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*TM 5-3810-305-23

TECHNICAL MANUAL

FIELD MAINTENANCE MANUALFOR

CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON

(ROUGH TERRAIN CRANE)LRT 110

TYPE I GENERAL PURPOSE

NSN 3810-01-165-0646TYPE II AIRBORNE/AIRMOBILE

NSN 3810-01-165-0647

*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes.

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

HEADQUARTERS, DEPARTMENT OF THE ARMY14 SEPTEMBER 2012 03 /15 /20 11 Re l(1 .8)r oo t(fr ntc ov er) w pn o(F 000 01 )

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WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understoodand applied during operation and maintenance of this equipment. Failure to observe these precautions could resul

in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons usedwithin the technical manual.

FIRST AID

For first aid information, refer to FM 4-25.11, First Aid.

EXPLANATION OF SAFETY WARNING ICONS

EAR PROTECTION - Headphones over ears shows that noise level will harm ears.

ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows thashock hazard is present.

EYE PROTECTION - Person with goggles shows that the material will injure the eyes.

FLYING PARTICLES - Arrows bouncing off face with face shield show that particles flying throughthe air will harm face.

HEAVY OBJECT - Human figure stooping under heavy object shows physical injury potential fromimproper lifting techniques.

HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush and harm.

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WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued

HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life orlimb.

HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy, moving partspresent a danger to life or limb.

HOT AREA - Hand over object radiating heat shows that part is hot and can burn.

MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of theequipment present a danger to life or limb.

MOVING PARTS - Human figure with an arm caught between gears shows that the moving parts ofthe equipment present a danger to life or limb.

GENERAL SAFETY WARNING DESCRIPTIONS

WARNING

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa)

nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa)when cleaning components. DO NOT direct compressed air against human skin. Failure tofollow this warning may result in injury. Make sure air stream is directed away from user andother personnel in the area. To prevent injury, personnel must wear protective goggles orface shield.

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GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Safety glassesmust be used when cleaning parts. Failure to follow this warning may result in injury or deathto personnel.

WARNING

Before performing this test, turn the crane power off then on again to ensure that an

existing two block warning and/or motion cut has not been overridden.

During this test, DO NOT use the cancel alarm button to clear audible warnings ormotion cuts.

During this test, DO NOT winch the hook block into the boom tip, in case the system doesnot cut the crane motions.

Slowly raise the hook block until it lifts the anti-two block weight and deactivates the anti-two block switch.

Failure to follow these warnings may result in damage to equipment or injury or deathto personnel.

WARNING

Keep hands out of path of spring-loaded tensioner.

Keep fingers from between belt and pulley.

Failure to follow these warnings may cause serious injury if tensioner slips.

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WARNING

Wear protective gloves when handling hot gear. Failure to follow this warning may causeinjury or death to personnel.

WARNING

Weight of crankshaft is approximately 80 lbs (36 kgs). Use adequate lifting equipment to liftand support crankshaft. Keep hands out of component. DO NOT lift over personnel or letpersonnel walk underneath suspended load. Failure to follow this warning may cause injuryor death to personnel.

WARNING

Weight of cylinder head is approximately 80 lbs (36 kgs). Use adequate lifting equipment tolift and support cylinder head. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may result in injury or death to personnel.

WARNING

Wear eye protection when driving ring gear from flywheel. Serious injury to personnel mayresult from flying metal fragments. DO NOT use a steel drift pin.

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WARNING

Wear protective gloves when installing ring gear. Serious injury to personnel may result if hotgear contacts skin.

WARNING

Weight of engine and transmission assembly is approximately 1,800 lbs (816 kgs). Useadequate lifting equipment to lift and support engine/transmission assembly. DO NOT lift overpersonnel or let personnel walk underneath suspended load. Failure to follow this warningmay cause injury or death to personnel.

WARNING

Weight of transmission is approximately 1,100 lbs (499 kgs). Use adequate lifting equipmentto lift and support transmission. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of engine is approximately 700 lbs (318 kgs). Use adequate lifting equipment to liftand support engine. DO NOT lift over personnel or let personnel walk underneath suspendedload. Failure to follow this warning may cause injury or death to personnel.

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WARNING

Weight of radiator and oil cooler assembly is approximately 300 lbs (136 kgs). Use adequatelifting device to lift and support radiator and oil cooler. DO NOT lift over personnel or letpersonnel walk underneath suspended load. Failure to follow this warning may cause injuryor death to personnel.

WARNING

Weight of converter assembly is approximately 60 lbs (27 kgs). Use adequate liftingequipment to lift and support converter assembly. DO NOT lift over personnel or let personnelwalk underneath suspended load. Failure to follow this warning may cause injury or death topersonnel.

WARNING

Weight of output disconnect group is approximately 67 lbs (30 kgs). Use adequate liftingequipment to lift and support output disconnect group. DO NOT lift over personnel or letpersonnel walk underneath suspended load. Failure to follow this warning may cause injuryor death to personnel.

WARNING

Weight of front cover is approximately 226 lbs (103 kgs). Use adequate lifting equipment tolift and support front cover. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING

Weight of clutch group is approximately 139 lbs (63 kgs). Use adequate lifting equipment tolift and support clutch group. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Wear protective gloves when handling hot bearing. Serious injury to personnel may result ifhot bearing contacts skin.

WARNING

Parts are under spring tension. Serious injury to personnel may result from flying parts.Always wear eye protection.

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WARNING

Never reinflate a tire that has been run flat or seriously underinflated without removing

and checking for tire tube or rim damage.

Never exceed 3 psi (21 kPa) inflation prior to placing tire and wheel assembly into inflationsafety cage or mounting on a tire change machine that has a positive lockdown device.

Always inflate tires that are mounted on rims with demountable side ring flanges or lockrings in an inflation safety cage.

When inflating tires in an inflation cage, always use extension air hose and pneumatictire inflator-gage.

Improperly seated side ring flanges or lock rings may fly off during inflation. Never attemptto seat a side ring flange or lock ring during inflation or after inflation.

Never inflate tires over 40 psi (276 kPa) to seat tire beads. If beads do not seat, deflate,demount, and check the tire/rim match. Mount and lubricate according to instructions.

When inflating tires mounted on the vehicle, all personnel must remain a minimum of10 ft (3.1 m) away from tire and not in possible path of lock ring or rim flange. Should theyfly off, serious injury or death may result.

Failure to follow these warnings may cause injury or death to personnel.

WARNING

Weight of axle assembly is approximately 1,323 lbs (600 kgs). Use adequate lifting equipmentto lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of differential assembly is approximately 120 lbs (54 kgs). Use adequate liftingequipment to lift and support differential assembly. DO NOT lift over personnel or letpersonnel walk underneath suspended load. Failure to follow this warning may cause injuryor death to personnel.

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WARNING

Heating differential mounting bolts to a temperature of 300F (149C) may be required tobreak down thread sealing compound. Wear protective equipment while heating and handlingdifferential mounting bolts. Failure to follow this warning may cause injury or death topersonnel.

WARNING

Wear protective equipment while heating and handling bearing cone. Failure to follow thiswarning may cause injury or death to personnel.

WARNING

Weight of pivot and spindle assembly is approximately 69 lbs (30 kgs). Use adequate liftingequipment to lift and support pivot and spindle assembly. DO NOT lift over personnel or letpersonnel walk underneath suspended load. Failure to follow this warning may cause injuryor death to personnel.

WARNING

Weight of housing assembly is approximately 631 lbs (286 kgs). Use adequate liftingequipment to lift and support housing assembly. DO NOT lift over personnel or let personnelwalk underneath suspended load. Failure to follow this warning may cause injury or death topersonnel.

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WARNING

Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipment

to lift and support brake drum. DO NOT lift over personnel or let personnel walkunderneath suspended load.

The brake linings contain asbestos. Wear a protective breather respirator whenperforming maintenance on the brake assembly and brake drum.

Care must be taken when cleaning the brake assembly. Clean the assembly as a whole

by using a solution of hot soapy water. Go over the assembly three times or enough tobe sure it is completely clean to prevent the asbestos fibers from being released into theair and circulated in the maintenance area.

DO NOT use compressed air to dry the brake assembly. Let it air dry.


WARNING

Weight of hub and studs is approximately 79 lbs (36 kgs). Use adequate lifting equipment tolift and support hub and studs. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may result in injury or death to personnel.

WARNING

Wear protective equipment while heating and handling seal runner. Failure to follow thiswarning may cause serious injury to personnel.

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WARNING

Weight of boom is approximately 3,100 lbs (1,406 kgs). Use adequate lifting equipment to liftand support boom. DO NOT lift over personnel or let personnel walk underneath suspendedload. Failure to follow this warning may result in injury or death to personnel.

WARNING

Weight of boom hoist cylinder is approximately 507 lbs (230 kgs). Use adequate liftingequipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnelwalk underneath suspended load. Failure to follow this warning may cause injury or deathto personnel.

WARNING

Heating nut to a temperature of approximately 300F (149C) may be required to break downthread sealing compound. Wear protective equipment while heating and handling parts.Failure to follow this warning may cause injury or death to personnel.

WARNING

Stay clear of boom hoist cylinder rod while extending and retracting to remove air.Serious injury to personnel may result if rod jumps unexpectedly.

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WARNING

Weight of hydraulic reservoir is approximately 190 lbs (86 kgs). Use adequate liftingequipment to lift and support hydraulic reservoir. DO NOT lift over personnel or let personnelwalk underneath suspended load. Failure to follow this warning may cause injury or death topersonnel.

WARNING

Weight of outrigger cylinder assembly is approximately 125 lbs (57 kgs). Use adequate liftingequipment to lift and support outrigger cylinder assembly. DO NOT lift over personnel or letpersonnel walk underneath suspended load. Failure to follow this warning may cause injuryor death to personnel.

WARNING

Weight of manifold is approximately 200 lbs (91 kgs). Use adequate lifting equipment to liftand support manifold. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of cab is approximately 250 lbs (113 kgs). Use adequate lifting equipment to lift andsupport cab. DO NOT lift over personnel or let personnel walk underneath suspended load.Failure to follow this warning may cause injury or death to personnel.

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WARNING

Weight of fender is approximately 99 lbs (45 kgs). Use adequate lifting equipment to supportfender. DO NOT lift over personnel or let personnel walk underneath suspended load. Failureto follow this warning may cause injury or death to personnel.

WARNING

Weight of toolbox is approximately 180 lbs (82 kgs). Use adequate lifting equipment to supporttoolbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failureto follow this warning may cause injury or death to personnel.

WARNING

Weight of beam is approximately 129 lbs (59 kgs). Use adequate lifting equipment to lift andsupport beam. DO NOT lift over personnel or let personnel walk underneath suspended load.Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of swing bearing is approximately 187 lbs (85 kgs). Use adequate lifting equipmentto lift and support swing bearing. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING

Weight of swing gearbox is approximately 125 lbs (57 kgs). Use adequate lifting equipmentto lift and support swing gearbox. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of counterweight is approximately 2,200 lbs (998 kgs). Use adequate lifting equipmentto lift and support counterweight. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of upperstructure is approximately 6,000 lbs (2,722 kgs). Use adequate lifting

equipment to lift and support upperstructure. DO NOT lift over personnel or let personnelwalk underneath suspended load.

Upperstructure must be properly supported when lowering to ground.


WARNING

Weight of boom tip section is approximately 1,500 lbs (680 kgs). Use adequate liftingequipment to lift and support boom tip section. DO NOT lift over personnel or let personnelwalk underneath suspended load. Failure to follow this warning may cause injury or death topersonnel.

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WARNING

Weight of boom extend cylinder is approximately 415 lbs (188 kgs). Use adequate liftingequipment to lift and support boom extend cylinder. DO NOT lift over personnel or letpersonnel walk underneath suspended load. Failure to follow this warning may causeinjury or death to personnel.

WARNING

Weight of hook block is approximately 235 lbs (107 kgs). Use adequate lifting equipment tolift and support hook block. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Make sure snapring is seated in groove in splined bore of cam. Snapring will keep brakeclutch assembly correctly positioned in center of friction brake pack. Brake may bind or failif snapring is not correctly installed. Failure to follow this warning may cause injury or deathto personnel.

WARNING

Weight of winch is approximately 300 lbs (136 kgs). Use adequate lifting equipment to lift andsupport winch. DO NOT lift over personnel or let personnel walk underneath suspended load.Failure to follow this warning may cause injury or death to personnel.

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WARNING

Remove jewelry and disconnect battery negative ground cable before performingmaintenance on this equipment. Failure to follow these warnings may result in injury or deathto personnel.

WARNING

Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) whencleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying partswith compressed air. DO NOT direct compressed air against human skin. Make sure airstream is directed away from user and other personnel in the area. User must wear protectivegoggles or face shield.

WARNING

DO NOT release cord as cable reel will pull harness rapidly. Rapidly moving harness mayresult in serious injury or death if it hits personnel.

WARNING

Safety glasses or face protection must be used when working with compressed air.Failure to follow this warning may result in serious injury to personnel.

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WARNING

Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipmentto lift and support brake drum. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may result in serious injury or death topersonnel.

WARNING

If necessary, heat differential mounting bolts to a temperature of 300F (149C) to break downsealant. Hot surface may cause burns or injury. Wear protective equipment while heating andhandling differential mounting bolts. Failure to follow this warning may result in serious injuryto personnel.

WARNING

Wear protective equipment while heating and handling spacer. Failure to follow this warningmay result in serious injury to personnel.

WARNING

When deflating tires, always ensure tire is completely deflated before removing from rim.Failure to follow this warning may result in serious injury or death to personnel.

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WARNING

When inflating tires, always ensure tires are properly seated. Improperly seated tires can

burst with explosive force.

DO NOT mix one type of wheel with a different type of tire. Improper seating of thesecomponents can cause tire and wheel to fly apart with explosive force.

Failure to follow these warnings may result in serious injury or death to personnel.

WARNING

Remove jewelry and disconnect battery negative ground cable before performing

maintenance on this equipment.

Wear protective eye covering. Serious injury to personnel may result from flying metalfragments.

Wear protective gloves when handling hot parts.

Failure to follow these warnings may result in injury or death to personnel.

WARNING

Keep all personnel away from winch and hook block area. Failure to follow this warning mayresult in death or serious injury to personnel.

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and useassistance during procedure. Ensure any lifting device used is in good condition and ofsuitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure tofollow this warning may result in injury or death to personnel.

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WARNING

Ensure to tag all cables and valve body properly before disconnecting. Failure to follow thiswarning may result in injury or death to personnel.

WARNING

Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipmentto lift and support brake drum. DO NOT lift over personnel or let personnel walk underneathsuspended load. Failure to follow this warning may result in serious injury or death topersonnel.

WARNING

Do not use outriggers to support vehicle. Failure to follow this warning may result in seriousinjury or death to personnel.

WARNING

Do not remove lifting device until hydraulic pressure has been built up. Failure to follow thesewarnings may result in damage to equipment or injury or death to personnel.

EXPLANATION OF HAZARDOUS MATERIALS ICONS

BIOLOGICAL - Abstract bug symbol shows that a material may contain bacteria or viruses thapresent a danger to life or health.

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EXPLANATION OF HAZARDOUS MATERIALS ICONS - Continued

CHEMICAL - Drop of liquid on hand shows that the material will cause burns or irritation to humanskin or tissue.

FIRE - Flame shows that a material may ignite and cause burns.

HYDRAULIC FLUID PRESSURE - Hydraulic fluid spraying human hand shows that fluid escaping

under great pressure can cause injury or death to personnel.

RADIOACTIVE - Identifies a material that emits radioactive energy and can injure human tissue ororgans.

VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.

HAZARDOUS MATERIALS DESCRIPTIONS

WARNING

ADHESIVES AND SEALANTS

Use caution when using adhesives and sealants. Prolonged inhalation of vapors can causelung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles anduse product in a well-ventilated area away from open flame. If ingested, keep individual calmand seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made,flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances.Failure to follow this warning may cause injury to personnel.

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HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

BATTERIES

Battery gases can explode. DO NOT smoke or allow sparks or open flames nearbatteries. Wear safety glasses or goggles when checking the batteries.

To avoid injury, eye protection and acid-resistant gloves must be worn when workingaround batteries. DO NOT smoke, use open flame, make sparks, or create otherignition sources around batteries. If a battery is giving off gases, it can explode and

cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, andbracelets. If jewelry or a tool contacts a battery terminal, a direct short will result ininstant heating, damage to equipment, and injury or death to personnel.

Sulfuric acid contained in batteries can cause serious burns. If battery corrosion orelectrolyte makes contact with skin, eyes, or clothing, take immediate action to stopthe corrosive burning effects. Seek medical attention in the event of an injury.

a. Eyes. Flush with cold water for no less than 15 minutes and seek medicalattention immediately.

b. Skin. Flush with large amounts of cold water until all acid is removed. Seekmedical attention as required.

c. Internal. If corrosion or electrolyte is ingested, drink large amounts of wateror milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seekmedical attention immediately.

d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralizeacid with baking soda or household ammonia.


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WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

Carbon monoxide is a colorless, odorless, deadly poison which, when breathed,deprives the body of oxygen and causes suffocation. Exposure to air containingcarbon monoxide produces symptoms of headache, dizziness, loss of muscularcontrol, apparent drowsiness, and coma. Permanent brain damage or death topersonnel can result from severe exposure.

Carbon monoxide occurs in exhaust fumes of internal combustion engines. It alsooccurs in exhaust fumes of engine coolant heater (arctic vehicle only). Carbonmonoxide can become dangerously concentrated under conditions of inadequateventilation. The following precautions must be observed to ensure safety of personnelwhen engine of crane is operated.

1. DO NOT operate engine in enclosed areas without adequate ventilation.2. DO NOT idle engine without adequate ventilation.3. DO NOT drive vehicle with inspection plates or cover plates removed.4. BE ALERT for exhaust poisoning symptoms. They are:

Headache

Dizziness

Sleepiness

Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:

Remove person from area.

Expose person to fresh air.

Keep person warm.

DO NOT permit physical exercise.

Administer cardiopulmonary resuscitation (CPR), if necessary.

Notify a medic.

6. BE AWARE. The field protective mask for Nuclear-Biological-Chemical (NBC)protection will not protect you from carbon monoxide poisoning.

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WARNING

CBRN EXPOSURE

If Chemical, Biological, Radioactive and Nuclear (CBRN) exposure is suspected, personnelwearing protective equipment must handle all air cleaner media. Contaminated filters mustbe handled using adequate precautions and must be disposed of by trained personnel.Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures.Failure to follow this warning may cause injury or death to personnel. Seek medical attention.

To order this CBRN decal use:

National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083

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WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and lowtoxicity material. However, it may be irritating to the eyes and skin. Use protective gloves andgoggles. Use in well-ventilated areas. Keep away from open flames and other sources ofignition. Failure to follow this warning may cause injury to personnel.

WARNING

If vehicle is parked indoors during performance of Preventive Maintenance Checks andServices (PMCS), DO NOT run engine unless exhaust fumes are vented to the outside.Failure to follow this warning may cause injury or death to personnel due to carbon monoxidepoisoning.

WARNING

Diesel fuel and other combustible materials are used in operation and maintenance of thisequipment. DO NOT smoke or allow open flames in areas where combustible materials arestored or used. Failure to follow this warning may cause injury or death to personnel.

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turnto safety notch to relieve pressure. Failure to follow this warning may cause death or injuryto personnel.

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WARNING

Never perform fan hub bearing end play check with the engine running. Failure to follow thiswarning may cause death or injury to personnel.

WARNING

Cooling system is pressurized. Use extreme caution and proper protection when removingradiator cap after operating temperature is reached. Steam and hot gases will be escapingthrough the radiator cap; avoid being burned by these escaping gases. When removing cap,loosen it slowly to the left, then pause a moment. Continue to turn cap until it can be removed.Failure to follow this warning may cause death or injury to personnel.

WARNING

DO NOT disconnect or remove any hydraulic system lines or fitting unless engine

is shut down and hydraulic system pressure has been relieved. Tighten allconnections before applying pressure. Escaping hydraulic fluid under pressure canpenetrate the skin.

At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool beforeremoving any hydraulic fitting.

Wear protective eye covering.

Avoid sudden movement of vehicle.

Use a container to catch any fluid that may drain from hoses or system. Dispose offluid IAW local policy and ordinances. Ensure all spills are cleaned up.


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WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant

and low-toxic material. However, it may be irritating to the eyes and skin. Useprotective gloves and goggles. Use in well-ventilated areas. Keep away from openflames and other sources of ignition.

Improper cleaning methods and use of unauthorized cleaning solvents may injurepersonnel and damage equipment.

Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW

authorized facilities procedures.

Eye shields must be worn when cleaning with a wire brush.

Particles blown by compressed air are hazardous. Use a maximum of 30 psi(207kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzlepressure when drying parts with compressed air. DO NOT direct compressed airagainst human skin. Make sure air stream is directed away from user and otherpersonnel in the area. User must wear protective goggles or face shield.


WARNING

When servicing equipment, performing maintenance, or disposing of materials such

as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, or ChemicalAgent Resistance Coating (CARC) paint, consult your unit/local hazardous wastedisposal center or safety office for local regulatory guidance.

Wear protective eye covering.

Dispose of contaminated drained fluids in accordance with the Standard OperatingProcedures (SOP) of your unit.


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WARNING

The brake linings contain asbestos. Wear protective breather respirator when

performing maintenance on the brake assembly and brake drum.

Care must be taken when cleaning the brake assembly. Clean the assembly as awhole by using a solution of hot soapy water. Go over the assembly three times orenough to be sure it is completely clean to prevent the asbestos fibers from beingreleased into the air and circulated in the maintenance area.

DO NOT use compressed air to dry the brake assembly. Let it air dry. Failure to follow these warnings may cause injury or death to personnel.

WARNING

Liquid nitrogen is extremely cold, having a temperature of -320F (-195C). Wear protectivegloves that will not absorb liquid nitrogen. Excess liquid nitrogen must be disposed of promptlysince liquid nitrogen will condense oxygen from the atmosphere. The mixture of liquid nitrogenand liquid oxygen is a powerful oxidizer and may react violently with easily oxidizablesubstances. Failure to follow this warning may cause injury or death to personnel.

WARNING

Remove jewelry and disconnect battery negative ground cable before performing

maintenance on this equipment.

Hot coolant and alkali contained in cooling system can burn severely. Even withcooling system drained, residual coolant remains in system lines and fittings.Wear protective goggles, face shield, and clothing when handling cooling systemcomponents. If coolant contacts eyes, skin, or clothing, flush with large amounts ofcold water and seek medical attention, if required.


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WARNING

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa)nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi(207 kPa) when cleaning components. DO NOT direct compressed air againsthuman skin. Failure to follow this warning may result in injury. Make sure air streamis directed away from user and other personnel in the area. To prevent injury,personnel must wear protective goggles or face shield.

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliantand low toxicity material. However, it may be irritating to the eyes and skin. Useprotective gloves and goggles. Use in well-ventilated areas. Keep away from openflames and other sources of ignition. Failure to follow this warning may cause injuryto personnel.

WARNING

Weight of differential assembly is approximately 120 lbs (54 kgs). Use adequate liftingequipment to lift and support differential assembly. DO NOT lift over personnel or letpersonnel walk underneath suspended load.

Use caution when using adhesives and sealants. Prolonged inhalation of vapors can

cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safetygoggles and use product in a well-ventilated area away from open flame. If ingested,keep individual calm and seek medical attention. DO NOT induce vomiting. If contactwith skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAWlocal policy and ordinances. Failure to follow this warning may cause injury topersonnel.

Failure to follow these warnings may result in serious injury or death to personnel.

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WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turnto safety notch to relieve pressure. Failure to follow this warning may result in serious injuryor death to personnel.

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HEADQUARTERS DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 14 SEPTEMBER 2012

TECHNICAL MANUAL

FIELD MAINTENANCE MANUAL

FOR

CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON(ROUGH TERRAIN CRANE)

LRT 110

TYPE I GENERAL PURPOSE

NSN 3810-01-165-0646

TYPE II AIRBORNE/AIRMOBILE

NSN 3810-01-165-0647

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend anyimprovements to the procedures in this publication, please let us know. The preferred method is tosubmit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the

Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet addressis https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must

complete the Access Request form the first time you use it. The DA Form 2028 is located under theTULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT.

Using this form on the TULSA Web site will enable us to respond more quickly to your comments andto better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments orDA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail

address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECHPUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is

[email protected]. The fax number is DSN 786-1856 or

Commercial (586) 282-1856. A reply will be furnished to you.

*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes.

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

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TABLE OF CONTENTS

Page NoWP Sequence No

HOW TO USE THIS MANUAL ......................................................................................................................... xlvii

Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF

OPERATION

GENERAL INFORMATION.......................................................................................................................... WP 0001

EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002

Figure 1. Major Components............................................................................................................... 0002-2




Table 1. Gear Range Values............................................................................................................ 0002-13

Figure 5. General Dimensions........................................................................................................... 0002-14

Figure 6. General Dimensions........................................................................................................... 0002-15

Figure 7. Radius from Centerline of Rotation.................................................................................... 0002-16

Figure 8. Crane Working Positions.................................................................................................... 0002-17

Figure 9. Lift Capacity (on Outriggers).............................................................................................. 0002-17

Figure 10. Lift Capacity (on Tires)....................................................................................................... 0002-18

Figure 11. Maximum Permissible Hoist Line Load.............................................................................. 0002-18

THEORY OF OPERATION.......................................................................................................................... WP 0003

Chapter 2 - TROUBLESHOOTING PROCEDURES

TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0004

TROUBLESHOOTING PROCEDURES ENGINE........................................................................................ WP 0005

TROUBLESHOOTING PROCEDURES HYDRAULICS.............................................................................. WP 0006

TROUBLESHOOTING PROCEDURES SWING CIRCUIT.......................................................................... WP 0007

TROUBLESHOOTING PROCEDURES BOOM HOIST CIRCUIT............................................................... WP 0008

TROUBLESHOOTING PROCEDURES BOOM EXTEND CIRCUIT........................................................... WP 0009

TROUBLESHOOTING PROCEDURES OUTRIGGER CIRCUIT................................................................ WP 0010

TROUBLESHOOTING PROCEDURES STEERING CIRCUIT................................................................... WP 0011

TROUBLESHOOTING PROCEDURES PUMPS......................................................................................... WP 0012

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TABLE OF CONTENTS - Continued

Page No.WP Sequence No.

TROUBLESHOOTING PROCEDURES RELIEF VALVES.......................................................................... WP 0013

TROUBLESHOOTING PROCEDURES BRAKES....................................................................................... WP 0014

TROUBLESHOOTING PROCEDURES ELECTRICAL SYSTEM............................................................... WP 0015

TROUBLESHOOTING PROCEDURES ANTI-TWO BLOCK SYSTEM....................................................... WP 0016

TROUBLESHOOTING PROCEDURES TRANSMISSION.......................................................................... WP 0017

TROUBLESHOOTING PROCEDURES AXLE ASSEMBLY........................................................................ WP 0018

TROUBLESHOOTING PROCEDURES WINCH......................................................................................... WP 0019

MSD-ICE TROUBLESHOOTING AND TEST PROCEDURE...................................................................... WP 0020

Figure 1. Remove Cap from DCA Receptacle..................................................................................... 0020-3

Figure 2. Schematics and Diagrams................................................................................................... 0020-7

Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION............................. WP 0021

Table 1. Leakage Definitions for PMCS............................................................................................. 0021-2

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0022

Table 1. Preventive Maintenance Checks and Services (PMCS)...................................................... 0022-2

Figure 1. Winch Lubrication Level Access Plug.................................................................................. 0022-3

Figure 2. Air Cleaner Element Maintenance........................................................................................ 0022-5

Figure 3. Engine Oil and Filter Change............................................................................................... 0022-6

Figure 4. Fuel Tank Drain Plug............................................................................................................ 0022-7

Figure 5. Hydraulic Suction Filter Removal......................................................................................... 0022-9

Figure 6. Transmission Fluid Change................................................................................................ 0022-10

Figure 7. Check Antifreeze Concentration......................................................................................... 0022-11

Figure 8. Check Axle Differential and Hub Oil Levels........................................................................ 0022-12

Figure 9. Check Axle Differential and Hub Oil Levels........................................................................ 0022-12

Figure 10. Check Fan Hub Bearing End Play...................................................................................... 0022-13

Figure 11. Winch Oil Change.............................................................................................................. 0022-14

Figure 12. Add Hydraulic Oil................................................................................................................ 0022-16

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Figure 13. Bleed Air from Hydraulic Reservoir.................................................................................... 0022-17

Figure 14. Swing Reduction Unit Oil Change...................................................................................... 0022-18

Figure 15. Differential Oil Filter............................................................................................................ 0022-19

Figure 16. Engine Coolant Change..................................................................................................... 0022-20

Figure 17. Engine Coolant Change..................................................................................................... 0022-21

Figure 18. Check Hydraulic Pressure Relief Valves............................................................................ 0022-22

Figure 19. Relief Valve Adjustment..................................................................................................... 0022-24

Chapter 4 - MAINTENANCE INSTRUCTIONS

SERVICE UPON RECEIPT......................................................................................................................... WP 0023

Figure 1. Vehicle Check Points........................................................................................................... 0023-3

POWER PACK ASSEMBLY MAINTENANCE............................................................................................. WP 0024

Figure 1. Power Pack Removal........................................................................................................... 0024-2










Figure 11. Power Pack Removal......................................................................................................... 0024-10





Figure 16. Transmission from Engine Removal.................................................................................. 0024-14

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Figure 19. Transmission to Engine Installation.................................................................................... 0024-17




Figure 23. Power Pack Installation...................................................................................................... 0024-21














ENGINE ASSEMBLY MAINTENANCE........................................................................................................ WP 0025

ENGINE MOUNT MAINTENANCE.............................................................................................................. WP 0026

Figure 1. Engine Mount Removal........................................................................................................ 0026-1

Figure 2. Engine Mount Installation..................................................................................................... 0026-2

CYLINDER HEAD MAINTENANCE............................................................................................................. WP 0027

Figure 1. Cylinder Head Removal....................................................................................................... 0027-2


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Figure 3. Cylinder Head Installation.................................................................................................... 0027-4


CRANKSHAFT PULLEY MAINTENANCE................................................................................................... WP 0028

Figure 1. Crankshaft Pulley Removal.................................................................................................. 0028-1

Figure 2. Crankshaft Pulley Installation............................................................................................... 0028-2

FLYWHEEL AND FLYWHEEL HOUSING MAINTENANCE........................................................................ WP 0029

Figure 1. Flywheel Removal................................................................................................................ 0029-1

Figure 2. Flywheel Removal................................................................................................................ 0029-2

Figure 3. Flywheel Installation............................................................................................................. 0029-3






REAR CRANKSHAFT SEAL MAINTENANCE............................................................................................ WP 0030

Figure 1. Rear Seal Removal.............................................................................................................. 0030-2



Figure 4. Rear Seal Installation........................................................................................................... 0030-4

Figure 5. Rear Seal Installation........................................................................................................... 0030-5

ROCKER LEVERS AND PUSH RODS MAINTENANCE............................................................................ WP 0031


Figure 2. Rocker Lever and Push Rods Removal............................................................................... 0031-2

Figure 3. Rocker Lever and Push Rods Disassembly......................................................................... 0031-3

Figure 4. Rocker Lever and Push Rods Disassembly......................................................................... 0031-3

Figure 5. Rocker Lever and Push Rods Inspection............................................................................. 0031-4


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Figure 8. Rocker Lever and Push Rods Assembly.............................................................................. 0031-5

Figure 9. Rocker Lever and Push Rods Assembly.............................................................................. 0031-6

Figure 10. Rocker Lever and Push Rods Installation............................................................................ 0031-6


FRONT GEAR COVER AND GASKET MAINTENANCE............................................................................ WP 0032

Figure 1. Tachometer Drive Removal.................................................................................................. 0032-2

Figure 2. Front Cover Removal........................................................................................................... 0032-3

Figure 3. Front Gear Train Installation................................................................................................. 0032-4

Figure 4. Front Cover Installation........................................................................................................ 0032-5

Figure 5. Tachometer Drive Installation............................................................................................... 0032-6

TIMING PIN ASSEMBLY MAINTENANCE.................................................................................................. WP 0033

Figure 1. Timing Pin Assembly Removal............................................................................................. 0033-1

Figure 2. Timing Pin Assembly Removal............................................................................................. 0033-2

Figure 3. Timing Pin Assembly Installation.......................................................................................... 0033-3

TAPPET COVER AND GASKET MAINTENANCE...................................................................................... WP 0034

Figure 1. Tappet Cover Installation..................................................................................................... 0034-3

VALVE COVERS AND GASKET MAINTENANCE...................................................................................... WP 0035

Figure 1. Valve Covers Removal......................................................................................................... 0035-1

Figure 2. Valve Covers Installation...................................................................................................... 0035-2

FRONT CRANKSHAFT SEAL MAINTENANCE.......................................................................................... WP 0036

Figure 1. Front Seal Removal.............................................................................................................. 0036-2

Figure 2. Front Seal Installation........................................................................................................... 0036-4

LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE.................................................... WP 0037

Figure 1. Lube Oil Cooler Removal..................................................................................................... 0037-2



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Figure 4. Lube Oil Cooler Disassembly............................................................................................... 0037-3

Figure 5. Lube Oil Cooler Disassembly............................................................................................... 0037-4

Table 1. Pressure Regulator Spring Limits......................................................................................... 0037-4

Figure 6. Lube Oil Cooler Inspection................................................................................................... 0037-5

Figure 7. Lube Oil Cooler Assembly.................................................................................................... 0037-6

Figure 8. Lube Oil Cooler Installation.................................................................................................. 0037-6



LUBE OIL PUMP MAINTENANCE.............................................................................................................. WP 0038

Figure 1. Lube Oil Pump Removal...................................................................................................... 0038-1

Figure 2. Lube Oil Pump Removal...................................................................................................... 0038-2

Figure 3. Lube Oil Pump Installation................................................................................................... 0038-3

OIL PAN AND SUCTION TUBE MAINTENANCE....................................................................................... WP 0039

Figure 1. Oil Pan and Suction Tube Removal..................................................................................... 0039-2

Figure 2. Oil Pan and Suction Tube Removal..................................................................................... 0039-3

Figure 3. Oil Pan and Suction Tube Installation.................................................................................. 0039-5

Figure 4. Oil Pan and Suction Tube Installation.................................................................................. 0039-6

OIL LEVEL GAGE MAINTENANCE............................................................................................................ WP 0040

Figure 1. Oil Level Gage Removal...................................................................................................... 0040-1

Figure 2. Oil Level Gage Removal...................................................................................................... 0040-2

Figure 3. Oil Level Gage Installation................................................................................................... 0040-3

INTAKE MANIFOLD COVER AND GASKET MAINTENANCE................................................................... WP 0041

Figure 1. Manifold Cover Plate Removal............................................................................................. 0041-1

Figure 2. Manifold Cover Plate Installation.......................................................................................... 0041-2

EXHAUST MANIFOLD AND GASKETS MAINTENANCE........................................................................... WP 0042

Figure 1. Exhaust Manifold Removal................................................................................................... 0042-1

Figure 2. Exhaust Manifold Removal................................................................................................... 0042-2

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Figure 3. Exhaust Manifold Installation................................................................................................ 0042-2

FUEL INJECTOR MAINTENANCE.............................................................................................................. WP 0043

Figure 1. Injector Nozzles Removal..................................................................................................... 0043-2

Figure 2. Injector Nozzles Removal..................................................................................................... 0043-2

Figure 3. Lube Oil Injector Nozzles Installation................................................................................... 0043-3

Figure 4. Injector Nozzles Installation.................................................................................................. 0043-4

FUEL INJECTION PUMP MAINTENANCE................................................................................................. WP 0044

Figure 1. Injection Pump Removal...................................................................................................... 0044-2






Figure 7. Injection Pump Disassembly................................................................................................ 0044-6







Figure 14. Injection Pump Disassembly.............................................................................................. 0044-10




Figure 18. Injection Pump Assembly................................................................................................... 0044-13



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Figure 29. Injection Pump Installation................................................................................................. 0044-19






FUEL LIFT PUMP MAINTENANCE............................................................................................................. WP 0045

Figure 1. Lift Pump Removal............................................................................................................... 0045-2

Figure 2. Lift Pump Installation............................................................................................................ 0045-3

AIR CLEANER ASSEMBLY MAINTENANCE............................................................................................. WP 0046

Figure 1. Air Cleaner Removal............................................................................................................ 0046-2

Figure 2. Air Cleaner Removal............................................................................................................ 0046-3

Figure 3. Air Cleaner Maintenance...................................................................................................... 0046-5

Figure 4. Air Cleaner Installation......................................................................................................... 0046-5

Figure 5. Air Cleaner Installation......................................................................................................... 0046-6

FUEL TANK MAINTENANCE...................................................................................................................... WP 0047

Figure 1. Fuel Tank Removal.............................................................................................................. 0047-1

Figure 2. Fuel Tank Removal.............................................................................................................. 0047-2

Figure 3. Fuel Tank Disassembly........................................................................................................ 0047-3

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Figure 4. Fuel Tank Disassembly........................................................................................................ 0047-3

Figure 5. Fuel Tank Assembly............................................................................................................. 0047-4

Figure 6. Fuel Tank Assembly............................................................................................................. 0047-5

Figure 7. Fuel Tank Installation........................................................................................................... 0047-6

Figure 8. Fuel Tank Installation........................................................................................................... 0047-7

FUEL LINES MAINTENANCE..................................................................................................................... WP 0048

Figure 1. Fuel Lines Removal.............................................................................................................. 0048-1

Figure 2. Fuel Lines Removal.............................................................................................................. 0048-2

Figure 3. Fuel Lines Installation........................................................................................................... 0048-3



FUEL INJECTION TUBES MAINTENANCE................................................................................................ WP 0049

Figure 1. High-Pressure Tubes Removal............................................................................................ 0049-2



Figure 4. Low-Pressure Tubes Removal............................................................................................. 0049-5



Figure 7. Fuel Drain Tubes Removal................................................................................................... 0049-8

Figure 8. Fuel Dr

tm 5-3810-305-23

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