.
TM 5-3810-307-24-1-1
purpose of the valve is to prevent reverse flow from
the piston side of the outrigger cylinders.
Incorporated within the valve cartridge is a thermal
relief valve set to open at 4,000 psi (27,580 kPa).
The valve associated with the superstructure cab
steering circuit is mounted on the center frame rail
just to the right of the outrigger check valve. The
valve prevents reverse flow from the front steering
cylinder, thus locking the cylinder when steering the
rear axle from the superstructure cab. Incorporated
in the valve are two thermal relief valves to provide
thermal protection for the front steering cylinder. The
thermal relief valves are set to open at 3800 psi
(26,201 kPa).
CAUTION
Do not damage the O-rings during
installation of the check valve. If the
check valve turns freely then gets hard to
turn, then easy to turn; remove the check
valve and check the O-rings. They have
probably been damaged by a sharp
edge of a port.
NOTE
The check valve should turn by hand
until compression of the O-rings begins.
4. Carefully install the check valve into the port
block until fully seated.
2-8-53 C-1
TM 5-3810-307-24-1-1

FRAME-MOUNTED VALVE. 3. Remove the valve and plug the ports.

Removal. Installation.

1. Remove the hoses and fittings from the valve, 1. Position the valve onto the frame and secure in
refer to Figure 2-8-21. place with two nuts and lockwashers, refer to Figure
2-8-21.
2. Remove the two nuts and lockwashers which
secure the valve to the frame. 2. Install the fittings and attach the hoses.

2-8-54
 TM 5-3810-307-24-1-1

Figure 2-8-21. Pilot-Operated Check Valves

2-8-55
TM 5-3810-307-24-1-1

CYLINDERS

GENERAL

This sub-section provides descriptive information for For information on how the cylinder functions in
all the hydraulic cylinders used on this crane. The individual circuits, refer to the Description and
description of the cylinder given here is for the Operation of that circuit.
cylinder itself.

MAINTENANCE

GENERAL. the component. The resulting value is the number of

There must be a gap between the ends of each wear
ring when it is installed onto the head. In addition,
each wear ring gap is to be located as follows.
Divide 360 degrees by the number of wear rings on
degrees each wear ring gap is to be located with
respect to each other.
The approximate wear ring gaps are as follows:

HEAD WEAR RING GAP TABLE

Head Size Wear Ring Gap

in. mm in. mm
1 to 4.75 25.4 to 120.66 0.125 3.175

5 to 10 127.0 to 254.0 0.187 4.750

greater than 10 greater than 254.0 0.250 6.350

2-8-56

Lift Cylinder
DESCRIPTION
The lift cylinder is the double-acting-type with a
cylinder bore of 7.5 in. (19.1 cm). The retracted
length of the cylinder from the center of the barrel
bushing to the center of the rod bushing is 102.6 in.
(260.6 cm). The extended length of the cylinder from
the center of the barrel bushing to the center of the
rod bushing is 184.6 in. (468.9 cm). Foreign matter
is prevented from entering the cylinder by a wiper
seal. An O-ring seal prevents oil leakage from the
MAINTENANCE
NOTE
For Removal and Installation procedures, refer to LIFT CIRCUIT in
Section 10.
DISASSEMBLY.
NOTE
Any maintenance requiring disassembly
of the cylinder should include replace-
ment of all cylinder seals and O-rings.
NOTE
It may be necessary to heat cylinder in
setscrew area to break cylinder head
loose from cylinder.
1. Remove the setscrew securing the cylinder
head and using a spanner wrench, unscrew the
cylinder head, refer to Figure 2-8-22.
WARNING
Do not use air pressure to remove the
cylinder rod assembly. Use only a
source of controlled hydraulic oil
pressure, if the rod is hard to remove.
TM 5-3810-307-24-1-1
cylinder. The backup rings protect the O-ring from
damage and prevent movement of the O-ring seal
during rod retraction and extension. The O-ring seal
between the rod side and the piston prevents internal
leakage.
The cylinder weighs approximately 685 lbs (310.7
kg) dry and 713 lbs (323.4 kg) wet.
CAUTION
Exercise extreme care when handling or
setting down the cylinder rod. Do not
damage the chrome surface.
2. Remove the cylinder rod assembly from the
cylinder barrel and cover the barrel to avoid
contamination.
CAUTION
When removing seals and rings, avoid
scratching grooved and gland surfaces.
NOTE
Aligning discarded seals and rings in the
order of disassembly will facilitate
installation of new items.
3. Remove the hydrolock piston seal to gain
access to the setscrew securing the piston to the
rod.
4. Remove the setscrew and unscrew the piston
from the cylinder rod.
2-8-57
2-8-58

TM 5-3810-307-24-1-1
Figure 2-8-22. Lift Cylinder
 TM 5-3810-307-24-1-1

5. Remove the remaining hydrolock seal and CAUTION

guide lock ring from the outside of the piston and the
O-ring and two backup rings from the inside of the
piston. Remove the rod spacer.
6. Remove the cylinder head from the rod.
7. Remove the O-ring and backup ring from the
outside of the head and the wear ring, buffer seal,
deep Z rod seal, and wiper ring from the inside of the
head.
Do not damage the O-rings during
installation of the holding valve. If the
holding valve turns freely then gets hard
to turn, then easy to turn; remove the
holding valve and check the O-rings.
They have probably been damaged by a
sharp edge of a port.
NOTE

8. If necessary, remove the holding valve from The holding valve should turn by hand
the port block. until compression of the O-rings begins.

INSPECTION. 4. Carefully install the holding valve into the port

block until fully seated.
1. Clean all parts with solvent and dry with
compressed air. Inspect all parts for serviceability. CAUTION

CAUTION When installing new seals and rings,

avoid stretching seals or scratching the
Before installing new seals and rings, grooved or gland surfaces.
clean all surfaces and carefully remove
burrs and nicks. Parts displaying NOTE
excessive wear or damage should be
replaced. Lubricate new seals and rings with clean
hydraulic oil.
2. Stone out minor blemishes and polish with a
fine crocus cloth. 5. Install the wear ring into the head

3. Clean with solvent and dry with compressed

air any parts that have been stoned and polished.

4. Inspect the barrel carefully for scoring.

ASSEMBLY.

NOTE

Steps 1, 2, 3, and 4 are used only if the

holding valve has been removed.

1. Check the inside of the port block for any

sharp edges or burrs and remove as necessary with
emery cloth.

2. Install new O-rings onto the holding valve, refer

to Figure 2-8-22.
Figure 2-8-23. Cylinder Head Seal Installation
3. Lubricate the holding valve and O-rings with
clean hydraulic oil.

2-8-59
TM 5-3810-307-24-1-1
6. Install the buffer seal, deep Z seal, and wiper
ring inside the head ensuring the seals are
assembled properly and installed in the correct
direction, refer to Figure 2-8-23.
7. Install the O-ring and backup ring onto the
outside of the head.
8. Install the cylinder head onto the rod.
9. Install the rod spacer. Install the O-ring and
backup rings inside the piston and install the piston
onto the rod. Secure the piston in place with the
setscrew.
Figure 2-8-24. Piston Seal Installation
10. Install the hydrolock seals and guide lock ring
onto the piston, refer to Figure 2-8-24 for proper seal
orientation.
2-8-60
CAUTION
Avoid scratching or damaging the
grooved or gland surfaces or the rings
and seals.
11. Lubricate the cylinder rod assembly with clean
hydraulic oil and install the rod assembly into the
cylinder with a slight twisting motion.
12. Clean all oil from the threads of the head and
coat the threads with NEVER-SEEZ (paste-type)
lubricant.
13. Using a spanner wrench, tighten the head
securely.
14. Install the setscrew to secure the cylinder
head.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.
15. Pressurize and cycle the cylinder. Check for
proper operation and any leakage.
 TM 5-3810-307-24-1-1

Steer Cylinder

DESCRIPTION

The 2.76 in. (7.01 cm) bore steer cylinder is the prevent internal and external leakage. A wiper ring is
double-acting-type and has a usable stroke of 7.48 mounted to the front of the cylinder to wipe dirt from
in. (19.00 cm). O-rings are used within the cylinder the rod as it is being retracted.
to

MAINTENANCE

NOTE

For Removal and Installation procedures, refer to STEER CYLINDERS in

Section 5.

DISASSEMBLY. 3. Pull the cylinder rod with piston from the

cylinder barrel and cover the barrel to avoid
NOTE contamination.

Any maintenance requiring disassembly 4. Remove the seal and wear ring from the
of the cylinder should include outside of the piston on the cylinder rod.
replacement of all cylinder seals and O-
rings. 5. Remove the caps and o-rings from the cylinder
barrel.
1. Unscrew the cylinder head from the cylinder
barrel, refer to Figure 2-8-25. CLEANING AND INSPECTION.

CAUTION 1. Clean all parts in a suitable solvent and blow

When removing seals and rings, avoid
scratching grooved and gland surfaces.
2. Remove the low temperature o-ring and
backup ring from the outside of the cylinder head
and the wiper ring, deep Z rod seal, and wear ring
from the inside of the cylinder head.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure if the cylinder rod is hard to
remove.
CAUTION
Exercise extreme care when handling or
setting down the cylinder rod. Do not
damage the chrome surface.
dry.
2. Check the piston rod for any damage to
include bends, scoring, rust spots, damaged threads,
or any other damage.
3. Check the piston and guide for scoring or other
damage.
ASSEMBLY.
CAUTION
When installing new seals and rings,
avoid stretching seals or scratching the
grooved or gland surfaces.
NOTE
Before installation, lubricate all parts and
surfaces freely with clean hydraulic oil.

2-8-61 C-1
TM 5-3810-307-24-1-1
1. Install the caps and o-rings on the cylinder
barrel, refer to Figure 2-8-25.
2. Install the seal and wear ring onto the outside
of the piston on the cylinder rod.
3. Install the wear ring, deep Z rod seal, and
wiper ring onto the inside of the cylinder head and
the backup ring and low temperature o-ring onto the
outside of the cylinder head.
4. Lubricate all components freely with clean
hydraulic oil.
2-8-62 C-1
5. Install the cylinder rod with piston into the
cylinder barrel with a slight twisting motion.
6. Install the cylinder head onto the cylinder
barrel.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.
7. Pressurize and cycle the cylinder.
Check for proper operation and any
leakage.
 TM 5-3810-307-24-1-1

1. Cylinder Barrel
2. O-ring
3. Cap
4. Seal
5. Wear Ring
6. Cylinder Rod and Piston
7. Wiper Ring
8. Deep Z Rod Seal
9. Backup Ring
10. Cylinder Head
11. Wear Ring
12. Low Temperature O-ring

Figure 2-8-25. Steer Cylinder

2-8-63 C-1
TM 5-3810-307-24-1-1

Telescope Cylinder

DESCRIPTION

The boom telescope cylinder has a 5.5 in. (13.9 cm)
bore. The cylinder is internally ported (rod ported).
Oil from the telescope control valve is routed to the
cylinder by external lines. Foreign material is
prevented from entering the cylinder during rod
retraction by a wiper seal in the head. O-ring seals
prevent internal and external leakage.
The retracted length of the telescope cylinder from
the end of the barrel to the center of the attachment
fittings is 24 ft (7.3 m). The cylinder has a stroke of
21.6 ft (6.5 m) which gives the cylinder an overall
extended length of 45.6 ft (13.9 m) from the end of
the cylinder barrel to the center of the attachment
fittings on the cylinder rod.
The cylinder weights approximately 1,305 lbs (591.9
kg) dry and 1,380 lbs (625.9 kg) wet.

MAINTENANCE

NOTE

For Removal and Installation procedures, refer to BOOM MAINTENANCE

in Section 10.

DISASSEMBLY. CAUTION

NOTE When removing seals and rings, avoid

Any maintenance requiring disassembly
of the cylinder should include
replacement of all cylinder seals and O-
rings.
1. Using a spanner wrench, unscrew the cylinder
head, refer to Figure 2-8-26.
WARNING
Do not use air pressure to remove the
cylinder rod assembly. Use only a
source of controlled hydraulic oil
pressure, if the rod is hard to remove.
CAUTION
Exercise extreme care when handling or
setting down the cylinder rod. Do not
damage the chrome surface.
2. Remove the cylinder rod assembly from the
cylinder barrel and cover the barrel to avoid
contamination.
scratching grooved and gland surfaces.
NOTE
Aligning discarded seals and rings in the
order of disassembly will facilitate
installation of new items.
3. Remove the hydrolock piston seal to gain
access to the setscrew securing the piston to the
rod.
4. Remove the setscrew and unscrew the piston
from the cylinder rod.
5. Remove the remaining hydrolock seal and
guide lock ring from the outside of the piston and the
O-ring and two backup rings from the inside of the
piston.
6. Remove the spacer from the rod and remove
the wear ring from the spacer.
7. Remove the cylinder head from the rod.

2-8-64
 TM 5-3810-307-24-1-1

8. Remove the O-ring and backup ring from the CAUTION

outside of the head and the wear rings, buffer seal,
deep Z rod seal, and wiper ring from the inside of the Do not damage the O-rings during
head. installation of the holding valve. If the
holding valve turns freely then gets hard
9. If necessary, remove the holding valve from to turn, then easy to turn; remove the
the port block. holding valve and check the O-rings.
They have probably been damaged by a
INSPECTION. sharp edge of a port.

1. Clean all parts with solvent and dry with NOTE

compressed air. Inspect all parts for serviceability.
The holding valve should turn by hand
CAUTION until compression of the O-rings begins.

Before installing new seals and rings, 4. Carefully install the holding valve into the port
clean all surfaces and carefully remove block until fully seated.
burrs and nicks. Parts displaying
excessive wear or damage should be CAUTION
replaced.
When installing new seals and rings,
2. Stone out minor blemishes and polish with a avoid stretching seals or scratching the
fine crocus cloth. grooved or gland surfaces.

3. Clean with solvent and dry with compressed NOTE

air any parts that have been stoned and polished.
Lubricate new seals and rings with clean
4. Inspect the barrel carefully for scoring. hydraulic oil.

ASSEMBLY. NOTE

NOTE Locate the gap of each wear ring 180

degrees with respect to each other.
Steps 1, 2, 3, and 4 are used only if the
holding valve has been removed. 5. Install the wear rings into the head.

1. Check the inside of the port block for any CAUTION

sharp edges or burrs and remove as necessary with
emery cloth. Improper installation of seals could
cause faulty cylinder operation.
2. Install new O-rings onto the holding valve, refer
to Figure 2-8-26. 6. Install the buffer seal, deep Z seal, and wiper
ring inside the head ensuring the seals are
3. Lubricate the holding valve and O-rings with assembled properly and installed in the correct
clean hydraulic oil. direction, refer to Figure 2-8-27.

2-8-65
2-8-66

TM 5-3810-307-24-1-1
Figure 2-8-26. Telescope Cylinder
 TM 5-3810-307-24-1-1

10. Install the O-ring and backup rings inside the

piston and install the piston onto the rod. Secure the
piston in place with the setscrew.

11. Install the hydrolock seals onto the piston, refer

to Figure 2-8-28 for proper seal orientation.

CAUTION

Avoid scratching or damaging the

grooved or gland surfaces or the rings
and seals.

12. Lubricate the cylinder rod assembly with clean

Figure 2-8-27. Cylinder Head Seal Installation
hydraulic oil and install the rod assembly into the
cylinder with a slight twisting motion.
7. Install the O-ring and backup ring onto the
outside of the head.
13. Clean all oil from the threads of the head and
coat the threads with NEVER-SEEZ (paste-type)
8. Install the cylinder head onto the rod.
lubricant.
9. Install the wear ring onto the spacer and the
14. Using a spanner wrench, tighten the head
spacer onto the rod.
securely.

15. Install the setscrew to secure the cylinder

head.

WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.

16. Pressurize and cycle the cylinder. Check for

proper operation and any leakage.

Figure 2-8-28. Piston Seal Installation

2-8-67
TM 5-3810-307-24-1-1
Oscillation Lockout Cylinder
DESCRIPTION
The oscillation lockout cylinders have 3.5 in. (8.9 cm)
diameter bores and are the double-acting-type. The
cylinders are mounted to the frame and the axles.
O-rings are used within the cylinders to prevent
internal and external leakage. A wiper ring is
mounted to the front of the cylinder barrels to wipe
dirt from the rod as it is retracted.
MAINTENANCE
NOTE
For Removal and Installation
CYLINDERS in Section 6.
DISASSEMBLY.
NOTE
Any maintenance requiring disassembly
of the cylinder should include
replacement of all cylinder seals and O-
rings.
1. Remove the setscrew securing the cylinder
head retaining ring and using a spanner wrench,
unscrew the retaining ring from the barrel, refer to
Figure 2-8-29.
WARNING
Do not use air pressure to remove the
cylinder rod assembly. Use only a
source of controlled hydraulic oil
pressure, if the rod is hard to remove.
CAUTION
Exercise extreme care when handling or
setting down the cylinder rod. Do not
damage the chrome surface.
2. Remove the cylinder rod assembly from the
2-8-68
The retracted length is 19.5 in. (49.5 cm) measured
from the center of the rod bushing to the center of
the barrel bushing. The extended length from the
center of the rod bushing to the center of the cylinder
bushing is 25.7 in. (65.4 cm).
Each cylinder weighs approximately 46 lbs (20.8 kg)
dry and 47.5 lbs (21.5 kg) wet.
procedures, refer to LOCKOUT
cylinder barrel and cover the barrel to avoid
contamination.
CAUTION
When removing seals and rings, avoid
scratching grooved and gland surfaces.
NOTE
Aligning discarded seals and rings in the
order of disassembly will facilitate
installation of new items.
3. Remove the hydrolock piston seal to gain
access to the setscrew securing the piston to the
rod.
4. Remove the setscrew and unscrew the piston
from the cylinder rod.
5. Remove the remaining hydrolock seal and
guide lock ring from the outside of the piston and the
O-ring and two backup rings from the inside of the
piston.
6. Remove the cylinder head from the rod
7. Remove the O-ring and backup ring from the
outside of the head and the wear ring, buffer seal,
deep Z rod seal, and wiper ring from the inside of the
head.
 TM 5-3810-307-24-1-1
2-8-69

Figure 2-8-29 Oscillation Lockout Cylinder

TM 5-3810-307-24-1-1

INSPECTION.

1. Clean all parts with solvent and dry with

compressed air. Inspect all parts for serviceability.

CAUTION

Before installing new seals and rings,

clean all surfaces and carefully remove
burrs and nicks. Parts displaying
excessive wear or damage should be
replaced.

2. Stone out minor blemishes and polish with a
fine crocus cloth.
3. Clean with solvent and dry with compressed
air any parts that have been stoned and polished.
4. Inspect the barrel carefully for scoring.
Figure 2-8-30. Cylinder Head Seal Installation
5. Install the cylinder head onto the rod.
6. Install the O-ring and backup rings inside the
piston and install the piston onto the rod. Secure
the piston in place with the setscrew.

ASSEMBLY. 7. Install the hydrolock seals and guide lock ring

onto the piston, refer to Figure 2-8-31 for proper
CAUTION seal orientation.

When installing new seals and rings, CAUTION

avoid stretching seals or scratching the
grooved or gland surfaces. Avoid scratching or damaging the
grooved or gland surfaces or the rings
NOTE and seals.

Lubricate new seals and rings with 8. Lubricate the cylinder rod assembly with
clean hydraulic oil. clean hydraulic oil and install the rod assembly into
the cylinder with a slight twisting motion.
1. Install the wiper ring into the head retaining
ring and install the retaining ring onto the rod, refer
to Figure 2-8-29.

2. Install the wear ring into the head.

CAUTION

Improper installation of seals could

cause faulty cylinder operation.

3. Install the buffer seal and deep Z seal inside

the head ensuring the seals are assembled properly
and installed in the correct direction. Refer to
Figure 2-8-30.

4. Install the O-ring and backup ring onto the

outside of the head.
Figure 2-8-31. Piston Seal Installation

2-8-70

9. Clean all oil from the threads of the retaining
ring and coat the threads with NEVER-SEEZ
(paste-type) lubricant.
10. Using a spanner wrench, tighten the retaining
ring securely.
11. Install the setscrew to secure the retaining
ring.
TM 5-3810-307-24-1-1
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic pressure.
12. Pressurize and cycle cylinder. Check for
proper operation and any leakage.
2-8-71
TM 5-3810-307-24-1-1

Outrigger Extension Cylinder

DESCRIPTION

The four extension cylinders have 1.5 in. (6.35 cm)
diameter bores. The cylinders are the double-acting-
type and are mounted to the outrigger beams. O-
rings are used within the cylinders to prevent internal
and external leakage. A wiper ring is mounted to the
front of the extension cylinder barrel to wipe dirt from
the rod as it is retracted. Each cylinder has a
retracted length of 84 in. (213.4 cm) from the center
of the rod bushing to the center of the cylinder
bushing. The extended length is 149.6 in. (379.9
cm).

MAINTENANCE

NOTE

For Removal and Installation procedures, refer to EXTENSION

CYLINDER in Section 12.

DISASSEMBLY. 2. Withdraw the cylinder rod assembly from the

cylinder barrel.
NOTE
NOTE
Any maintenance requiring disassembly
of cylinders should be accompanied by Cover the cylinder barrel opening to
replacement of all cylinder seals. preclude contamination from dust and
dirt.
1. Unscrew the collar from the cylinder barrel,
refer to Figure 2-8-32. 3. Secure the cylinder rod from moving at the rod
end; remove the piston locknut from the rod.
WARNING
Do not use air pressure to cycle or 4. Remove the piston from the rod.
pressurize the cylinder. Use only a
source of controlled hydraulic oil CAUTION
pressure if the rod assembly is hard to
remove. When removing seals and rings, avoid
scratching the grooved and gland
CAUTION surfaces.

Exercise extreme care when handling or 5. Remove the two piston seals from the piston
setting down the cylinder rod. Damage and the O-ring from the rod.
to the rod surface may cause
unnecessary maintenance and expense. 6. Remove the spacer.

7. Remove the head from the rod and remove the

gland seal from the out side of the head and the rod
seal and wiper seal from the inside of the head.

2-8-72
 TM 5-3810-307-24-1-1
2-8-73

Figure 2-8-32. Outrigger Extension Cylinder

TM 5-3810-307-24-1-1
INSPECTION.
1. Clean all parts with solvent and dry with
compressed air. Inspect all parts for serviceability.
CAUTION
Before installing new seals and rings,
clean all surfaces and carefully remove
burrs and nicks. Parts displaying
excessive wear or damage should be
replaced.
2. Stone out minor blemishes and polish with a
fine crocus cloth.
3. Clean with solvent and dry with compressed
air any parts that have been stoned and polished.
4. Inspect the barrel carefully for scoring.
ASSEMBLY.
CAUTION
When installing new seals and rings,
avoid scratching the grooved and gland
surfaces. Scratches cause seal wear
resulting in leakage.
NOTE
Before installation, lubricate all parts and
surfaces freely with clean hydraulic oil.
1. Install the wiper seal and rod seal into the head
and the gland seal onto the head. Install the head
onto the rod, refer to Figure 2-8-32.
2-8-74
2. Install the spacer onto the rod.
3. Install the O-ring onto the rod and the piston
seals onto the piston.
4. Install the piston onto the rod.
5. Install the piston locknut. Torque the locknut
99 to 121 lbs-ft (134.2 to 164.0 Nm).
CAUTION
Avoid scratching or damaging the
grooved or gland surfaces of the rings
and seals.
CAUTION
Exercise extreme care when handling or
setting down the cylinder rod. Damage
to the rod surface may cause
unnecessary maintenance and expense.
6. Install the cylinder rod assembly into the
cylinder barrel with a twisting motion.
7. Secure the collar to the cylinder barrel.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.
8. Pressurize and cycle the cylinder. Check for
proper operation and any leakage.
 TM 5-3810-307-24-1-1

Outrigger Stabilizer Cylinder

DESCRIPTION

The stabilizer cylinders have a 3.5 in. (8.9 cm)
diameter cylinder bore and are the double-acting-
type. The cylinders are pinned into tubes welded
onto the end of the outrigger beams. A port block is
welded to the end of the cylinder rod and a pilot-
operated check valve is threaded into the port block.
O-rings are used within the cylinder to prevent
internal and external leakage. A wiper ring is
mounted on the front of the stabilizer cylinder barrel
to wipe the rod as it is retracted into the barrel. The
cylinder is approximately 42.5 in. (107.9 cm) long
retracted and 63 in. (160 cm) long fully extended.
The cylinder weighs approximately 109 lbs (49.4 kg)
dry and 114 lbs (51.7 kg) wet.

MAINTENANCE

NOTE

For Removal and Installation procedures, refer to STABILIZER

CYLINDER in Section 12.

DISASSEMBLY.
NOTE
Any maintenance requiring disassembly
of the cylinder should include
replacement of all cylinder seals and O-
rings.
1. Remove the setscrew securing the cylinder
head and using a spanner wrench, unscrew the
cylinder head, refer to Figure 2-8-33.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure, if the rod is hard to remove.
CAUTION
Exercise extreme care when handling or
setting down the cylinder rod. Do not
damage the chrome surface.
CAUTION
When removing seals and rings, avoid
scratching grooved and gland surfaces.
NOTE
Aligning discarded seals and rings in the
order of disassembly will facilitate
installation of new items.
3. Remove the hydrolock piston seal to gain
access to the setscrew securing the piston tot he
rod.
4. Remove the setscrew and unscrew the piston
from the cylinder rod.
5. Remove the remaining hydrolock seal and
guide lock ring from the outside of the piston and the
O-ring and two backup rings from the inside of the
piston.
6. Remove the spacer from the rod.

2. Remove the cylinder rod assembly from the 7. Remove the cylinder head from the rod.
cylinder barrel and cover the barrel to avoid
contamination.

2-8-75
TM 5-3810-307-24-1-1

Figure 2-8-33. Outrigger Stabilizer Cylinder

2-8-76
 TM 5-3810-307-24-1-1

8. Remove the wear ring, O-ring, and backup ring CAUTION

from the outside of the head and the wear rings,
buffer seal, deep Z rod seal, and wiper ring from the Do not damage the O-rings during
inside of the head. installation of the check valve. If the
check valve turns freely then gets hard to
9. If necessary, remove the pilot-operated check turn, then easy to turn; remove the check
valve from the port block. valve and check the O-rings. They have
probably been damaged by a sharp
INSPECTION. edge of a port.

1. Clean all parts with solvent and dry with NOTE

compressed air. Inspect all parts for serviceability.
The check valve should turn by hand
CAUTION until compression of the O-rings begins.

Before installing new seals and rings, 4. Carefully install the check valve into the port
clean all surfaces and carefully remove block until fully seated.
burrs and nicks. Parts displaying
excessive wear or damage should be CAUTION
replaced.
When installing new seals and rings,
2. Stone out minor blemishes and polish with a avoid stretching the seals or scratching
fine crocus cloth. the grooved and gland surfaces.

3. Clean with solvent and dry with compressed NOTE

air any parts that have been stoned and polished.
Lubricate new seals and rings with clean
4. Inspect the barrel carefully for scoring. hydraulic oil.

ASSEMBLY. NOTE

NOTE Locate the gap of each wear ring 180

degrees with respect to each other.
Steps 1, 2, 3, and 4 are used only if the
check valve has been removed. 5. Install the wear rings into the head.

1. Check the inside of the port block for any

sharp edges or burrs and remove as necessary with
emery cloth.

2. Install new O-rings onto the check valve, refer

to Figure 2-8-33.

3. Lubricate the check valve and O-rings with

clean hydraulic oil.

Figure 2-8-34. Cylinder Head Seal Installation

2-8-77
TM 5-3810-307-24-1-1
CAUTION
Improper installation of seals could
cause faulty cylinder operation.
6. Install the buffer seal, deep Z seal, and wiper
ring inside the head ensuring the seals are
assembled properly and installed in the correct
direction, refer to Figure 2-8-34.
7. Install the wear ring, O-ring, and backup ring
onto the outside of the head.
8. Install the cylinder head onto the rod.
9. Install the spacer onto the rod.
10. Install the O-ring and backup rings inside the
piston and install the piston onto the rod. Secure the
piston in place with the setscrew.
Figure 2-8-35. Piston Seal Installation
2-8-78
11. Install the hydrolock seals and guide lock ring
onto the piston, refer to Figure 2-8-35 for proper seal
orientation.
CAUTION
Avoid scratching or damaging the
grooved or gland surfaces or the rings
and seals.
12. Lubricate the cylinder rod assembly with clean
hydraulic oil and install the rod assembly into the
cylinder with a slight twisting motion.
13. Clean all oil from the threads of the head and
coat the threads with NEVER-SEEZ (paste-type)
lubricant.
14. Using a spanner wrench, tighten the head
securely.
15. Install the setscrew to secure the cylinder
head.
WARNING
Do not use air pressure to cycle or
pressurize the cylinder. Use only a
source of controlled hydraulic oil
pressure.
16. Pressurize and cycle the cylinder. Check for
proper operation and any leakage.
 TM 5-3810-307-24-1-1

SECTION 9
SWING SYSTEM
TABLE OF CONTENTS
Page

SWING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
SWING GEARBOX AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
SWING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Torquing Turntable Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Inner Race Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Outer Race Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-18

2-9-1
TM 5-3810-307-24-1-1

LIST OF FIGURES
Number Title Page

2-9-1 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-7

2-9-2 Swing Gearbox and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-10
2-9-3 Inner and Outer Race Bolt Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-12
2-9-4 Special Turntable Bolt Torquing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-14
2-9-5 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-16
2-9-6 Backlash Adjusting Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17

2-9-2
 TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-9-6

Minor concentrations of acetic acid vapor may be produced during

application. Adequate ventilation should be provided when silicone RTV
is applied in confined areas.

WARNING 2-9-6
Eye contact with these silicone RTV materials may cause irritation. If eye
contact takes place, flush the eyes with water for 15 minutes and have the
eyes examined by a doctor.

WARNING 2-9-11

Failure to maintain proper torque of the turntable bearing attaching bolts

will result in damage to the crane and possible injury to personnel.

2-9-11
WARNING
It is mandatory that bearing attaching bolts be inspected for lack of torque
and retorqued, as required, after the first 300 hours of machine operation.
The bolts may loosen in service due to vibration, shock-loads, and
temperature changes, therefore, periodic inspection should be
accomplished every 500 hours thereafter, ensuring the bolts are properly
torqued.

2-9-3
TM 5-3810-307-24-1-1

WARNING SUMMARY (continued)

Page

WARNING 2-9-15

Ensure the lifting device is capable of fully supporting the weight of the
superstructure. Ensure the superstructure will not tilt or slide during lifting
and moving. Failure to do so may result in death of injury to personnel
and damage to equipment.

WARNING 2-9-15

Ensure the superstructure is fully supported before proceeding.

2-9-15
WARNING
Ensure that any blocking material used is capable of fully supporting the
weight of the superstructure and will not allow it to tilt or shift. Failure to
do so may result in death of injury to personnel.

2-9-17
WARNING
Anytime a grade 8 turntable bolt has been removed, it must be replaced
with a new grade 8 bolt and nut.

2-9-4
 TM 5-3810-307-24-1-1

SWING SYSTEM

DESCRIPTION

The superstructure has full 360 degrees rotation in
both directions and is equipped with free swing. A
positive swing lock and a pin-type swing lock are
both provided to lock the superstructure in position.
The positive swing lock consists of teeth that mesh
with the swing gear teeth at any point along the 360
degrees of rotation. The pin-type swing lock consists
of a round pin and a retainer weldment which locks
the turntable with the boom straight over the front or
rear. Both turntable locks are engaged and
disengaged from the cab. A brake pedal and swing
brake control are used to stop rotation.
The swing system consists of the hydraulic remote
control valve, control valve, pressure reducing valve,
brake pedal and power brake valve, two position
selector valve, swing drive, and the swing brake
assembly.

THEORY OF OPERATION

The system is supplied by the 16 gpm (60.5 lpm)
pump section. The oil flows from the pump to the
outrigger control valve. Bypass flow from the
outrigger control valve. Bypass flow from the
outrigger control valve supplies the swing circuit.
The bypass oil flows through swivel port 11 to the
pressure reducing valve. The pressure reducing
valve provides a constant flow to the control valve
bank containing the swing control valve. The
pressure reducing valve also provides a constant
5 gpm (18.9 lpm) flow at 250 psi (1723.7 kPa) to the
swing brake control and the swing brake valve for
application or release of the swing brake. Pilot
pressure signals from the hydraulic remote control
valve in the cab shift the spool in the control valve. If
the swing brake control is in the disengage position,
the superstructure will rotate in the direction selected
by the hydraulic remote control. Shifting the control
lever to neutral and depressing the brake pedal will
stop swing.

2-9-5
TM 5-3810-307-24-1-1
SWING MOTOR
DESCRIPTION
The swing motor is mounted on top of the swing
brake which is located on the top of the swing
MAINTENANCE
(Text Deleted)
REMOVAL.
1. Ensure the swing brake is engaged.
2. Clean the port area around the motor. Tag
and disconnect the hydraulic hoses from the motor
assembly (Figure 2-9-1). Cap or plug all openings.
CAUTION
Pull straight up on the motor assembly to
avoid damaging the splined shaft.
3. Remove the bolt and washers securing the
motor and lift the swing motor free.
INSTALLATION.
WARNING
Minor concentrations of acetic acid vapor
may be produced during application.
Adequate ventilation should be provided
when silicone RTV is applied in confined
areas.
WARNING
Eye contact with these silicone RTV
materials may cause irritation, if eye
contact takes place, flush the eyes with
water for 15 minutes and have the eyes
examined by a doctor.
2-9-6 C-1
gearbox in the center of the turntable. After the
brake releases, the motor drives the gearbox through
the brake.
1. Apply a thin film of silicone RTV sealant
between the motor and swing gearbox (Figure 2-9-1)
as follows:
a. Remove dirt, grease, or moisture from
the surface of the carrier and housing.
b. Dry the surface.
c. Apply a thin bead, maximum 0.125 in.
(3.175 mm) diameter, completely around one
mating surface and all fasteners holes to
ensure complete seal and prevent leaks.
d. Assemble the components immediately
to permit silicone RTV gasket material to
spread evenly.
CAUTION
Use care when engaging the swing
motor drive gear with the brake. Do not
force the shaft to engage.
2. Install the swing motor on the swing brake with
the capscrews and washers. Torque the bolts to 121
lbs-ft (164.0 Nm).
3. Connect the hydraulic hoses to the swing
motor.
TEST.
1. Test swing of superstructure in each direction.
Stop and start swing several times.
2. Inspect for hydraulic leaks and repair as
necessary.
 TM 5-3810-307-24-1-1

Figure 2-9-1. Swing Motor

2-9-7
TM 5-3810-307-24-1-1

SWING GEARBOX AND BRAKE

DESCRIPTION

The swing gearbox and brake, used in conjunction SWING GEARBOX.

with the swing motor, provides the rotating force to
move the swing bearing for superstructure rotation
and the means of stopping the bearing to prevent
swing.
SWING BRAKE.
The multi-disc swing brake assembly is mounted
between the swing motor and the swing gearbox.
The brake mechanism is a disc pack that is
hydraulically released and spring applied. The brake
has one hydraulic port.
The swing gearbox is bolted to the superstructure
base plate, and its pinion gear meshes with the ring
gear of the turntable bearing to rotate the turntable.
The swing brake is installed on top of the gearbox
and the swing motor is mounted on the brake. The
swing motor drives the gearbox through the brake
assembly. The swing gearbox utilizes double
reduction planetary gearing which results in a
component circular unit of high strength and
efficiency. The round gear case with horizontal
rotating gears ensures lubricant circulation.

MAINTENANCE

NOTE

For more detailed information, refer to the applicable SM package.

NOTE

The swing brake can be removed and disassembled independently of the

swing gearbox.

SWING BRAKE. 6. Carefully remove the brake assembly.

Removal. 7. Cover the brake port and the opening to

ensure that no dirt, dust, etc., gets into the gearbox.
1. Ensure that the turntable lock pin is installed.
Scribe a line along the sides of the motor, brake, and 8. Remove and discard the O-ring between the
gearbox to aid in correct alignment at assembly. brake and the gearbox.

2. Disconnect and tag all hydraulic lines to the Installation.

motor and the brake. Cap or plug all openings.
1. Lightly coat the mounting face of the brake and
3. Remove the motor. Refer to SWING MOTOR the shaft splines with NEVER-SEEZ (paste-type)
- REMOVAL in this section. lubricant.

4. Remove the bolts and washers securing the 2. Place a new, lubricated O-ring on the top of the
brake to the gear housing cover. Remove the brake. gear reducer.

5. Remove and discard the O-ring between the 3. Insert the brake shaft into the gear reducer.
motor and the brake.

2-9-8

4. Apply a light coat of NEVER-SEEZ (paste-
type) lubricant on the flange of the motor.
5. Place a new lubricated O-ring on the top of the
brake.
6. Fill the brake assembly. Refer to Chapter
One, Section 4 - LUBRICATION.
7. Insert the shaft of the motor into the brake and
push it into position.
NOTE
Both shafts must slide together freely.
Do not use bolts to force the units
together.
8. Insert the mounting bolts through the motor
flange, the brake, and the threaded hole in the gear
reducer mounting flange. Ensure the bolts are not
so long that they bottom out in the reducer before
clamping.
9. To prevent binding alternately tighten the bolts
until snug. Torque the bolts to 35 lbs-ft (47.4 Nm).
10. Connect the hydraulic lines to the brake
housing and motor.
SWING GEARBOX.
Removal.
1. Ensure the turntable lock pin is installed.
2. Disconnect and tag the hydraulic lines from the
swing motor and swing brake.
NOTE
The swing motor and swing brake may
or may not be removed at this time. If
not removing at this time, proceed to
step 6.
TM 5-3810-307-24-1-1
NOTE
The three sections that make up the
swing gearbox assembly are held
together by flanges and bolts. Prior to
separation, fine scribe lines should be
made at each joint to serve as an
alignment guide on assembly. Proceed
with removal of bolts. If sections resist
separation, tap on sides with fiber or
rubber mallet. DO NOT use a pry bar to
force separation.
3. Refer to SWING MOTOR - REMOVAL in this
section and remove the swing motor.
4. Refer to SWING BRAKE - Removal in this
section and remove the swing brake.
5. Remove the nine bolts securing the swing
gearbox assembly to the mounting plate on the
superstructure base plate.
6. Use a suitable lifting device and remove the
swing gearbox from the superstructure.
Installation.
1. Refer to SWING BRAKE - Installation in this
section and install the swing brake.
2. Refer to SWING MOTOR - INSTALLATION in
this section and install the swing motor.
3. Using an adequate lifting device, lift and
position the assembly onto the superstructure.
4. Apply medium strength thread locking
adhesive to threads of bolts and install the nine
grade 5 bolts securing the swing gearbox to the
mounting plate on the superstructure base plate.
Torque the bolts to 110 lbs-ft (149.1 Nm).
5. Connect the hydraulic lines to the swing motor
and brake as tagged during removal.
2-9-9
TM 5-3810-307-24-1-1

Figure 2-9-2. Swing Gearbox and Brake

2-9-10

SWING BEARING
DESCRIPTION
The swing bearing is an anti-friction roller bearing
that mates the superstructure to the carrier. The
bearing inner race is bolted to the superstructure and
the outer race is bolted to the carrier. The inner
MAINTENANCE
GENERAL.
The swing bearing is the most critical maintenance
point of the crane. It is here, at the centerline of
rotation, that stresses of loads are concentrated. In
addition, the bearing provides the only attachment
between the superstructure and carrier. Therefore,
proper care of the bearing and periodic maintenance
of the turntable-to-bearing attach bolts - IS A MUST -
to ensure safe and efficient operation.
TORQUING TURNTABLE BOLTS
General
WARNING
Failure to maintain proper torque of the
turntable bearing attaching bolts will
result in damage to the crane and
possible injury to personnel.
Maintaining proper torque value for bolts is extremely
important for structural strength, performance, and
reliability of the crane. Variations in torque can
cause distortion, binding, or complete separation of
the superstructure from the carrier.
CAUTION
Repeated retorquing may cause bolts to
stretch. If bolts keep working loose, they
must be replaced with new bolts of the
proper grade and size.
TM 5-3810-307-24-1-1
race contains two grease fittings for lubrication of the
bearing. The outer race incorporates 156 gear teeth
that mesh with the pinion gear of the swing gearbox
to provide rotation.
Proper identification of bolt grades is important.
When marked as a high strength bolt (grade 8), the
serviceman must be aware of bolt classifications and
that he is installing a high strength heat-treated
tempered component and the bolt must be installed
according to specifications. Special attention should
be given to the existence of lubricant and plating that
will cause variation from dry torque values. When a
high strength bolt is removed, or untorqued, the bolt
must be replaced with a new bolt of the same
classification.
WARNING
It is mandatory that bearing attaching
bolts be inspected for lack of torque, and
retorqued, as required, after the first 300
hours of crane operation. The bolts may
loosen in service due to vibration, shock-
loads, and temperature changes, there-
fore, periodic inspection should be
accomplished every 500 hours
thereafter, ensuring the bolts are
properly torqued.
KNOW YOUR TORQUE WRENCH! Flexible beam-
type wrenches, even though they might have a pre-
set feature, must be pulled at right angles and the
force must be applied at the center of the handle.
Force value readings must be made while the tool is
in motion. Rigid handle-type, with torque limiting
devices that can be pre-set to required values,
eliminate dial readings and provide more reliable,
less variable readings.
2-9-11
TM 5-3810-307-24-1-1

Figure 2-9-3. Inner and Outer Race Bolt Patterns

2-9-12
 TM 5-3810-307-24-1-1

NOTE Torque Values.

If multipliers and/or special tools are Torque all turntable bolts to 370 lbs-ft (501.6 Nm).
used to reach hard to get at areas,
ensure torque readings are accurate. Tools Required.

Torque wrenches are precision instruments and Figure 2-9-4 illustrates and lists the complete set of
must be handled with care. To ensure accuracy, special tools required to torque the turntable bolts.
calibrations must be made on a scheduled basis.
Whenever there is a possibility that a torque wrench Inner Race Torquing.
may have been either over-stressed or damaged, it
should immediately be removed from service until 1. Fully extend and set the outriggers.
recalibrated. When using a torque wrench, any
erratic or jerking motion can result in the application 2. Torque bolts 1, 20, 11, 30, 6, 25, 35, and 16, in
of excessive or improper torque. ALWAYS use a that order, to 296 lbs-ft (401.3 Nm), refer to Figure 2-
slow, even movement and STOP when the 9-3.
predetermined value has been reached.
3. Return to bolt 1 and torque each bolt
It is reported by the crane operator or suspected that sequentially in a clockwise direction to 370 lbs-ft
the crane has been overloaded beyond the (501.6 Nm).
capacities specified above the bold line on the
cranes' capacity chart, then all turntable bolts must Outer Race Torquing.
be inspected for looseness and retorqued to
specifications. 1. Fully extend and set the outriggers.

Turntable bolts should be torqued diametrically 2. Torque bolts 1, 19, 10, 28, 5, 23, 14, and 32, in
opposed, working in sequence from one side of the that order, to 296 lbs-ft (401.3 Nm), refer to Figure 2-
circle to the opposite side, rather than tightening 9-3.
adjacent bolts successively. Torque first to 50%,
then to the final torque value. 3. Return to bolt 1 and torque each bolt
sequentially in a clockwise direction to 370 lbs-ft
When using step wrenches, calculated wrench (501.6 Nm).
settings are valid only when the following conditions
are met. REMOVAL.

1. Torque wrenches must be those specified and 1. Fully extend and set the outrigger enough to
forces must be applied at the handle grip. The use take up the slack in the pads.
of handle extensions will change applied torque to
the bolt. NOTE

2. All handles must be parallel to the step wrench Do not raise the crane on the outriggers.
during final tightening. Multiplier reaction bars may
be misaligned no more than 30 degrees without 2. Ensure the boom is in the travel position and
causing serious error in torque. the swing lock is engaged.

3. Multiplier bar handles must be propped or 3. Elevate the boom slightly and shut down the
supported within the outer of the handle length, or engine.
serious under- or over-tightening will occur.
4. Remove the boom following the procedures
The inner race of the bearing is secured to the outlined in Section 10, BOOM.
turntable by 39 in. Grade 8 bolts. The outer race
of the bearing is secured to the carrier frame by 36 5. Tag and disconnect the battery cable from the
in. Grade 8 bolts. battery.

2-9-13
TM 5-3810-307-24-1-1

Quantity
Item Description Grove Part Number Required
1 1-1/8 in. Socket in. Drive 9-999-100142 1
2 in. Drive Torque Wrench 9-999-100159 1
3 10 in. Extension in. Drive 9-999-100138 1
4 13 in. Extension in. Drive 9-999-100137 1
5 Tool Box (Optional) Not Shown 9-999-100146 1

Orders for special tools shall be referred to:

Grove Product Support

Box 21
Shady Grove, Pennsylvania 17256-0021

Figure 2-9-4. Special Turntable Bolt Torquing Tools

2-9-14

6. Remove the hardware securing the electrical
swivel cover and remove the cover.
7. Disconnect the two pin lock-type electrical
connectors.
8. Remove the attaching hardware from the two
pin lock-type receptacles and remove them from the
mounting plate clear of the swivel.
9. Disconnect the two power lock connectors.
Pull the connects and wire clear of the swivel.
10. Install the electrical swivel cover and secure it
with the attaching hardware.
11. Tag and disconnect all oil lines, above the
carrier, from the swivel. Cap or plug all lines and
openings.
12. Disconnect the swivel links from
superstructure.
NOTE
If the same bearing is to be used again,
mark the pinion and bearing where the
teeth mesh (point of maximum
eccentricity). This will facilitate
installation and checking the gear
backlash.
13. Remove the swing gearbox. Refer to SWING
GEARBOX - Removal in this section.
WARNING
Ensure the lifting device is capable of
fully supporting the weight of the super-
structure. Ensure the super-structure will
not tilt or slide during lifting and moving.
Failure to do so may result in death or
injury to personnel and damage to
equipment.
CAUTION
Use spare pivot shafts or other material
capable of supporting the weight of the
superstructure. Do not damage the pivot
shaft bushings.
TM 5-3810-307-24-1-1
NOTE
If a lifting device capable of lifting the
entire superstructure is not available,
superstructure weight may be reduced
by removing various components such
as the hoist(s).
14. Install spare pivot shafts or other suitable
material through the lower lift cylinder pivot bushings
and through the boom pivot bushings.
15. Attach a suitable lifting device to the spare
pivot shafts and take in cable or chain to remove
slack. Do not pull up on the superstructure.
WARNING
Ensure the superstructure is fully
supported before proceeding.
the
16. Remove the bolts and washers attaching the
turntable bearing to the superstructure.
WARNING
Ensure that any blocking material used
is capable of fully supporting the weight
of the superstructure and will not allow it
to tilt or shift. Failure to do so may result
in death or injury to personnel.
17. Carefully lift the superstructure, guiding it over
the swivel, and set it on blocking that will not allow
the superstructure to tilt or shift. Leave the lifting
device attached.
NOTE
If the same bearing is to be used again,
mark the position of the bearing on the
carrier so it can be installed in the exact
position it was before removal.
18. Remove the bolts and washers attaching the
turntable bearing to the carrier.
2-9-15
TM 5-3810-307-24-1-1

Figure 2-9-5. Swing Bearing

2-9-16

NOTE
The bearing weighs approximately 387
lbs (175 kg). Ensure the bearing lifting
device is capable of supporting the
weight.
19. Using the lifting device, remove the turntable
bearing from the carrier.
INSPECTION.
Check the bearing teeth for chipping or cracking. If
any evidence of these is found, replace the bearing.
Ensure the bolt holes are free of dirt, oil, or foreign
material.
INSTALLATION.
WARNING
Anytime a Grade 8 turntable bolt has
been removed, it must be replaced with
a new Grade 8 bolt and nut.
Figure 2-9-6. Backlash Adjusting Shim
TM 5-3810-307-24-1-1
1. Using an appropriate lifting device, set the
turntable bearing in position on the carrier. If the
same bearing is being used, position it as marked
prior to removal.
2. Install the bolts and washers securing the
bearing to the carrier. Refer to Outer Race Torquing
in this sub-section.
NOTE
Installation is in the travel position.
Ensure the swing lock is disengaged
before attempting to mate the
superstructure to the bearing.
3. Using an appropriate lifting device, align the
superstructure over the bearing on the carrier.
Carefully lower the superstructure over the swivel
assembly into position on the bearing.
4. Install the bolts and washers. Refer to Inner
Race Torquing in this sub-section.
NOTE
If a new bearing is being installed, a new
pinion gear must also be used.
2-9-17
TM 5-3810-307-24-1-1

5. Install the swing gearbox (refer to SWING 11. Connect the two pin lock-type electrical
GEARBOX - Installation in this Section) with the connectors.
pinion aligning the high point (maximum eccentricity)
on the turntable bearing. Using a 0.005 in. (0.127 12. Install the electrical swivel cover.
mm) thick shim, check that backlash is 0.010 in.
(0.254 mm) [0.005 in. (0.152 mm) between adjacent 13. Install the boom following the procedures
teeth of pinion and bearing on both sides], refer to outlined in Section 10, BOOM.
Figure 2-9-6. If the pinion must be moved to achieve
proper backlash, contact your local Service 14. Connect the battery.
Representative or Manitowoc Crane CARE, PO Box
21, Shady Grove, PA. 17256-0021 TESTING.

6. Connect the swivel links to the superstructure. Activate the crane and check for proper function.

7. Connect all oil lines to the swivel. NOTE

8. Remove the hardware attaching the electrical
swivel cover and remove the cover.
9. Connect the two power lock connectors and
route the wires through the electrical swivel base
plate.
If the superstructure does not turn freely
after bearing and pinion replacement,
contact your local Service Representative
or Manitowoc Crane CARE, PO Box 21,
Shady Grove, PA. 17256-0021.

10. Install the two pin lock-type electrical

receptacles in the swivel base plate and secure with
the attaching hardware.

2-9-18 C-1
 TM 5-3810-307-24-1-1

SECTION 10
BOOM
TABLE OF CONTENTS
Page

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-10
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
BOOM EXTENSION AND RETRACTION CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
TELESCOPE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
LIFT CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
HOOK BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
BOOM HOSE REEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Boom Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-20
Tagline Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22

2-10-1
TM 5-3810-307-24-1-1

LIST OF FIGURES
Number Title Page

2-10-1 Three Section Cable Extended Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-7

2-10-2 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-9
2-10-3 Boom Extension and Retraction Cables Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-13
2-10-4 Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-17
2-10-5 Hook Block Reeving Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
2-10-6 Boom Hose Reel and Tagline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-21

2-10-2
 TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-10-6
Wear gloves when handling wire rope.

2-10-6
WARNING
2-10-10
Ensure all blocking and lifting devices are capable of supporting boom
assembly.

2-10-6
WARNING
Ensure the boom lift cylinder is properly supported before disconnecting it
from the boom.

2-10-6
WARNING
Shut down the crane before proceeding.

WARNING 2-10-10

Block the boom before doing any work under the boom.

WARNING 2-10-10

Failure to properly support the boom lift cylinder may result in death or
injury to personnel.

2-10-3
TM 5-3810-307-24-1-1

WARNING SUMMARY (continued)

Page

WARNING 2-10-10

If the hydraulic system must be activated to extend or retract the lift

cylinder, ensure the rod end is properly aligned with the lift cylinder attach
fitting.

WARNING 2-10-12

Never handle wire rope with bare hands.

WARNING 2-10-16

Ensure any blocking or cribbing used is capable of supporting the boom.

WARNING 2-10-16

Ensure the lifting/supporting device is capable of supporting the lift

cylinder.

WARNING 2-10-19
2-10-22
Hose reel is installed with a spring preload. Hold on to hoses when
disconnecting so reel does not spin freely causing possible damage to
equipment or personal injury.

WARNING
2-10-11
Boom/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.

2-10-4 C-1
 TM 5-3810-307-24-1-1

BOOM

DESCRIPTION

The boom is a three section 27 to 70 ft (8.2 to 21.3
m) cable extended boom.
The boom is trapezoidal in design and utilizes one
heavy duty 5.5 in. (13.9 cm) telescope cylinder. The
telescoping sections are supported on graphite
impregnated nylatron wear pads. Adjustable side
wear pads prevent metal-to-metal contact between
the sections. The boom nose consists of five
sheaves (two upper and three lower), mounted on
heavy duty tapered roller bearings and utilizes pin-
type guards to allow easy reeving.
Boom assembly lift is provided by one heavy duty
7.5 in. (18.9 cm) diameter bore lift cylinder. Boom
elevation is from -3 to 78 degrees.

THEORY OF OPERATION

EXTENSION. the sheaves at the end of the telescope cylinder

The rod end of the telescope cylinder is secured to
the boom base section and the cylinder barrel is
secured to the mid section. The four extension
cables are secured to the boom base section, routed
around four sheaves at the barrel end of the
telescope cylinder, and secured at the opposite end
to the fly section. The retraction cable is secured at
the outside front of the base section, routed around a
sheave mounted on the end of the mid section, and
secured at the opposite end to the fly section.
As the telescope cylinder extends, the cylinder
barrel, which is attached to the mid section, pulls the
mid section out along with it. At the same time,
push on the four extension cables. This causes the
extension cables to pull the fly section out at the
same time and rate that the telescope cylinder is
pulling out the mid section.
RETRACTION.
As the telescope cylinder is retracted, the mid
section, which is attached to the cylinder barrel, is
pulled in. At the same time, the sheave at the rear of
the mid section pushes on the retraction cable. This
causes the retraction cable to pull the fly section in at
the same time and rate that the telescope cylinder is
pulling in the mid section.

2-10-5
TM 5-3810-307-24-1-1

MAINTENANCE

REMOVAL. 7. Block the lift cylinder.

NOTE 8. Remove the bolts, washers, and retaining plate

securing the upper lift cylinder shaft to the attach
The boom may be disassembled with the fitting.
base section left on the crane if repair of
the base section is not necessary. 9. Remove the upper lift cylinder shaft.

NOTE 10. Activate the hydraulic system and withdraw the

lift cylinder rod enough to clear the attach fitting.
The boom weighs approximately 7,078
lbs (3,211 kg).
WARNING
1. Extend and set the outriggers and ensure the Shut down the crane before proceeding.
boom is fully retracted and in a horizontal position
over the front of the crane. 11. Take up the slack on the boom lifting device.

12. Remove the clip pin, plate, and retaining pin

WARNING
securing the boom pivot shaft. Remove the boom
Wear gloves when handling wire rope. pivot shaft.

2. Remove the hook block and wind all the wire 13. Raise the boom clear of the crane and lower to
rope onto the hoist drum. ground level for service.

3. Elevate the boom slightly to allow for DISASSEMBLY.

withdrawal of the lift cylinder rod end from the lift
cylinder attach fitting. NOTE

Steps 1 through 4 apply to a boom that is

WARNING to be disassembled with the base
Ensure all blocking and lifting devices section left on the crane.
are capable of supporting boom
assembly. 1. Extend and set the outriggers.

4. Attach a lifting device to provide equal weight 2. Place the boom in a horizontal position.
distribution and place the boom safety block in
position. Rest the boom on the safety block. 3. Completely retract the boom.

5. Disconnect any electrical wiring from the 4. Tag and disconnect the hydraulic lines to the
boom. telescope cylinder. Remove the telescope cylinder
holding valve. Cap all lines and openings.
6. Tag and disconnect the hydraulic lines to the
telescope cylinder. Cap the lines and openings.
WARNING
Ensure the boom lift cylinder is properly
supported before disconnecting it from
the boom.

2-10-6
 TM 5-3810-307-24-1-1
2-10-7

Figure 2-10-1. Three Section Cable Extended Boom Assembly

TM 5-3810-307-24-1-1
5. Remove the bolt, washer, and plate securing
the telescope cylinder retaining pin and remove the
pin.
6. Remove the nuts, jam nuts, and washers
securing the extension cables to the base section.
7. Remove the nut, jam nut, and washer securing
the retraction cable to the front of the base section.
8. Back off the setscrews on the adjustable wear
pads to provide additional clearance and withdraw the
mid and fly sections from the base section.
9. Remove the adjustable wear pads from the
inside of the base section.
10. Remove the lower wear pad from the outside of
the mid section and the upper wear pads and spring
assembly from the upper rear of the mid section.
11. Remove the bolts, washers, mounting plate,
and retaining pin securing the retraction sheave to
the mid section and remove the retraction sheave.
CAUTION
Do not let the telescope cylinder fall.
12. Place blocking beneath the telescope cylinder
in the fly section. Remove the bolts and washers
securing the telescope cylinder barrel to the mid
section.
CAUTION
Use care when removing the fly section
from the mid section. The telescope
cylinder is not firmly attached and can
slide.
13. Back off the setscrews on the adjustable wear
pads to provide additional clearance and withdraw
the fly section and telescope cylinder from the mid
section.
14. Remove the adjustable wear pads from the
mid section.
15. Remove the lower wear pads from the outside
of the fly section and the upper wear pads and spring
assembly from the upper rear of the fly section.
16. Remove the bolts securing the cover assembly
to the fly section. Remove the extension cables.
2-10-8
17. Remove the bolt, washer, and plate securing
the retraction cable retainer pin to the fly section.
Remove the retainer pin and the retraction cable.
18. Withdraw the telescope cylinder from the fly
section.
19. If the telescope cylinder is to be replaced,
remove the foot plate, sheave mounting assembly,
and sheaves from the telescope cylinder.
20. Refer to BOOM EXTENSION AND
RETRACTION CABLE MAINTENANCE in this
section for cable inspection.
ASSEMBLY.
1. If removed, install the foot plate, sheave
mounting assembly, and sheaves from the telescope
cylinder. Torque the bolts to 250 lbs-ft (338.9 Nm).
2. Route the extension cables through the cover
assembly, around the telescope cylinder sheaves,
and through the foot plate. To aid in assembly,
secure the cables to the cylinder by wrapping tape
around the cylinder in several places.
3. Position the telescope cylinder into the fly
section. Place blocking under the rear of the
telescope cylinder to aid in assembly. Install the
mounting plates on the telescope cylinder.
4. Secure the cover assembly to the fly section
with the bolts and washers. Torque the bolts to 31
lbs-ft (42.0 Nm).
5. Install the retraction cable and retaining pin
and secure the pin with the bolt, washer, and plate.
6. Install the lower wear pads and upper wear
pads and spring assembly onto the fly section.
7. Install the adjustable wear pads into the mid
section.
CAUTION
Use care when installing the fly section
into the mid section. The telescope cyl-
inder is not firmly attached and can slide.
8. Install the fly section and telescope cylinder
into the mid section.
 TM 5-3810-307-24-1-1

Figure 2-10-2. Boom Installation

2-10-9
TM 5-3810-307-24-1-1
9. Position the cylinder barrel in place and secure
with the bolts and washers. Torque the bolts to 250
lbs-ft (338.9 Nm). Remove the blocking under the
telescope cylinder.
10. Position the retraction sheave on the mid
section and install the retaining pin. Secure the pin in
place with the mounting plate, bolts, and washers.
Torque the bolts to 28 lbs-ft (37.9 Nm). Route the
retraction cable around the retraction sheave.
11. Install the lower wear pads and the upper wear
pads and spring assembly to the mid section.
12. Install the adjustable wear pads inside the
base section.
13. Install the mid and fly sections into the base
section.
14. Secure the retraction cable to the front of the
base section with the nut, jam nut, and washer.
15. Secure the extension cables to the rear of the
base section with the nuts, jam nuts, and washers.
Torque the jam nut to 20 lbs-ft (27.1 Nm), then
tighten the nut.
16. Install the telescope cylinder retaining pin and
secure in place with the bolt, washer, and plate.
Torque the bolt to 31 lbs-ft (42.0 Nm). Install the
telescope cylinder holding valve.
17. Connect the hydraulic lines to the telescope
cylinder as tagged during disassembly.
INSTALLATION.
NOTE
The following procedure applies to a
boom totally removed from the crane.
WARNING
Ensure all blocking and lifting devices are
capable of supporting the boom
assembly.
1. Attach an adequate lifting device to the boom
and suspend the boom over the machine.
2. Lower the boom into position and align the
boom pivot shaft mounting holes for installation of
the pivot shaft.
2-10-10
3. Lubricate and install the boom pivot shaft.
Secure in place with the retaining pin, clip pin, and
plate.
WARNING
Block the boom before doing any work
under the boom.
4. Block the boom in place.
5. Attach a suitable lifting device to the lift
cylinder.
WARNING
Failure to properly support the boom lift
cylinder may result in death or injury to
personnel.
6. Anchor a ratchet device to the boom and raise
the lift cylinder into place. Block the lift cylinder in
position.
WARNING
If the hydraulic system must be activated
to extend or retract the lift cylinder,
ensure the rod end is properly aligned
with the lift cylinder attach fitting.
7. Lubricate and install the upper lift cylinder
shaft. Secure in place with the bolts, washers, and
retaining plate. Torque the bolts to 75 lbs-ft (101.6
Nm).
8. Remove the boom and lift cylinder lifting
devices.
9. Activate the hydraulic system and remove the
boom and lift cylinder blocking devices. Lower the
boom to horizontal. Shut down the crane.
10. Connect the hydraulic lines to the telescope
cylinder as tagged prior to removal.
11. Connect any electrical wires as tagged prior to
removal.
12. Refer to BOOM EXTENSION AND
RETRACTION CABLE ADJUSTMENT in this section
for cable adjustments.

FUNCTIONAL CHECK.
1. Activate the hydraulic system and check for
proper operation and any leaks.
2. Ensure the boom will extend and retract
properly.
3. Ensure the lift cylinder will not allow the boom
to drift down until the operator lowers it.
4. Ensure all electrical components disconnected
during removal are operating properly.
TM 5-3810-307-24-1-1
INSPECTION.
Visually inspect telescoping sections for adequate
lubrication of all wear surfaces. Observe extended
sections for evidence of cracks, warping, or other
damage. Periodically check security of boom wear
pads. Check boom nose sheaves for security and
freedom of movement.
WARNING
Boom/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.
2-10-11 C-1
TM 5-3810-307-24-1-1
BOOM EXTENSION AND RETRACTION CABLES
MAINTENANCE
INSPECTION.
WARNING
Never handle wire rope with bare hands.
The following information is taken from a National
Consensus standard as referenced by Federal
Government Agencies.
All wire rope will eventually deteriorate to a point
where it is no longer usable. Wire rope shall be taken
out of service when any of the following conditions
exist.
1. In running ropes, six randomly distributed
broken wires in one lay or three broken wires in one
strand in one lay.
2. Wear of the original diameter of outside
individual wires. Kinking, crushing, bird caging, or
any other damage resulting in distortion of the rope
structure.
3. Evidence of any heat damage from any cause.
4. Reductions from nominal diameter of more
than:
0.016 in. (0.4 mm) for diameters up to and
including 0.3125 in. (8 mm)
0.031 in. (0.79 mm) for diameters 0.375 and
0.5 in. (10 and 13 mm) inclusive.
0.047 in. (1.19 mm) for diameters 0.5625 to
0.75 in. (14 to 19 mm) inclusive.
0.063 in. (1.59 mm) for diameters 0.875 to
1.125 in. (22 to 29 mm) inclusive.
0.094 in. (2.38 mm) for diameters 1.25 to 1.5
in. (32 to 38 mm) inclusive.
5. In standing ropes, more than two broken wires
in one lay in sections beyond end connections or
more than one broken wire at an end connection.
2-10-12
ADJUSTMENT.
NOTE
The retraction cable must be adjusted
before the extension cables.
1. Extend and set the outriggers, ensuring the
crane is level.
2. Ensure the boom is over the front and at a
horizontal position (boom angle elevation 0 degrees).
3. Extend the boom sections approximately one
foot (20.5 cm).
4. Loosen the extension cables by loosening the
jam nuts and locknuts. Do not remove the nuts.
5. Retract the boom sections slowly until the mid
and fly sections bottom out and note the point at
which the mid and fly sections bottom out. The stop
block on the bottom of the fly section bottom plate
should make contact with the mid section bottom
plate approximately 0.125 to 0.375 in. (0.31 to 0.95
cm) before the stop block or the bottom of the mid
section contacts the base section bottom plate.
NOTE
If the fly section bottoms out too early,
the retraction cable is too tight and must
be loosened. If the fly section bottoms
out too late, or fails to bottom out, the
retraction cable is too loose and must be
tightened.
6. Adjust the retraction cable adjusting nut and
jam nut on the left side of the base section until the
dimension outlined in step 5 if achieved.
7. Fully extend the boom, slowly. Fully retract the
boom and check that the stop block on the bottom of
the fly section has bottomed against the mid section
bottom plate. If contact has not been made, repeat
step 6.

8. Remove the locknuts from the extension
cables. Tighten all four jam nuts until the cable ends
extend approximately 2.75 to 3 in. (6.9 to 7.6 cm)
from the mounting plate on the boom base section.
9. Check the cable tension through the access
hole in the side of the boom. The cables should
have an equal amount of slack and not be resting
upon the telescope cylinder. Readjust the cables if
necessary.
10. Fully extend and retract the boom several
times. If any cable slap is present, readjust the
Figure 2-10-3. Boom Extension and Retraction Cables Adjustment
TM 5-3810-307-24-1-1
extension cables until no slap is present during
extension or retraction.
11. After the cables are adjusted to eliminate all
cable slap, check the cable tension through the
access hole in the side of the boom. All cables
should have equal tension. Readjust if necessary.
Install the locknuts.
12. Fully extend the boom and then fully retract it
again. Recheck the retraction cable adjustment and
readjust if necessary.
2-10-13
TM 5-3810-307-24-1-1

TELESCOPE CIRCUIT

DESCRIPTION

The boom telescope circuit consists of a
telescope/clamshell foot pedal actuated remote
control valve, telescope/clamshell directional control
valve, holding valve, and the telescope cylinder.
The telescope/clamshell directional control valve is
described under VALVES in Section 8.
Refer to VALVES in Section 8 for a complete
description of the telescope/clamshell remote control
valve. The boom telescope cylinder has a 5.5 in.
(13.9 cm) bore.
Foreign material is prevented from entering the
cylinder by a wiper seal during rod retraction. O-ring
seals prevent internal an external leakage. Refer to
CYLINDERS in Section 8 for a complete description
of the telescope cylinder.
The holding valve is threaded into the rod end of the
telescope cylinder. The holding valve functions
during the retraction, extension, or holding operation.
When holding the boom section at a given length, oil
is trapped in the cylinder by the holding valve. Refer
to VALVES in Section 8 for a complete description of
the holding valve.

THEORY OF OPERATION

The valve bank housing the telescope directional
control valve is supplied by flow from the 39 gpm
(147.6 lpm) middle pump section. Flow from the
pump travels through port 13 of the swivel to the
telescope directional control valve. When the foot
pedal for telescope functions is moved from neutral,
it sends a pilot pressure signal to the directional
control valve, which shifts the spool in the directional
control valve. This shift aligns the appropriate
passages in the control valve to route oil to the
telescope cylinder holding valve. The holding valve,
with its' internal makeup of valves and springs,
passes oil to and from the telescope cylinder. During
extension, oil unseats
the poppet (check) valve in the holding valve when
pressure is 6 4 psi (41.4 27.6 kPa). This oil is
routed to the piston side of the cylinder which forces
the rod out of the cylinder, causing the boom section
to extend.
During retraction, oil enters the retract port and flows
to the rod side of the cylinder. When pilot pressure
reaches a pre-determined value, the main poppet
unseats, and oil flows from the piston side of the
cylinder to the reservoir causing the boom section to
retract. All return flow from the directional control
valve goes through the swivel to the reservoir.

MAINTENANCE

REMOVAL AND INSTALLATION. DISASSEMBLY AND ASSEMBLY.

Removal and installation of the telescope cylinder Disassembly and assembly procedures of the
from the boom is described under disassembly and telescope cylinder and control valve are provided in
assembly of the boom. Refer to BOOM Section 8 under CYLINDERS and VALVES
MAINTENANCE in this Section. respectively.

2-10-14
 TM 5-3810-307-24-1-1

LIFT CIRCUIT

DESCRIPTION

The boom lift circuit consists of the lift hydraulic
remote controller, lift directional control valve, holding
valve, and the lift cylinder. These components
enable the boom to be raised or lowered to various
degrees of elevation ranging from -3 to 78 degrees
from horizontal.
The lift directional control valve is the closed spool-
type and is described under VALVES in Section 8 -
HYDRAULIC SYSTEM.
Refer to VALVES in Section 8 for a complete
description of the hydraulic remote controller.
The lift cylinder has a 7.5 in. (19.1 cm) bore and is
the double acting-type. Dirt and other foreign
material are prevented from entering the cylinder and
causing internal damage by a wiper seal during rod
retraction. Oil seals on both the piston and cylinder
head prevent internal and external hydraulic oil
leakage. Refer to CYLINDERS in Section 8 for a
complete description of the lift cylinder.
The holding valve is a balanced poppet-type
hydraulic valve. It is threaded into the port block
which is an integral portion of the lift cylinder barrel.
The holding valve functions when booming up
(cylinder rod extended), booming down (cylinder rod
retracted), or holding (cylinder rod stationary).

THEORY OF OPERATION

The directional control valve bank housing the lift
control valve is supplied by flow from the 39 gpm
(147.6 lpm) middle section of the hydraulic pump.
Flow from the pump travels through port 13 of the
swivel to the lift directional control valve.
When booming down, oil enters the retract port of
the port block and flows to the cylinder rod side.
When pilot pressure reaches a pre-determined
valve, the main poppet unseats and oil flows from
the piston side of the cylinder to the reservoir.

When booming up, oil unseats the poppet (check) All return flow from the control valve goes through
valve in the holding valve, letting oil flow to the piston the swivel to the reservoir.
side of the cylinder. Pressure is applied to the
piston, forcing the rod to extend, raising the boom.

2-10-15
TM 5-3810-307-24-1-1
MAINTENANCE
NOTE
Refer to Section 8 for lift cylinder
disassembly and assembly pro-cedures.
Maintenance not requiring removal of
the cylinder barrels, such as packing,
may be performed without removing the
cylinders from the turntable. However,
all disassembly and assembly should be
conducted in a clean dust-free area.
REMOVAL.
1. Extend and set the outriggers.
2. Elevate the boom slightly so that the lift
cylinder is extended approximately one foot (0.3 m).
WARNING
Ensure any blocking or cribbing used is
capable of supporting the boom.
3. Ensure the boom is fully supported by placing
blocking or cribbing under the boom. Rest the boom
on the blocking or cribbing.
4. Remove the bolt, washer, and plate securing
the lift cylinder upper pivot shaft to the boom.
5. Remove the bolts and nuts securing the lift
cylinder lower pivot shaft to the turntable.
WARNING
Ensure the lifting/supporting device is
capable of supporting the lift cylinder.
6. Attach an adequate lifting/supporting device to
the lift cylinder being removed.
7. Remove the upper pivot shaft. Activate the
hydraulic system and retract the lift cylinder enough
to clear the upper attach point.
2-10-16
8. Tag and disconnect all the hydraulic lines to
the cylinder. Cap or plug all openings with high
pressure fittings.
9. Pull the lower lift cylinder pivot shaft out far
enough to remove the cylinder.
10. Move the lift cylinder to a clean work area.
DISASSEMBLY AND ASSEMBLY.
Disassembly and assembly procedures of the lift
cylinder holding valve and control valve are provided
in Section 8 under CYLINDERS and VALVES,
respectively.
INSTALLATION.
1. Attach an adequate lifting device to the lift
cylinder and position the cylinder over the attach
fittings on the turntable.
2. Lower the lift cylinder into the attach fittings on
the turntable and align the lift cylinder bushing with
the attach fitting holes.
3. Install the lift cylinder lower pivot shaft and
secure with the bolts and nuts. Torque the bolt to
250 lbs-ft (338.9 Nm).
4. Connect the extend and retract hoses to the lift
cylinder.
5. Activate the crane's hydraulic system and align
the lift cylinder rod end with the attach point on the
boom. Install the upper pivot shaft through the
cylinder and boom attach points. Shut down the
engine.
6. Secure the upper pivot shaft with the bolts,
washers, and plate. Torque the bolt to 75 lbs-ft
(101.6 Nm).
7. Remove the lifting and supporting devices from
the boom and lift cylinders. Activate the hydraulic
system and check the lift cylinders for proper
operation and any leaks.
 TM 5-3810-307-24-1-1

Figure 2-10-4. Lift Cylinder

2-10-17
TM 5-3810-307-24-1-1

HOOK BLOCK

DESCRIPTION

The crane is equipped with a three sheave hook is equipped with a safety latch. Grease fittings are
block rated at 22 tons (19.9 metric tons). The hook provided to ensure lubrication of all moving parts.
block utilizes a one-piece pivot block and the hook

Figure 2-10-5. Hook Block Reeving Diagram

2-10-18
 TM 5-3810-307-24-1-1

BOOM HOSE REEL

DESCRIPTION

A hydraulic hose reel, with two hydraulic hoses, is
installed on the right side of the boom base section
to direct hydraulic oil for operation of the crane's
hydraulically operated attachments.
The reel incorporates four quick disconnects. Two
connect the hose reel to the crane hydraulic system
and the other two (at the ends of the hoses on the
reel) connect to the attachment. The reel is installed
with spring tension which is
overcome
allowing the hoses to extend as the attachment is
lowered, and reels in the hoses as the attachment is
raised.
A tagline assembly installed on the hoses should be
connected to the attachment so that there is slack in
the hoses between the tagline clamp and attachment
connection points. This will relieve the stress of the
hoses pulling on the connection points.

MAINTENANCE

BOOM HOSE REEL

Removal

WARNING
Hose reel is installed with a spring preload. Hold on to hoses when
disconnecting so reel does not spin freely causing possible damage to
equipment or personal injury.

a. If hose reel hoses (7, Figure 2-10-6) and taglines are connected to an attachment, disconnect hoses and
taglines from attachment and allow hose reel assembly (6) to slowly rotate counterclockwise until spring preload
is released. Cap ends of hoses and attachment ports.

b. Position boom over an elevated platform and lower boom until hose reel assembly (6) rests on platform.

c. Disconnect hydraulic hoses (1) at connectors (2) (one on each side of boom). Cap ends of hydraulic
hoses and connectors on boom.

d. Remove nuts (3), lockwashers (4), capscrews (5), and hose reel assembly (6) from boom mounting
bracket.

NOTE

There may be shim washer(s) between hose reel and boom mounting
bracket for alignment. Mark position and number of shim(s).

e. If necessary, remove hoses (1 and 7) from hose reel assembly (6). Cap ends of hydraulic hoses and
connectors on hose reel assembly.

f. If necessary, remove tagline assembly from hydraulic hoses (7), refer to TAGLINE ASSEMBLY Removal
procedures.

2-10-19
TM 5-3810-307-24-1-1

Installation

a. If removed, install tagline assembly on hydraulic hoses (7, Figure 2-10-6), refer to TAGLINE ASSEMBLY
Installation procedures.

b. If removed, remove caps and install hydraulic hoses (1 and 7) on hose reel assembly (6).

c. With hose reel assembly (6) on an elevated platform, lower boom to align hose reel assembly mounting
holes with boom mounting bracket.

NOTE

If necessary, install shim washer(s) as marked during removal.

d. Secure hose reel assembly (6) to boom with capscrews (5), lockwashers (4), and nuts (3).

e. Remove caps and connect hydraulic hoses (1) to connectors (2).

f. Preload hose reel spring by rotating hose reel assembly (6) clockwise seven turns, then maintain tension
by attaching tagline clips to stowage link on boom.

g. Attach hoses (7) and taglines to attachment as necessary.

2-10-20
 TM 5-3810-307-24-1-1

LEGEND

1. Hydraulic hose 6. Hose reel assembly 10. Locknut

2. Connector 7. Hydraulic hose 11. Capscrew
3. Nut 8. Locknut 12. Tagline retainer
4. Lockwasher 9. Capscrew 13. Tagline
5. Capscrew

Figure 2-10-6. Boom Hose Reel and Tagline Installation

2-10-21
TM 5-3810-307-24-1-1

TAGLINE ASSEMBLY

Removal

a. Mark position of tagline retainer (12, Figure 2-10-6) on hose reel hydraulic hoses (7) for installation
purposes.

WARNING
Hose reel is installed with a spring preload. Maintain tension on hoses
when disconnecting taglines so reel does not spin freely causing possible
damage to equipment or personal injury.

b. Ensure hydraulic hoses (7) are secured to maintain tension on hose reel spring, and disconnect clips of
taglines (13) from stowage link on boom or attachment as applicable.

c. Remove locknuts (8 and 10), capscrews (9 and 11), tagline retainer (12), and taglines (13) from hydraulic
hoses (7).

d. If necessary, remove taglines (13) from tagline retainer (12).

Installation

a. If removed, install taglines (13, Figure 2-10-6) on tagline retainer (12).

b. Position tagline retainer (12) on hydraulic hoses (7) as marked during removal. If position is lost, install
retainer so that hydraulic hoses (7) have a small amount of slack when attachment is raised to highest working
position, but without excessive slack when attachment is lowered.

c. Secure tagline retainer (12) on hoses (7) with capscrews (9 and 11) and locknuts (8 and 10).

d. Attach clips of taglines (13) to stowage link on boom or attachment as applicable.

2-10-22
 TM 5-3810-307-24-1-1

SECTION 11
HOISTS

TABLE OF CONTENTS
Page

HOISTS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Main and Auxiliary Hoist Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Adjustment of the Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
VANE TYPE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
CABLE IDLER DRUM AND FOLLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-11
HOIST TO BOOM ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
HOIST DRUM ROTATION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Main and Auxiliary Hoist Rotation Indicator Controller Unit . . . . . . . . . . . . . . . . . . . . . 2-11-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-15

LIST OF FIGURES
Number Title Page

2-11-1 Main and Auxiliary Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-5

2-11-2 Hoist (Vane-Type) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-8
2-11-3 Cable Idler Drum and Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-10
2-11-4 Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
2-11-5 Rotation Indicator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
2-11-6 Main and Auxiliary Hoist Rotation Indicator Controller Unit . . . . . . . . . . . . . . . . . . . 2-11-16

2-11-1
TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-11-14

Disconnect the batteries before performing any maintenance on this

system. Serious burns may result from accidental shorting or grounding
of live circuits.

2-11-2
 TM 5-3810-307-24-1-1

HOISTS

DESCRIPTION

One hoist type is available, the Grove HO-15C. The
hoist is a single speed unit and is fitted with a 16 inch
(28 cm) drum. The main hoist is mounted on the
counterweight. The auxiliary hoist is mounted
forward of the main hoist.
Each hoist uses a vane motor to drive the reduction
unit within the hoists. An overrunning clutch will
allow the hoist to be raised without releasing the
brake while holding the load until there is sufficient
pressure to release the brake when hoisting down.

THEORY OF OPERATION

The first section of the hydraulic pump supplies oil
through swivel port 12 to the hoist directional control
valve. Movement of the directional control valve
spool is controlled by pilot pressure signals received
from the remote control levers in the cab.
When the remote control lever is placed in a working
position, it sends a pilot pressure signal to shift the
valve spool in the directional control valve, thus
routing pressure and flow to drive the hoist.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

MAIN AND AUXILIARY HOIST ASSEMBLIES

Removal

NOTE

Main and auxiliary hoists are interchangeable. Procedures below can be

applied to either hoist unless otherwise noted.

a. Disconnect hoist cable from hook block, and remove cable from hoist by unwinding cable from hoist drum
onto a spare cable reel.

b. Ensure battery disconnect switch is in the OFF position.

c. Remove rotation indicator controller unit with mounting bracket, refer to MAIN AND AUXILIARY HOIST
ROTATION INDICATOR CONTROLLER UNIT Removal procedures.

d. Tag, disconnect, and cap three hydraulic lines from hoist.

e. Remove nuts (1, Figure 2-11-1) and washers (2) securing hoist to turntable counterweight.

f. Attach suitable lifting device to hoist (4) and lift hoist from turntable counterweight.

2-11-3
TM 5-3810-307-24-1-1

NOTE

Tag shims for mounting pad from which removed, to ease installation
leveling procedures.

g. Remove capscrews (3) from hoist (4) and shims (5) from turntable mounting pads.

Installation

a. Position shims (5, Figure 2-11-1), as marked during removal, on turntable mounting pads for hoist (4).

CAUTION

Ensure rear mounting capscrews (3) for main hoist (6) only, are installed
from bottom of counterweight assembly. Failure to follow this caution will
cause damage to roof-mounted air conditioner on carrier cab when
swinging superstructure.

b. Insert capscrews (3) in hoist (4) mounting holes.

c. Using suitable lifting device, lift hoist into position on turntable counterweight while ensuring capscrews
align and pass through shims (5) and mounting pad holes.

NOTE

Ensure crane is level by checking bubble level in superstructure cab prior

to leveling hoist. Adjust level using outriggers as necessary.

d. Check that hoist is level by placing a level across the top of the hoist. Insert or remove shims (5) to
mounting pads as necessary to level hoist.

e. Secure hoist (4) to turntable counterweight with washers (2) and nuts (1). Torque nuts to 385 lbs-ft (522
Nm).

f. Remove caps and tags, and connect three hydraulic lines to hoist.

g. Install rotation indicator controller unit with mounting bracket, refer to MAIN AND AUXILIARY HOIST
ROTATION INDICATOR CONTROLLER UNIT Installation procedures.

h. Install/reeve cable, refer to Operator's manual.

Functional Check

1. Attach a weight to the hook and raise and lower the load several times.

2. Check the hoist for smooth operation of the hoist motor and brake system.

3. Ensure the hydraulic connections are secure and free from leaks.

Servicing.

1. Remove the cable from the hoist (if applicable).

2. Rotate the hoist drum until one drain plug is at the highest point.

2-11-4
 TM 5-3810-307-24-1-1

LEGEND

1. Nut 4. Auxiliary hoist

2. Washer 5. Shim(s)
3. Capscrew 6. Main hoist

Figure 2-11-1. Main and Auxiliary Hoist Installation

2-11-5
TM 5-3810-307-24-1-1

3. Remove the drain plugs.

4. Fill the drum with lubricant until oil begins to flow from the horizontally positioned opening. Refer to
Chapter One, Section 4, LUBRICATION for proper lubricant.

5. Install the pipe plugs.

Adjustment of the Motor Control Valve.

If adjustment of the motor control valve is necessary, contact Grove Product Support in Shady Grove, PA for
proper procedures.

2-11-6
 TM 5-3810-307-24-1-1

VANE TYPE MOTOR

DESCRIPTION

The vane type motor is a fixed displacement, rotary
balanced motor that converts hydraulic oil flow into
rotary mechanical motion. The motor consists of
four basic subassemblies; a body or housing and
shaft with a permanently lubricated bearing, a front
port
plate assembly consisting of the port plate with a
built-in check valve, a cam ring assembly containing
the rotor, vanes, vane springs and cam ring, and the
end cap assembly consisting of the end cap and
needle bearing.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

REMOVAL. INSTALLATION.

1. Drain the oil from the drum by removing the 1. Using a new gasket, position the motor and
plugs. gasket to the left end cover. Secure the motor and
gasket in place with the bolts and washers.
2. Tag and disconnect the hydraulic lines from
the motor and the hoist motor control valve. Cap or 2. Connect the hydraulic line as tagged during
plug all lines and openings. removal.

3. Remove the hex head bolts and washers 3. Fill the drum with oil. Refer to Chapter One,
securing the motor to the left end cover; remove the Section 4 - LUBRICATION in this manual.
motor; discard the motor gasket.

2-11-7
TM 5-3810-307-24-1-1

Figure 2-11-2. Hoist (Vane-Type) Motor

2-11-8

CABLE IDLER DRUM AND FOLLOWER
DESCRIPTION
The main and auxiliary hoists are equipped with an
idler drum on the forward side of the hoist. The idler
drum on the main hoist is used to keep the hoist
cable from coming in contact with the auxiliary hoist,
while the idler drum on the auxiliary hoist is used to
keep the hoist cable from coming in contact with the
boom.
MAINTENANCE
Removal.
1. Loosen the adjusting nuts and remove the
tension springs.
2. Remove the bolts, washers, and nuts securing
the lever welds to the arm weldments. Remove the
lever welds.
3. Remove the bolts securing one of the side
plates, ensure the roller assembly is not dropped
when the side plate is removed.
4. Remove the bolts and washers securing the
side plates to the hoist, and lift the idler drum
assembly from the crane.
Disassembly.
NOTE
The idler drum and cable follower should
be disassembled in a clean work area.
1. Remove the hex head bolt, lockwasher, and
end cap securing the idler shaft to the side plate.
2. Remove and lay the side plate aside.
3. Remove the idler shaft from the drum
assembly.
4. Remove the remaining side plate and lay
aside.
5. Remove the bearings from the drum assembly.
TM 5-3810-307-24-1-1
The cable follower is mounted on the forward side of
its respective hoist. The cable follower applies a
downward spring pressure against the cable onto the
hoist drum, to ensure that the cable will be uniformly
wound onto the hoist drum, and also prevent cable
jumping under abnormal line conditions.
6. Remove the two hex head bolts and washers
securing the angle to the cable follower shaft.
7. Remove the angle and shim washer from the
end of the cable follower shaft and slide the roller
assembly off the shaft.
8. Remove the shaft bearings and the other shim
washer from the roller assembly.
Cleaning and Inspection.
1. Clean all grease from the shafts and bearings.
2. Check the inner shafts, the rollers, and the
shaft bearings for cracks, scoring, or grooving.
Replace if necessary.
3. Check the spring tension. If the springs will not
provide sufficient tension when adjusted, replace
them.
Assembly.
1. Install the inner shaft bearings into the roller
assembly.
2. Install one shim washer on the inner shaft.
3. Install the roller assembly on the inner shaft
and install a shim washer on the end.
4. Ensure the roller assembly and bearings are
fully seated and install the angle iron on the end of
the inner shaft.
2-11-9
TM 5-3810-307-24-1-1

Figure 2-11-3. Cable Idler Drum and Follower

2-11-10

5. Install the two hex head bolts and washers
securing the angle to the roller assembly and
completely fill the roller assembly with grease
through the grease fitting on the end of the shaft.
6. Install the two bearings in the idler drum and
ensure they are fully seated.
7. Install the left hand side plate over the arm
weldment of the cable follower, if provided, and
install the lever weldment with the hardware
provided.
8. Install the idler shaft through the hole provided
at the top of the side plate.
9. Install the idler drum assembly over the shaft
and completely fill the drum assembly with grease
through the grease fitting on the end of the shaft.
10. Install the right hand side plate over the arm
TM 5-3810-307-24-1-1
weldment of the cable follower, if provided, and
install the lever weldment with the hardware
provided.
11. Install the end of the idler shaft through the
hole provided in the top of the side plate.
12. Install the end cap, bolt, and lockwasher
securing the idler shaft to the side plate.
Installation.
1. Using a suitable lifting device, align the holes
in the side plates with those provided on the hoist
and secure with the existing hardware.
2. Install the tension springs and adjust the
springs to provide equal tension across the roller
assembly.
3. Refer to Chapter One, Section 4 -
LUBRICATION and lubricate the cable idler drum
and follower as specified.
2-11-11
TM 5-3810-307-24-1-1
HOIST TO BOOM ALIGNMENT
PROCEDURE.
1. Lower the boom to the level position.
2. Find a line on top of the hoist drum which is
parallel to the drum axis as follows.
a. Use a Miracle Point Gauge and find a
zero degree dial point next to each flange on
top of the drum.
NOTE
If this special equipment is not available,
sufficient accuracy in locating a center-
line may be obtained by using a steel
square against the machined inner
surfaces of both flanges. It is advisable
to avoid using any cast surfaces in this
procedure unless a check from both
flanges indicates that the resultant line is
straight.
Figure 2-11-4. Hoist to Boom Alignment
2-11-12
b. Draw a line between the hoist drum
flanges, passing through both points as
located above and determine the midpoint.
3. Find the midpoint of the lines drawn across the
top of the base boom section, perpendicular to its
length, at both ends of the boom section. (Figure
points A and B).
4. Check as follows to see if the hoist is aligned
perpendicularly to the boom.
a. String a chalk line from point A, (outer
boom centerline) across the base section
centerline and the hoist drum midpoint.
b. Pull the line taunt, aligning it directly over
the top of point B.
c. With a protractor, measure the angle be-
tween the chalk line and the cross line drawn
on the hoist. If the measurement of the angle
exceeds 90 degrees degree, realignment
will be necessary.

CAUTION
Do not alter holes or stop-blocks on the
crane mounting plate, as very small
adjustments result in large angular
changes. Extreme care should be taken
to avoid over correction.
TM 5-3810-307-24-1-1
5. If realignment is necessary, remove the hoist
mounting bolts and shift the hoist as necessary to
achieve the minimum angular tolerance. Trial and
error location may be necessary for proper line-up of
the bolt holes and stop blocks. If all bolts cannot be
inserted or the stop blocks interfere with line-up, a
slight elongation of the hoist bolt holes and/or
shimming of the mounting lugs might be necessary.
2-11-13
TM 5-3810-307-24-1-1

HOIST DRUM ROTATION INDICATOR

DESCRIPTION

The hoist drum rotation indictor is an electrically
operated system (one for each hoist) that provides
the operator with a touch indication of drum rotation
so he will know if and at what speed the drum is
rotating, even under the most distracting conditions.
The indictor assembly consists of three main parts -
the magnetic sensor, the controller unit, and the
indicator unit. The magnetic sensor is installed in
the hoist motor to sense rotation of the motor shaft
and thus indirectly the hoist drum. The sensor is
connected by electrical wiring to the controller unit
that acts as a pulse generator and sends a pulsating
signal (proportional to rotation speed) to the indicator
unit. The indicator unit is located in the control lever
handle and pulsates in time with the signal from the
controller unit.

MAINTENANCE

GENERAL and do not require periodic maintenance. If a

malfunction occurs, repairs should be limited to the
WARNING electrical harness and replacing a faulty unit. To
Disconnect the batteries before determine which unit is at fault, interchange known
performing any maintenance on this good units from other hoist drum rotation indicator
system. Serious burns may result from systems, if available. Hook them in, one at a time,
accidental shorting or grounding of live and operate the affected hoist. By a process of
circuits. elimination, the faulty unit can be easily detected. If
difficulty persists, contact Grove Product Support,
The sensor, controller, and indicator units are sealed Box 21, Shady Grove, Pennsylvania 17256.

Figure 2-11-5. Rotation Indicator Unit

2-11-14
 TM 5-3810-307-24-1-1

MAIN AND AUXILIARY HOIST ROTATION INDICATOR CONTROLLER UNIT

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Disconnect electrical connector from magnetic sensor unit at hoist motor.

c. Disconnect electrical connector for controller unit (7, Figure 2-11-6) from superstructure electrical harness.

d. Remove screws (1) and cover (2) from controller unit (7).

e. Remove nut (3), lockwasher (4), washer (5), capscrew (6), and controller unit (7) from mounting bracket
(11).

f. If necessary, remove nut (8), lockwashers (9), washers (10), and mounting bracket (11) from
counterweight.

Installation

a. If removed, install mounting bracket (11, Figure 2-11-6) on counterweight with washers (10), lockwashers
(9), and nuts (8).

b. Install hoist rotation indicator controller unit (7) on mounting bracket (11) with capscrew (6), washer (5),
lockwasher (4), and nut (3).

c. Install cover (2) on controller unit (7) with screws (1).

d. Connect electrical connectors for controller unit (7) to superstructure electrical harness and magnetic
sensor at hoist motor.

2-11-15
TM 5-3810-307-24-1-1

LEGEND

1. Screw 5. Washer 9. Lockwasher

2. Cover 6. Capscrew 10. Washer
3. Nut 7. Controller unit 11. Mounting bracket
4. Lockwasher 8. Nut

Figure 2-11-6. Main and Auxiliary Hoist Rotation Indicator Controller Unit

2-11-16
 TM 5-3810-307-24-1-1

SECTION 12
OUTRIGGERS

TABLE OF CONTENTS
Page

OUTRIGGER CIRCUIT
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
OUTRIGGER BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-7
EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
STABILIZER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
INTEGRATED OUTRIGGER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
SOLENOID VALVE STACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-13
PILOT OPERATED CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
Cylinder Mounted Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
Frame Mounted Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14

LIST OF FIGURES
Number Title Page

2-12-1 Outrigger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-4

2-12-2 Outrigger Beam Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-6
2-12-3 Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-9
2-12-4 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-11

2-12-1
TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-12-5
Ensure any blocking material used is capable of supporting the weight of
the outrigger beam. Do not allow it to tilt or slide. Failure to do so may
result in death or injury to personnel.

2-12-2

OUTRIGGER CIRCUIT
DESCRIPTION
The outrigger circuit consists of four extension
cylinders, four stabilizer cylinders, an integrated
outrigger valve, extension and stabilizer solenoid
valves, and (pilot operated) check valves. The front
two extension cylinders are mounted in the front
outrigger beams and the rear two extension cylinders
are mounted in the rear outrigger beams. The front
and rear stabilizer cylinders are mounted on their
respective stabilizer boxes; in turn the stabilizer
boxes are mounted on the end of each outrigger
beam. Each stabilizer cylinder has a port block
incorporated into the cylinder rod. A fifth check
valve, mounted to the frame, is positioned inline
between the integrated outrigger valve and the
outrigger circuit to prevent reverse flow from the
piston side of the outrigger cylinders. The integrated
outrigger valve is located on the left side
THEORY OF OPERATION
The appropriate OUTRIGGER SELECTOR switch
and OUTRIGGER EXTEND/RETRACT switch must
both be held in position. Flow from the 16 gpm (60.5
lpm) pump section supplies the outrigger circuit.
Depressing one of the OUTRIGGER SELECTOR
switches causes that solenoid valve to open. As the
EXTEND/RETRACT switch is moved, the integrated
outrigger valve shifts allowing flow to either the
extend or retract line as applicable. If the
EXTEND/RETRACT switch is in the EXTEND
position, the flow continues through the open
solenoid valve to the piston side of the cylinder. If
the stabilizer(s) is/are to be extended, the flow first
unseats the cylinder check valve then extends the
cylinder. The oil from the rod end flows through the
integrated outrigger valve, and then to the reservoir.
When the EXTEND/RETRACT switch is in the
RETRACT position, the flow through the selector
TM 5-3810-307-24-1-1
of frame to the rear of the swivel. The extension and
stabilizer solenoid valves are bolted to the frame at
the outrigger beams.
The OUTRIGGER SELECTOR controls are located
in the superstructure cab on the front console. Both
the selector valve and the solenoid valves are
electrically actuated from the control panel. The
solenoid switches must be held depressed to actuate
the solenoid valve. The selector valve switch is
spring loaded to the OFF position. The control panel
is placarded with switch positions.
A sight bubble level is mounted on the front console
in the superstructure cab. The sight bubble level
provides the operator with a visual indication of
crane level attitude.
valve is directed to the rod side of the cylinder. The
oil in the piston side flows through the open solenoid
back to the integrated outrigger valve. If a stabilizer
cylinder is to be retracted, then pilot pressure from
the pressurized retract line unseats the cylinder
check valve allowing oil to flow from the piston side
through the open solenoid valve to the integrated
outrigger valve. The integrated outrigger valve
directs the flow to the reservoir.
The integrated outrigger valve has two internal relief
valves. A 300 psi (2068.5 kPa) thermal relief is in
the retract circuit and a 2000 psi (13,790 kPa) relief
protects the extend circuit.
The frame mounted pilot operated check valve has a
thermal relief set to open at 4000 psi (27,580 kPa).
2-12-3
2-12-4

TM 5-3810-307-24-1-1
Figure 2-12-1. Outrigger Assembly

OUTRIGGER BOX ASSEMBLY
DESCRIPTION
The outrigger box assembly consists of an outrigger
beam, a 3.5-inch (10.4 cm) stabilizer cylinder, a
THEORY OF OPERATION
When the outrigger extension is activated, it extends
or retracts the outrigger beam within the outrigger
box. The jack cylinder is mounted to the end of the
beam. The jack cylinder applies force to
MAINTENANCE
REMOVAL.
1. Extend the outrigger slightly to facilitate
attaching a lifting device to the outrigger beam.
2. From the opposite side of the outrigger
housing, remove the end cover.
3. Tag and disconnect the hydraulic lines at the
cylinder end of the extension cylinder. Cap all lines
and fittings.
NOTE
Do not allow the end of the outrigger
extension cylinder to fall when the
cylinder mounting shaft is removed. Use
an adequate soft support to cushion any
distance the rod will drop.
4. Remove the cotter pin securing the cylinder
mounting shaft. Remove the shaft and lay the
cylinder on the cutout in the outrigger beam.
5. Attach a suitable lifting device to the outrigger
beam.
6. Pull the outrigger beam out of the outrigger
box, readjusting the lifting attachment to prevent the
extension cylinder from falling to the ground when
the outrigger beam clears the outrigger box.
TM 5-3810-307-24-1-1
2.5-inch (6.35 cm) extension cylinder, and the
required hoses and mounting hardware.
the outrigger beam vertically. This sequence of
events provides for lifting and stabilizing the crane for
operation.
WARNING
Ensure any blocking material used is
capable of supporting the weight of the
outrigger beam. Do not allow it to tilt or
slide. Failure to do so may result in
death or injury to personnel.
NOTE
The outrigger beam weighs
approximately 600 lbs (272 kg).
7. Position the outrigger beam on the blocking
material.
INSPECTION.
Inspect the outrigger beams for bends, evidence of
cracks, or other damage. Check the outrigger beam
internally for hydraulic fluid, which may indicate a
leaking cylinder, loose connection, or damaged
hydraulic line.
2-12-5
2-12-6

TM 5-3810-307-24-1-1
Figure 2-12-2. Outrigger Beam Removal
 TM 5-3810-307-24-1-1

INSTALLATION. 3. Secure the cylinder barrel to the housing with

the washer, shaft and cotter pin.
1. Attach a suitable lifting device to the outrigger
beam. 4. Connect the hydraulic lines as tagged prior to
removal.
2. Slide the beam into the outrigger housing and
align the cylinder bushing with the mounting hole. 5. Install the end cover.

2-12-7
TM 5-3810-307-24-1-1
EXTENSION CYLINDER
DESCRIPTION
Two outrigger extension cylinders are utilized within
each outrigger box assembly. The extension
cylinders provide the force for the outrigger beam's
horizontal movement. The cylinders have a 2.5 inch
(6.35 cm) diameter bore and are the double acting
type. Each cylinder has a retracted length of 84
inches (213.4 cm) measured from the center of the
barrel bushing to the center of the rod bushing.
MAINTENANCE
NOTE
Refer to CYLINDERS in Section 8 for
Disassembly and Assembly of the
cylinder.
REMOVAL.
1. Remove the outrigger beam, refer to OUTRIG-
GER BEAM - REMOVAL in this Section.
2. Remove the cotter pin and clevis pin securing
the rod end of the extension cylinder to the outrigger
beam.
3. Pull the extension cylinder from the outrigger
beam until the hydraulic hoses on the rod end of the
cylinder can be accessed. Tag and disconnect the
hoses from the rod end of the cylinder.
4. Pull the cylinder to the end of the beam. Tilt it
so the clamp assembly will clear the access hole in
the beam and remove the cylinder.
5. If necessary, remove the clamp assembly from
the cylinder.
2-12-8
The extended length of the cylinders from the center
of the rod bushing to the center of the barrel bushing
is 149.6 inches (380.0 cm). It is attached to the
outrigger box by means of a pin through a clevis on
the barrel end of the cylinder. Attachment of the rod
end to the outrigger beam is by means of a pin
through a bushing. The cylinder weighs
approximately 81 lbs (36.7 kg).
INSTALLATION.
1. If removed, install the clamp assembly onto the
cylinder.
2. Tilt the cylinder so the clamp assembly will
clear the access hole and place the cylinder in the
beam.
3. Position the extension cylinder so the hydraulic
port on the rod end of the cylinder can be accessed.
Connect the hydraulic hoses to the ports as tagged
during removal.
4. Push the cylinder into the outrigger beam.
Align the cylinder rod with the clevis in the beam and
secure in place with the clevis pin and cotter pin.
5. Install the outrigger beam, refer to
OUTRIGGER BEAM - INSTALLATION in this
Section.
FUNCTIONAL CHECK.
1. Activate the hydraulic system; extend and
retract the outrigger.
2. Observe the operation of the outrigger beam.
3. Check the hydraulic connections for any
evidence of leakage.
 TM 5-3810-307-24-1-1

Figure 2-12-3. Extension Cylinder

2-12-9
TM 5-3810-307-24-1-1
STABILIZER CYLINDER
DESCRIPTION
Four stabilizer cylinders are used on the crane, one
at the end of each outrigger beam. The stabilizer
cylinders provide the force for the outrigger beam's
vertical movement. The cylinders have a 3.5 inch
(8.9 cm) diameter bore and are the double acting
type. Each cylinder has a retracted length of 42.5
MAINTENANCE
NOTE
Refer to CYLINDERS in Section 8 for
Disassembly and Assembly of the
cylinders.
REMOVAL.
1. Extend the outrigger beam slightly for
improved access to the stabilizer cylinder; shut down
the engine.
2. Tag and disconnect the hydraulic hoses from
the stabilizer cylinder.
3. Remove the cylinder cap.
4. Place a jack capable of supporting the weight
of the stabilizer cylinder at the base of the cylinder
barrel. Jack up the cylinder just enough to relieve
any pressure on the cylinder retaining pin.
5. Remove the cotter pins securing the cylinder
retaining pin and remove the cylinder retaining pin.
6. Jack the stabilizer cylinder up just enough to
insert the retaining pin back into the cylinder. Insert
the retaining pin into the lugs on the cylinder and
secure in place with the cotter pins.
CAUTION
Use a nylon strap to remove the cylinder.
This will ensure the retaining pin is not
damaged.
2-12-10
inches (107.9 cm) measured from the end of the
cylinder barrel to the end of the cylinder rod. The
extended length of the cylinder from the end of the
cylinder barrel to the end of the cylinder rod is 63.5
inches (161.3 cm). The stabilizer cylinder weighs
approximately 114 lbs (51.7 kg).
7. Fasten a nylon strap onto the cylinder retaining
pin and use an adequate lifting device to lift the
stabilizer cylinder out of the tube on the beam
assembly.
INSTALLATION.
1. Place a jack beneath the cylinder tube on the
outrigger beam. Using the same method as
described under REMOVAL, lower the stabilizer
cylinder into the cylinder tube on the outrigger beam
until the retaining pin is just above the tube. Position
the jack so that it will support the cylinder in this
position. Remove the lifting device from the cylinder.
2. Remove the retaining pin and cotter pins from
the cylinder.
3. Lower the jack until the holes in the cylinder
rod align with the holes in the outrigger beam.
Secure the cylinder in place with the retaining pin
and cotter pins.
FUNCTIONAL CHECK.
1. Activate the hydraulic system.
2. Extend and retract the stabilizer cylinder.
3. Check for smooth operation of the cylinder.
4. Check all hydraulic connections and hoses for
evidence of leakage.
 TM 5-3810-307-24-1-1

Figure 2-12-4. Stabilizer Cylinder

2-12-11
TM 5-3810-307-24-1-1

INTEGRATED OUTRIGGER VALVE

DESCRIPTION

The integrated outrigger valve consists of five sub- on the left side of the frame to the rear of the swivel
assemblies; two solenoid valves, an inlet section, an assembly.
outlet section, and a working section. It is located

NOTE

For a more detailed description and maintenance of the integrated

outrigger valve, refer to VALVES in Section 8 - HYDRAULIC SYSTEM.

2-12-12
 TM 5-3810-307-24-1-1

SOLENOID VALVE STACK

DESCRIPTION

Each solenoid valve stack assembly consists of four an assembly kit. The solenoid valve stacks are
valve sections, four 24-volt solenoid assemblies, located on the outrigger boxes.
and

NOTE

For more detailed information and maintenance of the outrigger solenoid

valve stacks refer to VALVES in Section 8 - HYDRAULIC SYSTEM.

2-12-13
TM 5-3810-307-24-1-1

PILOT-OPERATED CHECK VALVE

DESCRIPTION

There are two different types of pilot-operated check FRAME-MOUNTED VALVE.

valves utilized in the outrigger circuit.
CYLINDER-MOUNTED VALVE.
The valve is located in the outrigger stabilizer port
block. The check valve provides two functions; the
first function is a holding valve, the second function
provides a thermal relief of the stabilizer.
The valve is located on the inside frame rail near the
integrated outrigger valve. The purpose of the valve
is to prevent reverse flow from the piston side of the
outrigger cylinders. Incorporated within the valve
cartridge is a thermal relief valve set to open at 4000
psi (27,580 kPa).

NOTE

For more detailed information and maintenance of the pilot-operated

check valves, refer to VALVES in Section 8 - HYDRAULIC SYSTEM.

2-12-14
 TM 5-3810-307-24-1-1

SECTION 13
SWIVELS

TABLE OF CONTENTS
Page

SWIVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
14 PORT AIR/HYDRAULIC SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-6
ELECTRICAL SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-10

LIST OF FIGURES

Number Title Page

2-13-1 Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-4

2-13-2 Air/Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-7
2-13-3 Connector Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-10
2-13-4 Electrical Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-11

2-13-1
TM 5-3810-307-24-1-1

WARNING SUMMARY

Page

WARNING 2-13-9

Disconnect the batteries before performing any maintenance on the electrical

system. Serious burns may result from accidental shorting or grounding of
live circuits.

2-13-2

SWIVELS
DESCRIPTION
The main swivel installation is a two part assembly
consisting of a 14 port air/hydraulic swivel, and an
electric swivel. Solid connections cannot be used to
transfer oil, or electricity between the carrier and
superstructure due to the continuous 360 degree
swing. The use of swivels efficiently accomplishes this
function.
The barrel portion of the air/hydraulic swivel is attached
to the superstructure by four bolts which connect to
mounting lugs on the barrel. The spool portion of the
swivel rides upon a thrust ring at the top of the swivel
barrel. A retainer arm bolted to the bottom of the
spool, keeps the spool aligned with the carrier. The
other end of the retainer is keyed to a lug on the carrier
frame, which allows the retainer to float, so that the
swivel does not bind, as the barrel rotates with the
superstructure.
TM 5-3810-307-24-1-1
The center of the electrical swivel, or collector core
assembly, is secured by setscrews to a center post
which is bolted to the spool of the air/hydraulic swivel.
This holds the collector core assembly stationary with
reference to the carrier.
The outer portion of the swivel, consists of brush
assemblies mounted on studs threaded into the swivel
base plate/mounting bracket, enclosed in a protective
cover. This assembly is attached to a bracket on the
turntable bearing plate which rotates with the air/
hydraulic swivel barrel and superstructure.
The electrical swivel also includes cam plates which
actuate micro switches to provide area definition
switching needed for steering, axle oscillation lockout
functions.
2-13-3
TM 5-3810-307-24-1-1

Figure 2-13-1. Swivel Assembly

2-13-4
 TM 5-3810-307-24-1-1

14 PORT AIR/HYDRAULIC SWIVEL

DESCRIPTION

Each of the ports on the spool and barrel of the swivel PORT TEST PRESSURE FUNCTION
is stamped with the port number. The function and test NUMBER
pressure of each port is described below. 7 500 psi (3447.5 kPa) Return

8 3500 psi (24132.5 kPa) Steer-Rear Axle

PORT TEST PRESSURE FUNCTION
NUMBER 9 3500 psi (24132.5 kPa) Steer-Rear Axle

1 150 psi (1034 kPa) Throttle (Air) 10 3500 psi (24132.5 kPa) Supply-Steer

2 150 psi (1034 kPa) Park Brake (Air) 11 3500 psi (24132.5 kPa) Supply-O/R & Swing/AC

3 150 psi (1034 kPa) Secondary Supply (Air) 12 3500 psi (24132.5 kPa) Supply-Main/Aux Hoist

4 150 psi (1034 kPa) Primary Supply (Air) 13 3500 psi (24132.5 kPa) Supply-Lift/Tele/Clamshell

5 150 psi (1034 kPa) Delivery 1-Front (Air) 14 500 psi (3447.5 kPa) Return

6 150 psi (1034 kPa) Delivery 2-Rear (Air)

THEORY OF OPERATION

The hydraulic swivel allows oil to flow from the main
pump and steer pump, to the various crane functions
on the superstructure. All oil is routed into the spool
portion of the swivel where, through a series of
internally drilled passages, oil is transferred to a
circumferential channel on the spool exterior. This
channel corresponds with a mating port on the barrel
of the swivel. Each channel is separated by a series
of Teflon and O-ring seals that prevents transfer of oil
and pressure. Return oil flow from the crane functions
is accomplished in the same manner through another
set of ports.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

REMOVAL. and the turntable side plate. Shut down the engine.

1. Extend and set the outriggers. Ensure the crane 3. Measure the distance from the top of the lift
is level. cylinder to the base of the boom section where the lift
cylinder attaches. Cut a piece of 4 x 4-inch (10.16 x
2. Elevate the boom and note at what boom angle 10.16 cm) oak to fit.
you have the most clearance between the lift cylinder

2-13-5
TM 5-3810-307-24-1-1
NOTE
It might be necessary to raise the boom
slightly to allow installation of the blocking.
This blocking is to add extra support for the
boom. Any seepage or leakage in the
holding valve or internally in the cylinder
will allow the boom to settle over a period
of time.
4. Use the oak blocking to block between the barrel
of the lift cylinder and the boom base section.
5. Remove the electrical swivel, refer to
ELECTRICAL SWIVEL - REMOVAL in this Section.
6. Bleed air pressure from the air system at the air
system reservoirs.
7. Tag and disconnect six air lines at the air/hydra-
ulic swivel, ports 1 thru 6. Install plugs, couplers, and
fittings in each of the disconnected air lines except for
those connected to port nos. 5 and 6. Bundle the
disconnected air lines in plastic wrap and tie wraps.
Then tie wrap them to the carrier, up and out of the
way. Cover/plug the six air line openings in the
air/hydraulic swivel.
NOTE
Use suitable drip pan to catch hydraulic oil.
Remove the split flange hydraulic return
line hose connected to air/hydraulic swivel
port no. 14 last.
8. Tag and disconnect seven hydraulic hoses on
the bottom of the air/hydraulic swivel, ports 7 thru 13.
Install plugs in the hydraulic hoses and caps on the
air/hydraulic swivel ports. Cover all loose hydraulic
hoses with plastic wrap/bag and tape or tie wrap. Then
tie wrap them to the carrier, up and out of the way.
NOTE
There will be considerable hydraulic oil
draining from the hydraulic drain line hose.
2-13-6
9. Remove the bolts securing the split flange
hydraulic return line hose at the hydraulic tank and
allow hydraulic oil to drain into drain pan. Then
remove bolts securing split flanges at air/hydraulic
swivel port no. 14. Install flange plugs in both open
ports and secure with split flanges and bolts. Cover
both ends of hydraulic return line hose with plastic
wrap and tape and stow in storage box.
10. Tag and disconnect the hydraulic lines from the
spool of the swivel. Cap all lines and openings.
NOTE
The hydraulic swivel weighs approximately
203 lbs (92 kg).
11. Position an adequate supporting device beneath
the swivel.
12. Remove the bolts, and washers securing the
swivel to the superstructure and lower the swivel to the
ground.
INSTALLATION.
1. Raise the swivel into position.
2. Secure the swivel to the turntable with the
bushings, bolts, and washers. Torque the bolts to 250
lbs-ft (338.9 Nm).
3. Install the electrical swivel, refer to ELECTRICAL
SWIVEL - INSTALLATION in this Section.
4. Install the hydraulic lines to the spool as tagged
during removal.
5. Remove protective covers on both ends of
hydraulic return line hose. Remove flange plugs in
hydraulic tank and in air/hydraulic swivel port no. 14.
Retain split flanges and attaching hardware. Install
hydraulic return line hose between port no. 14 and
hydraulic tank. Secure with bolts and split flanges.
6. Cut tie wraps; remove plastic wrap/bags, plugs,
and caps; and connect seven hydraulic hoses on the
bottom of the air/hydraulic swivel, ports 7 thru 13 as
tagged. Remove all tags.
 TM 5-3810-307-24-1-1

Figure 2-13-2. Air/Hydraulic Swivel

2-13-7
TM 5-3810-307-24-1-1

7. Cut tie wraps; remove plastic wrap/bags; and 9. Service the hydraulic tank with oil, MIL-L-2104.
connect three multi-pin electrical connectors at the
electrical slip ring as tagged. Secure cable clamps to 10. Remove the blocking material from the lift
frame with two bolts. Be sure to capture the slip ring cylinders.
ground wire in one of the two clamp bolts. Remove all
tags. 11. Activate all systems; cycle all functions and
observe for proper operation and any leakage.
8. Cut tie wraps and remove plugs, covers,
couplers, and fittings in each of the disconnected air
lines. Connect all six air lines to the air/hydraulic
swivel, ports 1 thru 6, as tagged. Remove all tags.

2-13-8
 TM 5-3810-307-24-1-1

ELECTRICAL SWIVEL

DESCRIPTION

The electrical swivel consists of brushes, collector
rings, and a cover assembly. The swivel uses 46 sets
of brushes and collector rings.
Each collector ring and lead assembly is mounted on a
nylon bushing/insulator. These are stacked together to
form the collector core. The core assembly extends
though the swivel mounting plate and is attached to
the center post with set screws. Collector ring leads
are formed into one harness which is routed downward
through the center post, and the center of the hydraulic
swivel. Extending from the base of the hydraulic
swivel, the harness is separated and routed into four
connectors which mate with receptacles from the
carrier wiring harness.
Brushes with leads, are mounted in pairs, on holder
arms, to match each ring. Tension springs on the
holder arms assure contact between brushes and the
collector rings. The brush arm assemblies (one for
each ring) stacked alternately on two brush holding
studs which are threaded into the swivel mounting
plate. The stack is completed by a nylon plate
attached across both studs. It acts as a bearing for the
outer end of the collector core, and holds the brush
arms firmly on the studs, in proper alignment with the
rings. Leads from the brush sets are formed into four
connectors, attached to the mounting plate, which
mate with connectors on the superstructure wiring
harness.
The electrical swivel also incorporates a cam plate and
area definition switches. These switches control
functions in the load moment indicating system,
superstructure steering, and the axle oscillation
system.
The swivel is protected by a sealed cover which is
attached by two bolts to the base plate/mounting
bracket.

MAINTENANCE

NOTE

For more detailed information refer to the applicable SM package.

REMOVAL. NOTE

1 Perform steps 1 through 4 of 14 PORT AIR/- Do not disconnect the collector ring wires
HYDRAULIC SWIVEL - REMOVAL in this Section. crimped at the top of the swivel assembly.

3. Locate the four connectors which join the

WARNING
Disconnect the batteries before performing
any maintenance on the electrical system.
Serious burns may result from accidental
shorting or grounding of live circuits.
collector ring harness to the receptacles for the carrier.
4. Tag and disconnect the two rectangular
connectors from the carrier wiring. Removal of the
connector from the wire is not required.

2. Position battery disconnect switch to OFF. 5. Tag the round connectors and their receptacles
with numbers 1 and 2. Disconnect both connectors
from the chassis wiring receptacles.

2-13-9
TM 5-3810-307-24-1-1
NOTE
The round connectors are too large to go
through the center of the hydraulic swivel.
They must be removed.
6. Tag each wire on connector 1. Using pin
removal tools listed in Section 14 - ELECTRICAL
SYSTEM, remove the pins, with wires still attached,
and mark each wire with the pin socket number in the
connector. Collect the wires and secure into one
bundle. Mark the bundle with the connector number.
7. Repeat step 6 for connector 2.
8. Secure the rectangular connectors, and the
wires from the connectors 1 and 2, so the harness can
be withdrawn through the center of the swivel.
9. Remove the attachment screws and remove the
swivel cover and seal.
10. Tag and disconnect the two rectangular
connectors.
11. Tag and disconnect the two round connectors
from the receptacles on the mounting plate.
Figure 2-13-3. Connector Receptacle
12. Remove the screws securing the round
connector receptacles to the mounting plate.
2-13-10
13. Tag and disconnect the receptacles.
14. Remove the rectangular connectors and wires
(part of the superstructure wiring harness) and secure
them and the round connector receptacles to the
turntable side plates.
15. Remove the bolt securing the swivel base to the
mounting bracket.
16. Remove three setscrews securing the swivel
core assembly to the center post.
CAUTION
When withdrawing the wiring harness
through the center of the swivel, ensure
the rectangular connectors do not get
caught and damaged.
17. Remove the swivel and wiring harness from the
crane.
INSTALLATION.
1. Route the collector core wiring harness through
the center of the hydraulic swivel, and insert the center
post into the base of the core assembly
2. Install the bolt attaching the swivel base to the
mounting bracket, finger tighten.
NOTE
Area definition switches in the swivel will
not function at the proper time unless the
core assembly is positioned correctly.
3. Rotate the collector core assembly on the center
post as required, so that the front of the core assembly
is aligned with the front of the crane.
4. Secure the collector core assembly to the center
post by tightening three setscrews in the collector
core.
5. Tighten the bolt securing the swivel to the
bracket.
6. Install the rectangular connectors and wires into
the connector receptacle cutout on the mounting plate.
 TM 5-3810-307-24-1-1

Figure 2-13-4. Electrical Swivel

2-13-11
TM 5-3810-307-24-1-1

7. Install the round connector receptacles into the 10. Connect each of the wires from connector one
mounting plate and secure with the screws. into connector one.

8. Connect the round connectors and the 11. Connect each of the wires from connector two
rectangular connectors as tagged. into connector two.

9. Install the swivel cover, gasket, and screws.
NOTE
Steps 10 and 11 are performed on the
collector ring harness after it has been
routed down through the hydraulic and air
swivel.
12. Plug the round and rectangular connectors into
the chassis wiring receptacles.
13. Connect the batteries.
14. Activate all systems; cycle all functions and
observe for proper operation.

2-13-12
 TM 5-3810-307-24-1-1

SECTION 14
ELECTRICAL SYSTEM

TABLE OF CONTENTS
Page

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-14
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-14
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
NATO Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Electrical Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-21
Windshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-22
Panel Light Dimmer Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-23
Indicator Lights (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-24
Indicator Lights (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-27
Backup Alarm (Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-28

2-14-1
TM 5-3810-307-24-1-1

TABLE OF CONTENTS (continued)

Page

Backup Alarm (Superstructure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-29

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-29

LIST OF FIGURES
Number Title Page

2-14-1 Major Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-6

2-14-2 Carrier Circuit Breaker Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-12
2-14-3 Superstructure Circuit Breaker Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-13
2-14-4 Battery Connection Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
2-14-5 NATO Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
2-14-6 Instrument Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
2-14-7 Electrical Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
2-14-8 Ignition Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-21
2-14-9 Windshield Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-22
2-14-10 Panel Light Dimmer Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-23
2-14-11 Indicator Lights (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-26
2-14-12 Indicator Lights (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-27
2-14-13 Backup Alarm Installation (Carrier). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-28
2-14-14 Backup Alarm Installation (Superstructure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-29

LIST OF TABLES
Name Title Page

2-14-1 AMP Extraction Tool Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-15

2-14-2 AMP Crimping Tool Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-15
2-14-3 Deutsch Extraction Tool Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-15
2-14-4 Deutsch Crimping Tool Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-15

2-14-2
 TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-14-14
If it should become necessary to perform electrical maintenance on live or hot
circuits, remove all rings, watches, and other jewelry before performing
maintenance as serious burns result from accidental grounding or shorting
circuits.

WARNING 2-14-14
Ensure the batteries are disconnected before performing any maintenance on
an electrical circuit.

2-14-3/(2-14-4 Blank)

ELECTRICAL SYSTEM
DESCRIPTION
The electrical system is 24-volt operation with 24-volt
starting, consisting of an alternator, and four 12-volt
lead-acid batteries, series-parallel connected. The
system is a single wire ground return type, utilizing the
machine's structure as ground.
Electrical power is transferred to and from the carrier
and superstructure through the electrical swivel. For
more detailed information on the electrical swivel, refer
to Section 13 - SWIVELS.
Electrical schematics and wiring diagrams are located
at the back of this manual. Refer to Figure 2-14-1 for
locations of major electrical components.
All electrical circuits are protected by circuit breakers in
the fuse and relay panel located beneath the control
panel of each cab. Refer to Figures 2-14-2 and 2-14-3
for identification of circuit breakers.
ALTERNATOR.
The alternator is mounted on the engine and is belt
driven. It is a 70 ampere alternator with 24-volt
TM 5-3810-307-24-1-1
output terminals. When the engine is running, the 24-
volt terminal supplies power to the machine electrical
circuits and the voltage to recharge the batteries and
maintain them at a full state of charge.
BATTERIES.
The four 12-volt batteries are located in a box on the
right side of the carrier in front of the fuel tank. The
cover is secured with an adjustable draw latch and
hinges downward to open. A two-position battery
disconnect switch is located below the battery box.
The switch completes or interrupts the battery circuit by
connecting or disconnecting the circuit to ground.
JUNCTION BOX.
The junction box is located on the left rear exterior wall
of the carrier cab. It contains terminal blocks, rectifiers,
relays, and diodes for the carrier electrical circuits.
2-14-5
TM 5-3810-307-24-1-1

CARRIER CAB

Figure 2-14-1. Major Electrical Components (Sheet 1 of 6)

2-14-6
 TM 5-3810-307-24-1-1

SUPERSTRUCTURE CAB

Figure 2-14-1. Major Electrical Components (Sheet 2 of 6)

2-14-7
2-14-8

TM 5-3810-307-24-1-1
CARRIER FRAME

Figure 2-14-1. Major Electrical Components (Sheet 3 of 6)

 CARRIER FRAME

TM 5-3810-307-24-1-1
2-14-9

Figure 2-14-1. Major Electrical Components (Sheet 4 of 6)

2-14-10

TM 5-3810-307-24-1-1
SUPERSTRUCTURE

Figure 2-14-1. Major Electrical Components (Sheet 5 of 6)

 1. CAB IDENT. LIGHTS 17. DOME LIGHT 35. REAR STEER UNPINNED 54. ARM REST LOCKOUT
2. STOP LIGHT & LOW AIR 18. A/C CONNECTOR SWITCH SOLENOID
PRESSURE SWITCHES 19. SEAT HARNESS CONNECOR 36. OIL COOLER TEMP. SWITCH 55. A/C IDLE BOOST SOLENOID
3. A//C CONNECTORS 20. CIRCULATING FAN 37. TAIL/FLOOD LIGHT 56. BACKUP ALARM
4. DOME LIGHT 21. WINDSHIELD WIPER MOTOR 38. OIL COOLER FAN MOTOR 57. HOIST ROTATION MAGNETIC
5. WINDSHIELD WASHER 22. HEADLIGHT 39. PARK BRAKE SWITCH SENSOR
BOTTLE 23. SIDE MARKER LIGHT 40. REAR WHEEL SENSOR 58. A/C COMPRESSOR
6. HEATER FAN MOTOR & 24. DRIVING HORN (CENTER 59. LMI LOCKOUT MANIFOLD
RESISTORS 25. ALTERNATOR 41. REAR WHEEL SENSOR VALVE
7. DOOR SWITCH 26. FRONT WHEEL SENSOR (LEFT) 60. CLAMSHELL SOLENOID
8. APC 100 CONNECTORS (LEFT) 42. BULKHEAD CONNECTORS 61. A/C CONTROL BOX
9. FRONT CONSOLE 27. FRONT WHEEL SENSOR 43. AIR DRYER 62. CAB HEATER
CONNECTORS (CENTER) 44. FRONT DIFF. LOCK SWITCH 63. SWING BRAKE SWITCH
10. STEERING COLUMN 28. STARTER 45. FRONT DIFF. LOCK SOLENOID 64. DRIVE HORN

TM 5-3810-307-24-1-1
CONNECTOR 29. BATTERY JUNCTION BOX 46. MAIN JUNCTION BOX 65. WINDSHIELD WASHER
11. WINDSHIELD WIPER MOTOR 30. BATTERY DISCONNECT 47. BOOM REST SWITCH BOTTLE
12. CIRCULATING FAN SWITCH 48. FULE LINE HEATER 66. FUEL LINE HEATER &
13. WORK LIGHT 31. BATTERY BOX 49. FUEL TEMP. SWITCH THERMOSTAT
14. STEERING COLUMN 32. FUEL LEVEL SENDER 50. 2WD SELECT SWITCH 67. SWING BRAKE SOLENOID
CONNECTOR 33. REAR STEER PINNED 51. FUEL HEATER RELAY 68. LOW AIR PRESS. SWITCHES
15. BOOST SWITCH SENSOR 52. STEER REVERSING SOLENOID 69. A/C CONDENSER
16. HEATER SWITCH 34. REAR DIFF. LOCK SWITCH 53. HYD. OIL COOLER TEMP.
2-14-11

SWITCH

Figure 2-14-1. Major Electrical Components (Sheet 6 of 6)

TM 5-3810-307-24-1-1

CIRCUIT BREAKERS

NUMBER AMP FUNCTION

CB1 15 S/S POWER, CARRIER ELECT SHIFT

CB2 10 REV LIGHT/ALARM/AIR DRYER

CB3 10 TORQ CONV/PARK BRAKE MODE

CB4 10 VOLTMETER/WARN LIGHTS/BUZZER

CB5 10 DIFF LOCK/OSCILL SOLENOID

CB6 10 WIPER/WASHER

CB7 15 HEATER FAN

CB8 20 LIGHT SWITCH

CB9 20 AIR CONDITIONER

CB10 10 TURN SIG/HAZARD LIGHTS

CB11 10 DOME LIGHT

CB12 10 HORN

CB13 10 LEFT HEADLT LO BEAM

CB14 10 RIGHT HEADLT LO BEAM

CB15 10 RIGHT HEADLT HI BEAM

CB16 10 LEFT HEADLT HI BEAM

CB17 10 TAIL/MARKER/IDENT LIGHTS

CB18 10 TAIL/MARKER/IDENT LIGHTS

CB19 5 GAUGE/PANEL LIGHTS

CB20 15 ENG START/COLD START

Figure 2-14-2. Carrier Circuit Breaker Identification

2-14-12
 TM 5-3810-307-24-1-1

CIRCUIT BREAKERS

NUMBER AMP FUNCTION

CB1 15 HEATER FUEL LINE

CB2 15 A/C CONDENSER FANS

CB3 5 HOIST ROTATION INDICATORS

CB4 5 GAUGES/BUZZER/WARN LIGHTS

CB5 10 CAB CIRCULATING FAN

CB6 10 WINDSHIELD WIPER/WASHER

CB7 15 OUTRIGGERS

CB8 10 SWING BRAKE/TRANS SELECT/FRONT STEER

CB9 10 CRANE FUNCTIONS/SEAT/ARM REST LOCKOUT SOLENOID

CB10 10 STEER LOCK/FRONT STEER INDICATOR

CB11 15 STEER REV/LMI LOCKOUT

CB12 5 OIL COOLER FAN RELAY

CB13 10 DOME LIGHT

CB14 10 WORK LIGHT

CB15 10 FLASHER/TURN SIGNAL SWITCH

CB16 10 DRIVE/PANEL/GAUGE LIGHTS

CB17 15 OIL COOLER FAN

CB18 20 CAB HEATER

CB19 10 HORN/HORN RELAY

CB20 20 A/C BLOWER FAN & CONTROLS

Figure 2-14-3. Superstructure Circuit Breaker Identification

2-14-13
TM 5-3810-307-24-1-1

MAINTENANCE

GENERAL. 4. Incorrect wire size.

Electrical system maintenance includes replacement of 5. Worn brushes.

damaged components. Standard wiring practices
should be observed when replacement is necessary. 6. Improper spring tension on the brush assembly.

7. Loose setscrews on the collector ring assembly.

WARNING
If it should become necessary to perform To isolate electrical problems, a multimeter should be
electrical maintenance on live or hot used. The multimeter, when used properly, can
circuits, remove all rings, watches, and provide readings necessary for service personnel to
other jewelry before performing determine the following:
maintenance as serious burns result from
accidental grounding or short-ing circuits. 1. Opens in the electrical system.

2. Resistance in the electrical system.

WARNING
If problem is not in the swivel, there may be a loose or
Ensure the batteries are disconnected
corroded connection in the pin type connectors. Check
before performing any maintenance on an
the connectors to ensure that the wire pins are properly
electrical circuit.
seated and engaged in the receptacle. If the male and
female pins show any signs of corrosion, use a good
CAUTION
quality electrical contact cleaner or a fine sandpaper to
clean them. When the pins show signs of arcing or
Never replace original wiring with wiring of
burning, it will probably be necessary to replace them.
a smaller diameter.
Since the contacts are crimped on the wires, it is not
possible to remove them for reuse.
Most problems associated with the electrical system
can be traced to the electrical swivel. Problems
The following tables list the tools necessary for
common to the swivel are:
connector maintenance.
1. Improper mounting.
Use the proper extraction tool to remove the contact(s)
from the plug or receptacle. Cut the wire as close to
2. Foreign material between the brushes and slip
the contact as possible. After cutting, the wire will most
rings.
likely be too short. Use of a wire that is too short will
cause another failure due to excessive strain on the
3. Incorrect wiring from the swivel to the
crimped joint when the contact is inserted into the plug
components.
or receptacle. Add a short length of the same size wire
to the short wire by crimp splice or solder. Use heat
shrinkable tubing or other suitable material to insulate
the splice.

2-14-14
 TM 5-3810-307-24-1-1

Table 2-14-1. AMP Extraction Tool Table

Description AMP Part Number Grove Part Number

14 gauge wire (connectors) 305183 9-999-100176

12 to 8 gauge wire (connectors) 91019-3 9-999-100175

4 to 9 circuit (in-line connectors) 453300-1 N/A

15 circuit (in-line connectors) 458944-1 N/A

... N/A means not available.

Table 2-14-2. AMP Crimping Tool Table

Description AMP Part Number Grove Part Number

Tool Die Tool Die

14 to 12 gauge wire 69710-1 90145-1 9-999-100177 N\A

10 to 8 gauge wire 69710-1 90140-1 9-999-100177 9-999-100178

4 to 9 circuit (in-line connectors) 69710-1 90306-1 9-999-100177 N/A

15 circuit (in-line connectors) 90299-1 -- N/A --

N/A means not available.

Table 2-14-3. Deutsch Extraction Tool Table

Description Deutsch Part Number Grove Part Number

12 gauge wire 114010 9-999-100194

16 gauge wire 0411-204-1605 9-999-100195

8-10 gauge wire 114008 7-902-000012

4-6 gauge wire 114009 7-902-000009

Table 2-14-4. Deutsch Crimping Tool Table

Description Deutsch Part Number Grove Part Number

12 gauge wire HDT-12-00 9-999-100192

16 gauge wire HDT-16-00 9-999-100193

8-10 gauge wire CONSULT FACTORY

4- 6 gauge wire CONSULT FACTORY

2-14-15
TM 5-3810-307-24-1-1

ALTERNATOR. 3. Position the belt around the alternator pulley.

Removal. 4. Adjust the alternator until the proper belt tension

is obtained and tighten the attaching hardware. (Refer
1. Open the engine compartment door. to Alternator Belt Tension and Attaching Hardware
Torque Table).
2. Tag and disconnect the electrical leads from the
terminals on the alternator. 5. Connect the electrical leads to the terminals as
tagged during removal.
3. Loosen the alternator attaching hardware and
remove the belt or belts from the alternator pulley. BATTERIES.

4. Remove the attaching hardware from the belt Removal.

tension adjusting bracket.
1. Unhook the cover and hinge it downward
5. Remove the nut, washers, and bolt attaching the
alternator to the mounting bracket and remove the 2. Tag and disconnect all leads from the batteries'
alternator. terminals starting with the negative terminals.

Installation. 3. Remove the nuts, washers, and lockwashers

from the angle brackets hold down rods and remove
1. Position the alternator on the mounting bracket the angle hold down brackets.
and secure with the bolt, washers, and nut. Do not
tighten at this time. 4. Remove each battery and the plywood spacer
they sit on.
2. Install the hardware attaching the alternator to
the belt tension adjusting bracket.

Figure 2-14-4. Battery Connection Panel

2-14-16
 TM 5-3810-307-24-1-1

Installation. and secure the rods to the brackets with nuts,

washers, and lockwashers.
1. If necessary, replace the plywood before
installing the batteries. 4. Connect all leads to the batteries' terminals start-
ing with the positive terminals.
2. Install each battery.
5. Close the battery cover.
3. Install the angle hold down brackets and rods;

NATO SLAVE RECEPTACLE

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Remove capscrew (1, Figure 2-14-5), lockwasher (2), and negative battery cable (3) from NATO slave
receptacle (11).

c. Remove capscrew (4), lockwasher (5), and positive battery cable (6) from NATO slave receptacle (11).

d. Remove nuts (7), lockwashers (8), washers (9), screws (10), and NATO slave receptacle (11) from vehicle.

Installation

CAUTION

Observe polarity symbols on rear of receptacle when installing. Ensure "-"

symbol is to rear of carrier.

a. Install NATO slave receptacle (11, Figure 2-14-5) on vehicle with screws (10), washers (9), lockwashers (8),
and nuts (7).

b. Connect positive battery cable (6) to "+" side of NATO slave receptacle (11) with lockwasher (5) and capscrew
(4).

c. Connect negative battery cable (3) to "-" side of NATO slave receptacle (11) with lockwasher (2) and capscrew
(1).

2-14-17
TM 5-3810-307-24-1-1

LEGEND

1. Capscrew 7. Nut
2. Lockwasher 8. Lockwasher
3. Negative battery cable 9. Washer
4. Capscrew 10. Screw
5. Lockwasher 11. NATO slave receptacle
6. Positive battery cable

Figure 2-14-5. NATO Slave Receptacle

2-14-18
 TM 5-3810-307-24-1-1

INSTRUMENTS. Installation.

NOTE 1. Connect the electrical leads as marked prior to

removal.
Procedures are typical for all instruments/
gauges except dual air gauges. Air 2. Place the gauge into position on the panel and
gauges require disconnection of air lines. secure it with the attaching hardware.

Removal. 3. Position the cab front cover plate and connect

the work lights. Secure the cover plate with the
1. Remove applicable dash panel to the extent that attaching wing nuts.
access to instrument hardware is possible, refer to
DASH PANEL in Section 1. Functional Check

2. Remove the hardware securing the gauge to the
dash panel; then remove the gauge.
3. Tag and disconnect the electrical leads to the
gauge; then tape the lead ends.
Start the engine and observe for proper functioning of
the repaired indicator. (Refer to Operator's Manual).
Troubleshoot further as necessary any system
malfunction not corrected by repair or replacement of
the indicator or associated wiring.

Inspection. ELECTRICAL SWITCHES.

1. Examine gauges for cracked and broken lenses. NOTE

Check gauge terminals and mounting studs for Procedures are typical for all switches
damage. except AIR CONDITIONER and PANEL
DIM switches in superstructure cab, and
IGNITION and WIPER/WASHER switches
in both cabs.

Removal.

1. Remove applicable dash panel to the extent that

access to switch hardware is possible, refer to DASH
PANEL in Section 1.

2. Remove the hardware securing the switch to the

dash panel; then remove the switch.

3. Tag and disconnect the leads from the switch;

then tape the lead ends.

Inspection.

1. Visually check the switch for evidence of cracks,

damaged connections, or other damage.
Figure 2-14-6. Instrument Removal and
Installation 2. Check wiring for damaged insulation or damaged
terminals.
2. Check wiring for damaged insulation or damaged
terminals.

2-14-19
TM 5-3810-307-24-1-1

3. Perform the following check to determine switch Installation.

serviceability.
1. Connect the electrical leads as marked prior to
a. Using an ohmmeter, check for continuity removal.
between the switch terminals with switch in ON or
activated position. 2. Position the switch on the panel and secure it
with the attaching hardware.
b. Position switch to OFF. Ohmmeter should
register zero (no continuity). 3. Reinstall the right side console or install cab front
access panel.

Functional Check.

Operate the switch as described in the Operator's

Manual. Observe it for proper functioning in the
applicable circuit. Continue troubleshooting as
necessary any system or circuit malfunction not
corrected by repair or replacement of the switch or
associated wiring.

Figure 2-14-7. Electrical Switch Removal and

Installation

2-14-20
 TM 5-3810-307-24-1-1

IGNITION SWITCH

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Remove retaining ring (1, Figure 2-14-8) and ignition switch (2) from dash panel.

c. Tag and disconnect electrical leads from ignition switch (2).

Installation

a. Connect electrical leads to ignition switch (2) and remove tags.

b. Install ignition switch (2, Figure 2-14-8) in dash panel with retaining ring (1).

LEGEND

1. Retaining ring
2. Ignition switch

Figure 2-14-8. Ignition Switch Installation

2-14-21
TM 5-3810-307-24-1-1

WINDSHIELD WIPER/WASHER SWITCH

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Disconnect electrical connector for windshield wiper/washer switch (4, Figure 2-14-9).

c. Loosen set screw and remove knob (1) from switch (4).

d. Remove nut (2), washer (3), and windshield wiper/washer switch (4) from dash panel.

Installation

a. Position windshield wiper/washer switch (4, Figure 2-14-9) in dash panel, and secure with washer (3) and nut
(2).

b. Install knob (1) on windshield wiper/washer switch (4) and tighten set screw.

c. Connect electrical connector for windshield wiper/washer switch (4).

LEGEND

1. Knob, switch 3. Washer

2. Retaining nut 4. Wiper/washer switch

Figure 2-14-9. Windshield Wiper/Washer Switch

2-14-22
 TM 5-3810-307-24-1-1

PANEL LIGHT DIMMER CONTROL (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Tag and disconnect electrical leads from rheostat (4, Figure 2-14-10).

c. Loosen screw (part of knob). Then remove knob (1), nut (2), washer (3), and rheostat (4) from dash panel.

Installation

a. Position rheostat (4, Figure 2-14-10) in dash panel and secure with washer (3) and nut (2).

b. Install knob (1) on stem of rheostat (4). Tighten screw (part of knob).

c. Connect electrical leads to rheostat (4) and remove tags.

LEGEND

1. Knob
2. Nut
3. Washer
4. Rheostat

Figure 2-14-10. Panel Light Dimmer Control (Superstructure Cab)

2-14-23
TM 5-3810-307-24-1-1

INDICATOR LIGHTS (CARRIER CAB)

Removal

a. Ensure battery disconnect switch is in OFF position.

b. Remove main alert light strip as follows:

(1) Remove access panel from top of dash panel.

(2) Tag and disconnect electrical leads from LED clusters (21, Figure 2-14-11).

(3) Remove nuts (1), lockwashers (2), washers (3), screws (4), light strip (5), and panel (6) from dash panel.

c. Remove rear steer light strip as follows:

(1) Remove nuts (7, Figure 2-14-11), lockwashers (8), washers (9), screws (10), light strip (11), and panel
(12) from dash panel.

(2) Tag and disconnect electrical leads from LED clusters (21).

d. Remove turn signal LED clusters as follows:

(1) Remove access panel from top of dash panel.

(2) Tag and disconnect electrical leads from LED cluster (17, Figure 2-14-11).

(3) Remove nuts (13), lockwashers (14), washers (15), screws (16), LED cluster (17), gasket (18), and
panel (19).

e. Remove LED clusters from light strips as follows:

NOTE

LED clusters are different colors depending on purpose of indicator light.

Mark position of each LED cluster to light strip to ensure correct colored
cluster is reinstalled.

(1) Remove capscrews (20) securing each LED cluster to light strip (5 or 11) as applicable.

(2) Remove LED cluster (21) and gasket (22) from light strip.

Installation

a. Install LED clusters on light strips as follows:

(1) Position gasket (22, Figure 2-14-11) and LED cluster (21) on light strip (5 or 11) as applicable. Ensure
arrow on diode is pointing up.

(2) Secure LED cluster (21) and gasket (22) with capscrews (20).

2-14-24
 TM 5-3810-307-24-1-1

b. Install turn signal LED clusters as follows:

(1) Position panel (19, Figure 2-14-11), gasket (18), and LED cluster (17) in dash panel. Ensure arrow on
diode is pointing up.

(2) Secure panel (19), gasket (18), and LED cluster (17) with screws (16), washers (15), lockwashers (14),
and nuts (13).

(3) Connect electrical leads, remove tags, and install access panel on top of dash panel.

c. Install rear steer light strip as follows:

(1) Position light strip (11, Figure 2-14-11) near dash panel, connect electrical leads, and remove tags.

(2) Position panel (12) and light strip (11) in dash panel and secure with screws (10), washers (9),
lockwashers (8), and nuts (7).

d. Install main alert light strip as follows:

(1) Position panel (6, Figure 2-14-11) and light strip (5) in dash panel and secure with screws (4), washers
(3), lockwashers (2), and nuts (1).

(2) Connect electrical leads, remove tags, and install access panel on top of dash panel.

2-14-25
TM 5-3810-307-24-1-1

LEGEND

1. Nut 9. Washer 16. Screw

2. Lockwasher 10. Screw 17. LED cluster
3. Washer 11. Light strip 18. Gasket
4. Screw 12. Panel 19. Panel
5. Light strip 13. Nut 20. Capscrew
6. Panel 14. Lockwasher 21. LED cluster
7. Nut 15. Washer 22. Gasket
8. Lockwasher

Figure 2-14-11. Indicator Lights (Carrier Cab)

2-14-26
 TM 5-3810-307-24-1-1

INDICATOR LIGHTS (SUPERSTRUCTURE CAB)

Removal

a. Ensure battery disconnect is in OFF position.

b. Unscrew knobs and move LMI display console aside. Then remove access panel from top of dash panel.

c. Tag and disconnect electrical leads.

NOTE

Different colored indicator lights are used depending on purpose of indicator

light. Mark position of each light to dash panel to ensure correct colored light
is reinstalled.

d. Pinch locking tabs (Figure 2-14-12) on sides of light and remove light from dash panel.

Installation

a. Push light (Figure 2-14-12) into dash panel until locking tabs on sides of light pop out.

b. Connect electrical leads and remove tags.

c. Install access panel on top of dash panel. Install LMI display console.

Figure 2-14-12. Indicator Lights (Superstructure Cab)

2-14-27
TM 5-3810-307-24-1-1

BACKUP ALARM (CARRIER)

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Disconnect backup alarm (6, Figure 2-14-13) electrical connector from carrier electrical harness.

c. Remove nuts (1), lockwashers (2), washers (3), capscrews (4), washers (5), and backup alarm (6) from carrier
frame.

Installation

a. Insert capscrews (4, Figure 2-14-13) with washers (5) through holes in carrier frame.

b. Position backup alarm (6) over capscrews (4) and install ground wire on capscrew (4) on terminal side of
backup alarm.

c. Secure backup alarm (6) to carrier frame with washers (3), lockwashers (2), and nuts (1).

d. Connect electrical connector to carrier electrical harness.

LEGEND

1. Nut 3. Washer 5. Washer

2. Lockwasher 4. Capscrew 6. Backup alarm

Figure 2-14-13. Backup Alarm Installation (Carrier)

2-14-28
 TM 5-3810-307-24-1-1

BACKUP ALARM (SUPERSTRUCTURE)

Removal

a. Ensure battery disconnect switch is in the OFF position.

b. Tag electrical leads and disconnect superstructure electrical harness lead from backup alarm (4, Figure 2-14-
14).

c. Remove nuts (1), lockwashers (2), washers (3), ground wires, backup alarm (4), and washers (5) from
superstructure frame.

Installation

a. Position washers (5, Figure 2-14-14) and backup alarm (4) on studs on superstructure frame.

b. Place ground wires from backup alarm (4) and superstructure electrical harness on stud at terminal side of
backup alarm.

c. Secure backup alarm (4) to carrier frame with washers (3), lockwashers (2), and nuts (1).

d. Connect superstructure electrical harness lead to backup alarm (4).

LEGEND

1. Nut 3 Washer 5. Washer

2. Lockwasher 4. Backup alarm

Figure 2-14-14 Backup Alarm Installation (Superstructure)

2-14-29/(2-14-30 Blank)
 TM 5-3810-307-24-1-1

SECTION 15
EMERGENCY STOWAGE SYSTEM
TABLE OF CONTENTS
Page

EMERGENCY STOWAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-3

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-3
3-WAY VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-4
PUMP/MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
ELECTRICAL CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-10

LIST OF FIGURES
Number Title Page

2-15-1 3-Way Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-5

2-15-2 Pump/Motor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-7
2-15-3 Electrical Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-9

2-15-1
TM 5-3810-307-24-1-1

WARNING SUMMARY
Page

WARNING 2-15-4
2-15-6
Do not attempt to loosen fittings in pressurized lines or while hydraulic
pumps are in operation.

2-15-4
WARNING
2-15-6
Ensure that all hydraulic systems are shut down and the pressure is
relieved.

2-15-8
WARNING
If it should become necessary to perform electrical maintenance on live or
hot circuits, remove all rings, watches, and other jewelry before
performing maintenance as serious burns result from accidental
grounding or shorting circuits.

WARNING 2-15-8

Ensure the batteries are disconnected before performing any

maintenance on an electrical circuit.

2-15-2
 TM 5-3810-307-24-1-1

EMERGENCY STOWAGE SYSTEM

DESCRIPTION

This Section describes the emergency stowage electrical control box.

system. Description of individual components is
discussed in their individual Sections.
The emergency stowage system is located at the
center left side of the vehicle and consists of a 3-way
valve assembly, pump/motor assembly, and an
In the event of a hydraulic failure (pumps, engine,
etc.), the emergency stowage system is used to
safely lower a suspended load, retract the boom,
swing the boom over the front, and retract the
outriggers in order to tow the crane to a maintenance
area.

2-15-3
TM 5-3810-307-24-1-1

3-Way Valve Assembly

DESCRIPTION

The 3-way valve assembly is a manually operated hydraulic flow of the emergency stowage pump, all
ball valve used to direct flow to either the crane hoist craning functions can not be supplied at the same
functions or telescope and lift functions during time. It is therefore necessary to reposition the valve
emergency stowage operations. Due to the limited control lever to operate the different functions.

MAINTENANCE

REMOVAL. 5. Remove adapters (9 and 11) from 3-way valve

(5), and adapter (10) from check valve (12). Cap or
1. Ensure battery disconnect switch is in OFF plug all openings.
position.
6. Remove check valve (12) and adapters (13
2. Remove screw (1, Figure 2-15-1) and lever (2) and 14) from 3-way valve (5). Cap or plug all
from 3-way valve (5). openings.

3. Remove screws (3), washers (4), and 3-way INSTALLATION.

valve (5) from mounting plate.
1. Install adapters (13 and 14, Figure 2-15-1) and
check valve (12) in 3-way valve (5).
WARNING
Do not attempt to loosen fittings in 2. Install adapters (9 and 11) in 3-way valve (5),
pressurized lines or while hydraulic and adapter (10) in check valve (12).
pumps are in operation.
3. Connect hydraulic hoses (6, 7, and 8) to
adapters (9, 10, and 11) and remove tags.
WARNING
4. Install 3-way valve (5) on mounting plate with
Ensure that all hydraulic systems are
washers (4) and screws (3).
shut down and the pressure is relieved.
5. Install lever (2) on 3-way valve (5) with screw
4. Tag and disconnect hydraulic hoses (6, 7, and
(1).
8) from adapters (9, 10, and 11). Cap or plug all
openings.
Functional Check.

Operate emergency stowage system. Check 3-way

valve for proper operation and any leakage.

2-15-4
 TM 5-3810-307-24-1-1

LEGEND

1. Screw 6. Hydraulic hose 11. Adapter

2. Lever 7. Hydraulic hose 12. Check valve
3. Screw 8. Hydraulic hose 13. Adapter
4. Washer 9. Adapter 14. Adapter
5. 3-Way Valve 10. Adapter

Figure 2-15-1. 3-way Valve Installation

2-15-5
TM 5-3810-307-24-1-1

Pump/Motor Assembly

DESCRIPTION

The emergency stowage system pump/motor
assembly is comprised of a 24 VDC electric motor
and a positive displacement, gear-type, single
section hydraulic pump with an output of 2 gpm (7.6
lpm).
The electric motor, operates on power received
through the electrical control box to drive the
hydraulic pump which provides the hydraulic flow
required for emergency stowage operations.

MAINTENANCE

REMOVAL. 6. If necessary, match mark hydraulic pump (9)

housing to motor (10) housing, remove capscrews
1. Ensure battery disconnect switch is in OFF (14) and lockwashers (15), and separate hydraulic
position. pump (9) from motor (10).

2. Tag and disconnect electrical cables from INSTALLATION.

terminals of motor (10, Figure 2-15-2).
WARNING
Do not attempt to loosen fittings in
pressurized lines or while hydraulic
pumps are in operation.
WARNING
Ensure that all hydraulic systems are
shut down and the pressure is relieved.
1. If separated, position hydraulic pump (9,
Figure 2-15-2) on motor (10), align match marks on
housings, and secure hydraulic pump (9) to motor
(10) with lockwashers (15) and capscrews (14).
2. Install adapters (11, 12, and 13) on hydraulic
pump (9).
3. Install pump/motor assembly (8) on mounting
bracket with washers (7), capscrews (6), washers
(5), and new locknuts (4).

4. Connect hydraulic hoses (3, 2, and 1) on

3. Tag and disconnect hydraulic hoses (1, 2, and
hydraulic pump adapters (13, 12, and 11) and
3) from hydraulic pump adapters (11, 12, and 13).
remove tags.
Cap or plug all openings.
5. Connect electrical cables to terminals of motor
4. Remove locknuts (4), washers (5), capscrews
(10) and remove tags.
(6), washers (7), and pump/motor assembly (8) from
mounting bracket.
Functional Check.
5. Remove adapters (11, 12, and 13) from
Operate emergency stowage system. Check
hydraulic pump (9). Cap or plug all openings.
pump/motor assembly for proper operation and any
leakage.

2-15-6
 TM 5-3810-307-24-1-1

LEGEND

1. Hydraulic hose 6. Capscrew 11. Adapter

2. Hydraulic hose 7. Washer 12. Adapter
3. Hydraulic hose 8. Pump/motor assembly 13. Adapter
4. Locknut 9. Hydraulic pump 14. Capscrew
5. Washer 10. Motor 15. Lockwasher

Figure 2-15-2. Pump/Motor Assembly Installation

2-15-7
TM 5-3810-307-24-1-1
Electrical Control Box Assembly
DESCRIPTION
The emergency stowage system electrical control
box assembly is comprised of an ON/OFF control
switch, a 400 amp power relay, two 44 joules metal
oxide varistor (MOV) assemblies, and a wiring
harness to connect the control switch to the relay.
The control switch receives power from the vehicle's
MAINTENANCE
REMOVAL.
WARNING
If it should become necessary to perform
electrical maintenance on live or hot cir-
cuits, remove all rings, watches, and other
jewelry before performing maintenance as
serious burns result from accidental
grounding or shorting circuits.
WARNING
Ensure the batteries are disconnected
before per-forming any maintenance on
an electrical circuit.
CAUTION
Never replace original wiring with wiring
of a smaller diameter.
1. Ensure battery disconnect switch is in OFF
position.
2. Tag and disconnect electrical cables from 1/2
in. terminals of power relay (11, Figure 2-15-3), and
pull cables from control box (4).
3. Remove locknuts (1), washers (2), capscrews
(3), and control box (4) from vehicle mounting plate.
2-15-8
batteries through the NATO slave receptacle. When
the switch is moved to ON, power is sent to the
power relay which closes and transfers battery
power to operate the electric motor to drive the
hydraulic pump. The switch can also be powered by
an external 24 VDC source connected to the NATO
slave receptacle.
REPAIR.
1. Disassemble electrical control box (4, Figure 2-
15-3) as necessary to replace worn, damaged, or
defective components:
a. Remove nuts (5 and 6), then tag and
remove MOV assemblies (7) and
electrical wires from power relay (11).
b. Remove nuts (8), washers (9), screws
(10), and power relay (11) from control
box (4).
c. Tag and disconnect electrical wires from
ON/OFF switch (14).
d. Remove nut (12), switch guard (13), and
switch (14) from control box (4).
2. Assemble electrical control box (4, Figure 2-
15-3) as necessary:
a. Install ON/OFF switch (14) and switch
guard (13) in control box (4) with nut
(12).
b. Connect electrical wires to switch (14)
and remove tags.
c. Install power relay (11) in control box (4)
with screws (10), washers (9), and nuts
(8).
d. Install MOV assemblies (7) and electrical
wires on power relay (11) with nuts (5
and 6). Remove tags.
 TM 5-3810-307-24-1-1

LEGEND

1. Locknut 6. Nut 11. Power relay

2. Washer 7. MOV assembly 12. Nut
3. Capscrew 8. Nut 13. Switch guard
4. Control box 9. Washer 14. ON/OFF switch
5. Nut 10. Screw, pan head

Figure 2-15-3. Electrical Control Box Assembly

2-15-9
TM 5-3810-307-24-1-1

INSTALLATION. Functional Check.

1. Install control box (4, Figure 2-15-3) on vehicle Operate emergency stowage system. Check system
mounting plate with capscrews (3), washers (2), and for proper operation.
new locknuts (1).

2. Insert electrical cables through strain reliefs in

bottom of control box (4) and connect cables to 1/2
in. terminals on power relay (12).

2-15-10
 TM 5-3810-307-24-1-1

SECTION 16
PREPARATION FOR STORAGE OR SHIPMENT

TABLE OF CONTENTS
Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-1
PRESERVATION, PACKAGING, PACKING, MARKING, AND SHIPPING REQUIREMENT . . . . . . . . . . 2-16-1
SHORT TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-1
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-2
PREPARATION FOR SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-2

INTRODUCTION

Before storing the crane for long periods or shipping it to a distant location, certain preparations must be made to
ensure operational readiness when the crane is placed in service again.

PRESERVATION, PACKAGING, PACKING, MARKING, AND SHIPPING REQUIREMENTS

General

These instructions provide minimum preservation and interim storage requirements for the crane. Components
not to be painted will be coated with a preservative, whose application, removal, or use will not damage the
mechanism, structure, or function of the component or end item.

SHORT TERM STORAGE

The crane should be stored in an "operation-ready" status wherein all fluid levels and lubrication points are
maintained in an operational status.

Diesel Engine

Refer to TM 5-3810-307-24-2-2, page 14-23 for short term diesel engine storage instructions.

Fuel Tank

Draining of fuel tanks is not required. If fuel tank is empty, no preservation is required.

Sealing of Openings

Openings that will permit direct entry of water will be sealed with pressure-sensitive tape conforming to PPP-T-60,
Type IV. Large openings will be bridged with waterproof barrier material conforming to PPP-B-1055, and the
edges of the barrier material secured to adjacent surfaces with tape.

Lubricating System

Lubricate the equipment in accordance with the lubrication chart. Check lubricant for level and condition.
Operate the engine until it reaches normal operating temperature to ensure complete lubrication of bearings,
gears, etc. The oil will remain in the crankcase.

2-16-1 C-1
TM 5-3810-307-24-1-1

NOTE

Once the crane is stored, periodically cycle the crane through all of its crane
functions.

LONG TERM STORAGE

In long term storage where periodic cycling of crane functions is not feasible, preserve the crane in accordance
with the procedures contained in MIL-STD-162E, Preparation for Shipment, Storage, Cycle Maintenance (of)
Material Handling Equipment (Level A).

Diesel Engine

Refer to TM 5-3810-307-24-2-2, page 14-25 for long term diesel engine storage instructions.

Batteries and Cables

Batteries filled and fully charged will be secured in the battery compartment. The cable terminals will be
disconnected and secured to the battery support with tape to prevent grounding.

Packaging

Loose components on the crane should be secured with rope or tape to prevent damage. The cab door should
be secured in the closed position with strapping.

Marking

Waterproof shipping tags will be affixed to the crane. The tags may be white or manila colored cloth or paper.
The information required should be printed in waterproof ink or type; and the tag waterproofed with shellac, spar
varnish, laminated plastic or other suitable transparent waterproofing compound.

PREPARATION FOR SHIPMENT

1. Remove the hook block and anti-two block weight. Stow both of these in a shipping container.

2. Start the diesel engine and take up wire rope onto hoist drum. Secure wire rope end.

3. Engage the superstructure locking pin and lower the boom until it rests on the boom cradle.

4. Engage the positive swing lock.

5. Retract and raise the outriggers, if necessary. Remove and stow the outrigger stabilizer pads on the rear of
the crane.

6. Prepare the superstructure cab for shipment as follows:

(a) Cushion and tape the LMI console, defroster fan, and load chart.

(b) Tape seat arm rest in down position.

(c) Tape fire extinguisher in its bracket.

(d) Tape both sliding windows closed.

(e) Fold mirror in toward crane.

2-16-2 C-1
 TM 5-3810-307-24-1-1

7. Prepare the boom for shipment by taping the boom hose reel hoses to the lower boom nose sheave shaft.

8. Fold both hoist mirrors down against boom.

9. Prepare the carrier cab for shipment as follows:

(a) Cushion and tape the defroster fan.

(b) Tape fire extinguisher in its bracket.

(c) Tape both sliding windows closed.

(d) Fold mirrors (on cab and on carrier right side) in toward crane.

10. Ensure battery disconnect is in off position.

WARNING
The diesel fuel is flammable. Do not smoke or use open flame when
draining the fuel tank. Flames and explosion could result in severe personal
injury or death.

11. Drain the fuel tank.

12. Preserve the crane in accordance with MIL-STD-162, Preparation for Shipment, Storage Cyclic
Maintenance of Material Handling Equipment (Level A).

2-16-3/(2-16-4 Blank)
 TM 5-3810-307-24-1-1

APPENDIX A

MAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION

A-1. THE ARMY MAINTENANCE SYSTEM

a. This introduction (section I) provides a general explanation of all maintenance and repair
functions authorized at various maintenance levels under the standard Army Two-Level
Maintenance System concept.

b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and
responsibility for the performance of maintenance functions on the identified end item or
component. The application of maintenance functions to the end item or component will be
consistent with the capacities and capabilities of the designated maintenance levels, which are
shown on the MAC in column (4) as:

Field Maintenance - includes two subcategories: Unit and Direct Support.

Unit - includes two subcolumns, C (operator/crew) and O (organizational) maintenance.

Direct Support - includes an F subcolumn.

Sustainment Maintenance includes two subcategories: General Support and Depot

Maintenance.
General Support - includes an H subcolumn.
Depot - includes a D subcolumn.

c. Section III lists the tools and test equipment (both special tools and common tool sets) required
for each maintenance function as referenced from section II.

d. Section IV contains supplemental instructions and explanatory notes for a particular

maintenance function.

A-2. MAINTENANCE FUNCTIONS

Maintenance functions will be limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical

and/or electrical characteristics with established standards through examination (e.g., by sight,
sound, or feel).

b. Test. To verify serviceability and to detect incipient failure by measuring the mechanical or
electrical characteristics of an item and comparing those characteristics with prescribed
standards.

A-1 C-1
TM 5-3810-307-24-1-1

A-2. MAINTENANCE FUNCTIONS - Continued

c. 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, chemical,
or gases.

d. Adjust. To maintain, within prescribed limits, by bringing into proper or exact position, 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 equipments used in precision measurement. Consists of
comparisons of two instruments, one of which is a certified standard of known accuracy, to
detect and adjust any discrepancy in the accuracy of the instrument being compared.

g. Remove/Install. To remove and install the same item when required to perform service or
other maintenance functions. Install may be the act of emplacing, seating, or fixing into
position a spare, repair part, or module (component or assembly) in a manner to allow the
proper functioning of an equipment or system.

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place.

i. Repair. The application of maintenance services (inspect, test, service, adjust, align, calibrate,
replace) or other maintenance actions (welding, grinding, riveting, straightening, facing,
remachining, or resurfacing) 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 like new
condition.

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable

equipment to a like new condition in accordance with the 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 equipment/components.

A-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II

a. Column (1) - Group Number. Column 1 lists functional group code numbers, the purpose of
which is to identify components, assemblies, subassemblies, and modules within the next
higher assembly.

b. Column (2) - Component/Assembly. Column 2 contains the names of components,

assemblies, subassemblies, and modules for which maintenance is authorized.

A-2 C-1
 TM 5-3810-307-24-1-1

A-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II - Continued

c. Column (3) - Maintenance Function. Column 3 lists the functions to be performed on the
item listed in column 2.

d. Column (4) - Maintenance Level. 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 level of maintenance. If the number or complexity of
tasks within the listed maintenance function vary at different maintenance levels, appropriate
work time figures will be shown for each level. 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 and typical field operating conditions. This time includes
preparation time, (including necessary disassembly/assembly time), troubleshooting/fault
location time, and quality assurance/quality control time in addition to the time required to
perform the specific tasks identified for the maintenance function authorized in the
maintenance allocation chart. The symbol designations for the various maintenance levels are
as follows:

C - Operator/Crew (Field Maintenance)

O - Organizational (Field Maintenance
F - Direct Support (Field Maintenance)
H - General Support (Sustainment Maintenance)
D Depot (Sustainment Maintenance)

e. Column (5) - Tools and Equipment. Column 5 specifies by code, those common tool sets,
(not individual tools) and special tools, TMDE, and support equipment required to perform the
designated function.

f. Column (6) - Remarks. Column 6 identifies remarks defined in Section IV.

A-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION

III

a. Column (1) - Reference Code. The tool and test equipment reference code correlates with a
code used in the MAC, Section II, column 5.

b. Column (2) - Maintenance Level. The lowest level of maintenance authorized to use the tool
or test equipment.

c. Column (3) - Nomenclature. This column lists the name and nomenclature of the tools and
test equipment required to perform the maintenance function.

d. Column (4) - National/NATO Stock Number. This column lists the National/NATO stock
number of the specific tool or test equipment.

e. Column (5) - Tool Number. This column lists the manufacturer's part number of the tool
followed by the Contractor and Government Entity (CAGE) code (five digits) in parenthesis.

A-3 C-1
TM 5-3810-307-24-1-1

A-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV

a. Column (1) - Reference Code. This code refers to the appropriate item in Section II, Column
6 of the MAC.

b. Column (2) - Remarks. This column provides the required explanatory information necessary
to clarify items appearing in Section II of the MAC.

A-4 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART

FOR
ALL-TERRAIN CRANE AT422T

(1) (2) (3) (4) (5) (6)

Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Ref Code
Unit Direct General
Support Support Depot

C O F H D

01 DIESEL ENGINE INSPECT 0.1 0.1 0.1 1

TEST 0.5 3,6,13,14
SERVICE 0.1 0.2 1
REPLACE 16.0 6,7
REPAIR 0.3 1.0 32.0 6,7 I
0101 CRANKCASE, BLOCK
CYLINDER HEAD:
CYLINDER HEAD INSPECT 0.1 3,6,7
REPLACE 6.0 1,6
REPAIR 8.0 1,7,11,27,28
BLOCK INSPECT 1.0 6,7
REPLACE 16.0 1,6,7
REPAIR 8.0 1,6,7,25,26
0102 CRANKSHAFT:
CRANKSHAFT INSPECT 0.3
REPLACE 4.0 1,6
FRONT SEAL, CRANKSHAFT REPLACE 4.0 29
REAR SEAL,CRANKSHAFT REPLACE 4.0
0103 FLYWHEEL ASSEMBLY:
FLYWHEEL INSPECT 0.1
REPLACE 2.0 1,6
FLYWHEEL HOUSING INSPECT 0.1
REPLACE 8.0 1,6
0104 PISTONS, CONNECTING
RODS:
PISTONS INSPECT 1.0
REPLACE 8.0 1,6
CONNECTING RODS INSPECT 0.5
REPLACE 3.0 1,6
0105 VALVES, CAMSHAFT, &
TIMING SYSTEM:

A-5 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T

(1) (2) (3) (4) (5) (6)

Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

0105 ROCKER LEVER ASSY INSPECT .1

REPLACE 4.0 6,7
VALVES INSPECT 0.1 0.1
ADJUST 0.5 1.0 1
REPLACE 2.0 6,7
CAMSHAFT INSPECT 0.1
REPLACE 2.0 6,7,14
0106 ENGINE LUBRICATION
SYSTEM:
OIL COOLER INSPECT 0.1 0.1
REPLACE 2.0 6,7
OIL PAN INSPECT 0.1 0.1
REPLACE 3.0 6,7
LUBE OIL PUMP INSPECT 0.1
REPLACE 3.5 6,7
03 FUEL SYSTEM:
0301 FUEL INJECTOR: REPLACE 1.0 6,7,24
0302 FUEL PUMPS:
FUEL INJECTION PUMP INSPECT 0.1
REPLACE 1.0 1,6,7
FUEL TRANSFER PUMP INSPECT 0.1
REPLACE 0.5 1,6
0304 AIR INTAKE SYSTEM:
AIR CLEANER ASSY INSPECT 0.1 0.1 0.1
SERVICE 0.2 0.2
REPLACE 1.0
REPAIR 0.5
0305 TURBOCHARGER: INSPECT 0.1 0.1
REPLACE 2.0 6,7

A-6 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

0306 TANKS, LINES,

FITTINGS, HEADERS:
FUEL TANK ASSY INSPECT 0.1 0.1
SERVICE 0.1 0.1 3,4
REPLACE 2.0 1,6,7
FUEL LINES/FITTINGS INSPECT 0.1 0.1
REPLACE 0.5 1,2,7
0309 FUEL FILTERS:
FUEL FILTER/WATER INSPECT 0.1 0.1
SEPARATOR, HEATED SERVICE 0.1 1
REPLACE 1.0 6,7
REPAIR 1.0 6,7,13
FUEL FILTER INSPECT 0.1 0.1
REPLACE 1.0 6
0311 ENGINE STARTING AID:
COLD START ASSY INSPECT 0.1 0.1
TEST 0.2 3
SERVICE 0.2 6,7
REPLACE 1.0 6,7
0312 ACCELERATOR,
THROTTLE/CHOKE:
THROTTLE AIR INSPECT 0.1 0.1
CYLINDER TEST 0.5
SERVICE 0.1 0.5 6 E
REPLACE 1.0 6,7
REPAIR 1.0 6,7
FOOT THROTTLE VALVE INSPECT 0.1 0.1
REPLACE 1.0 1,6,7
04 EXHAUST SYSTEM:
MUFFLER & PIPES INSPECT 0.1 0.1
REPLACE 1.0 1,6,7
05 COOLING SYSTEM: R
0501 RADIATOR: INSPECT 0.1 0.1 0.1 7,1
SERVICE 0.1 .01
REPLACE 2.0 1,6,7
REPAIR 1.0 1,6,7,10 J
A-7 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

0503 THERMOSTAT &

HOUSING, GASKET &
CLAMPS:
THERMOSTAT & INSPECT 0.1
HOUSING TEST 0.5 1,6,11
REPLACE 1.0 1
HOSES & CLAMPS INSPECT 0.1 0.1 1
REPLACE 0.5 1
0504 WATER PUMP: INSPECT 0.1 0.1
REPLACE 1.5 6,7
0505 FAN ASSEMBLY:
FAN INSPECT 0.1 0.1 0.1 1
REPLACE 0.5 1,6
DRIVE BELT INSPECT 0.1 0.1
REPLACE 0.3 1
06 ELECTRICAL SYSTEM:
0601 ALTERNATOR: INSPECT 0.1 0.1 0.1 1,6,7,13
TEST 0.2 0.2 1,13
REPLACE 1.0 1
0603 STARTING MOTOR: INSPECT 0.1 0.1 0.1 1
TEST 0.2 0.2 1,6,5,11
REPLACE 1.5 1,6
0607 INSTRUMENT/CONTROL
PANEL:
CARRIER CAB INSPECT 0.1 0.1
SWITCHES/CIRCUIT REPLACE 0.5 6,13
BREAKERS & GAUGES-
INSTRUMENTS
SUPERSTRUCTURE INSPECT 0.1 0.1
CAB SWITCHES/ REPLACE 0.5 1
CIRCUIT BREAKERS &
GAUGES -
INSTRUMENTS
0608 MISCELLANEOUS
ITEMS:

A-8 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

FUSE AND RELAY INSPECT 0.1 0.1 1,3

PANEL REPLACE 0.5 1
REPAIR 0.5 1
0609 LIGHTS:
VEHICLE HEAD, TAIL, INSPECT 0.1 0.1 1,3
STOP, BACKUP, SPOT, REPLACE 0.5 1
FLOOD, CLEARANCE, REPAIR 0.2 1 A
BLACKOUT LIGHTS
0611 HORNS & BACKUP INSPECT 0.1 0.1 1,3
ALARMS: REPLACE 0.3 1
0612 BATTERIES, STORAGE: INSPECT 0.1 0.1 1,7
TEST 0.2 7
SERVICE 0.1 7
REPLACE 0.5 1,7
BATTERY CABLES INSPECT 0.1 0.1
REPLACE 0.3 1
0613 HULL OR CHASSIS
WIRING HARNESSES:
WIRING HARNESSES INSPECT 0.1 0.1
TEST 0.5 0.5 1,13
REPLACE 2.0 1,13
REPAIR 0.2 3.0 1,13 B
07 TRANSMISSION:
0705 AUTOMATIC POWER TEST 1.0 3,6,13
SHIFT CONTROL: REPLACE 1.0 6
TRANSMISSION INSPECT 0.1 3,6,13
SHIFT CONTROL VALVE REPLACE 3.0 3,6,13
0710 TRANSMISSION ASSY: INSPECT 0.1 0.1 0.1 0.1 1,3,6,13
SERVICE 0.1 1.0 1
TEST 1.0 1,3,6,13
REPLACE 4.0 6,7,13
REPAIR 16.0 3,6,7,13

A-9 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T

(1) (2) (3) (4) (5) (6)

Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

09 PROPELLER &
PROPELLER SHAFTS:
DRIVE LINE INSPECT 0.2
ASSEMBLIES SERVICE 0.1 7
REPLACE 1.5 6,7
REPAIR 1.0 6,7,11
10 FRONT AXLE:
1000 FRONT AXLE ASSY: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7,11
REPLACE 4.0 6,7,11
REPAIR 8.0 6,7,11
1002 DIFFERENTIAL: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7,11
REPLACE 4.0 6,7,11
REPAIR 3.0 6.0 6,7,11 P
1003 PLANETARY DRIVE: INSPECT 0.1 0.1 1
SERVICE 0.3 1,7,11
REPLACE 4.0 6,7,11
REPAIR 4.0 6,7,11
11 REAR AXLE:
1100 REAR AXLE ASSY: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7
REPLACE 4.0 6,7,11,14
REPAIR 8.0 6,7,9,11,14
1102 DIFFERENTIAL: INSPECT 0.1 0.1 1
SERVICE 0.2 1,7
REPLACE 4.0 6,7,11,14
REPAIR 3.0 6.0 6,7,9,11,14 P
1103 PLANETARY DRIVE: INSPECT 0.1 0.1 1
SERVICE 0.3 1,7
REPLACE 4.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14

A-10 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T

(1) (2) (3) (4) (5) (6)

Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

12 BRAKES:
1202 SERVICE BRAKE SHOES INSPECT 0.5 0.5 1,7
AND RELATED PARTS: ADJUST 0.2 0.2 1,7
REPLACE 4.0 1,7,9,14
REPAIR 2.0 1,7,9,14 M
1208 AIR BRAKE SYSTEM:
BRAKE CHAMBER INSPECT 0.1 0.1
REPLACE 1.0 6,7,14
REPAIR 1.0 6,7,14 N
AIR RESERVOIRS INSPECT 0.1 0.1 0.1
REPLACE 1.0 6,7
AIR DRYER INSPECT 0.1 0.1
TEST 0.2 1,7
SERVICE 0.1 0.5 1,7 E
REPLACE 1.0 1,7,14
AUTOMATIC DRAIN INSPECT 0.1 0.1
VALVE TEST 0.5 1,7,14
SERVICE 0.1 0.5 1,7 E
REPLACE 1.0 1,7,14
SERVICE AND PARK INSPECT 0.1 0.1
BRAKE RELAY VALVES TEST 0.2 0.5 1,6,7
SERVICE 0.1 0.5 1,6 E
REPLACE 1.0 1,6,7,14
CARRIER AND INSPECT 0.1 0.1
SUPERSTRUCTURE CAB TEST 0.5 6
BRAKE VALVES SERVICE 0.1 0.5 1,6,7 E
REPLACE 1.5 6,7
SPRING BRAKE INSPECT 0.1 0.1
CONTROL VALVE TEST 0.5 6
SERVICE 0.1 0.5 1,6,7,11 E
REPLACE 1.0 6,7,11
LINES, HOSES, INSPECT 0.1 0.1
FITTINGS REPLACE 0.4 1,2,7,11
1209 AIR COMPRESSOR INSPECT 0.1 0.1
ASSY: SERVICE 0.1 0.5 1,6,7 E
REPLACE 1.5 6,7,11,14
REPAIR 4.0 6,7,11,14
A-11 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

AIR GOVERNOR INSPECT 0.1 0.1

TEST 0.5 6,7,11
SERVICE 0.2 0.5 1,6,7,11 F
REPLACE 1.0 1,6,7,11
1211 TRAILER BRAKE INSPECT 0.1 0.1
COMPONENTS AND REPLACE 0.5 1,6,7,11
TIRE INFLATION
CONNECTIONS:
13 WHEELS AND TRACKS:
1313 TIRES: INSPECT 0.1 0.1
SERVICE 0.1 0.1 1,6
REPLACE 1.0 6,7,11
14 STEERING:
1401 CARRIER CAB INSPECT 0.1 0.1
STEERING WHEEL, ADJUST 0.3 6
COLUMN, AND REPLACE 2.0 6,7,11
LINKAGE: REPAIR 1.0 6,7,11
SUPERSTRUCTURE CAB INSPECT 0.1 0.1
STEERING WHEEL, ADJUST 0.3 6
COLUMN, SELECTOR REPLACE 2.0 6,7,11
VALVES, AND LINKAGE: REPAIR 1.0 6,7,11
STEERING MITER GEAR INSPECT 0.1
SERVICE 0.1 1,7,11
REPLACE 0.5 6,7,11
REPAIR 1.5 6,7,11
1410 STEERING PUMP: INSPECT 0.1 0.1
REPLACE 1.0 6,7,11,14
1411 HOSES, LINES, INSPECT 0.1
FITTINGS: REPLACE 0.5 1,6,7,11,12
1412 STEERING CYLINDER: INSPECT 0.1 0.1
REPLACE 0.5 1,6,7
REPAIR 1.0 6,7,11,12
15 FRAME, TOWING
ATTACHMENTS:
1501 CARRIER FRAME: INSPECT 0.1 0.1
REPLACE 32.0 1,6,7,11,12,
13,14,17,23

A-12 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T

(1) (2) (3) (4) (5) (6)

Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

1503 PINTLE HOOK: INSPECT 0.1 0.1

SERVICE 0.1 1,7
REPLACE 0.5 1,7,11
1507 LEVELING GEAR/JACKS
OUTRIGGER ASSY INSPECT 0.1 0.1 0.1
SERVICE 0.1 1,7,11
REPLACE 6.0 6,7,11,12,14
STABILIZER CYLINDER INSPECT 0.1 0.1
WITH HOLDING VALVE REPLACE 1.5 6,7,11,12,14
EXTENSION CYLINDER INSPECT 0.1 0.1
WITH HOLDING VALVE REPLACE 3.0 6,7,12
18 BODY, CAB, HOOD
AND HULL:
1801 CAB AND COVERS:
CARRIER CAB INSPECT 0.1 0.1 0.1
REPLACE 4.0 6,7,11,12,14
REPAIR 1.5 2.0 6,7,11,12,14, D,O
15,16
SUPERSTRUCTURE INSPECT 0.1 0.1 0.1
CAB REPLACE 4.0 6,7,11,12,14
REPAIR 1.5 2.0 6,7,11,12,14, D,O
15,16
ACCESS COVERS, INSPECT 0.1 0.1
BATTERY BOX & REPLACE 0.5 1,7,11
TOOL BOX
1806 UPHOLSTERY SEAT:
CARRIER SEAT INSPECT 0.1 0.1
REPLACE 0.5 1,7,11
SUPERSTRUCTURE INSPECT 0.1 0.1
SEAT REPLACE 1.0 1,7,11
22 BODY CHASSIS AND
ACCESSORIES:
2202 MIRRORS AND INSPECT 0.1 0.1
DEFROSTER FANS REPLACE 0.4 1

A-13 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

2207 CAB HEATERS:

CARRIER CAB HEATER INSPECT 0.1 0.1
REPLACE 1.5 1,6,7,11
REPAIR 1.0 1,6,7,11
SUPERSTRUCTURE INSPECT 0.1 0.1 0.1
CAB HEATER SERVICE 0.1 0.1 0.5 1,6,7,11 E,G
REPLACE 2.0 1,6,7,11,13
REPAIR 1.5 1,6,7,11,13
2210 DATA PLATES:
DATA PLATES AND INSPECT 0.1 0.1
DECALS REPLACE 0.5 1,7,11
24 HYDRAULIC SYSTEM: R
2401 HYDRAULIC PUMP: INSPECT 0.1 0.1 0.1
REPLACE 2.0 6,7,11,12
PUMP DISCONNECT INSPECT 0.1 0.1 0.1 1
REPLACE 2.0 6,7,11
2402 HYDRAULIC CONTROL
VALVES:
PILOT OPERATED INSPECT 0.1 0.1
CHECK VALVES REPLACE 0.5 6,7,11,12
REPAIR 1.0 6,7,11,12 C
INTEGRATED INSPECT 0.1 0.1
OUTRIGGER VALVE REPLACE 1.0 6,7,11,12
REPAIR 2.0 6,7,11,12
OUTRIGGER SOLENOID INSPECT 0.1 0.1
VALVE STACK REPLACE 1.0 6,7,11,12
REPAIR 0.5 6,7,11,12
DOUBLE SELECTOR INSPECT 0.1 0.1
VALVE REPLACE 0.5 6,7,11,12
HOIST MOTOR INSPECT 0.1 0.1
CONTROL VALVE REPLACE 0.5 6,7,11,12
SOLENOID VALVES INSPECT 0.1 0.1
REPLACE 0.5 6,7,11,12
DIRECTIONAL CONTROL INSPECT 0.1 0.1
VALVES PILOT-OPR REPLACE 1.0 6,7,11,12

A-14 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

REMOTE CONTROL INSPECT 0.1 0.1

VALVE REPLACE 1.0 6,7,11,12
JOYSTICK CONTROL INSPECT 0.1 0.1
VALVE REPLACE 1.0 6,7,11,12
2406 OIL COOLER, LINES, INSPECT 0.1 0.1
FITTINGS: REPLACE 1.0 6,7,11,12
2407 CYLINDERS:
LIFT CYLINDER WITH INSPECT 0.1 0.1
HOLDING VALVE SERVICE 0.1 1,7,11
REPLACE 4.0 6,7,11,12
TELESCOPE CYLINDER INSPECT 0.1 0.1
WITH HOLDING VALVE SERVICE 0.1 1,7,11
REPLACE 3.0 6,7,11,12
2408 RESERVOIR AND FILTER INSPECT 0.1 0.1 0.1
SERVICE 0.1 0.2 1,7,11 H
REPLACE 2.0 6,7,11,12,14
52 AIR CONDITIONER
COMPONENTS:
CARRIER CAB INSPECT 0.2 1,7,11
AIR CONDITIONER TEST 0.5 3,6,7,11,14
SERVICE 0.5 6,7,11,14
REPLACE 2.0 6,7,11,14
REPAIR 2.0 3,6,7,11,14
SUPERSTRUCTURE INSPECT 0.2 1,7,11
CAB AIR TEST 0.5 3,6,7,11,14
CONDITIONER SERVICE 0.5 6,7,11,14
REPLACE 2.0 6,7,11,14
REPAIR 2.0 3,6,7,11,14
68 WARNING, SCANNING,
AND SIGNALING
DEVICES:
6801 LMI/ANTI-TWO INSPECT 0.1 0.1 1,7,11
BLOCK SYSTEM: ADJUST 0.5 3,6,7,11
TEST 1.0 3,6,7,11,13
REPLACE 4.0 3,6,7,11
REPAIR 3.0 3,6,7,11,13

A-15 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

74 CRANES, SHOVELS,
AND EARTH MOVING
EQUIPMENT
7411 CRANE OR CLAMSHELL
COMPONENTS:
BOOM ASSEMBLY INSPECT 0.1 0.1 0.2 1,6,7,11
SERVICE 0.3 1,7,11
REPLACE 10.0 6,7,11,14
REPAIR 6.5 6,7,11,14
BOOM SHEAVES INSPECT 0.1 0.1 0.1
SERVICE 0.1 1,7,11
REPLACE 0.5 1,7,11
REPAIR 0.5 6,7,11,14
HOOK BLOCK INSPECT 0.1 0.1 0.1
SERVICE 0.1 1,7,11
REPLACE 1.0 1
REPAIR 2.0 1,7,11,18
WIRE ROPE INSPECT 0.1 0.1
SERVICE 0.3 1,7,11
REPLACE 1.0 1,18
CLAMSHELL ASSEMBLY INSPECT 0.1 0.1 0.1
REPLACE 1.0 1
REPAIR 1.5 6,7,11,18
GRAPPLE ASSEMBLY INSPECT 0.1 0.1 0.1
REPLACE 1.0 1
REPAIR 1.5 6,7,11,18
7413 PILE DRIVER INSPECT 0.1 0.1
ATTACHMENT REPLACE 1.0 1,18
SHIPPING/STORAGE INSPECT 0.1
CONTAINER SERVICE 0.1
REPAIR 0.2 0.5 1,6,20
LEAD TOWER INSPECT 0.2
ASSEMBLY SERVICE 0.3
REPAIR 0.2 1.0 1,2,6
REPLACE 1.0
SPOTTER ASSEMBLY INSPECT 0.1
SERVICE 0.2
REPAIR 0.5 1.0 1,2,6,20

A-16 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D
REPLACE
1.0
IMPACT HAMMER INSPECT 0.2
SERVICE 0.8
REPAIR 1.5 1,2
REPLACE 1.0
FUEL SYSTEM INSPECT 0.3
SERVICE 0.5 1.0 1,2
REPAIR 1.5 1,2
REPLACE 2.0 1,2
HAMMER TRIP SYSTEM INSPECT 0.3
SERVICE 0.2
REPAIR 1.5 1,2
REPLACE 2.0 1,2
LUBE OIL SYSTEM INSPECT 0.5
SERVICE 1.0 1,2
REPAIR 1.0 1,2
REPLACE 2.5 1,2
7417 HOISTS:
MAIN HOIST INSPECT 0.1 0.1 0.1
ADJUST 0.5 1,7,11
SERVICE 0.5 1,7,11
REPLACE 2.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14
MAIN HOIST MOTOR INSPECT 0.1 0.1 0.1
REPLACE 1.0 6,7,11,12,14
REPAIR 2.0 6,7,11,12,14
AUXILIARY INSPECT 0.1 0.1 0.1
HOIST ADJUST 0.5 1,7,11
SERVICE 0.5 1,7,11
REPLACE 2.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14
AUX HOIST MOTOR INSPECT 0.1 0.1 0.1
REPLACE 1.0 6,7,11,12,14
REPAIR 2.0 6,7,11,12,14
HOIST ROTATION INSPECT 0.1
INDICATOR REPLACE 0.5 1,3,6,7,13

A-17 C-1
 TM 5-3810-307-24-1-1

Section II. MAINTENANCE ALLOCATION CHART - Continued

FOR
ALL-TERRAIN CRANE AT422T
(1) (2) (3) (4) (5) (6)
Maintenance Level
Tools and Remarks
Field Sustainment
Group Maintenance Equipment Code
Number Component/Assembly Function Unit Direct General Ref Code
Support Support Depot

C O F H D

7419 TURNTABLE:
SWING BEARING INSPECT 0.1 0.1 0.1
SERVICE 0.3 1,6,7,11
REPLACE 8.0 6,7,11,12,13,
14,18
PLANETARY DRIVE INSPECT 0.1 0.1
AND GEAR REDUCER SERVICE 0.2 1,7,11
REPLACE 4.0 6,7,11,14
REPAIR 4.0 6,7,9,11
SWING MOTOR INSPECT 0.1 0.1
REPLACE 1.5 6,7,11,14
AIR/HYDRAULIC INSPECT 0.1 0.1
SWIVEL TEST 1.0 6,7,11,14
REPLACE 6.0 6,7,11,14
REPAIR 4.0 6,7,9,11,14
ELECTRICAL SWIVEL INSPECT 0.1 0.1
REPLACE 4.0 6,7,11,13,14
REPAIR 2.0 2.0 6,7,9,11,13,14 Q

A-18 C-1
 TM 5-3810-307-24-1

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

TOOL OR TEST
EQUIPMENT MAINTENANCE NATIONAL
REF CODE LEVEL NOMENCLATURE STOCK NUMBER TOOL NUMBER
1 O TOOL KIT, GENERAL 5180-00-177-7033 SC5180-90-CL-N26
MECHANIC'S
AUTOMOTIVE
2 O SHOP EQUIPMENT, 4910-00-754-0654 SC4910-95-CL-A74
AUTOMOTIVE MAINT
AND REPAIR, ORG LEVEL
COMMON NO. 1
3 O MULTIMETER, DIGITAL 6625-01-139-2512 N60449
4 F SHOP EQUIPMENT, 4940-00-209-6239 SC4940-95-CL-A63
CANVAS AND GLASS
SHOP, SHELTER MTD
5 F TEST STAND, AUTO 4910-00-767-0218 MIL T4544
GENERATOR AND
STARTER, FLOOR
MTD
6 F,H TOOL KIT, MASTER 5180-00-699-5273 SC5180-90-CL-N05
MECHANIC'S
7 F,H SHOP EQUIPMENT, 4910-00-754-0705 SC4940-95-CL-A31
AUTOMOTIVE MAINT
AND REPAIR, FIELD,
BASIC, LESS POWER
8 F,H SHOP EQUIPMENT, 4940-01-150-3113 SC4940-95-CL-B05
ELECTRICAL REPAIR,
SEMITRAILER MTD
9 F,H SHOP EQUIPMENT, 3470-00-754-0708 SC3470-95-CL-A02
MACHINE SHOP,
FM BASIC
10 F,H SHOP EQUIPMENT, 4940-00-357-7268 SC4940-95-CL-A08
WELDING, FIELD
MAINTENANCE
11 F,H SHOP EQUIPMENT, 4910-00-754-0706 SC4910-95-CL-A62
AUTO MAINTENANCE AND
REPAIR, FM SUPPL NO. 1
12 F,H TOOL OUTFIT, HYD 4940-01-036-5784 SC4940-95-CL-B07
SYSTEM TEST AND
REPAIR, 3/4 TON
TRAILER MTD

A-19 C-1
 TM 5-3810-307-24-1

Section III. TOOL AND AND TEST EQUIPMENT REQUIREMENTS - Continued

TOOL OR TEST
EQUIPMENT MAINTENANCE NATIONAL
REF CODE LEVEL NOMENCLATURE STOCK NUMBER TOOL NUMBER
13 F,H TOOL KIT, AUTO, 5180-00-754-0655 SC5180-95-CL-B08
FUEL AND ELECTRIC
SYSTEM REPAIR
14 F,H SHOP EQUIPMENT, 4910-00-754-0650 SC4910-95-CL-A72
AUTO MAINTENANCE
AND REPAIR, COMMON
NO. 2
15 F,H TOOL KIT, BODY 5180-00-357-7731 SC5180-90-CL-N62
AND FENDER REPAIR
16 F,H TOOL KIT, 5180-00-754-0643 SC5180-90-CL-N34
METALWORKERS
17 F,H TOOL KIT, MACHINIST, 5280-00-511-1950 SC5280-95-CL-A02
POST-CAMP-STATION
18 F,H TOOL KIT, RIGGING, 5180-00-596-1513 SC5180-90-CL-N17
WIRE ROPE
19 F,H TOOL KIT, WELDERS 5180-00-754-0661 SC5180-90-CL-N39
20 F,H TORCH, ARC WELD, 3431-00-165-4112 MIL W80105
GAS SHIELD, 400 AMP
21 F,H WELDING MACHINE, 3431-00-620-5999 425ACDCG
ARC, TRANSFORMER,
300 AMP AC/DC
22 H SHOP EQUIPMENT, 4930-01-006-3229 SC4940-95-CL-B02
GENERAL PURPOSE
REPAIR, SEMI-
TRAILER MTD
23 H STAND, MAINTENANCE, 4910-00-241-3329 150-AX
AUTO AXLE, WHEEL
MTD, FRONT AND REAR
AXLE UNIT
24 H TEST SET, DIESEL 4910-00-317-8265 5910359
INJECTOR
25 H LINER PULLER 5120-01-143-2032 3376015
26 H LINER DRIVER 5120-00-999-1206 ST-1229
27 H INTAKE VALVE SEAT 5120-01-289-1250 3377396
EXTRACTOR
28 H EXHAUST VALVE SEAT 5120-01-287-3666 ST-1276-1
EXTRACTOR
29 F INSERTER,SEAL 5120-01-476-1516 3824498

A-20 C-1
 TM 5-3810-307-24-1

Section IV. REMARKS

REMARKS
CODE REMARKS

A Repair of lights limited to bulb replacement.

B Harness repair at Organizational level limited to connector replacement.
C Repair of all holding and check valves limited to replacement of seal kits.
D Cab repair at the Organizational level includes replacing window glass, door assembly,
locks, brackets, etc.
E Service at Organizational level is for record keeping purposes only.
F Service at Organizational level is limited to replacement of governor filter.
G Service at Crew level limited to servicing fuel tank.
H Service at Crew level limited to servicing hydraulic reservoir.
I Limited Field Repair authorized (Seals, Gaskets, Bearings, Plugs & Cylinder Head).
J Radiator repair limited to replacement of pressure cap, drain valve & soldering minor
leaks.
K Alternator repair limited to bearings, brushes and voltage regulator replacement.
L Starter repair limited to bearings, brushes and solenoid replacement.
M Repair limited to replacement parts on the brake shoes.
N Repair is limited to replacement of parts on the brake chambers.
O Repair limited to light body work and replacement of down parts..
P Differential repair at the Field level is limited to input / output seal replacement.
Q Electric swivel repair at the field level is limited to cleaning or replacing the brushes /
contacts.
R Espar Hydronic engine coolant heater and Arctic Fox Hydra Liner hydraulic tank
heaters installed on some cranes. If installed, procure spare parts in accordance with
TM 5-3810-307-24P, Appendix A. If field installation is required, order the installation
kits (two) identified in Appendix A and install the kits in accordance with TM 5-3810-
307-24-1-2, Appendix J.

A-21/(A-22 Blank) C-1

 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX

Description Page No./Pkg. No.

Air Compressor, Cummins/Wabco Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix I

Air Compressor, Holset Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C
Air Compressor, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Conditioner (Carrier Cab), Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Air Conditioner (Carrier Cab), Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-43
Air Conditioner (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Air Conditioner (Carrier Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-37
Air Conditioner (Carrier Cab), Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36
Air Conditioner (Carrier Cab) Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix B
Air Conditioner (Superstructure Cab), Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45
Air Conditioner (Superstructure Cab), Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-60
Air Conditioner (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45
Air Conditioner (Superstructure Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-47
Air Conditioner (Superstructure Cab), Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45
Air Dryer, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Air Dryer, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Air Dryer, Preventive Maintenance and Serviceability Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Air Dryer, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Air Governor, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Governor, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Governor, Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Air Governor, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Governor, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Governor, Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air Intake System, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25 & 3/SM01-001-0
Air Intake System, Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM01-001-0
Air Intake System, Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM01-001-0
Air Intake System, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/SM01-001-0
Air Intake System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26 & 3/SM01-001-0
Air Intake System, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM01-001-0
Air Pressure Gauge, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Air Pressure Gauge, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Air Pressure Gauge, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Air Reservoirs, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Air Reservoirs, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Air System Components, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-8
Air System Components, Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-8
Air System Components, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Air System, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Air System, Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Air System, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Air System, Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-6
Air Valves, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-36
Alignment, Hoist to Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
Alternator, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Alternator, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Alternator, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16

Index-1 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

A - Continued

Alternator Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix D

Automatic Drain Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Automatic Drain Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Automatic Drain Valve, Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Automatic Drain Valve, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Automatic Drain Valve, Preventive Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Automatic Drain Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Automatic Drain Valve, Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Automatic Powershift Control (APC 100), Automatic/Manual Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Checkout Kit, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-18
Automatic Powershift Control (APC 100), Checkout Kit, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 2-3-25
Automatic Powershift Control (APC 100), Clutch Pressure Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Control Box Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-29
Automatic Powershift Control (APC 100), Control Box Diagnostics, 4WD Diagnosis . . . . . . . . . . . . . . . . . 2-3-34
Automatic Powershift Control (APC 100), Control Box Diagnostics, Gear Select Input Diagnosis . . . . . . . . . 2-3-32
Automatic Powershift Control (APC 100), Control Box Diagnostics, Speed Sender Input Diagnosis . . . . . . . 2-3-33
Automatic Powershift Control (APC 100), Control Box Diagnostics, Throttle Tests . . . . . . . . . . . . . . . . . . 2-3-31
Automatic Powershift Control (APC 100), Control Box Diagnostics, Torque Converter Lockup Diagnosis . . . . 2-3-33
Automatic Powershift Control (APC 100), Diagnostic LEDs Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Direct Engagement Protection . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Downshift Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Engine Speed Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Four Wheel Drive Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Gear Selection Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Input and Output Checks with Checkout Kit. . . . . . . . . . . . . . . . 2-3-19
Automatic Powershift Control (APC 100), Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Installation of Checkout Kit and Start-up Screens . . . . . . . . . . . . 2-3-19
Automatic Powershift Control (APC 100), Lockup Request Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Lockup Solenoid Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Low Clutch Pressure Warning . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-19
Automatic Powershift Control (APC 100), Manual/Automatic Shared System Diagnostics . . . . . . . . . . . . . 2-3-28
Automatic Powershift Control (APC 100), Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Override System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-13
Automatic Powershift Control (APC 100), Overspeed and Low Clutch Pressure Indicator, Output . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Replacement of Checkout Kit EPROM . . . . . . . . . . . . . . . . . . . 2-3-26
Automatic Powershift Control (APC 100), Shift Solenoids Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Shifting Problem Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-27
Automatic Powershift Control (APC 100), Test Procedures with Checkout Kit . . . . . . . . . . . . . . . . . . . . . 2-3-19
Automatic Powershift Control (APC 100), Test Procedures without Checkout Kit . . . . . . . . . . . . . . . . . . . 2-3-27
Automatic Powershift Control (APC 100), Throttle Position Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Transmission RPM/Pressure Indicator Diagnosis . . . . . . . . . . . . 2-3-27
Automatic Powershift Control (APC 100), Turbine Speed Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-17
Automatic Powershift Control (APC 100), Two Wheel Drive Solenoid Output . . . . . . . . . . . . . . . . . . . . . 2-3-17
Axle, Front, Hydraulic Power Bleeding and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
Axle Oscillation System, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
Axle Oscillation System, Superstructure Over Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3

Index-2 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

A - Continued

Axle Oscillation System, Superstructure Over Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3

Axle Oscillation System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
Axle Proximity Sensor Assemblies, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-17
Axle Proximity Sensor Assemblies, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Axle Proximity Sensor Assemblies, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
Axle Proximity Sensor Assemblies, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Axle Unit with Differential Lock, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32/SM03-026-0
Axles, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Axles, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-6
Axles, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5
Axles, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-5

Backup Alarm (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-28

Backup Alarm (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-28
Backup Alarm (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-29
Backup Alarm (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-29
Batteries, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Batteries, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Batteries, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Batteries, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Bearings, Antifriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Bearings, Double Row, Tapered Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Bearings, Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Bearings, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Bearings, Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Bearings, Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Boom, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-8
Boom, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Boom, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Boom, Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Boom Extension and Retraction Cables, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Boom Extension and Retraction Cables, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Boom Extension and Retraction Cables, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Boom, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
Boom Hose Reel, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Boom Hose Reel, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-20
Boom Hose Reel, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Boom Hose Reel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
Boom, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
Boom, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-10
Boom, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Boom, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-6
Boom Rest Switch, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
Boom, Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5
Boom, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-5

Index-3 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

B - Continued

Brake Actuator (Expander Unit), Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25

Brake Actuator (Expander Unit), Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Brake Actuator (Expander Unit), Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-25
Brake Assembly, Service, Initial Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Assembly, Service, Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Chamber (Front Wheels), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-29
Brake Chamber (Front Wheels), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Brake Chamber (Front Wheels), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-27
Brake Chamber (Rear Wheels), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-34
Brake Chamber (Rear Wheels), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Brake Chamber (Rear Wheels), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-33
Brake Drum, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake Linings, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Brake System, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23
Brake System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-23

Cable Idler Drum and Follower, Hoist, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9

Cable Idler Drum and Follower, Hoist, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Cable Idler Drum and Follower, Hoist, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Cable Idler Drum and Follower, Hoist, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Cable Idler Drum and Follower, Hoist, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-11
Cable Idler Drum and Follower, Hoist, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Cable Idler Drum and Follower, Hoist, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Cabs, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7
Cabs, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Carburetor Adjustment, Heater (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
Carrier Cab, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Carrier Cab, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-96
Carrier Cab, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-94
Circuit Breakers (Carrier Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-12
Circuit Breakers (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-13
Checkout Kit, Automatic Powershift Control (APC 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-18
Cleanliness, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Clutch Assemblies, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65/SM02-025-0
Cold Start System, Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26
Cold Start System, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-30
Cold Start System, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-29
Cold Start System, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-27
Compressor, Air, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Compressor, Air, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Converter Lockup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Crane, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3
Cylinders, General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56
Cylinders, Maintenance, General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-56

Index-4 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

Dash Panel (Carrier Cab), Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-89

Dash Panel (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-89
Dash Panel (Superstructure Cab), Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-91
Dash Panel (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-91
Defroster Control (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-69
Defroster Control (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-69
Description, Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3
Diesel Heater, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM14-001-0
Diesel Heater, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM14-001-0
Diesel Heater, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM14-001-0
Diesel Heater, Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/SM14-001-0
Diesel Heater, Table of Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM14-001-0
Diesel Heater, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM14-001-0
Diesel Heater, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/SM14-001-0
Diesel Heater, Warning Safety Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/SM14-001-0
Differential and Carrier Assembly, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29/SM03-026-0
Differential, Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30/SM03-026-0
Differential, Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30/SM03-026-0
Direct/General Support Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-11
Directional Control Valve, Hydraulic, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Directional Control Valve, Hydraulic, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-31
Directional Control Valve, Hydraulic, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Directional Control Valve, Hydraulic, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Directional Control Valve, Hydraulic, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Disassembly and Assembly, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Double Check Valves, Air, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Double Check Valves, Air, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Double Check Valves, Air, Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Double Check Valves, Air, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Double Check Valves, Air, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Double Check Valves, Air, Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Double Selector Valve, Hydraulic, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Double Selector Valve, Hydraulic, Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Double Selector Valve, Hydraulic, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Double Selector Valve, Hydraulic, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Double Selector Valve, Hydraulic, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Double Solenoid Valves, Axle Oscillation, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Double Solenoid Valves, Axle Oscillation, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Double Solenoid Valves, Axle Oscillation, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Double Solenoid Valves, Axle Oscillation, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Double Universal Joint Shaft Bearing and Steering Knuckle Bearing, Installation . . . . . . . . . . . . . 25/SM03-026-0
Double Universal Joint Shaft Bearing and Steering Knuckle Bearing, Removal . . . . . . . . . . . . . . 23/SM03-026-0
Drive Lines, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Drive Lines, Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Drive Lines, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6

Index-5 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

D - Continued

Drive Pinion Bearing, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27/SM03-026-0

Drive Plate, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61/SM02-025-0
Drive Train, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-5
Drive Train, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Dual Brake Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Dual Brake Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Dual Brake Valve, Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Dual Brake Valve, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Dual Brake Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Dual Brake Valve, Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26

Electrical Control Box, Emergency Stowage System, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8

Electrical Control Box, Emergency Stowage System, Functional Check. . . . . . . . . . . . . . . . . . . . . . . . 2-15-10
Electrical Control Box, Emergency Stowage System, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-10
Electrical Control Box, Emergency Stowage System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Electrical Control Box, Emergency Stowage System, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Electrical Control Box, Emergency Stowage System, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-8
Electrical Switches, Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Electrical Switches, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Electrical Switches, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Electrical Switches, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Electrical Swivel, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM13-007-0
Electrical Swivel, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-007-0
Electrical Swivel, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9 & 3/SM13-007-0
Electrical Swivel, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-007-0
Electrical Swivel, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9 & 3/SM13-007-0
Electrical Swivel, Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-007-0
Electrical System, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Electrical System, Maintenance, General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-14
Emergency (Standby) Steering Valve and Pump, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Emergency (Standby) Steering Valve and Pump, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-20
Emergency (Standby) Steering Valve and Pump, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Emergency (Standby) Steering Valve and Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Emergency Stowage System, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-3
Engine and Transmission Assembly, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9
Engine and Transmission Assembly, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Engine, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Engine, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Espar Engine Coolant Heater, Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix J
Exhaust System, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38
Exhaust System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38
Extension Cylinder, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Extension Cylinder, Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Extension Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Extension Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Extension Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8

Index-6 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

F,G

Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7

Foot Throttle Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Foot Throttle Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Foot Throttle Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
Four-way Air Solenoid Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-34
Four-way Air Solenoid Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-34
Four-way Air Solenoid Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-34
Fuel Filter, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel Pump, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel System, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Fuel System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Fuel Tank Assembly, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Fuel Tank Assembly, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Fuel Tank, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19
Gaskets, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Grounds, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4

Heated Fuel Filter/Water Separator, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19

Heated Fuel Filter/Water Separator, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
Heated Fuel Filter/Water Separator, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22
Heater (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-24
Heater (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Heater (Carrier Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21
Heater (Superstructure Cab), Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
Heater (Superstructure Cab), HI-LO Control and Microswitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . 2-1-35
Heater (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
Heater (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Heater (Superstructure Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25
Heater Control (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-71
Heater Control (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-71
Heater Control (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-77
Heater Control (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-77
Heater Control (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-77
Heater Fuel Pump (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-101
Heater Fuel Pump (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-101
HI-LO Control and Microswitch Adjustment, Heater (Superstructure Cab) . . . . . . . . . . . . . . . . . . . . . . . 2-1-35
Hoist (Grove Model HO-15), Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/SM11-010-1
Hoist (Grove Model HO-15), Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/SM11-010-1
Hoist (Grove Model HO-15), Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM11-010-1
Hoist (Grove Model HO-15), Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/SM11-010-1
Hoist (Grove Model HO-15), Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM11-010-1
Hoist (Grove Model HO-15), Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM11-010-1
Hoist (Grove Model HO-15), Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM11-010-1
Hoist Control Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Hoist Control Valve, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Hoist Control Valve, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37

Index-7 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

H - Continued

Hoist Control Valve, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37

Hoist Control Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Hoist Drum Rotation Indicator, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Hoist Drum Rotation Indicator, Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-14
Hoist Motor, Vane Type, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/SM11-011-0
Hoist Motor, Vane Type, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM11-011-0
Hoist Motor, Vane Type, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7 & 3/SM11-011-0
Hoist Motor, Vane Type, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM11-011-0
Hoist Motor, Vane Type, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Hoist Motor, Vane Type, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7 & 3/SM11-011-0
Hoist Motor, Vane Type, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Hoist Motor, Vane Type, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM11-011-0
Hoist Rotation Indicator Controller Unit, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-15
Hoist Rotation Indicator Controller Unit, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-15
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-12
Hoists, Adjustment of Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
Hoists, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Hoists, Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Hoists, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Hoists, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Hoists, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Hoists, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Hoists, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Holding Valve, Assembly/Description/Disassembly/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-041-0
Holding Valves, Hydraulic, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Holding Valves, Hydraulic, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Holding Valves, Hydraulic, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Holding Valves, Hydraulic, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-47
Hood, Engine, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Hood, Engine, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Hook Block, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
How to Use This Manual, Volume 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
How to Use This Manual, Volume 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Hydraulic Filter, Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
Hydraulic Filter, Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
Hydraulic Lines, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Hydraulic Oil Cooler, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-11
Hydraulic Power Bleeding and Adjustment (Front Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
Hydraulic Pump, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/SM08-015-0
Hydraulic Pump, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19 & 3/SM08-015-0
Hydraulic Pump, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM08-015-0
Hydraulic Pump, General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM08-015-0
Hydraulic Pump, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19
Hydraulic Pump, Lubrication and Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/SM08-015-0
Hydraulic Pump, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19 & 3/SM08-015-0
Hydraulic Pump, Recommended Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/SM08-015-0
Hydraulic Pump, Recommended Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/SM08-015-0
Hydraulic Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-19

Index-8 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

H - Continued

Hydraulic Pump, Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-015-0

Hydraulic Pump, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-015-0
Hydraulic Pump, Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/SM08-015-0
Hydraulic Pump Disconnect, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Hydraulic Pump Disconnect, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Hydraulic Pump Disconnect, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Hydraulic Pump Disconnect, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Hydraulic Pump Distribution, Section One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Pump Distribution, Section Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Pump Distribution, Section Three . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Relief Valves, Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Hydraulic Relief Valves, Controllers (Joysticks), Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . 2-8-29
Hydraulic Relief Valves, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
Hydraulic Relief Valves, Five Section Valve Bank Main Relief Valve Settings . . . . . . . . . . . . . . . . . . . . . 2-8-27
Hydraulic Relief Valves, Front or Rear Steer, Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . 2-8-28
Hydraulic Relief Valves, Lift - Retract, Circuit Relief Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-28
Hydraulic Relief Valves, Main Relief Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Hydraulic Relief Valves, Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
Hydraulic Relief Valves, Maintenance, Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Hydraulic Relief Valves, Outrigger, Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Hydraulic Relief Valves, Single Section Valve Bank Main Relief Valve Settings (Swing Circuit) . . . . . . . . . . 2-8-27
Hydraulic Relief Valves, Swing Brake, Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
Hydraulic Relief Valves, Telescope - Retract, Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . 2-8-28
Hydraulic Remote Control Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Hydraulic Remote Control Valve, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Hydraulic Reservoir and Filter, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Reservoir, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-18a
Hydraulic Reservoir Heating Elements, Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . Appendix J
Hydraulic Systems, Binding Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Hydraulic Systems, Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Hydraulic Systems, Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Hydraulic Systems, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-9
Hydraulic Systems, Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-11
Hydraulic Systems, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Hydraulic Systems, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Hydraulic Systems, Keep the System Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Hydraulic Systems, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-11
Hydraulic Systems, Parts Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Hydraulic Systems, Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-12
Hydraulic Systems, Sealing Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Hydraulic Systems, Supply Pressure and Return Circuit, Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Systems, Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Hydraulic Valves, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
Hydraulic Valves, Usage Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23

Index-9 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

I

Ignition Switch, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-21

Ignition Switch, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-21
Indicator Lights (Carrier Cab), Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-24
Indicator Lights (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-24
Indicator Lights (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-27
Indicator Lights (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-27
Instruments, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Instruments, Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Instruments, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Instruments, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Integrated Differential Lock, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33/SM03-026-0
Integrated Differential Lock, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33/SM03-026-0
Integrated Outrigger Valve, Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM08-017-1
Integrated Outrigger Valve, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM08-017-1
Integrated Outrigger Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-017-1
Integrated Outrigger Valve, Description, Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Integrated Outrigger Valve, Description, Outrigger System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
Integrated Outrigger Valve, Description, Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
Integrated Outrigger Valve, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-017-1
Integrated Outrigger Valve, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Integrated Outrigger Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49
Integrated Outrigger Valve, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49 & 3/SM08-017-1
Integrated Outrigger Valve, Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/SM08-017-1
Integrated Outrigger Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-49

Joystick Control Valve, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-33

Joystick Control Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Joystick Control Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Junction Box, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5

Kessler Axle, Adjustment Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/SM03-026-0

Kessler Axle, Axle Unit with Differential Lock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32/SM03-026-0
Kessler Axle, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM03-026-0
Kessler Axle, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30/SM03-026-0
Kessler Axle, Differential and Carrier Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 29/SM03-026-0
Kessler Axle, Drive Pinion Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27/SM03-026-0
Kessler Axle, General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM03-026-0
Kessler Axle, General Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/SM03-026-0
Kessler Axle, Integrated Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32/SM03-026-0
Kessler Axle, Loctite Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM03-026-0
Kessler Axle, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM03-026-0
Kessler Axle, Planetary Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/SM03-026-0
Kessler Axle, Single Stage Carrier Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31/SM03-026-0
Kessler Axle, Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM03-026-0
Kessler Axle, Steering Knuckle to Axle Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 26/SM03-026-0
Kessler Axle, Wheel End (Planetary Gear Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/SM03-026-0

Index-10 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

Leakage Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4

Lift Circuit, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Lift Circuit, Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Lift Circuit, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Lift Circuit, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Lift Circuit, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Lift Circuit, Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-15
Lift Cylinder, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-59
Lift Cylinder, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-57
Lift Cylinder, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-57
Lift Cylinder, Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-59
Lift Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-57
List of Specifications, Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3
Load Moment Indicator (LMI) System, Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . Appendix G
Lock Cylinder, Rear Steer, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-7
Lockout Cylinders, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Lockout Cylinders, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Lockout Cylinders, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Lockout Cylinders, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Locks, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Loctite, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-2
Low Pressure Indicating Switch, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-006-0
Low Pressure Indicating Switch, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-006-0
Low Pressure Indicating Switches, Air, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Low Pressure Indicating Switches, Air, Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Low Pressure Indicating Switches, Air, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4-3
Lubrication, General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4-3
Lubrication, Symbol Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3
Lubrication, Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-11
Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-12
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-4

Maintenance Allocation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A

Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Miter Gear, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM04-020-0
Miter Gear, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10 & 3/SM04-020-0
Miter Gear, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM04-020-0
Miter Gear, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM04-020-0
Miter Gear, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Miter Gear, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10 & 3/SM04-020-0
Miter Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Muffler and Piping, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-39
Muffler and Piping, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-38

Index-11 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

N,O

NATO Slave Receptacle, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17

NATO Slave Receptacle, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Organizational PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-3
Organizational Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3
Organizational Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3
Oscillation Lockout Cylinder, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-70
Oscillation Lockout Cylinder, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-68
Oscillation Lockout Cylinder, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-68
Oscillation Lockout Cylinder, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-70
Oscillation Lockout Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-68
Outrigger Box Assembly, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Outrigger Box Assembly, Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Outrigger Box Assembly, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-7
Outrigger Box Assembly, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Outrigger Box Assembly, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Outrigger Box Assembly, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-5
Outrigger Circuit, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
Outrigger Circuit, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
Outrigger Extension Cylinder, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-74
Outrigger Extension Cylinder, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-72
Outrigger Extension Cylinder, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-72
Outrigger Extension Cylinder, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-74
Outrigger Extension Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-72
Outrigger Solenoid Valve Stack, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-018-0
Outrigger Solenoid Valve Stack, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-018-0
Outrigger Solenoid Valve Stack, Description. . . . . . . . . . . . . . . . . . . . . . . . 2-8-51 & 2-12-13 & 3/SM08-018-0
Outrigger Solenoid Valve Stack, Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-018-0
Outrigger Solenoid Valve Stack, Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Outrigger Solenoid Valve Stack, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Outrigger Solenoid Valve Stack, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Outrigger Solenoid Valve Stack, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51 & 3/SM08-018-0
Outrigger Solenoid Valve Stack, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-51
Outrigger Solenoid Valve Stack, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM08-018-0
Outrigger Stabilizer Cylinder, Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-77
Outrigger Stabilizer Cylinder, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-75
Outrigger Stabilizer Cylinder, Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-75
Outrigger Stabilizer Cylinder, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-77
Outrigger Stabilizer Cylinder, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-75

P,Q

Panel Light Dimmer Control, (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-23

Panel Light Dimmer Control, (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-23
Parking Brake Control (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-79
Parking Brake Control (Superstructure Cab), Operating and Leakage Check . . . . . . . . . . . . . . . . . . . . . 2-1-79
Parking Brake Control (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-79
Pile Driver System, Berminghammer, Instructions for Maintenance, Troubleshooting, and Repair . . . . Appendix K

Index-12 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

P,Q - Continued

Pilot Operated Check Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53 & 2-12-14

Pilot Operated Check Valve, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Pilot Operated Check Valve, Frame Mounted Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-14
Pilot Operated Check Valve, Cylinder Mounted, Description . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53 & 2-12-14
Pilot Operated Check Valve, Cylinder Mounted, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Pilot Operated Check Valve, Cylinder Mounted, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Pilot Operated Check Valve, Frame Mounted, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-53
Pilot Operated Check Valve, Frame Mounted, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-54
Pilot Operated Check Valve, Frame Mounted, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-54
Planet Carrier Assemblies, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/SM09-004-0
Planet Carrier Assemblies, Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM09-004-0
Planet Carrier Assemblies, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM09-004-0
Planet Carrier Assemblies, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM09-004-0
Planetary Gears, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/SM03-026-0
Planetary Gears, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/SM03-026-0
PMCS, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-3
PMCS Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-3
PMCS Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4
Powershift Transmission, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Preparation for Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-2
Preservation, Packaging, Packing, Marking, and Shipping Requirements, Introduction . . . . . . . . . . . . . . . 2-16-1
Pressing Parts, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Pressure Protection Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-012-0
Pressure Protection Valve, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-012-0
Pressure Protection Valves, Air, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Pressure Protection Valves, Air, Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Pressure Protection Valves, Air, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Pressure Protection Valves, Air, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Pressure Protection Valves, Air, Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Pressure Reducing Valve, Air, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-31
Pressure Reducing Valve, Air, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-31
Pressure Reducing Valve, Hydraulic, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Pressure Reducing Valve, Hydraulic, Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Pressure Reducing Valve, Hydraulic, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Pressure Reducing Valve, Hydraulic, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Pressure Reducing Valve, Hydraulic, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Pump/Motor Assembly, Emergency Stowage System, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Pump/Motor Assembly, Emergency Stowage System, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Pump/Motor Assembly, Emergency Stowage System, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Pump/Motor Assembly, Emergency Stowage System, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6

R-12 Relay Valve, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM07-014-0

R-12 Relay Valve, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM07-014-0
R-12 Relay Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-014-0
R-12 Relay Valve, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM07-014-0
R-12 Relay Valve, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM07-014-0
R-12 Relay Valve, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-014-0

Index-13 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

R - Continued

Radiator and Air Cooler, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-35

Radiator and Air Cooler, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32
Rear Axle, Alignment and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-12
Rear Axle Steering Unlock Switch, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Rear Axle Steering Unlock Switch, Operation Check/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Rear Axle Steering Unlock Switch, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-20
Rear Steer Lock Cylinder, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-7
Relay Shaft Alignment, Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Relay Valves (R-12), Air, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Relay Valves (R-12), Air, Leakage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Relay Valves (R-12), Air, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Relay Valves (R-12), Air, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Relay Valves (R-12), Air, Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Removal and Installation, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Reservoirs, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-005-0
Reservoirs, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-005-0
Reservoirs, Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-005-0

Safety Valve, Air, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18

Safety Valve, Air, Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Safety Valve, Air, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Safety Valve, Air, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Seat Assembly (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Seat Assembly (Carrier Cab), Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Seat Assembly (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Seat Assembly (Superstructure Cab), Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Seat Assembly (Superstructure Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Seat Belt (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Seat Belt (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Seat Belt (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Seat Belt (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12
Selector Valve, Steering, Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-13
Selector Valves, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-13
Selector Valves, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-13
Service Brakes, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Service Brakes, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Service Brakes, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-24
Service Maintenance Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... v
Shift Control (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-86
Shift Control (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-86
Shift Control (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-87
Shift Control (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-87
Shims, General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16-1
Single Selector Valve, Hydraulic, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Single Selector Valve, Hydraulic, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45

Index-14 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

S - Continued

Single Selector Valve, Hydraulic, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45

Single Selector Valve, Hydraulic, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Single Selector Valve, Hydraulic, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-45
Single Stage Carrier, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31/SM03-026-0
Skylight Wiper (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Skylight Wiper (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Skylight Wiper (Superstructure Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-19
Solenoid Valve, Hydraulic, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Solenoid Valve, Hydraulic, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Solenoid Valve, Hydraulic, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Solenoid Valve, Hydraulic, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Solenoid Valve, Hydraulic, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Spring Brake Control Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Spring Brake Control Valve, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Spring Brake Control Valve, Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-31
Spring Brake Control Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Stabilizer Cylinder, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Stabilizer Cylinder, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Stabilizer Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Stabilizer Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Stabilizer Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Starting/Cranking Motor, Repair and Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix E
Steer Cylinder, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Steer Cylinder, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Steer Cylinder, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Steer Cylinder, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Steer Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-61
Steer Cylinders, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Steer Cylinders, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Steer Cylinders, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Steer Cylinders, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Steering Gear, Centering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-7
Steering Gear, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Steering Gear, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-7
Steering Gear, Instructions for Operation, Maintenance, and Inspection . . . . . . . . . . . . . . . . . . . . Appendix H
Steering Gear, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Steering Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Steering Gear, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Steering Knuckle Bearing and Double Universal Joint Shaft Bearing, Removal . . . . . . . . . . . . . . 23/SM03-026-0
Steering Knuckle Bearing and Double Universal Joint Shaft Bearing, Installation . . . . . . . . . . . . . 25/SM03-026-0
Steering Knuckle, Installation to Axle Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26/SM03-026-0
Steering Pump, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM04-019-0
Steering Pump, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14 & 3/SM04-019-0
Steering Pump, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM04-019-0
Steering Pump, Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM04-019-0
Steering Pump, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Steering Pump, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14 & 3/SM04-019-0
Steering Pump, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Steering Pump, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM04-019-0

Index-15 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

S - Continued
Steering System Filter Check Valve, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23
Steering Systems, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Systems, Front Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Systems, Front Axle Steering from the Superstructure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Systems, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-4
Steering Systems, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-4
Steering Systems, Rear Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Systems, Rear Axle Steering from the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Systems, Relay Shaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Steering Systems, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Systems, Theory of Operation, Front Axle Steering from the Superstructure . . . . . . . . . . . . . . . . 2-5-4
Steering Systems, Theory of Operation, Front Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . 2-5-3
Steering Systems, Theory of Operation, Rear Axle Steering from the Carrier . . . . . . . . . . . . . . . . . . . . . 2-5-4
Steering Systems, Theory of Operation, Rear Axle Steering for the Superstructure. . . . . . . . . . . . . . . . . . 2-5-4
Stop Light Switch, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-017-0
Stop Light Switch, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Stop Light Switch, Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Stop Light Switch, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Stop Light Switch, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Stop Light Switch, Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-17
Stop Light Switch, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-017-0
Superstructure Cab, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8
Superstructure Cab, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-99
Superstructure Cab, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-97
Swing Bearing, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Swing Bearing, Inner Race Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Swing Bearing, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17
Swing Bearing, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17
Swing Bearing, Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Swing Bearing, Outer Race Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Swing Bearing, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Swing Bearing, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-18
Swing Bearing, Tools Required, Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Swing Bearing, Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-13
Swing Bearing, Torquing Turntable Bolts, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Swing Brake, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM09-004-0
Swing Brake, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Brake, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM09-004-0
Swing Brake, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Brake, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM09-004-0
Swing Brake, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Brake, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM09-004-0
Swing Gearbox and Brake, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8 & 3/SM09-004-0

Index-16 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

S - Continued

Swing Gearbox, Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM09-004-0

Swing Gearbox, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM09-004-0
Swing Gearbox, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-8
Swing Gearbox, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM09-004-0
Swing Gearbox, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Swing Gearbox, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Swing Gearbox, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM09-004-0
Swing Lock Control (Superstructure Cab), Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-85
Swing Lock Control (Superstructure Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-83
Swing Lock Control (Superstructure Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-83
Swing Motor, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Swing Motor, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Swing Motor, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Swing Motor, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Swing Motor, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Swing System, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5
Swing System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5
Switches, Electrical, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Switches, Electrical, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Switches, Electrical, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Switches, Electrical, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Swivel, 14 Port Air/Hydraulic, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Swivel, 14 Port Air/Hydraulic, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-6
Swivel, 14 Port Air/Hydraulic, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Swivel, 14 Port Air/Hydraulic, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Swivel, 14 Port Air/Hydraulic, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
Swivel Assembly, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-006-0
Swivel Assembly, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-006-0
Swivel Assembly, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-006-0
Swivel Assembly, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-006-0
Swivel Assembly, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-006-0
Swivel Assembly, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-006-0
Swivel, Electrical, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/SM13-007-0
Swivel, Electrical, Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-007-0
Swivel, Electrical, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9 & 3/SM13-007-0
Swivel, Electrical, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-007-0
Swivel, Electrical, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-10
Swivel, Electrical, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9 & 3/SM13-007-0
Swivel, Electrical, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
Swivel, Electrical, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM13-007-0
Swivels, Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
Symptom Index, Direct/General Support Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-11
Symptom Index, Organizational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3

Index-17 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

T,U

Tagline Assembly, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22

Tagline Assembly, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22
Telescope Circuit, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Telescope Circuit, Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Telescope Circuit, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Telescope Circuit, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Telescope Circuit, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-14
Telescope/Clamshell Control Valve, Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Telescope/Clamshell Control Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Telescope/Clamshell Control Valve, Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Telescope Cylinder, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-65
Telescope Cylinder, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-64
Telescope Cylinder, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-64
Telescope Cylinder, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-65
Telescope Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-64
Three Way Air Solenoid Valve, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Three Way Air Solenoid Valve, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Three (3-) Way Valve Assembly, Emergency Stowage System, Description . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Three (3-) Way Valve Assembly, Emergency Stowage System, Installation . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Three (3-) Way Valve Assembly, Emergency Stowage System, Maintenance . . . . . . . . . . . . . . . . . . . . . 2-15-4
Three (3-) Way Valve Assembly, Emergency Stowage System, Removal . . . . . . . . . . . . . . . . . . . . . . . 2-15-4
Throttle Air Cylinder and Throttle Linkage, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-17
Throttle Air Cylinder and Throttle Linkage, Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18
Throttle Air Cylinder and Throttle Linkage, Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18
Throttle Air Cylinder and Throttle Linkage, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Throttle Control Cylinder, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-008-0
Throttle Control Cylinder, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-008-0
Throttle Control Cylinder, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-008-0
Throttle Control Cylinder, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-008-0
Throttle Control Cylinder, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-008-0
Throttle Control Cylinder, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM07-008-0
Throttle Fast/Slow Control (Superstructure Cab), Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Throttle Fast/Slow Control (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Throttle Fast/Slow Control (Superstructure Cab), Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Throttle Fast/Slow Control (Superstructure Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-81
Tilt Steering Column (Carrier Cab), Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-65
Tilt Steering Column (Carrier Cab), Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-63
Tilt Steering Column (Carrier Cab), Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-63
Tilt Steering Column and Steering Control Valve (Superstructure Cab), Installation . . . . . . . . . . . . . . . . . 2-1-68
Tilt Steering Column and Steering Control Valve (Superstructure Cab), Removal. . . . . . . . . . . . . . . . . . . 2-1-66
Tilt Steering Column and Steering Control Valve (Superstructure Cab), Repair . . . . . . . . . . . . . . . . . . . . 2-1-66
Torque Converter with Lock-up, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/SM02-027-0
Torque Converter with Lock-up, Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/SM02-027-0
Torque Converter with Lock-up, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM02-027-0
Torque Converter with Lock-up, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM02-027-0
Torque Converter with Lock-up, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM02-027-0
Torque Values and Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7
Towing or Push Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97/SM02-025-0

Index-18 C-1
 TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

T,U - Continued

Trailer Air Brake System Components, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-36

Trailer Air Brake System Components, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-36
Trailer Air Supply and Parking Brake (Carrier Cab) Control Assembly, Installation . . . . . . . . . . . . . . . . . . 2-1-76
Trailer Air Supply and Parking Brake (Carrier Cab) Control Assembly, Operating and Leakage Check . . . . . 2-1-76
Trailer Air Supply and Parking Brake (Carrier Cab) Control Assembly, Removal . . . . . . . . . . . . . . . . . . . 2-1-73
Trailer Air Supply and Parking Brake (Carrier Cab) Control Assembly, Repair . . . . . . . . . . . . . . . . . . . . . 2-1-73
Transmission Control Valve, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Transmission Control Valve, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Transmission Oil Cooler, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Transmission Oil Cooler, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Transmission Oil Cooler, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Transmission Oil Cooler, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
Transmission Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9
Transmission/Torque Converter, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/SM02-025-0
Transmission/Torque Converter, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40/SM02-025-0
Transmission/Torque Converter, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7 & 3/SM02-025-0
Transmission/Torque Converter, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18/SM02-025-0
Transmission/Torque Converter, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/SM02-025-0
Transmission/Torque Converter, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41/SM02-025-0
Transmission/Torque Converter, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9 & 9/SM02-025-0
Transmission/Torque Converter, Major Transmission Components . . . . . . . . . . . . . . . . . . . . . 63/SM02-025-0
Transmission/Torque Converter, Operation of Powershift Transmission . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Transmission/Torque Converter, Servicing the Machine after Transmission Overhaul . . . . . . . . . . 97/SM02-025-0
Transmission/Torque Converter, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7 & 3/SM02-025-0
Transmission/Torque Converter, Towing or Push Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 97/SM02-025-0
Transmission/Torque Converter, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/SM02-025-0
Troubleshooting, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5-3
Troubleshooting Table, Direct/General Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-14
Troubleshooting Table, Organizational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-5
V

Vane Type Motor (HO-15C Hoist), Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/SM11-011-0

Vane Type Motor (HO-15C Hoist), Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM11-011-0
Vane Type Motor (HO-15C Hoist), Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM11-011-0
Vane Type Motor (HO-15C Hoist), Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM11-011-0
Vane Type Motor (HO-15C Hoist), Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM11-011-0
Vane Type Motor (HO-15C Hoist), Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM11-011-0
Vane Type Motor (HO-15C Hoist), Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM11-011-0
Vane Type Motor, Hoist, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Vane Type Motor, Hoist, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Vane Type Motor, Hoist, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Vane Type Motor, Hoist, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7

W,X,Y,Z

Water Cooling System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32

Water Cooling System, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/SM01-002-0

Index-19 C-1
TM 5-3810-307-24-1-1

ALPHABETICAL INDEX - Continued

Description Page No./Pkg. No.

W,X,Y,Z - Continued

Water Cooling System, Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM01-002-0

Water Cooling System, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32 & 3/SM01-002-0
Water Cooling System, Effects of Cooling System Neglect. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM01-002-0
Water Cooling System, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/SM01-002-0
Water Cooling System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32 & 3/SM01-002-0
Water Cooling System, Pressure Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/SM01-002-0
Water Cooling System, Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/SM01-002-0
Water Cooling System, Seasonal Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/SM01-002-0
Water Cooling System, Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/SM01-002-0
Water Cooling System, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/SM01-002-0
Welded Structures, Fatigue of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Wheel Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-7
Wheel Assemblies, Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Wheel End (Planetary Gear Axle), Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19/SM03-026-0
Wheel End (Planetary Gear Axle), Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/SM03-026-0
Wheels and Tires, Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Wheels and Tires, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-22
Windshield Wiper/Washer, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17
Windshield Wiper/Washer, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15
Windshield Wiper/Washer, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17
Windshield Wiper/Washer Switch, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-22
Windshield Wiper/Washer Switch, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-22
Winterizing the ATEC Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix J
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-11
Wires and Cables, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4

Index-20 C-1
 TM 5-3810-307-24-1-1
6
(48) 3(R) 6 BRN LEFT S/S POWER 5
(45) 2(W) 873 BLK 901 FRONT STEER 901 RELAY 51 112 TO POWER TO POWER
51 K 5
BLU INDICATOR SWITCHES
601 FUSE FU51 FUSE FU52 105
BRN
(SEE PAGE 4) (SEE PAGE 4)
(46) 2(X) 874 BLK 112 112
51 BLU 52 52
CENTER 901 901 901 TO ANTI-RESTART
(40) 3(T) 112 2 TO FUEL 151
RELAY TO START RELAY, HEATER RELAY
(42) 3(W) 52 (SEE PAGE 4)
ELECTRIC SHIFTER REV FORWARD FUEL SOLENOID, & (SEE PAGE 4)
(41) 3(V) 901 1 2 3 N 6 5 4 3 2 1
BLK 2 810 OIL COOLER RELAY
(43) 3(X) 644 NEUTRAL 606 606 RED 3
20 19
810 (SEE PAGE 4)
(21) 1(R) 936 597 367 RELAY 367 YEL 4
16 15 1
(23) 1(S) 937 598 368 GRN 5
8 7
(27) 1(U) 938 609 644 2 843 BLU 6 CB20 IGNITION SWITCH
(29) 1(V) 943 789 51 PARK 372 BRN 7
2 1
52 709 2
K RELAY 370
10 9
WHT 1 901 601 15A 601 I B
810
606 ORN 9
18 17
(25) 1(T) 940 788 403 K B/O 35 4 POS
14 13
782 419 VIO 10 112 RELAY 3
22 21
840 718 718 712 712
TRANSMISSION
SOLS GRN TURBINE SPEED 583 51
BLK 1 ST 597 597 1086 RED K
F G J E L A G 418
718 B
1087 BLK 712 712
BLK FWD LO GRN 788 788 B ENGINE RPM 718 718 810 810
A
149 RED
G ACC
BLK FWD HI GRN 789 789 K
148 BLK CONVERTER 804 RELAY
B
LOCK UP SOL K 35 35 51
BLK 2 ND GRN 598 598 APC100 448 448 51 104 51 K
H TRANSMISSION Q 101
CONTROL UNIT THROTTLE POSITION POWER
BLK REV GRN 609 609 916 44
D SEE SHEET 3 T SELECT MODE SOLS
718 51
W ENG IDLE RELAY PARK BRAKE
839 448 51 A(CARR)
712
840 718 A 918 918 44 K TORQUE 718 51 105 105
U
367 371 C 401 CONV
TRANS CLUTCH PRESS B(S/S)
STEER LOW K 935 O 920 44 44 UNLOCKED 901 51 180
S
UNPINNED SPEED 103 914 P X R
CLUTCH PRESS LOW 740 A 51 CB1
RELAY RELAY 51 /TRANS O/S 810 810 810 105
221 BACKUP RELAY 905 905 A 51 L/U LIGHT 15A
CB4
K 371 609 8 8 8 RELAY 151 A 40
404 621 843 51 516 516 51 BACKUP 10A

619 839 836 K ALARM FUEL PREHEAT

(2) 2(A) 907 CB3
51 STEER K AIR 408 AIR DRYER 44 44 44 180
DRYER RELAY 10A
907 907 UNPIN 102 CB2 330
RELAY 135 7 7 7 105
1(W) 934 935 10A 3 WATT
(31) BACKUP/REAR DRIVE LTS TRINARY P/SW THERMOSTAT AIR COND 1%
51 588 28 28 89 BLK/WHT WHT ORG-HI
WHT BLK 1 2 BLK/WHT EVAP H CB9
2WD SELECT 7 28 B RED 180
K CONDENSER BLK
M ORG 1 YEL-MED M 87
21 51 221 405 51 588 51 W W COMP CLUTCH 51 BLK
MORG PUR 3 2 RED-LO L 20A
K 89 C 51 PUR
TYP LED CIRCUIT
(32) 2(Q) 331 331 110 51 51 BLK YEL 4 3 WHT WHT-COM 40
621 K
621 CARRIER STEER
(4) 2(B) 159 159 TRINARY P/SW TRANS DISCONNECTED
(6) 2(C) 169 169 169 361 HIGH TEMP BLK 626
782 901 730 TRANS SELECT 361 51 BLK LEGEND
(10) 2(E) 441 441 914 914 4WD 142 STEER 621 REAR STEER 250
(8) 2(D) 941 941 935 935 2WD PUMP SWS LO OIL UNPINNED DEG LOW AIR PRESS
BATTERY CABLES
(12) 2(F) 221 221 836 REAR STEER UNPINNED 836 GROUND ENG TEMP PRESS 621 51 42
2(R) 479 441 440 159 546 542 51 OPTIONAL CABLES

REAR STEER UNPINNED

(34)
(30) 2(P) 478 PARK BRAKE 51 857 857 51 PUMP STANDARD WIRING

DIFF LOCKED
(26) 2(N) 477 782 FRONT REAR
542 641 641 ENGAGED
(18) 2(J) 476 DIFF LOCK SWS 836 621 546 144 51 OPTIONAL WIRING
(14) 2(G) 10 10 941 31 31 ENGINE BUZZER EXISTING WIRING

PARK BRAKE
221 641 40
TACH SENDER 32 32 I 40 A R
FURNISHED WIRING,
R R
10 51 554 51 40 40 40
R R
40 R
40 40 BUT NOT USED
G FUEL TRANS
479 LEVEL 51 CONNECTED WIRES
OIL TEMP STOP LTS
25 25 t VOLTMETER 583 583 B/O DRIVE LTS
549 R A 40 V 51 582 A B/O MARKER LTS NON-CONNECTED WIRES
ENG OIL CB8
OUTRIGGERS 478 PRESS 51 40 40 41 PANEL BRIGHT F 587 105
OFF FUSIBLE LINK WIRE
(9) 1(J) 79 EXT 4 4 OP 40 GAUGE LIGHTS CB19 PANEL DIM 20A 20A
(11) 1(K) 80 RET 362 SPEEDOMETER 54 54 582 582
30
OFF SERVICE STOP LTS
51 ENG W/HI BEAM IND 5A
477 TEMP 53 53 B PARK SERVICE DRIVE LTS
(1) 1(A) 75 RFE 3 3 t U 132 583 B/O SIDE/TAIL LTS
W W W W W W W W E
(5) 1(F) 77 RRE 355 40 140
51 I
476 141 730 J SERVICE LTS
10 10 51 53
76 LFE I 221 W 53
(3) 1(C) 51
(7) 1(H) 78 LRE 51 51 44 TACH/ 51 585 D
BLACKOUT HEADLT 12 12 12
K K SPEEDO PANEL BLACKOUT 786 H SIDE & MARK LTS
HOUR HEADLIGHT MS 51113-1
(13) 1(L) 81 RFS 409 411 SENDER LTS 51 W 53 PANEL BRIGHT
(17) 1(N) 83 RRS 51 51 44 585 PANEL DIM LIGHT SW 51 51
K G W A A A R A A A R
K 11 M HEAD LTS OFF
(15) 1(M) 82 LFS 410 412 730 730 PARK 51
L FRONT TRIPLE RIGHT LEFT
(19) 1(P) 84 LRS 44 44 44 44 584 N B/O STOP LTS FRONT REAR
134 CB13 123 ID LIGHTS LEFT RIGHT RIGHT
718 HEADLIGHTS
LO-BLK
840 10A 586 C TURN SW STOP SIGNAL REAR FRONT MID CLEARANCE
FRONT/REAR RT STEER REAR STEER SOL 841 LEFT RIGHT LO-BLK 133
CB14
SIDE MARKER LIGHTS LIGHTS
3(Y) 792 RT 792 51 841 840 51 GRN 10A 41 K STOP LT SW
(33) 51 GRN W W
841 REAR HI-RED 131 CB15 730 730
3(Z) 793 LT 793 792 RT 792 10A 586 786
(35) STEER CB16
840 2WD HI-RED 132 122 11 51 786
FRONT/REAR LT STEER LT 793 RELAY 132 10A 123 COLUMN SWITCHES 12 12 CB17 K LIGHTS
51 935 122 TURN TURN BEAMS
10A 105 RELAY
LOCK STEER CB18
721 721 B K 584 584 13 731 731 105

HEAD FLASH
(16) 2(H) R L R L R HI-LO
STEER 721 LOCK SW 416
L W LOCK 583 583 10A
(20) 2(K) 722 UNLOCK 722 R L 840 914 786 786 13 13 13
SOL

HAZARD
722 17 16
875 875 584 583 786 584 583 786 786 583 15 786 583
A 718 718 15 14
REAR STEER 221 632 23 24 21 22 23 24 21 22 491 483 460 491 483 460 51 A 51 A 51 R
REAR STEER R R R A R
PINNED SOL REAR STEER INDICATOR SWITCHES W R R R W R R R W W A A W W A A
PINNED 221

385 WR
51 875 221 BRN

12 GB

15 RY

13 RB
RIGHT

511 G
LEFT LEFT

3 GW

2 WU
LEFT RIGHT

9 GO
REAR TRIPLE

5 OU

196 O
872

44 U
51 BLK 840 B/O B/O SERV
SERV
B/O B/O SERV SERV SERV B/O SERV 51 SERV B/O SERV 51 FRONT MID REAR FRONT REAR
K BRN K 51 BLU STOP TAIL TAIL
STOP/
STOP TAIL TAIL STOP/ PARK PARK TURN PARK PARK TURN
ID LIGHTS
CENTER TURN SIDE MARKER LIGHTS CLEARANCE
907 413 867 BLK 221 CENTER 414 TURN
L FRONT TURN
SIDE SIDE
LIGHTS
SENSOR L REAR R REAR 51 51 R FRONT TURN 36 38 CB10
51 BLU PINNED 51 866 17 16 38 730
SENSOR
G 840 840 DIFF 930 931 586 10A
51 869 REAR DIFF LOCK LOCK 932 933 11 11 95 CB11
A 51 870 868 BRN 51 631 631 15 15 123 123 10A
RIGHT A 51 871 840 14 14 122 122 FLASHER 98 98 CB12
BLK
LEFT K 51 BLU 51 831 831 36 36 L 38 K 10A
415 LEFT RIGHT G LEFT 106 HORN SW
SENSOR G 931 931 X 97 YEL
(36) 2(S) 930 FRONT DIFF LOCK DOME LT TURN TURN 933 P
WHT 95 SIGNAL SIGNAL

SH
(37) 2(T) 932 51 51 15 99
W IND

AUX1_SHT_UA
(38) 2(U) 15 CAB DOOR SW IND 14 14 51 HORN
(39) 2(V) 14 BLK 45 95 95 95 95 HORN
(24) 2(M) 831 831 712 RELAY 712
BOOM REST 630 CB5 180
(22) 2(L) 942 939 939 630 CAB CIRC FAN W/SW
10A

FRONT REAR 712 51 BLK

20 20 51 YEL 68
K M
713 630
402 51 939 939 WASHER WIPER/WASHER
714 713 K 51 M 67 WASHBRN TIME RED 68 68 CB6
51 51 406 51 51 64 HI WHT DELAY CAB 10A
OSCILLATE LO YEL WIPER/ BLK 51 558
RF LF RELAYS LR RR 51 M 65 HEATER FAN HI
51 51 51 51 66 PARK BLU WASHER 102 CB7

WINDSHEILD
SWITCH M 558 RES RES 559
LO
15A
FO-1. Electrical Schematic (Sheet 1 of 4)
FRONT AXLE OSCILL SOLS REAR AXLE OSCILL SOLS WIPER 1 1

FO-1/FO-2 Blank
 6 SWIVEL - 49 SLIP RINGS
TM 5-3810-307-24-1-1
112 47 30A
IGNITION SW 6 48 60A
2 52
112 B I 601 CAB STRAP 23 49 60A 23
4 POS
35 3 HEATER FUEL 601 901
ACC K LINE HEATER 112
RELAY 101 51 948 51
S/S D6 40 7.5A
102 IGNITION K 650 901
RELAY 103 D5 52 42 7.5A
6 30 DEG 51 650 52
ELECTRIC SHIFTER
180 REV FWD 901 41 7.5A
27 MAGNETIC SENSOR 3 2 1 N 1 2 3
CB1 15A
51 CONTROLLER 2
52 RED 3
14 13
BLK 2 644 644 43 7.5A
948 MAIN G GRD +10V R 1.37K 9 10
YEL 4 597
WHT 27 27 27 W +BAT IN W 1 4 3 4
GRN 5 598 597 21 7.5A
CB2 15A
BLK 508 508 B OUT COM B 3 901 WHT 1
7 8
BLU 6 372
661 /8 /4 G 1 2
BRN 7 609 598 23 7.5A
HOIST ROT INDICATORS 15 16
ORN 9 789
CB3 5A MAGNETIC SENSOR 372 25 7.5A
27 27 51 CONTROLLER 372
2 S/S 951 951 609 609
AUX G GRD +10V R 1.37K BACKUP 27 7.5A
WHT 27 27 27 W +BAT IN W 1 4 51 S/S
509 509 ALARM 70 789
BLK B OUT COM B 3 BACKUP 29 7.5A
/8 /4 G ALARM K
RELAY 104 805 619 2 7.5A
BUZZER
CB4 5A D2 169
40 40 40 40 40 40 40 641 169 6 7.5A
D1 D3 619 440
VOLTMETER 10 7.5A
661 40 V 51 40 LO AIR
R R SWING BRAKE R A R R R
PRESS D7 31 8 7.5A
180 143 539 ON 159 STEER PUMP FAILED
619
STEER PINNED 619 221 12 7.5A
WIPER/WASHER 51 169 ENG/TRANS DISTRESS
WASHER I t OP t I 440
51 51 51 51 51 51
DIFF LOCKED 10 14 7.5A
51 TIME 31
M 67 68
WASH BRN RED PARK BRAKE ON
DELAY 221 3 18 7.5A
64 HI WHT WIPER/ BLK 10 TACH
51 65 LO YEL WASHER 3 ENG TEMP 4 26 7.5A
M SWITCH
66 PARK BLU 51 4 OIL PRESS
25 TRANS OIL TEMP 25 30 7.5A
WIPER
WINDSHIELD CAB CIRC
FAN W/SW 32 FUEL LEVEL 32 34 7.5A
CB5 10A
113 YEL BLK 51 133 32 7.5A
M
CB6 10A
159 4 7.5A
68
OUTRIGGERS 79 EXT 79
CB7 15A 9 7.5A
46 46
CB8 10A
80 RET 80 11 7.5A
44 44
75 RFE 75 1 7.5A
46
DOME LT SWING BRAKE 77 RRE
CB13 10A L R L R HI LO
50 51
77 5 7.5A
6 95 95 44
W
76 LFE 76 3 7.5A
TURN
46
WORK LT CLAMSHELL

HAZARD
78 LRE
CB14 10A
56 51 FLASHER 51
78 7 7.5A
55 W G 81 RFS
CB15 10A
X
P 81 13 7.5A
38 38 44 342 51 46
L 83 RRS 83 17 7.5A

WR 385

511
44

12

15

13
133 274 51

GW 3

GO 9

OU 5
WU 2
15 G
82 LFS 82 15 7.5A

RB
GB

RY
U

O
G
14 TELE 46
36 932 84 LRS 84
DRIVE/PANEL LEFT G RIGHT G 19 7.5A
CB16 10A 133 TURN TURN 930 TRANS SELECT
30 IND 15 44 148 2 WHEEL 934 934 7.5A
D4 51 IND 51 14 4 WHEEL 630
31
54 54 FRONT STEER 792 792 7.5A
R 33
44
L 793 793 7.5A
53 53 W W 35
W W W W W W W 932 7.5A
PANEL 51 51 37
180 LTS DIMMER GAUGE LTS TACH 930 7.5A
LT PANEL LTS 36
CRANE FUNCT SEAT TAPE LEFT RIGHT L/O SOL 15 7.5A
CB9 10A 38
794 794 799 800 706 707 51 STEER LOCK
10A LOCK 721 14 7.5A
CB10 ARM REST L/O SWS 720 39
720
113 UNLOCK 722 721
CB11 15A 16 7.5A
71
OIL COOLER FAN TEMP SW CONSOLE 722 7.5A
CB12 5A
71 71 DIFF LOCK 20
522 530 51 DEFROST FAN
K HYD OIL COOLER 630 831 831
485 51 24 7.5A
FAN 201 ORN YEL
HI
RELAY FAN MTR 113 M BLK AREA DEFIN
120 DEG
CB17 15A LO
486 RED BLU 71 #2 (SWIVEL)
6 520 521 521 RED M BLK 51 805 51 28 7.5A
DIESEL HEATER
HEATER HTR STEER 7.5A
CB18 20A
37 37 FUEL PUMP REVERSING SOL 44
59 A2B
HTR M M AREA DEFIN
CB19 10A 58 #3 (SWIVEL)
98 99 99 SW FRONT AXLE OSCILL 7.5A
HORN LMI 22
51 CPU
K 873 873 7.5A
98 102 97 97 AREA DEFIN FRONT STEER 45
#1 (SWIVEL) INDICATION K
HORN RELAY STER WHEEL 105
A
98 HORN
99 AIRCOND RELAY BOX 874 LEFT
SWING 51 K 870
88 88 88 88 106 A
HORN RIGHT
AIRCOND CONDENSER 807 B 869
92 51 540 51 51 51 BINARY A
K1 K2 K3 K4 PRESS SW
720 868 CENTER
88 B(1) W N 89 AUX HOIST AUX UP 866 866
661 87 91 73A 780 51 G
661 X(1)
88 B(2) U B AUX
661 K5
SWING PRESS SW 874 874
UNLOCK 46 7.5A
AUX DN
R A(B) 88 51 51 51 51 B(3) B 44 197 51 SOLS
B A(A) 540 540 540 540
87 87 B(4) O O O B 73B
M
BRN A(C) 91 91 91
UNLOCK SOLS
FANS RLY 73B
IDLE BOOST P/SW O B 51 51 MAIN UP
180 M C
92 663 663 991 991
Y(1)
CONDENSOR FANS 73C 51 LIFT DN
51 E(6) B COMPRESSOR
CB20 20A
60 91 E(5) U IDLE BOOST SOL CLUTCH 73D 51 TELE OUT
92 E(4)
92 W 991 51
THERMOSTAT
LO 61 E(1) Y Y-LO
60 MED 62 E(2)
E(3)
R R-MED
M
B AIRCOND
EVAPORATOR
FO-1. Electrical Schematic (Sheet 2 of 4)
B HI 63 O O-HI
A/C SW EVAP FAN
FO-3/FO-4 Blank
 TM 5-3810-307-24-1-1

55 +24VDC 55 AUTO MODE LT

MANUAL SHIFT 63 G 51
OVERRIDE PB SHIFTER 63 A 63
55 55 42 RELAY 55 71 M
71 71 MANUAL MODE LT
52 MANUAL 71 R 51
51 R1 MODE
51 R11 LATCH
71 71
D204 12 A 12
788 788 2.5A 44 59 69 M
FU1 FWD LO
D206 R2
52 51 OUT 69
371 FWD LO IN 371 1 1
D203 13 A 13
609 609 2.5A 45 61 54 M 20 20
FU2 71 37 PASS "D"
D207 R3 REV CONNECTOR
372 52 51 OUT
1 1 1
372 REV IN 372 2 2
23 PASS A 2 2
D201 14 3 3 3
CONNECTOR 597 2.5A 46 57 64 M 4 4 4
+24VDC POWER IN A 718 FU3 71 5 5
FWD LO SOL OUT B 788 R4 1ST 6 6
SHIFTER FWD LO IN C 371 51 OUT 7 7 7
REV SOL OUT D 609 8 8 8
372 367 1ST IN 367
SHIFTER REV IN E A 9 9
1ST SOL OUT F 597 D202 15 10 10
367 598 2.5A 47 58 66 M 11
SHIFTER 1ST IN G 11 11
2ND SOL OUT H 598 FU4 71 12 12 12
SHIFTER 2ND IN J 368 368 R5 2ND 13 13 13
FWD HI SOL OUT K 789 51 OUT 14 14 14 14
SHIFTER FWD HI IN L 370 15 15 15 15
883 368 2ND IN 368 16
NOT TRANS LO RANGE RLY OUT M A 16 16
USED TRANS LO RANGE IN N 863 D205 19 17 17 17 APC100
935 789 2.5A 48 60 67 M 63 18
2 WD SOL OUT O 18 18 AUTO
4 WD IN P 914 FU5 71 19 19 19 19 TRANS
CONV LOCK SOL OUT Q 905
448
51 R6 FWD
OUT
HI
21
20
21
20 20 CONTROL
CLUTCH SPEED LT OUT R 7 22 22
21 21 UNIT
CLUTCH PRESS IN S FWD HI IN 22 22
THROTTLE POS IN T 8 370 370 23 23 23
23 D208 16 A 24 24
ENG IDLE IN U 26 883 1A 49 53 68 M 3 25
(NOT USED) ENG BRAKE IN V 25 25
NEGATIVE GROUND W 51 FU6 71 26 26 26
(NOT USED) R AXLE UNLOCKED NEG IN X 51 R7 LO OUT
RANGE
28
27 27
28 28
29 29 29
863 LO RANGE IN 863 30 30 30
31
935 4A D210 50 55 35 A 31 31
32 32
FU7 70 70 33 33
2 WD R12 71 34 34 34
LOAD OUT 51 2WD 35 35
R8 INTERLOCK 35 35
51 36 36
37 37 37
914 4 WD IN 914
448 2.5A 37 CONV LOCK SOL OUT 37
FU8
905 CLUTCH SPD LT OUT 905 34 34

7 7
LEGEND
8 8
BATTERY CABLES
23 23
OPTIONAL CABLES
26 26 STANDARD WIRING
51 51 OPTIONAL WIRING
EXISTING WIRING
FURNISHED WIRING,
BUT NOT USED
CONNECTED WIRES
NON-CONNECTED WIRES
FUSIBLE LINK WIRE
ENGINE A EN1 28
RPM IN B EN2 29

30
CARRIER CAB TURBINE A
RPM IN B
TR1
TR2 31

APC100 MODE CONTROL

FUSE & RELAY BOX FO-1. Electrical Schematic (Sheet 3 of 4)
FO-5/FO-6 Blank
 TM 5-3810-307-24-1-1

TO ACC
105
RELAY
(SEE PAGE 1)

TO SUPER 100 A
5 5
POWER RELAY FU51
(SEE PAGE 1)
100 A
105 FU52
OIL
1
K COOLER
RELAY TRANS OIL
835 301
COOLER FAN
833 RED M BLK 57

200 F FU53
100 A
834 834 796

FUEL 196 196 171 150

HEATER
TO SWITCH 1 RELAY
1 950 834
(SEE PAGE 1) K
51 151 151 417
START 170 24V BATTERY SET
TO FUEL 196 RELAY
151 30 F
PREHEAT LT 151 636 51
ALTERNATOR K
(SEE PAGE 1) 170 171
170
B 152 501
FUEL LINE HTR 332
51 146 R 157 156
BATTERY
157 INTERVEH DISCONN
51 146 PULL
SOCKET
K HOLD
150
FUEL LINE SEP ANTI-RESTART FUEL 762 763
51 502
30 F RELAY SHUTOFF START
TO NEUTRAL 2
RELAY 2 RELAY MOTOR
EMER
(SEE PAGE 1) 636 636 51 24V
HOLD K STOWAGE
51 BLK RED 198 198
SYS
503 5A
51 1314 1315 1318
PULL EMER
WHT 711 711 156 STOWAGE K
FUEL SOL SYS
763 M 1313 1318
51 18 711
COLD
START
ENGINE COMPONENTS 762 762
SOL OPEN 60 F
CLOSE 45 F

FO-1. Electrical Schematic (Sheet 4 of 4)

FO-7/FO-8 Blank
 TM 5-3810-307-24-1-1
A

14 PASS SWIVEL
3.50" DIA BORE B
LOCKOUT CYLINDERS PORTS 1 THRU 6
FRONT AXLE (REF) ARE AIR
7
(4) P.O. CHECK VALVE CARTRIDGE
8
A 9

B AXLE 10 SUPERSTRUCTURE
LH RH LOCKOUT VALVE CONTINUED ON SHEET 2
11
LF EXT LF STAB RF STAB RF EXT
12
SOL SOL SOL SOL
C 13
14 14
PO CHECK
VALVE
14 13 12 11 10 9 8 7
A
B

V C
LR EXT LR STAB RR STAB RR EXT
3.50" DIA BORE C VALVE STACKS
LOCKOUT CYLINDERS SOL SOL SOL SOL
REAR AXLE (REF)
P 4000

A
B AXLE
LH RH LOCKOUT VALVE

(4) EXTENSION CYLINDER

2.50" DIA BORE

A
(4) STABILIZER CYLINDER
3.50" DIA BORE

CHECK VALVE
7 PSI CRACK
SELECTOR
VALVE

P
2500 PSI

2.0 REAR STEER

S
GPM LOCKOUT VALVE
2 1
A T

4 3
M
STAND-BY 0.603
VALVE & FLOW IN 3/REV VALVE SPOOLS
SWITCH SHOWN 'PULLED'
(SUPERSTRUCTURE
STEERING MODE)
P1 P2 EMERGENCY STOWAGE PUMP E
LH RH
SINGLE (FRONT AXLE)
SELECTOR F A LH RH
FRONT STEER (2) 2.76" (70MM) DIA BORE
VALVE B
REAR STEER S/S
D
C
FRONT STEER CARRIER (REAR AXLE)
3 4
DOUBLE (2) 2.76" (70MM) DIA BORE
FRONT STEER S/S
SELECTOR VALVE REAR STEER CARRIER
MAIN STEER PUMP C V B T

A P
MAIN STEER PUMP
FLOW SWITCH AXLE 2175
C V CARRIER REAR
DISCONNECT PRIORITY FLOW PSI STEER VALVE
VALVE 8 GPM + 1 1 2 P.O. CHECK
- 0.5 GPM VALVE
PR
RELIEF FEED
2300
2300 PSI +50/-0 CHECK VALVE
CRACK INTEGRATED O/R VALVE
65 PSI
APPROX
2500 PSI AT P
IN .062 DIA ORIFICE
GROUND-DRIVEN FULL FLOW 250
2500 A B A B
STEERING PUMP 10.6 ENGINE RPM
GPM
AXLE DISCONNECT 24.3 GAGE
B1-ROTATIONAL 2500 RPM 22.3
1.68 IN 3/REV GPM SAMPLING
THEORETICAL TRANSMISSION VALVE

S T FILTER -BETA 10 FILTER -BETA 20

2500 RPM 41.4 41.4 16.8
RATIO OF 70 RATIO OF 75
38.9 38.9 16.2
SUMP GPM GPM GPM IN
CHECK VALVE PB
7 PSI CRACK

300
25 25
2500 2000
.06 DIA
ORIFICE

STEER O/R

7 PSI TANK
CRACK

CARRIER
HYD RESERVOIR 63 GAL CAPACITY FILTER ISOLATION VALVES FO-2. Hydraulic Schematic (Sheet 1 of 2)
FO-9/FO-10 Blank