TM 5-3810-305-10

TECHNICAL MANUAL●

OPERATOR’S MANUAL

FOR

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

(ROUGH TERRAIN CRANE)MODEL LRT 110

Type I

CONSISTS OF:

General Purpose (3810-01-165-0646)

Type II Airborne/Airmobile(3810-01-165-0647)

This technical manual is an authentication of the manufacturers commercial literature and does not conform with the for-mat and content specified in AR 25–30, Military Publications, This technical manual does, however, contain available

Distribution Restriction: Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

9 AUGUST 1991

information that is essential to the operation and maintenance of the equipment.

WARNING

If NBC exposure is suspected, all air filter me-dia should be handled by personnel wearingprotective equipment. Consult your unit N B COfficer or NBC NCO for appropriate handlingor disposal instructions.

IF NBC EXPOSURE IS SUSPECTED ALLAIR FILTER MEDIA WILL BE HANDLEDBY PERSONNEL WEARING FULL NBCPROTECTIVE EQUIPMENT. SEE OP-ERATOR/MAINTENANCE MANUAL.

7690-01-114-3702

To order this NBC decal use:National Stock Number (NSN) -7690-01-114-3702Part Number (PN) – 12296626Commercial and Government Entity Code (CAGEC) – 19207

TM 5-3810-305-10

lNSERTLATEST UPDATED PAGES /WORK PACKAGES DESTROY SUPERSEDED DATA

LIST OF EFFECTED PAGES/ WORK PACKAGESNote The portion of text or illustration effected by the updates is indicated by a vertical line in theouter margins of the page Updates to wiring diagrams are indicated by shaded areas

Dates of issue for original and updated pages/ work packages areOriginal O 09 Aug 91Change 1 01 Nov 00

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 16 AND TOTAL NUMBER OFWORK PACKAGES IS 876 CONSISTING OF THE FOLLOWING:

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TM 5-3810-305-10INSERT LATEST UPDATED PAGES /WORK PACKAGES DESTROY SUPERSEDED DATA

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B

TM 5-3810-305-10c-1

HEADQUARTERS

DEPARTMENT OF THE ARMYWASHINGTON, DC, fA/ovember2000

CHANGE

NO. 1

OPERATOR’S MANUALCRANE, WHEEL MOUNTED,

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

MODEL LRT 110

CONSISTS OF:

Type I General Purpose(NSN 3810-01-165-0646)

Type II Airborne/Airmobile(3810-01-165-0647)

TM 5-3810-305-10, 9 August 1991 is changed as follows

1 Remove old pages and insert new pages as indicated below

2 New or changed material is indicated by a vertical bar in the margin

3 Added or revised illustrations are indicated by a vertical bar adjacent to the illustration

Remove Pages Insert Pages

List of Effective Pagesi and ii i and ii1-7 thru 1-8 1-7 thru 1-81-19 thru 1-20 1-19 thru 1-20

Approved for public release, distribution is unlimited

File this sheet in the front of the publication for reference purposes

0025801 DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: 255732, TM 5-3810-305-10.

By Order of the Secretary of the Army:

ERIC K. SHINSEKI General, United States Army

Chief of Staff Official:

JOEL B. HUDSON Administrative Assistant to the

Secretary of the Army

TM 5-3810-305-10c-1

TECHNICAL MANUAL HEADQUARTERSDEPARTMENT OF THE ARMY

TM 5-3810-305-10 WASHINGTON, DC, fAlovember2000

OPERATOR’S MANUAL

FOR

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

(ROUGH TERRAIN)MODEL LRT 110

CONSISTS OF-

Type I General Purpose(NSN 3810-01-165-0646)

Type II Airborne/Airmobile(3810-01 -165-0647)

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication If you find any mistakes or if you know of a way to improvethe procedures, please let us know Submit your DA Form 2028-2 (Recommended Changes toEquipment Technical Publications), through the internet, on the Army Electronic Product Sup-port (AEPS) website The internet address is http //aeps ria army mil If you need a password,scroll down and click on “ACCESS REQUEST FORM” The DA Form 2028 is located in theONLINE FORMS PROCESSING section of the AEPS Fill out the form and click on SUBMITUsing this form on the AEPS will enable us to respond quicker to your comments and bettermanage the DA Form 2028 program You may also mail, fax or e-mail your letter, DA Form2028, or DA Form 2028-2 direct to Commander, U S Army Tank-automotive and ArmamentsCommand, ATTN AMSTA-AC-NML, Rock Island, IL 61299-7630 The e-mail address is amsta-ac-nml@Xia.armY. mil The fax number is DSN 793-0726 or Commercial (309) 782-0726

IThis technical manual is an authentication of the manufacturers commercial literature and doesnot conform with the format and content specified in AR 25-30 Military Publications This techni-cal manual does, however, contain information that is essential to the operation and mainte-nance of the equipment

I

Distribution Restriction Approved for public release, distribution is unlimited

i

TABLE OF CONTENTS TM5-3810-305-10

Title

CHAPTER I INTRODUCTIONSection ISection IISection IIISection IVSection VSection VISection VIISection VIIISection IXSection XSection XISection XIl

Purpose and FunctionCapabilitiesPerformance CharacteristicsEquipment SpecificationsPower and Utility RequirementsEnvironmental RequirementsList of Items FurnishedList of Items RequiredStorage DataTools and Test EquipmentWarranty InformationSafety Precautions

CHAPTER 2 PREPARATION FOR USE

CHAPTER 3 GENERAL THEORY OF OPERATION

CHAPTER 4 OPERATION INSTRUCTIONS AND FUNCTIONSSection I Use of Operator’s Controls and IndicatorsSection II Initial Adjustments and Control SettingsSection III Start-upSection IV Operation Under Normal ConditionsSection V Wire Rope InstructionsSection VI Operation Under Emergency or Abnormal ConditionsSection VII ShutdownSection VIII Transportability

CHAPTER 5 TYPE II SUPPLEMENTSection I SectionalizationSection II Transportability

APPENDIX

APPENDIX

A p p e n d i x

A p p e n d i x

A p p e n d i x

A p p e n d i x

Index

A NEW EQUIPMENT PREPARATION

B LUBRICATION INSTRUCTIONS

C References

D Components Of End Item and Basic Issue Item List

E Additional Authorization List

F Operator/Crew PMCS

Page

1-11-31-51-51-111-241-241-241-241-241-251-271-27

2-1

3-1

4-14-34-104-174-184-284-564-714-72

5-15-25-46

A-1

I-1

ii

B-1

C-1

D-1

E-1

F-1

TM5-3810-305-10

CHAPTER 1INTRODUCTION

The purpose of this chapter is to introduce the operator to the LRT 110 Crane functions, capabilities,performance. data and specifications. A special section on safe operation of the equipment is also in-cluded at the end of the chapter.

Section Title Page

I Purpose and Function 1-3General 1-4Major Component Nomenclature 1-4

II Capabilities 1-5

III Performance CharacteristicsGeneralEngineElectrical SystemTransmissionTorque ConverterWheelsAxlesBrakesSuspensionSteeringHydraulic SystemSwing SystemDrawbarPintle HookOutriggersBoomWinchBoom CylindersCounterweightDecibel Level Chart

1-51-51-51-61-61-71-71-71-71-71-71-81-81-81-81-91-91-91-91-101-10

IV Equipment Specifications 1-11

Weights 1-11

Dimensions 1-11

Capacities 1-15

Capacity Chart Notes 1-16

Load Ratings on Outriggers 1-19

1-1

TM5-3810-305-10

Section

V

VI

VII

VIII

IX

X

XI

XII

Title

Load Ratings on TiresMaximum Permissible Hoist Line LoadRadius From Centerline of RotationWorking Area Diagram

Power and Utility Requirements

Environmental Requirements

List of Items FurnishedHook BlockCableBoom Angle IndicatorBoom Length Markers

List of Items Required

Storage Data

Tools and Test Equipment

Warranty Information

Safety PrecautionsIntroductionGeneral WarningsGeneral CautionsSafety DecalsMinimum Safety Requirements For

Work Platforms Suspended FromLoad Line or Rigidly MountedOn Boom

Page

1-201-211-221-23

1-24

1-24

1-241-241-241-241-24

1-24

1-24

1-25

1-27

1-271-271-271-361-41

1-42

1-2

TM5-3810-305-10

Section IPurpose and Function

Figure 1-1. Major Component Locations (Left Side)

Figure 1-2. Major Component Locations (Right Side)

1-3

TM5-3810-305-10

General

The purpose of this manual is to familiarizeoperators with the operation and maintenance ofthe LRT 110 Crane. This manual providesinformation and data for operation and lubric-ation. The operator of the LRT 110 Crane mustnot attempt to operate the vehicle before he hasobtained a thorough understanding of the manualcontents.

The LRT 110 Crane is a wheel-mounted, self-contained, two- and four-wheel drive, two- andfour-wheel steering crane. A diesel enginepowers the LRT 110 Crane, driving through apowershift transmission with tandem pumphydraulic power for operation of the crane,outriggers, fully revolving upperstructure andsteering system.

The LRT 110 Crane design meets all the appli-cable requirements of OSHA, EPA, PCSA Std.#4, ANSI B30.5 and the specified SAE Stan-dards.

Major Component Nomenclature

NOTE

All directional references in thismanual (right or left, front orrear, etc.) correspond to theposition of the operator whenfacing forward in operator’s cab.

Upperstructure: The upperstructure includesthe counterweight and hydraulic winch.

Boom Attachment: The boom attachment in-cludes the crane boom, boom lift cylinder andhook block.

Carrier: The carrier includes the chassis, frame,engine, transmission, swing bearing, planetaryaxles, outriggers, operator’s cab, fuel tank,hydraulic reservoir, batteries and tool compart-ment.

1-4

TM5-3810-305-10

Section IICapabilities

The LRT 110 Crane is capable of

● Lifting 15,000 pounds at a 10-foot radius or 4,000 pounds at a 30-foot radius, throughout a 360-degreerotation on outriggers.

● Lifting 13,600 pounds straight over the front on tires.

● A travel speed of up to 22 miles per hour on a level hard surface.

● A travel speed of up to 2.5 miles per hour carrying a 4,500 pound load at a 20-foot radius straight overthe front.

● Rough terrain travel when switched into four-wheel drive.

● Continuous operation in temperatures of up to 120 degrees F or altitudes of up to 5,000 feet.

● Fording up to 30 inches of water.

● Operating in ammunition and petroleum dumps.

Section IllPerformance Characteristics

General

The following are performance specifications for the LRT 110 Crane.

Engine

Type Cummins 4B3.9Four cylinder

Bore and Stroke 4.02 x 4.72 in.(102 x 120mm)

Displacement 239.3 in.(3.92 L)

Maximum Gross Horsepower 80 hp (60 kw) at 2,800 rpm

1-5

TM5-3810-305-10

Maximum Gross Torque 184 lb-ft (249 Ν⋅ m) at 2,800 rpm

Net Power 60 hp (44.7 kw) at 2,800 rpm

Air Filter Dry type

Electrical System

Alternator 24 V, 40 amp

Battery 440 cold cranking amp at 24 V

Transmission

Type

Shift Controls

Funk, Powershift

Four speeds forward/reverse

Forward/reverse lever

Gear speed (1 thru 4)select lever

Two/four-wheel driveselect lever

Gear RangesForward/ Gear Maximum Maximum GradeabilityTwo- or Speed Tractive At Stall

Four- Wheel EffortDrive

1 3.3 mph 18,830 lb 99.2%(5.3 km/h) (8,54 1 kg)

2 6.2 mph 9,930 lb 38.8%(9.9 km/h) (4,504 kg)

3 11.4 mph 5,400 lb 19.1%(18.3 km/h) (2,449 kg)

4 22.0 mph 2,900 lb 9.2%(35.4 km/h) (1,315 kg)

1-6

TM 5-3810-305-10c-1

Torque Converter

Type

Wheels

Type

Tires

Axles

Type

Brakes

Type

Suspension

Type

Driving Mode

Steering

Type

Modes

Turning Radius

Single stage, three elementFree wheel stator (Size 1175 in, STR-29) I

Disc825x22 5 in (210 x572 mm)

108 in wheelbase (2,743 mm)

12 0x22 5, 14 PRRadial115 psi (793 kPa) pressure

Soma, planetary, Model 3Ratio total reduction of1961 1

Hydraulically boosted hydraulic, dualsystem with front-to-rear split

Oscillating rear axleAutomatic hydraulic lockout

Two-wheel, rear drive for hardsurfaces at high speedsFour-wheel drive for off-road, rough terrain

Full fluid linked power steelingAuxiliary steering pump driven by wheelrotation provides steering and braking dulingpower loss

Two-wheel steering, four-wheelsteering, crab steering

Two-wheel 32 ft, 2 in (980 m)Four-wheel 18 ft, 4 in (5 59 m)

I

I

1-7

TM 5-3810-305-10c-1

Hydraulic Svstem

Hydlaulic Pump Drive

Steering, Brake and Swing Circuit

Winch Circuit

Boom Hoist, Telescopeand Outligger Circuit

Hydraulic Valve Bank Hoist,Telescope, Swing, Outrigger

Winch Valve

Oil Filtration

Swing Svstem

Type

Speed

Drawbar

Continuous Pull

Pintle Hook

Towing Capacity

Outriggers

Type

One tandem hydraulic pump,driven off transmission at O 87 times engine rpm

Pump 21 gal(79 5L) per mirdoperating at 2,440 rpmand 2,650 psi (18,272 ld?a)Priority flow 10 gal(37 8 L) per min2,500 psi (17,238 kPa)

18 gal (68 1 L) pel rein/operating at 2,440 rpmand 2,650 psi (18,272 kPa)

21 gal (79 5 L) per mird operatingat 2,440 rpm and 2,750 psi (18,961 IcPa)

Foul-spool, two-way valve

Single-spool, two-way valve

Full flow system with 100-mesh (140-micron)screen and 10-micron return filter

Worn gear reduction unitpowered by hydraulic motor

No load 308 rpm

10,000 lb(4,536 kg)

40,000 lb(18,144 kg)

Flipper7 in (178 mm) lift on12 00x 225, 14 PR standard tires

1-8

TM5-3810-305-10

Extend Time per Outrigger

Retract Time per Outrigger

Boom

Type

Construction

Point Sheaves

Retraction

Base and Tip Sections

Maximum Line Speed(NO LOAD)

Drum Capacity

Rope Size

4.50 sec

4.00 sec

Standard, two section35.75 ft ( 10.90 m)

All welded, box beam

Cast, ductile iron, mountedon non-friction bearings.Two sheave boom head

To 21.75 ft (6.63 m)(PCSA Standards)

70,000 psi (483 N/mm2) material

First layer: 177 ft(53.95 m) per min

Third layer: 216 ft(65.84 m) per min

350 ft (107 m)Five layers

1/2 in. 6 x 9 Independent Wire Rope Core(IWRC), Improved Plow Steel (IPS), Preformed

NOTE

All cylinders contain pilot check valves.

Boom Hoist Time 28.5 sec

Boom Down Time 25.3 sec

Telescope Extend Time 27.2 sec

Telescope Retract Time 22.7 sec

Counterweight

Weight 2,200 lb (998 kg)

1-9

Boom Cylinders

W i n c h

TM5-3810-305-10

Decibel Level Chart Exposing the unprotected human ear to soundlevels above 85 dB (measured on the “A” scale)for prolonged periods can result in permanenthearing loss.

Within the 85-dB envelope, hearing protection is In order to avoid hearing loss, ear plugs orrequired. Failure to follow this procedure could other suitable protective devices should be worncause SERIOUS INJURY. when working within the 85 dBA envelope (40 ft

maximum from the nearest surface of the crane)NOTE as shown on Figure 1-3.

Sound levels in the operators cab can reach 87Radius dimensions illustrated in Decibel Level dBA with the cab closed and therefore operatorsChart are from center of rotation. Points on the should wear hearing protection while operatingprofile are from nearest surface of the crane. the LRT 110 Crane.

1-10

Figure 1-3. Decibel Level Chart - 85 - dB Profile

TM5-3810-305-10

Section IVEquipment Specifications

Weights

Vehicle Weight Distribution:

Front

Rear

Total

Hook Block(One sheave)

Dimensions

Winch:

Drum Diameter

Drum Length

Flange Diameter

Cylinders:

Boom Extend

10,760 lb(4,881 kg)

12,110 1b(5,493 kg)

22,870 lb(10,374 kg)

235 lb(107 kg)

8.5 in.(216 mm)

12.25 in.(311 mm)

14.56 in.(370 mm)

Bore: 4.0 in.(102 mm)

Stroke: 168 in.(4.27 m)

Rod: 3 in.(76 mm)

Boom HoistBore: 8.5 in.(216 mm)

Stroke: 39.3 in.(998 mm)

Rod: 3 in.

Type II (Differences)

ll,710 lb(5,312 kg)

12,520 lb(5,679 kg)

24,230 lb(10,991 kg)

(76 mm)

1-11

TM5-3810-305-10

Outrigger: Bore: 5.0 in.(127 mm)

Stroke: 17.75 in.(45 1 mm)

Rod: 3.0 in.(76 mm)

Figure 1-4. General Dimensions

1-12

TM5-3810-305-10

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

NOTE

All dimensions assume boom fully retracted and crane equipped with standard tires

Overall Length 25 ft, 8.16 in.(7.83 m)

Centerline of Rotation 17 ft, 8 in.

to Boom End (5.39 m)

Boom End to Front of Carrier 6 ft, 6.5 in.(1.99 m)

Tailswing Radius 7 ft, 9 in.(2,36 m)

Centerline of Rotation to 4 ft, 8.5 in.Boom Pivot (1.44 m)

Height of Cab 6 ft, 2 in.(1.88 m)

Ground Clearance to 14.4 in.Transmission (366 mm)

Ground Clearance to 15 in.

Outrigger Box (38 1 mm)

Centerline of Rotation 4 ft, 2.9 in.

to Centerline of Rear Axle (1.29 m)

Wheelbase 9 ft(2.74 m)

Centerline of Front 14 ft, 4 in.

Outrigger Box to (4.37 m)

Centerline of RearOutrigger Box

Overall Length of Carrier 19 ft, 1.6 in.(5.83 m)

1-13

TM5-3810-305-10

13. Overall Travel Width

14. Overall Height

Figure 1-5. General Dimensions

15. Ground Clearance to LowestPoint of Axle

16. Outrigger Extension BelowGrade

17 Track

18. Width of Carrier

19. Effective Width ofOutriggers

20 Overall Width Over Floats

8 ft(2.44 m)

7 ft, 8.5 in.(2.35 m)

14 in.(356 mm)

7.3 in.(185 mm)

6 ft, 10.3 in.(2.09 m)

8 ft(2.44 m)

12 ft, 4.9 in.(3.78 m)

13 ft, 7.9 in.(4.16 m)

1-14

TM5-3810-305-10

Capacities

Cooling System

Fuel

Crankcase

Hydraulic System

Hydraulic Oil Reservoir

Transmission:

Capacity

Refill

Axle:

Hub (es)

Differential

Swing Reduction Unit

Winch

28 qt(26.5 L)

44 gal(166.5 L)

11 qt(10.4 L)

45 gal(170.3 L)

23.8 gal(90. 1 L)

20.5 qt(19.4 L)

12 qt(11.4L)

3 qt(2.8 L)

14 qt(13.2 L)

3 qt(2.8 L)

2 qt(1.9L)

1-15

TM5-3810-305-10

Capacity Chart Notes

● Never lift or swing load directly overoperator’s compartment or over groundpersonnel in the work area, Failure tofollow this procedure could causeDEATH or serious injury.

● All notes on the Capacity Chart must betreated as WARNING’S. Failure tofollow these procedures could causeDEATH or serious injury.

NOTE

The following is a direct copy ofthe notes on the Capacity Chartfound on the machine. For clari-fication of the notes, refer topage 1-18.

GENERAL

1.

2.

3.

Crane load ratings as determined by boomlength, radius and boom angle apply to thiscrane only as originally manufactured andequipped. THEY ARE MAXIMUM LOADRATINGS.

The crane and its load ratings are in accor-dance with Power Crane and Shovel Associa-tion Standard No. 4, SAE Crane Load Stabil-ity Test Code J-765a, SAE Method of Test forCrane Structure J-1063, and Safety Code forCranes, Derricks and Hoists, ANSI B30.5-1982.

Improperly operated or maintained equipmentcan be dangerous. The operator and otherpersonnel should read and fully understandthe Operator’s Manual furnished by the manu-facturer before operating or maintaining this

4.

machine. Rules for safe operation of equip-ment should be adhered to at all times. Ifeither manuals or lift chart are missing, theyshould be ordered by machine serial numberthrough the distributor.

Operators and supervisors must fully under-stand Safety Standards for Mobile HydraulicCranes ANSI B30.5 or latest, and be familiarwith Federal, State and local safety regula-tions. Consult section of Operator’s andService Manual for more exacting descriptionof the use of this lift chart.

SET-UP

5.

6.

7.

8.

9.

Crane load ratings are based on the machinebeing leveled and standing on a firm, uniformsupporting surface.

Crane load ratings on outriggers are based onall outrigger beams fully extended and thetires raised free of the supporting surface.

Crane load ratings on tires depend on appro-priate inflation pressure and tire conditions.Caution must be exercised when increasingair pressure in tires. Consult Operator’sManual for precautions.

Consult appropriate section of Operator’s andService Manual for more exact description ofhoist line reeving.

The use of more parts of line than required byload may result in having insufficient rope toallow the hook block to reach the ground.

10. Properly maintained wire rope is essential tosafe crane operation. Consult Operator’sManual for proper maintenance and inspec-tion requirements.

1-16

TM5-3810-305-10

11. When spin resistant wire is used, the allow-able rope loading shall be the breakingstrength divided by five (5) unless otherwisespecified by wire rope manufacturer.

OPERATION

12. Crane load ratings must not be exceeded.DO NOT ATTEMPT TO TIP THE MA-CHINE TO DETERMINE ALLOWABLELOADS.

13. Crane load ratings are for lift crane service.Applications for other than lift crane (clam-shell and magnet) are permitted. Due tosignificant variations in materials and appli-cations, consult factory for optimum capabil-ity.

14. Weight of hooks, hook blocks, slings and allother load handling devices must be consid-ered part of the load to be handled and mustbe subtracted from the load ratings to obtainthe allowable load to be lifted.

15. Crane load ratings are based on freely sus-pended loads. SIDE LOAD ON BOOM ORJIB IS EXTREMELY DANGEROUS.

16. Practical working loads depend on the sup-porting surface, wind velocity, pendulumaction, jerking or sudden stopping of loads,hazardous surroundings, experience of per-sonnel, proper operation, tire inflation, tirecondition, traveling with loads, multiplemachine lifts, proximity of electrical wires,etc. Appropriate reduction of load ratingsmust be made for these and any other condi-tions which may affect practical workingloads.

17. Crane load ratings with an asterisk (*) beside

them are based on the machine’s structuralstrength. All other ratings are based onstability and do not exceed the specifiedpercentage of tipping load as determined bySAE Crane Stability Test Code J765a.

18. For all boom lengths between the retractedand extended boom length, the rated loadsare determined by boom angle only shown inthe extended boom column. For boom anglesnot shown, use capacity of the next lowerboom angle.

19. When either radius or boom length, or both,are between listed values, the smaller of thetwo load ratings shall be used.

20. Load ratings are dependent upon the cranebeing maintained according to manufacturer’sspecifications.

21. The maximum load which may be telescopedis limited by boom angle, hydraulic pressure,boom lubrication, etc. It is safe to attempt toextend and retract within the limits of the ca-pacity chart.

22. It is recommended that load handling de-vices, including hooks and hook blocks, bekept away from boom head at all times.

23. The boom angles shown on the capacity chartgive an approximation of the operating radiusfor a specified boom length. The boomangle, before loading, should be greater toaccount for boom deflection.

24. DO NOT LIFT LOAD OVER OPERATOR.

1-17

TM5-3810-305-10

25.

26.

27.

28.

Operating Radius: The horizontal distancefrom the axis of rotation before loading to thecenter of the vertical hoist line or tackle withload applied.

Freely Suspended Load: Load hanging freewith no direct external force applied exceptby the hoist rope.

Side load: Horizontal force applied to thelifted load either on the ground or in the air.

Working Arc: Areas measured in a circulararc around the centerline of rotation as shownon the working area diagram.

CLARIFICATIONS

All notes on the Capacity Chart must be treated as WARNINGS. Failure to follow theseprocedures could cause DEATH or serious injury.

NOTES 4 & 8

The Service manual and Operator’s manual are the same, Operation manual.Operator’s manual, refer to section XII.

NOTE 7

Consult this manual, page 1-20, Load Ratings on Tires; tire pressure must be maintainedat 90 psi.

NOTES 5, 8 & 10

Consult Hoist Line Reeving (refer to page 2-2) and Wire Rope Instructions (refer topage 4-28).

NOTE 13

The use of clamshells, magnets or work platforms, which are not provided with the ma-chine, is not permitted.

1-18

DEFINITIONS

TM 5-3810-305-10c-1

LOAD RATINGS ON OUTRIGGERS

ON OUTRIGGERSBOOM LENGTH BOOM LENGTH

21 75Ft 3575 Ft.Retracted Extended

RADIUS E FRONT 360° & FRONT 360° RADIUS

10 51° 15,000* 15,000* 70° 15,000* 15,000* 1012 43° 15,000* 15,000* 66° 15,000* 15,000* 1213 40° 15,000* 15,000* 64° 15,000* 15,000* 1314 35° 15,000* 14,1OO* 62° 15,000* 14,1OO* 1415 29° 14,1OO* 13,000 161° 14,1OO* 13,200 1520 51° 10,3OO* 7,900 2025 38° 7,700* 5,400 2528 27° 6,300 4,500 2830 17° 5,700 4,000 30

1-19

TM 5-3810-305-10c-1

Load Ratinas On Tires

NOTES”

1 For Pick and Carry Operation, boom must be centered over the front of the machine

2 The load should be restrained from swinging.

3 Creep Speed is crane movement of less than 200 ft (61 m) in a 30-rninute period and not exceeding1 Omph (1 6km/h)

RECOMMENDED TIRE PRESSURE

12R22.5 STATIONARY TRAVELLOAD RANGE H 115 Dsi 115 nsi

A

B

c

D

Notes for On Tires Cspacltles

For Pick and Cerry operetlon,boom must be centared ovartha front of tha mschlna

Tha load should be restrainedfrom swinging

Creep Spead is crane movamentof lass than 200 ft (61 m) In a30 minute period and not ax-ceeding 10 mph (1 6 kmih)

Refer to General Notes for addi-tional information

ON TIRESR M MA A I

12R22.5 LR - H:

: x. N.STATIONARY

PICK & CARRY y

u CREEP 12.6 klPkI lJ

s IX IX 360° ST. OVER FRONT s

10 710 510 7,300’ 12,800’ 9,800’ 8,700’ 1012 67° 43” 5,800 11,000’ 8,400’ 7,400’ 12

15 63° 29° 4,100 7,500 6,800” 6,000’ 15

20 57° 0° 2,600 4,700 4,700 4,500’ 20

25 40° o“ 1,900 3,400 3,400 3,400 25

28 29° 0° 1,600 2,800 2,800 2,800 2a

30 17° 0° 1,400 2,600 2,600 2,600 30

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TM5-3810-305-10

MAXIMUM PERMISSIBLE HOIST LINE LOAD

Line Parts I I 2 I 3Maximum Load 6,000 lb 12,000 lb 15,000 lb

(2,722 kg) (5,443 kg) (6,804 kg)Boom Head 1 1 -D 1-2Hook Block I D I 1 I 1-D

1, 2, D = Cable to sheave position and dead end. Sheaves are numbered left to right.Wire Rope = 6 x 19 Class, 23,000 lb (10,433 kg) minimum breaking strength; l/2-inch diameter.I. P.S., I. W.R.C., Preformed

1-21

1

TM5-3810-305-10

Figure 1-6. Radius from Centerline of Rotation

1-22

TM5-3810-305-10

NOTE

Never lift or swing load directly Working areas are areas meas-above operator’s compartment or ured in a circular arc aroundover ground personnel in the centerline or rotation.work area. Failure to follow thisprocedure could cause DEATHor serious injury.

CRANE WORKING POSITIONS

Figure 1-7. Working Area Diagram

1-23

TM5-3810-305-10

Section VPower and Utility Requirements

* *NOT APPLICABLE**

Section VIEnvironmental Requirements

**NOT APPLICABLE**

Section VIIList of Items Furnished

Hook Block: A 10-ton single-sheave hook block Boom Lenght Markers: Boom length markers is provided with swivel hook and safety latch. are located on both sides of the inner boom toSheaves comply with SAE J-881. The weight of indicate retraced length of 21.75 ft (6.63 m) or athe hook block provides adequate overhaul of the fully extended boom length of 35.75 ft (10.90 m)cable, insuring smooth cable operation of the hy - and are used in conjunction with Capacity Chart.draulic winch.

Cable; A l/2-inch diameter, 6 x 19 class cableof right regular lay, having an independent wirerope core and constructed of improved plowsteel, is provided, having a 3.5:1 safety factor inaccordance with SAE J-959. The winch drumcapacity is such that when the crane is properlyreeved, three wraps of cable are maintained at alltimes on the hoist drum.

Boom Angle Indicator: A mechanical boom Figure 1-8. Boom Lenght Markerangle indicator conforming to SAE J375 isprovided for angular boom elevations.

Section VlllList of Items Required

**NOT APPLICABLE**

Section IXStorage Data

LRT 110 Cranes being placed in storage must be 30 days or less. Extended Storage is defined asadequately protected from deterioration during more than 30 days.

extended periods of idleness. Proper protectioninsures that the crane can be restored to service NOTE

with minimum effort.For a complete list of storage instruc-

What specific preparation procedures are re- tions for the LRT 110 Crane, refer to

quired depends upon the length of time the crane Koehring Commercial Maintenance

is to be stored. Short Term Storage is defined as Instructions.

1-24

TM5-3810-305-10

Section XTools and Test Equipment

Figure 1-9. Tools and Test Equipment

1-25

TM5-3810-305-10

The LRT 110 Crane Tool Kit Consists ofTool Use Qty

1 Wrench, 3/4 x 7/8 Emergency swing2 Wrench, 9/16 x 5/83 Wrench, 5/8 x 11/164 Wrench, 3/4 x 7/85 Wrench, 12 inch,

Adjustable6 Wrench, Lug7 H a n d l e8 Adapter, -8 to -69 Cap, -410 Reducer, -6 to -411 Tee, -812 Plug, -413 Plug, -614 Plug, -lo15 Plug, -1216 Disconnect, (Quick),

Female17 Adapter, -6 to -418 Hose19 Adapter, -6 to -620 Cap, -621 Cap, -1222 Adapter, -12 to -823 Wrench, He. , 5/1624 Wrench, He: . 5/3225 Hose26 Pin27 Hose28 Pump, Hand29 Adapter30 Hose31 Elbow32 Plug, Pipe, -433 Plug, Cap34 Adapter, Hex,

(Axle Plug)35 Link

36 Cylinder, Ether

Hose connectionsHose connectionsHose connections

All purposeWheel nutsLug wrenchHose adapterEmergency hoseWinch brake hoseEmergency hose adapterOpen hose endsOpen hose endsOpen hose endsOpen hose ends

Reservoir tankHose adapterOutrigger emergency returnHose adapterHose capHose capHose adapterBoom hold valveExtend cylinder hold valveHand pump supply hoseEngages handle on hand pumpPressure supply from hand pumpEmergency crane operationHose adapterTest guage connectorHose fittingHose plugHose cap

Axle check plug removalHook block to pintle air

transportCold start assist

(in container)

111

11121111113

231121111111111112

1

1

1

1-26

1

TM5-3810-305-10

Section XlWarranty Information

Refer to Warranty Technical Bulletin, TB 5-3810-305-15.

Section XIISafety Precautions

Introduction

The LRT 110 Crane is designed toconform to all applicable SAE, ANSI and

OSHA safety requirements.

As a crane operator, your responsibility forsafety is not lessened by the operational aids andwarning devices provided.

Guard against a false sense of security. Failureto follow even a single safety precaution cancause DEATH or SERIOUS INJURY. You areresponsible for your own safety as well as othersworking around you.

Warning decals are placed conspicuously on thevehicle warning of hazards including the dangerof electrocution if the boom or load is swung intopower lines.

In addition to the following list, WARNINGS,CAUTIONS and NOTES appear throughout themanual directly above the procedure to whichthey apply.

indicates a hazard whichcan result in DEATH or serious injury.

I CAUTIONis a reminder of safety

practices or directs attention to usage practicesthat may result in damage to equipment.

NOTE is a statement containing information thatwill make the procedure easier to perform.

Exercise good judgment whenoperating the LRT 110 Crane.Read and understand all safetyprecautions before operating thecrane. Failure to follow theseprecautions could cause DEATHor serious injury.

Genera WarningsI

Do not attempt to operate theLRT 110 Crane until all operat-ing instructions have been readand understood. Knowledge ofcontrols alone is inadequatepreparation to operate this ve-hicle. Failure to follow thisprocedure could cause DEATHor serious injury.

To avoid many dangerous prac-tices, play it safe by followingcorrect procedures. Failure tofollow these procedures couldcause loads to fall causingDEATH or serious injury.

1-27

TM5-3810-35-10

Be aware of limited work areawhile working on the deck areaof the LRT 110 Crane. The deckand fender surface is small andcan become slippery in inclementweather. Failure to follow thisprocedure could cause DEATHor serious injury.

Never disconnect hydraulic linesor fittings before venting pres-sure. Turn dipstick cap 1/4 turnto safety notch to relieve pres-sure. Failure to follow thisprocedure could cause SERIOUSINJURY.

Alert all personnel that theupperstructure is to be lifted offthe carrier. Keep all uninvolvedpersonnel clear of the vehiclewhile hoisting and removal aretaking place. Check all pinconnections, cable alignment andmachine bubble level beforeproceeding with the lift. Failureto follow this procedure couldcause DEATH or serious injury.

Keep hands and arms clear of allpinch points while checking thealignment of the upperstructureand the earner mounting surface.Failure to follow this procedurecould cause SERIOUS INJURY.

Keep arms and hands from underupperstructure. Failure to followthis procedure could causeSERIOUS INJURY.

Vehicle must be level to preventpossible loss of control of upper-structure when lifting off ofground. DEATH or seriousinjury may result if upperstruc-ture gets out of control.

Check that all pins and pin locksare installed and secured prop-erly. DEATH or serious injurymay result if upperstructurecomes loose.

Stay clear of hoisted upperstruc-ture while it is being positionedover carrier. Failure to followthis procedure could causeDEATH or serious injury.

Turn the face during the follow-ing procedure to avoid havinghydraulic oil splash in face oreyes. Failure to follow thisprocedure could cause SERIOUSINJURY.

1-28

TM5-3810-305-10

Weight of (component) is ap-proximately XX lb (XX kg). Usetwo people to properly supportand lift (component). Failure tofollow this procedure could causeDEATH or serious injury.

Unwarranted use of BY-PASSswitch can result in damage tothe LRT 110 Crane and causeDEATH or serious injury.

Cooling system is pressurized.Use extreme caution and properprotection when removingradiator cap after operatingtemperature is reached. Whenremoving cap, loosen it slowly tothe left, then pause a moment.Steam and hot gases will beescaping through the radiatorcap; avoid being burned by thesegases. Continue to turn cap untilit can be removed. Failure tofollow this procedure could causeSERIOUS INJURY.

● Battery gases can explode. Do notsmoke or allow sparks or open flamesnear batteries. Wear safety glasses orgoggles when checking the batteries.Failure to follow this procedure couldcause DEATH or serious injury.

corrosion or electrolyte makes contact,take immediate action to stop theburning effects:

EYES: Flush with cold water forno less than 15 minutes and seekmedical attention immediately.

SKIN: Flush with large amountsof cold water until all acid isremoved. Seek medical attentionas required.

INTERNAL: If corrosion orelectrolyte is ingested, drinklarge amounts of water or milk.Follow with milk of magnesia,beaten egg or vegetable oil. Seekmedical attention immediately.

CLOTHING/EQUIPMENT:Wash area with large amounts ofcold water. Neutralize acid withbaking soda or household ammo-nia.

Failure to follow this procedurecould cause DEATH or seriousinjury.

The operator must exercise soundjudgment in positioning outrig-gers. The outriggers should notbe set near holes, on rockyground or on extremely softground. Setting outriggers insuch locations may result in thevehicle tipping, causing DEATHor serious injury.

● Sulfuric acid contained in batteries cancause serious bums. If battery

1-29

TM5-3810-305-10

The LRT 110 Crane must belevel prior to extending boom orlifting loads. To achieve thiscondition, outriggers should beextended to lift carrier wheels offthe ground. Use bubble levelnext to the operator’s seat toinsure that vehicle is level. Thebubble must be centered in circle.Failure to follow this procedurecould cause DEATH or seriousinjury.

Hook latch is intended to retainloose slings or devices underslack conditions. It is not in-tended to be an anti-foulingdevice. Caution should be usedto prevent the latch from support-ing any of the load. Periodic in-spection of latch must be made toinsure its proper operatingcondition. Failure to follow thisprocedure could cause DEATHor serious injury.

An operator must be guided bythe Capacity Chart mounted onvehicle when considering loadweights. Rated loads must neverbe exceeded. Failure to followthis procedure could causeDEATH or serious injury.

The intent of the information isto prevent any possibility ofeither reverse winding of therope on the winch drum, causingbreakage of winch cable, or theunseating of cable from winchdrum, resulting in uncontrolledfall of the hook block and load.Failure to follow this procedurecould cause DEATH or seriousinjury.

Never lift and swing a loaddirectly over operator’s compart-ment or over ground personnel inthe work area. Failure to followthis procedure could causeDEATH or serious injury.

Using an axe or hatchet to cutwire rope may be dangerous. Ifnecessary to use, proceed withgreat caution. Failure to followthis procedure could causeSERIOUS INJURY. Portablehydraulic and mechanical ropecutters are available. In remoteareas, however, it may at timesbe necessary to use less desirablecutting methods.

Incorrect cable type or size willnot function properly and may bedangerous when used. Failure tofollow this procedure could causeDEATH or serious injury.

1-30

TM5-3810-305-10

If exhaust gases or exposuresymptoms are observed, ventilate

Make certain slings, ties and the area immediately and treathooks are of sufficient capacity, affected personnel:properly set and secure beforeperforming any lift operation. ●

Failure to follow this procedurecould cause DEATH or seriousinjury. ●

●

●

Always use a qualified signalman and ●

observe load while the equipment is inoperation. ●

When spotting a load, it may becomenecessary to alter the boom angle orlength, If adjustment is necessary,consult the LRT 110 Capacity Chart

Administer artificial respiration, ifrequired.

Expose affected personnel to fresh air.

Keep affected personnel warm.

Do not permit physical exertion.

Refer to FM 21-11, First Aid ForSoldiers for a more detailed descriptionof treatment procedures.

before performing a lift. Failure to Never operate equipment withfollow this procedure could cause personnel on the hook or a load.DEATH or serious injury. Failure to follow this procedure

could cause DEATH or seriousinjury.

Exhaust gases can produce symp-toms of headache, dizziness andloss of muscular control. Crane operators must always beDEATH, permanent brain dam- prepared to take emergencyage or other serious injury may action while a load is suspendedbe caused by exhaust gases. in the air. Never leave the

operator’s compartment with aload suspended. Failure tofollow this procedure could causeDEATH or serious injury.

1-31

●

TM5-3810-305-10

Keep all parts of body and toolsaway from moving cable. Fail-ure to follow this procedurecould cause DEATH or seriousinjury.

Never allow boom or load toswing into power lines. If thecrane must be operated in thevicinity of power lines, followthese safety precautions:

● Contact the power company and haveall power lines and ground wires turnedoff.

● Never allow any portion of theequipment, including cable, hook block,lines and load, closer to power linesthan the distances shown on theElectrical Warning (Danger) Decal.

● Know the maximum height and reachof the crane and erect a suitablebarricade around all power sources.

● Warn all personnel in the work area ofthe power source and electrocutionhazard.

● If contact with a power source doesoccur, DO NOT STEP OFF THECRANE. Stay on the vehicle until thepower is turned off or the equipment islowered and clear of the power source.

● If fire or other conditions force theoperator to leave the crane, jump offand away, keeping all parts of the bodyclear of the equipment.

Failure to follow these proce-dures could cause DEATHserious injury.

Diesel fuel and other combustiblematerials are used in the opera-tion and maintenance of thisequipment. Do not smoke orallow open flames in areas wherecombustible materials are storedor used. Failure to follow thisprocedure could cause DEATHor serious injury.

No personnel are permitted onthe deck while rotating upper-structure. Failure to follow thisprocedure could cause DEATHor serious injury.

Improperly attached wire ropeterminals lead to serious orpossibly unsafe conditions.Failure to follow this procedurecould cause DEATH or seriousinjury.

1-32

TM5-3810-305-10

When using U-bolt clips, ex-treme care must be exercised tomake certain that they are at-tached correctly. Failure tofollow this procedure could causeDEATH or serious injury.

Failure to make a termination inaccordance with the instructions,or failure to periodically checkand retighten to the recom-mended torque, will cause areduction in efficiency rating,which could cause DEATH orserious injury.

Failure to install wedge socketsin accordance with the instruc-tions could cause DEATH orserious injury.

Clamp the dead end close to thesocket to prevent the rope andwedge from disengaging fromthe socket. Failure to follow thisprocedure could cause DEATHor serious injury.

During the execution of thisprocedure, the danger exists ofuncontrollably dropping a load.Rotate the upperstructure to asafe position. Failure to followthis procedure could causeDEATH or serious injury.

Entry of air into lowering portwill cause winch motor to cavi-tate. The winch motor loweringport tee must be capped to pre-vent load from free falling whenhand pump pressure is applied.Failure to follow this procedurecould cause DEATH or seriousinjury.

When working the hand pump,clear all personnel from the area.Failure to follow this procedurecould cause DEATH or seriousinjury.

When lowering boom to a hori-zontal position, work from sideof upperstructure, not underboom. Failure to follow thisprocedure could cause DEATHor serious injury.

1-33

TM5-3810-305-10

Everyone must be clear of thearea before moving hoist controllever. Failure to follow thisprocedure could cause DEATHor serious injury.

Starting fluid is toxic and highlyflammable. Container is pressur-ized to act as an expellent. Donot heat container and do notdischarge starting fluid in con-fined areas or near an openflame. Failure to follow thisprocedure could cause SERIOUSINJURY.

Adequate ground bearing supportmust be provided for the outrig-ger when operating on softsurface. Be alert for signs ofLRT 110 Crane movementduring operations. Failure tofollow this procedure couildcause DEATH or serious injury.

Never use less than the numberof parts of line called for by theCapacity Chart. Failure to followthis procedure could causeDEATH or serious injury.

Within the 85-dB envelope,hearing protection is required.Failure to follow this procedurecould cause SERIOUS INJURY.

All notes on the Capacity Chartmust be treated as WARNINGS.Failure to follow these proce-dures could cause DEATH orserious injury.

When use of a work platform isleast hazardous to personnel andis the only practical means ofaccomplishing a task, makecertain all personnel followminimum safety procedures.Failure to follow these proce-dures could cause DEATH orserious injury.

Read and understand all safetyprecautions before attempting anoperation using a work platform.Failure to follow this procedurecould cause DEATH or seriousinjury.

1-34

TM5-3810-305-10

All safety procedures and criteriaestablished are the MINIMUMrequirements for use of a workplatform on the LRT 110 Crane.Applicable government andindustry standards must also beadhered to. Failure to follow thisprocedure could cause DEATHor serious injury.

Never use a work platform ifinspection indicates a structuralor mechanical fault of any kind.Failure to follow this procedurecould cause DEATH or seriousinjury.

No personnel are permitted onthe work platform during theperformance of any test. Do notallow personnel on work plat-form if any test procedure indi-cates a malfunction in equip-ment. Failure to follow thisprocedure could cause DEATHor serious injury.

No operations with a workplatform are authorized “ontires.” Always make certain theLRT 110 Crane is on a stablesurface with the outriggers fullyextended. Failure to follow thisprocedure could cause DEATHor serious injury.

Never use a work platform nearenergized power lines or groundcables. Failure to follow thisprocedure could cause DEATHor serious injury.

Never allow electrically con-nected electrode holders tocontact metal components of awork platform. Electrode holdercontact can cause burning and/ormelting of work platform suspen-sion which could allow the workplatform to fall. Failure tofollow this procedure could causeDEATH or serious injury.

Dry cleaning solvent P-D-680used to clean parts is toxic andflammable. Use only in wellventilated areas and avoid con-tact with eyes, skin or clothing.Wear the proper protectiveclothing and equipment: gogglesor safety glasses, face shield andgloves. Do not breath vapors. Donot use near sparks or openflames and do not smoke whileusing it. Failure to follow thisprocedure could cause DEATHor serious injury.

1-35

TM5-3810-305-10

CAUTION ICompressed air used for cleaning Make sure three sheaves andpurposes must not exceed 30 psi cable are in alignment with(207 kPa). Safety glasses must boom. Failure to follow thisbe used when cleaning parts. procedure could cause damage toFailure to follow this procedure equipment.could cause DEATH or seriousinjury. CAUTION

General Cautions

In addition to personnel hazards, the operator isalso responsible for avoiding potential damage toequipment.

C A U T I O N

When removing hook block fromstorage bracket, pay out cablewhile raising boom to preventdamage to windshield.

CAUTION

DO NOT use a torque wrench forremoval purposes. Failure tofollow this procedure could causedamage to equipment.

Keep all hoses out of the waywhen lowering upperstructure.Make sure the winch extensionhoses are not pinched against theoutrigger beam as the upperstruc-ture is lowered. This could resultin damage to the extension hoses.

C A U T I O N

Do not allow outrigger beam,located under upperstructure, tocontact winch hoses. Failure tofollow this procedure could causedamage to equipment.

C A U T I O N

Make sure the base plate openingclears the connections on therotary manifold. Failure tofollow this procedure could causedamage to equipment.

1-36

TM5-3810-305-10

When attaching hook block tohook block tieback, take up cableslowly while lowering boom toprevent damage to windshield.

If disconnect system malfunc-tions and hook block is drawninto the boom point, vehicle maybe damaged. Care should betaken when performing discon-nect test.

Do not make directional changes CAUTIONbetween forward and reversewhile vehicle is in motion. If any gauge fails to operate, shutFailure to follow this procedure engine off and notify mainte-could cause damage to equip- nance. Failure to follow thisment. procedure could cause damage to

equipment.

Do not attempt to move thevehicle with the parking brakeengaged. Failure to follow thisprocedure could cause damage toequipment.

I CAUTION INever operate engine with oillevel below the ADD 1 QT markor above the FULL mark. Fail-ure to follow this procedurecould cause damage to equip-ment.

I CAUTION I

CAUTION

Release starter button as soon asthe engine starts. If engine stallsduring start-up procedure, allowengine to stop revolving beforere-engaging starter. Failure tofollow this procedure could causedamage to equipment.

C A U T I O N

When operating on hard surfaces,use two-wheel drive only. Fail-ure to do so may result in severedrive line “wind-up” and compo-nent failure.

Keep tension on cable to preventdamage from slack.

1-37

CAUTION

CAUTION

TM5-3810-305-10

Speed is not to exceed 25 mph(40 km/h). Failure to follow thisprocedure could cause damage toequipment.

CAUTION

Traveling with high transmissiontemperature (above 250 degreesF [121 degrees C]) can causedamage to vehicle. Do not shutengine off when transmission isoverheating.

C A U T I O N

Never shift between forward andreverse while the LRT 110 Craneis in motion. Failure to followthis procedure could causedamage to equipment.

Downshifts should not be madewhen vehicle speed exceedsmaximum speed of next lowerrange. Downshifting at exces-sive speeds will overspeed drivetrain components and causedamage to drive shafts

Do not operate for extendedperiods with wide-open throttleat speeds below minimumsshown. Failure to follow thisprocedure could cause damage toequipment.

Under emergency or extremetraveling circumstances, it ispossible to stop the LRT 110Crane with the parking brake.However, this results in rapidbrake wear. After stopping 3 or4 times by this method, parkingbrake adjustment should bemade. Failure to follow thisprocedure could cause damage toequipment.

CAUTION IA dirty cab can result in damageto instruments and controls.

Always consider possible ob-structions which may be encoun-tered during swings when vary-ing boom height or length.Think swing through, consider-ing all obstacles, before makingswing. Failure to follow thisprocedure could cause damage toequipment.

CAUTION INever hold controls in an “acti-vated’ position once hoist/lowercylinder or extend/retract cylin-der has reached its limit of travel,This can cause overheating ofhydraulic oil.

1-38

CAUTION

TM5-3810-305-10

ALWAYS START AND STOP Insufficient tire pressure reducesSWINGS GRADUALLY.Stopping swing too abruptly willcause load to oscillate andimpose side loads on boom. Thiswill cause damage to boom.

the “On Tires” capacity. At-tempts to pick rated capacitywithout properly inflated tiresmay cause vehicle to tip and/orresult in damage to tires andrims.

I CAUTION II CAUTION I

Never pull to the side with acrane boom. Crane booms arenot designed for excessive sidepull and may collapse if sub-jected to excessive side loading.

CAUTION

Do not continue to pull block upafter contact has been made withboom head. This will result indamage to boom head andsheaves. The cable may also bebroken, causing load to drop.

When spotting load, it may benecessary to alter boom length orboom angle. In making theseadjustments, the operator mustguard against exceeding ratedload as determined by the Capac-ity Chart. Failure to follow thisprocedure could cause damage toequipment.

Traveling over uneven terrainwith rear axle oscillation lockedout can result in instability.Excessive boom length can alsocause instability depending onterrain and wind pressure. Fail-ure to follow this procedurecould cause damage to equip-ment.

I CAUTION INever use a chromate-basecorrosion inhibitor when coolantcontains ethylene glycol. Useonly nonchromate-base inhib-itors. Chromate-base inhibitorsreacting with ethylene glycol canproduce chromium hydroxide,commonly known as “greenslime.” This substance reducesthe heat transfer rate and cancause serious engine overheating.

I CAUTION IWater added to battery can freezebefore it mixes with electrolyte.During very cold weather, addwater to battery just prior to, orduring operation of, vehicle. Ifvehicle is not to be run, connectan external charger to battery ifadding water.

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TM5-3810-305-10

BE ALERT FOR SIGNS OFPUMP CAVITATION. Thehydraulic oil provides lubricationfor pumps. When too heavy orstiff, it will not flow fast enoughto meet pump demand and avacuum or “cavitation” will becreated. A “screaming” noiseindicates inadequate pumplubrication and, if allowed tocontinue for more than a shortperiod, will result in seriousdamage to pumps.

I CAUTION IIf the LRT 110 Crane is to betowed a distance of more than 1mile (1.6 km) and/or at speedsgreater than 3 mph (4.8 km/h),the front driveshaft must bedisconnected from the front axle.As an alternative to disconnect-ing the driveshaft, if (he engine isoperable, the engine may bestarted and allowed to idle duringthe towing process. This willcirculate lubricant in the trans-mission, lubricating the clutchesduring the towing operation.Failure to disconnect the drive-shaft or to run the engine willcause internal damage to thetransmission as the vehicle istowed.

The tow bar MS500048 is theonly tow bar to be used on thisvehicle. If not available, seeorganizational maintenance.Failure to follow this procedurecould cause damage to equip-ment.

Be certain correct socket andwedge as supplied are used.Failure to follow this procedurecould cause damage to equip-ment.

CAUTION

Loops formed by overrun cancause kinks and dog legs in thecable, resulting in damage andpremature cable failure.

I CAUTION INever use a steel hammer orpinch bar to move cable over ondrum. These tools can easilydamage cable.

If traveling more than five mileson improved roads or two mileson rough terrain or unimprovedroads, remove anti-two blockweight and chain from the switchand secure it to the anchor pointof the wedge socket locatedeither on the boom head or hookblock, whichever is accessible.Failure to follow this procedurecould cause damage to the hookblock switch.

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TM5-3810-305-10

Safety Decals

Figure 1-10. Safety Decals

1-41

Read and follow all safety decals.Failure to follow this procedurecould cause DEATH or seriousi n j u r y .

TM5-3810-305-10

Minimum Safety Requirements for Work LRT 110 Crane Equipment RequirementsPlatforms Suspended From Load Line or For Use of a Work PlatformRigidly Mounted on Boom

1. The LRT 110 Crane must be in complianceGeneral with PCSA Std. No. 4 and ANSI B30.5-1982.

When use of a work platform isleast hazardous to personnel andis the only practical means ofaccomplishing a task, makecertain all personnel follow theseminimum safety procedures.Read and understand all safetyprecautions listed in this sectionbefore attempting an operationusing a work platform. Allsafety procedures and criteria es-tablished in this section are theMINIMUM requirements for useof a work platform on the LRT110 Crane. Applicable govern-ment and industry standards mustalso be adhered to. Failure tofollow this procedure could causeDEATH or serious injury.

There are two methods for mounting a workplatform on the LRT 110 Crane. The first is tosuspend the work platform from the load line.The second is to rigidly mount the work platformto the boom.

Before attempting any operation using a workplatform, all of the conditions listed here must bemet, including crane equipment and work plat-form requirements and procedures for inspection,rigging, testing and operation.

2. In addition, the following equipment and/orcontrols must be included and functioning onthe LRT 110 Crane:

a. For use of a work platform suspendedfrom a load line:

● An operable anti-two block warningdevice which automatically deactivatesthe control function bringing about thetwo-blocking condition.

● A boom angle indicator.

● Capacity Chart (refer to page 1-19).

● A boom extension indicator,

● A winch drum rotation indicator.

b. For use of a work platform rigidlymounted to the boom:

● A boom angle indicator.

● Capacity Chart (refer to page 1-19).

● A boom extension indicator

● A means to rigidly attach a Koehringsupplied and/or approved workplatform to the boom tip.

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TM5-3810-305-10

LRT 110 Crane Work PlatformRequirements

1. Work platforms suspended from a load lineor rigidly mounted to the boom shall complywith all applicable government and/or indus-try standards relating to design and manufac-ture, including, but nor limited to, ANSIA92.2-1979.

a.

b.

Design considerations for a work platformsuspended from a load line include:

● Material and design safety factors.

● Construction, including fasteners andwelding.

● Flooring.

● Hand rails.

● Toe boards.

● Safety lanyard attachments.

● Gates.

● Hoisting and tag line attachments.

● Load limit, occupant limit and workplatform weight instructions on labelsand warnings.

Design considerations for a work platformrigidly mounted to the boom include:

● Material and design safety factors.

● Construction, including fasteners andwelding.

● Flooring,

●

●

Hand rails.

Toe boards.

Safety lanyard attachments.

Gates.

A means of adjusting and locking thework platform level.

Load limit, occupant limit and workplatform weight instructions on labelsand warnings.

2. Specifications for a work platform must be inwriting and must describe the platformweight, load and occupancy limit, method ofplatforms inspection and maintenance andprocedures for attachment to the LRT 110Crane. The above, plus any appropriate pre-cautionary information applicable to theplatform must be permanently placed either inthe vehicle or on the work platform.

Inspection, Rigging, Testing andOperating a Work Platform for the LRT110 Crane

1. The inspection, operation and safety require-ments for a work platform suspended from aload line or rigidly mounted to the boom mustat all times comply with PCSA Std. No. 4 andall appropriate government regulations.

2. In addition, all of the following limitationsand minimum safety requirements apply:

1-43

TM5-3810-305-10

Never use a work platform ifinspection indicates a structuralor mechanical fault of any kind.Failure to follow this procedurecould cause DEATH or seriousinjury.

a. Inspection: A complete inspection of theLRT 110 Crane and the work platformmust be performed prior to any operation.

Inspection is to be performed daily or eachtime the operator is replaced or the LRT110 Crane is converted from material topersonnel handling.

Inspection must include the boom and allmechanical and rigging equipment vital tothe safety of work platform operation.

Before a work platform suspended from aload line may be used, the followingadditional inspections must be performed:

Inspection of hook and wire rope.

Daily inspection of load line.

The anti-two block device must becalibrated to sound a warning anddeactivate the control function bringingabout the two-blocking conditionwhenever the hook block assembly,platform or fall ball assembly is lessthan 3 ft (914 mm) from the boom tip.

Inspect hook latches on fall ballassemblies and sheave block assembliesmaking certain they close and lock,eliminating hook throat openings andare full-load bearing hook latches with

●

●

●

manual trigger releases. As analternative, shackles with bolts, nutsand retaining pins may be used.

Inspect wire rope ends making certainthey are properly anchored to boom,fall ball, hook blocks and drums (referto page 2-3).

With the boom at maximum elevationand the work platform on the ground orat its lowest operational level, inspectthe hoist drum making certain at leastthree wraps of wire rope remain.

Make certain the minimum safetyfactors for wire rope are adhered to atall times.

Use 7:1 as the minimum safety factor formanufacturer’s specified wire rope and10:1 as the minimum safety factor forrotation resistant rope for the combinedweight of lifting attachments, platform,personnel and tools.

b.

No personnel are permitted onthe work platform during theperformance of any test. Do notallow personnel on work plat-form if any test procedure indi-cates a malfunction in equip-ment. Failure to follow thisprocedure could result inDEATH or serious injury.

Testing: The following daily test proce-dures are to be performed on the LRT 110Crane and the work platform whenever theoperator changes or a significant change inlifting conditions occurs.

1-44

TM5-3810-305-10

To test the work platform and equipment, use thefollowing procedure:

1.

2.

3.

4.

5.

●

Load the work platform with ballast at least 2times the weight of intended load.

●

Acceleration and decelerationmust be smooth and controlled.Failure to follow this procedure

●

could cause damage to equip-ment.

Raise and lower the load at maximum linespeed.

●

Test the control/braking function by bringingthe load to a smooth stop.

The specific operation to be undertaken shall●

be performed in its entirety.

When the test is completed, inspect the workplatform and equipment for any evidence ofdamage or defect.

.All limiting and warning devices shall be acti-vated by each control function which may createa two-blocking condition.

before using a work platform:

Make certain the LRT 110 Crane islevel and stable, with outriggers fullyextended on a solid, level surface.

Make certain the operator isexperienced and in good physical andemotional condition.

Make certain the operator does notleave his station. While the workplatform is in use, the operator is toremain in the vehicle with the enginerunning.

All unauthorized personnel will leavethe LRT 110 Crane working area whilea work platform is in use.

All operations using a work platformmust be planned by the operator alongwith supervisors, signal personnel andpersonnel to be lifted prior to theoperation.

The crane operator must avoid anysharp or sudden movements while awork platform is in use.

No operations with a workplatform are authorized “OnTires,” Always make certainLRT 110 Crane is on a stablesurface with the outriggers fully

or serious injury.

Never use a work platform nearenergized power lines or groundcables. Failure to follow this

the procedure could cause DEATH

extended. Failure to follow this● Always maintain at least twice the

procedure could cause DEATH distance from power lines required byor serious injury. OSHA 29CFR, Part 1910, while a work

platform is in use.c. Operation and safety: Always observe the

following operation and safety procedures

1 -45

TM5-3810-305-10

● Make certain the combined weight ofthe work platform plus any attachmentdevices, personnel, tools and equipmentdoes not exceed 1/2 of the liftingcapacity specified by the CapacityChart (refer to page 1-19).

● Never travel the LRT 110 Crane whilea work platform is occupied.

● Make certain that no more than onecrane function at a time is operatedwhile the work platform is in use.

● Make certain personnel have radio ortelephone communication with thecrane operator at all times while thework platform is in use.

In the event of a communication failure, per-sonnel on the work platform must be returnedto the ground immediately using hand signals,No operations using a work platform are toperformed without functioning communica-tion equipment.

If other cranes or equipment are in the area ofa work platform operation, communicationbetween all machine operators will also bemaintained.

● Make certain work platforms are notused in winds on excess of 10 mph (16km/h), rain, snow, ice, sleet, electricalstorms or other adverse conditions.

● Make certain personnel never stand ontop rail, midrail or toe board of workplatform.

● Make certain personnel keep all partsof the body, tools and other equipmentinside the work platform area duringraising or lowering operations.

● Before positioning a work platform,make certain the vehicle is away fromany overhead obstacles.

● Before a work platform is raised orlowered, make certain all ropes,electrical cords, hoses, etc. are freefrom entanglement.

● After positioning a work platform,make certain all locks are set before anywork is performed.

● When off the ground, make certain thework platform is secured beforepersonnel enter or leave.

When working from a work platform, beltingoff or otherwise attaching a work platform toan adjacent pole, structure or other equipmentshall not be permitted, except when personnelare entering or leaving the work platform.

● Make certain all movement bypersonnel on a work platform is done ina slow and controlled manner.

● Make certain personnel on the workplatform wear safety belts with lanyardsattached to hook or shackle.

● Lifting a work platform is a singlecrane operation. Never use more thanone crane to lift a work platform.

● Never use a work platform to lift anexternal load.

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TM5-3810-305-10

Never allow electrically con-nected electrode holders tocontact metal components of awork platform. Electrode holdercontact can cause burning and/ormelting of work platform suspen-sion which could allow the workplatform to fall. Failure tofollow this procedure could causeDEATH or serious injury,

● If a welding operation is to beperformed, make certain electrodeholders do not contact metalcomponents of the work platform.

● When the work platform is suspendedfrom a load line, a stabilizing tag linemust be attached to the work platformand controlled to minimize any swayingmotion.

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TM5-3810-305-10

CHAPTER 2PREPARATION FOR USE

The purpose of this chapter is to familiarize the operator with the preparation of cable for use.

Title Page

Hoist Line Reeving 2-2Installing Wedge Socket On Cable 2-3Spooling Cable On Drums 2-3Installing Cable On Winch 2-4

2-1

TM5-3810-305-10

Hoist Line Reeving

When reeving the machine in preparation for anyjob, it should be kept in mind that hoisting andlowering speeds decrease as the number of partsof line increases. For most efficient use of theLRT 110 Crane, it is therefore desirable to useminimum required number of parts for lifting.

Never use less than the numberof parts of line called for by theCapacity Chart. Failure to followthis procedure could causeDEATH or serious injury.

To determine the number of parts needed, referto the Capacity Chart, page 1-21.

1.

2.

3.

4.

Remove socket and wedge from cable andthread it through the hook block for 2-partand 3-part reeving (Figure 2-1 ).

When required number of parts has been de-termined, reeve cable as shown.

Attach a wedge-type cable socket to cabledead end and secure it to either the boomhead or hook block as required.

Dead end cable on hook block for an oddnumber of line parts, and on boom peak for aneven number of parts.

The crane has sufficient cable provided to allowhook to reach ground level with any boom lengthand elevation when reeved with minimum partsof line required for the load being lifted.

Figure 2-1. Hoist Line Reeving

2-2

TM5-3810-305-10

Installing Wedge Socket on Cable

CAUTION

Be certain correct socket andwedge as supplied are used.Failure to follow this procedurecould cause damage to equip-ment.

When installing wedge-type sockets on cable,use the following procedure:

1. Lead cable through socket and forma largeloop. Draw cable end back through socketapproximately 2 in. (50.8 mm) (Figure 2-2).

Figure 2-2. Cable Loop

2. Insert wedge and allow cable strands to adjustaround it (Figure 2-3).

Figure 2-3. Inserted Wedge

3. Seat wedge and loop just tightly enough to

4.

5.

Make lifts of gradually increased loads untilwedge is finally seated. Avoid imposingshock loading on cable until wedge is firmlyin place.

With no more than 2 in. (50.8 mm) of cableprotruding, clamp dead end of cable with acable clamp (Figure 2-4).

Figure 2-4. Clamped Cable

Spooling Cable on Drums

Care must be exercised when installing cable onwinch drum. Improper spooling can result incable damage through crushing, kinking, doglegs, abrasion and cutting. Poorly installed cablewill also adversely affect operating characteris-tics of machine by causing uneven application offorce and motion. This, in turn, can cause pre-mature fatiguing and failure of cable.

1. Inspect and clean winch thoroughly beforeproceeding with installation.

2. Check lagging and drum flanges for cracks,breaks and excessive wear.

3. Check for deformed or outsized drum andexcessive undercutting at base of flange.These indicate that repair or replacement ofdrum is necessary.

allow handling by attaching socket to a strongsupport and engaging winch to take a strainon cable.

2-3

TM5-3810-305-10

4.

5.

6.

7.

After correcting any defects revealed by in-spection and determining that the winch is ingood operating condition, spool cable (referto Chapter 4, Section V, Wire Rope Instruc-tions, page 4-28).

Place a pipe or bar through the reel center.

Mount the cable shipping reel with the barhorizontal on jacks or a suitable supportingstructure (Figure 2-5).

Draw the cable from the top of the reel, inorder to avoid reverse bending as it is spooledonto the winch drum.

Figure 2-5. Spooling Cable on Winch Drum

I CAUTION ILoops formed by overrun cancause kinks and dog legs in thecable, resulting in damage andpremature cable failure.

8. Apply braking force to the reel flange toprevent overrun as the cable is being drawnoff.

9. Using a timber or block, apply force againstthe shipping reel flange to provide the re-quired breaking force.

Installing CabIe on Winch

Install cable on winch drum in accordance withthe following procedure:

1.

2.

3.

Position cable over boom tip sheave and routeback to winch drum.

Position winch drum with cable anchor pocketon top.

Insert cable into small opening of cablepocket. Loop cable around clamp and backinto pocket about 3/4 of the way through thepocket. Use cable clamp for 1/2 in. cable(refer to Koehring Commercial Parts Man-ual). Insert small end first. Pull on cable andthe clamp will slip into the pocket, securingthe cable (Figure 2-6).

Figure 2-6. Securing Cable on Winch

4. Rotate the drum slowly to insure that firstlayer of cable is evenly wound onto drum.

2-4

TM5-3810-305-10

5.

6.

Install remainder of cable. Tension cable bybraking shipping reel and slowly operatewinch in the raise mode to wind cable ontowinch drum.

CAUTION

Never use a steel hammer orpinch bar to move cable over ondrum. These tools can easilydamage cable.

Using a lead or brass hammer, tap cable overagainst preceding turns, making sure that ad-jacent turns are tight against one another.

After cable is wound onto winch drum, reevecable as desired.

2-5 (2-6 blank)

TM5-3810-305-10

CHAPTER 3GENERAL THEORY OF OPERATION

The purpose of this chapter is to provide the operator with a general description of the LRT 110 Craneand an overall view of its components and their functions.

Title Page

General Theory of Operation 3-2Transmission Theory of Operation 3-2Axle Theory of Operation 3-2Winch Theory of Operation 3-3

3-1

TM5-3810-305-10

General Theory of Operation

The LRT 110 Crane is a self-contained vehiclefeaturing 7 1/2 ton maximum lifting capacity,optional four-wheel drive, outriggers for addedstability during lifting operations and threedifferent steering modes: front wheel steeringfor normal driving, crab steering for diagonalmoves and four-wheel steering for minimum-radius turns.

Power originates from an in-line, four-cylinder,diesel engine mounted at the rear of the vehicle.The transmission is mounted directly on theengine and is used to turn drive shafts and topower the tandem hydraulic pump. One-half ofthe tandem hydraulic pump supplies hydraulicpressure to the winch, and the other half supplieshydraulic pressure to actuate the boom telescopecylinder, boom hoist cylinder, boom swingmotor, outrigger cylinders, axle lockout cylindersand steering controls, and to provide hydraulicassistance for the brake system.

The boom is a two-section telescope-type with arotating boom support. Two large-diameter,double-acting hydraulic cylinders telescope andhoist the boom assembly. The hydraulic swingmotor and worm gear rotate the upperstructure.The cable and hook block assembly are operatedby the hydraulic winch. The hydraulic andelectrical systems on the upperstructure are con-nected to the rest of the vehicle by the hydraulicrotary manifold and electrical collector ring.

Transmission Theory of Operation

The transmission is capable of four-speed shift-ing in both forward and reverse. Direction andspeed are selected through hydraulically actuatedmultiple-disc clutches. The clutches are powerabsorbing, allowing shifts under full enginepower in both forward and reverse. The clutchesare hydraulically controlled and spring released.Hydraulic control makes the clutches self-adjusting. Each clutch is made of friction platesand polished-steel reaction plates.

The transmission receives power from the enginethrough the torque converter. The torque con-verter is fluid driven, creating a smooth andshock-free drive. Fluid drive also eliminatesengine stalling and lugging when vehicle has aheavy load. With light loads, the torque con-verter is able to transmit engine power directly tothe transmission at most engine speeds with notorque multiplication. This provides variable andautomatic speed ratios, reducing need for shiftinggears.

Axle Theory of Operation

The front and rear axles have remote breathers toallow operation in up to 30 in. (762 mm) ofwater. The rear axle has lockout cylinders toprovide increased stability during hoisting.Steering for each axle is enhanced by dual-actinghydraulic cylinders which are tied together by asingle tie rod which provides smooth, sharp,synchronized turning with minimum alignmentand adjustment requirements. The service brakesare shoe-type hydraulic units, and are part of theaxle. The front axle has a disc brake that can beused either as a parking brake or as an emer-gency brake. Each axle has its own differential.

3-2

TM5-3810-305-10

Winch Theory of Operation

The winch is made up of four basic assemblies:winch base, hydraulic motor and brake valve,brake cylinder and motor support, and drumassembly. The hydraulic motor turns the gears inthe drum assembly, working the cable.

The winch has a dual braking system: a dynamicbrake and a static brake. These two types ofbrakes work together to control the speed of thedrum assembly. The dynamic brake uses hy-draulic pressure to operate the brake valve whichcontrols the flow of hydraulic oil to the hydraulicmotor, The static brake is made of multiple-friction discs, a brake clutch assembly, and ahydraulic piston and cylinder. The static brake isautomatically applied unless it is released bybrake valve pilot pressure at a level lower thanthat required to open the pilot-operated spoolvalve.

Either brake system does not affect the winchduring hoisting operations. When the operator’scontrol is placed in neutral, rollers between thecam and outer race wedge to prevent the drumassembly from turning. The brake valve stops oilflow from the hydraulic motor. For lowering aload slowly, the operator can allow only enoughoil to release the brake without engaging the hy-draulic motor. The heat build-up is dissipated bythe hydraulic oil. For faster lowering, the hy-draulic pressure is increased by the operator toboth release the brake and engage the hydraulicmotor.

3-3 (3-4 blank)

TM5-3810-305-10

CHAPTER 4OPERATING INSTRUCTIONS AND FUNCTIONS

The purpose of this chapter is to familiarize the operator with controls and instruments necessary for theoperation of the LRT 110 Crane. Included also are the Preventive Maintenance Checks and Services(PMCS) and vehicle operating procedures.

Do not attempt to operate the LRT 110 Crane until all operating instruc-

Section

I

II

III

IV

V

tions have been read and understood. Knowledge of controls alone isinadequate preparation to operate this vehicle. Failure to follow thisprocedure could cause DEATH or serious injury.

Title

Use of Operator’s Controls and IndicatorsControls and Instruments

Initial Adjustments and Control SettingsChecks and InspectionsOperator ObservationsCable InspectionPreventive Maintenance Checks and Services (PMCS)Operator Troubleshooting

start-upStarting the Engine

Operation Under Normal ConditionsOperating the EngineBefore Moving the LRT 110 CranePre-Move ChecklistMoving the Vehicle to a Job SiteUpshifting and Downshifting RecommendationsStopping the EngineLift Procedure on OutriggersLift Procedure “On Tires”Hand Signals for LRT 110 Crane Operation

Wire Rope InstructionsWire Rope Identification and ConstructionWire Rope InstallationUnreeling and UncoilingSeizing Wire RopeCutting Wire RopeEnd Fittings and/or AttachmentsSocketingWire Rope ClipsU-Bolt ClipsFist Grip Clips

Page

4-3

4-104-114-124-134-15

4-17

4-184-184-184-184-204-204-204-254-27

4-284-304-314-344-354-354-364-374-384-39

4-1

TM5-3810-305-10

Section Title

Wedge SocketsDrums, Plain (Smooth)Flexibility of Wire RopeBreaking in a New Wire RopeWire Rope and Operation InspectionGuideline to Inspections and Reports for Equipment,

Wire Rope and Wire Rope SlingsWire Rope InspectionIllustrated Examples of Possible Wire Rope DamageRope Inspection SummaryEquipment InspectionCable Lubrication

VI Operation Under Emergency and Abnormal ConditionsEmergency Load Lowering ProcedureUnusual Operating Conditions

VII ShutdownVehicle Shutdown Procedures

VIII TransportabilityLand TransportAir TransportRail TransportMarine Transportation

Page

4-404-424-424-434-43

4-444-454-514-544-554-55

4-564-64

4-71

4-724-744-754-76

4-2

TM5-3810-305-10

Section IUse of Operator’s Controls and Indicators

Figure 4-1. Control and Instrument Identification.

The controls and instruments are illustrated from operator’s view point with the machine in travel posi-tion.

4-3

TM5-3810-305-10

Controls and Instruments

1. Tachometer/Hour Meter indicates enginerpm (normal idle 800 rpm; governed 2,950 rpm)and operating hours of engine (Figure 4-2).

2. Dash Lights illuminate dash panel and sidesloping dash panel (Figure 4-3).

3. Rear Axle Centering Indicator light is offwhen axle is centered with wheels parallel to lineof travel for two-wheel steering. Light is onwhen wheels are off center. When light is off,switch to two-wheel steering (Figure 4-2).

4. Horn is activated when pushed, and is deacti-vated when blackout lighting is used.

5. Engine Water Temperature Gauge indicatesengine coolant temperature (temperature range is140 to 220 degrees F [60 to 104 degrees C];approximately 190 degrees F [88 degrees C] isnormal operating temperature).

6. Engine Oil Pressure Gauge indicates engineoil pressure (idle of 10 psi [69 kpa] minimum togoverned speed no load of 55 psi [379 kPa]; coldoil may read 90 psi [621 kPa]).

7. Fuel Gauge indicates amount of fuel in fueltank.

Figure 4-3. Slide Sloping Dash Panel

8. Cold Start is recommended for ambient tem-peratures below 32 degrees F (O degrees C ) andrequired at 10 degrees F (-12 degrees C) andbelow.

9. Transmission Temperature Gauge indicatesoil temperature out of convertor (normal range is160 to 190 degrees F [71 to 88 degrees C]; cooldown is required above 250 degrees F[121degrees C]).

10. Voltmeter indicates battery condition (24volts is normal indication).

4-4

Figure 4-2. Dash Panel

TM5-3810-305-10

11. Ignition Switch turns electrical circuits ONand OFF, and stops engine in the OFF position(Figure 4-3).

NOTE

Starter will not activate unlesstransmission is in neutral.

12. Starter Button starts engine.

13. Windshield Wiper Switch has three posi-tions: OFF, LO, and HI.

14. Work Light Switch turns three flood lightson and off, and is deactivated when blackoutlighting is used.

15. Vehicle Light Switch provides on/off opera-tion of service drive lights, stop lights, blackoutmarker and blackout drive lights.

16. Dash Light Switch turns dash panel andinstrument lights on.

17. Outrigger Switch (Front) activates valvefor independent operation of front left or rightoutriggers.

18. Outrigger Switch (Rear) activates valve forindependent operation of rear left or right outrig-gers.

19. Steering Selector has three positions: four-wheel is full clockwise position, two-wheel iscenter position, and crab is full counterclockwiseposition. Switch to crab or four-wheel steeringonly when axles are centered (axle center indica-tor light is out), or steering will be limited andmay be locked (Figure 4-4). If wheels shouldbecome locked, switch to two-wheel steering,

Figure 4-3. Side Sloping Dash Panel

turn front wheels, switch back to crab or four- 21. Swing Lever contols rotation of upperstruc -wheel steering and center rear wheels. ture: push to swing right; pull to swing left.

20. Outrigger Control Lever raises or lowersWhen the upperstructure is 5 degrees off front

outrigger beams. Each beam operates independ-center, rear axle pivot cylinders are locked into

ently with control switches: pull to raise; push toposition to maintain stability for crane work

lower (Figure 4-5).(Figure 4-6).

4-5

Figure 4-6. Swing Lever

Figure 4-5. Outtrigger Lever

Figure 4-4. Steering Selector

TM5-3810-305-10

CAUTION

Do not make directional changesbetween forward and reversewhile vehicle is in motion.Failure to follow this procedurecould cause damage to equip-ment.

22. Forward-Neutral-Reverse Shift Leverselects direction of travel. Must always be inneutral when starting engine and making cranelifts (Figure 4-7),

23. Transmission Speed Shift Lever has fourtransmission speeds from 1 thru 4 in eitherforward or reverse travel. Start travel in 1st gear.

Figure 4-7. Right Hand

24. Two Wheel-Four Wheel Drive Shift Leverselects drive mode: two-wheel drive for hard-surface travel and four-wheel drive for off-roaduse. It may be necessary to creep to get gears toalign.

25. Bubble Level indicates if vehicle is levelprior to making a lift (level is with bubble incenter of circle).

26. Circuit Breakers protect electrical circuitsduring minor electrical malfunctions. Circuitbreakers must be reset if tripped.

27. Boom Hoist Lever raises or lowers boom:pull to raise boom; push to lower boom (Figure4-8).

28. Boom Telescope Lever extends or retractsboom: push to extend boom; pull to retract boom(Figure 4-9).

Figure 4-8. Boom Hoist Le erv Figure 4-9. Boom Telescope

29. Winch Lever lowers or raises load: push tolower load; pull to raise load (Figure 4- 10).

Figure 4-10. Winch Lever

4 - 6

TM5-3810-305-10

30. Turn Signal Lever activates right- or left-hand turn signals, plus emergency flashers, and isdeactivated when blackout lights are on (Figure4-11).

Figure 4-11. Turn Signal Lever

31. Anti-Two Block Panel is equipped with anaudio/visual anti-two block warning system de-signed to alert operator of impending two-blockconditions (i.e., the hook or hook block is beingdrawn into boom point sheaves). The vehicle isequipped with a shut-off disconnect system onthe control linkage. It is activated when the hookblock contacts the anti-two block counterweight:winch hoisting will cease, and boom will notextend or lower; raising and retracting boom andwinch down functions will remain active. Ap-propriate counteraction should be taken to pre-vent two-blocking (Figure 4-12).

Figure 4-12. Anti-two Block Panel

Anti-Two Block Warning Light is a visualwarning light to indicate approaching two-blockcondition.

Anti-Two Block Audible Horn WarningSwitch is used to deactivate the audible warningsystem while traveling.

Unwarranted use of BY-PASSswitch can result in damage tothe LRT 110 Crane and causeDEATH or serious injury.

Anti-Two Block BY-PASS Switch allows anoperator to override the anti-two block system.This then allows hook or block to be drawncloser to boom point. It is recommended that theBY-PASS switch be used only in cases of ex-treme emergency. The operator must exercisesound judgment.

32. Diagnostic Connector Panel is located inrear of operator’s cab to plug in Vehicle TestModule (VTM) to run STE/ICE tests. Fuel shut-off switch is part of STE/ICE system and alwaysremains on unless it is used for STE/ICE tests(Figure 4-13). Panel also has lubrication fittingfor turntable bearing. For lubrication instructions,refer to Appendix B.

Figure 4-13. Diagnostic Connector Panel

4 - 7

TM 5-3810-305-10

33. Speedometer indicates travel speed in mphand km/h. An audible warning will sound at 25mph (40 km/h) (Figure 4-14).

33

Figure 4-14. Speedome ert

34. Accelerator Pedal increases fuel flow andengine speed (Figure 4-1 ).

C A U T I O N

Do not attempt to move thevehicle with the parking brakeengaged. Failure to follow thisprocedure could cause damage toequipment.

35. Parking Brake Lever activates parkingbrake: push down to engage parking brake; pullup to release. Always engage parking brakebefore leaving vehicle. Minor adjustments maybe made by turning the knob on the end of theparking brake lever clockwise to tighten thebrake. When the parking brake is properlyadjusted the crane cannot drive through it in thirdgear.

36. Brake Pedal activates hydraulic servicebrakes.

37. Heater Switch turns fan ON or OFF and islocated on top of heater behind operator’s seat.

38. Seat Adjust Lever adjusts seat front to rearand is located under left-hand comer of seat.

39. Heater Shut-Off Valve shuts off flow ofheated coolant and is located below the left sideof heater, behind operator’s seat.

40. Boom Angle Indicator indicates angle ofboom from 0 thru 75 degrees elevation, in 1-degree increments.

41. Fire Extinguisher is located on left-handside of cab on rear wall for emergency fires.

42. Defroster Fan is mounted on upper rightcomer of cab and is controlled by ON-OFFswitch on mounting base.

4-8

TM5-3810-305-10

43, Boom Length Markers are located on sideof boom and are used to indicate boom length.

44. Capacity Chart is located in cab on left-hand side and is used to determine proper liftcapacity.

45. Steering Wheel controls direction of vehicle.

Figure 4-1. Control and Instrument Identification

4 - 9

TM5-3810-305-10

Section IIInitial Adjustments and Control Settings

Checks and lnspections

The following items should be checked each daybefore start-up and start of operations. Check allfluid levels with vehicle parked on level ground.

Cooling system is pressurized.Use extreme caution and properprotection when removingradiator cap after operatingtemperature is reached. Whenremoving cap, loosen it slowly tothe left, then pause a moment.Steam and hot gases will beescaping through the radiatorcap; avoid being burned by thesegases. Continue to turn cap untilit can be removed. Failure tofollow this procedure could causeSERIOUS INJURY.

Coolant - Check to be sure level is near top ofradiator tank. Check through inspection hole inhood.

General Condition - Inspect vehicle in generalfor wear, leakage and damage.

Leakage - Make a ground checkvehicle for signs of leaks.

CAUTION

below the

Never operate engine with oillevel below the ADD 1 QT markor above the FULL mark. Fail-ure to follow this procedurecould cause damage to equip-ment.

Engine Oil - The level should be indicated onthe dipstick (Figure 4-15). Oil level should bechecked when engine is cold.

Transmission Oil - Check transmission oil leveldipstick with engine running and transmission inneutral. Check at a transmission operatingtemperature of 160 to 190 degreesF(71 to 88degrees C). Insure that oil is at FULL lineindicated on dipstick.

Hydraulic System - Check hoses, tubes, compo-nents, reservoir dipstick, valves, pumps, motors,connections, cylinder mounting bushings andpins. The system level, with all cylinders re-tracted in travel mode, should be at FULL markon dipstick located on reservoir fill cap.

Lubrication - Perform daily lubrications asshown in lubrication chart (refer to Appendix B).

Diesel fuel and other combustiblematerials are used in the opera-tion and maintenance of thisequipment. Do not smoke orallow open flames in areas wherecombustible materials are storedor used. Failure to follow thisprocedure could cause DEATHor serious injury.

Fuel/Water Separator - Drain water from fuel/water separator, mounted on outer fuel filter.

Fuel - Check fuel gauge. Engine fuel should beadequate for sustained operations. When addingfuel use ASTM NO. 2 or 2D climatized DieselFuel.

FULL

Figure 4-15. Engine, Oil Level

4-10

TM5-3810-305-10

Air Cleaner - With engine running, check aircleaner restriction indicator located on outside ofhood support assembly (yellow is normal; redrequires service). Reset indicator each time hoodis opened by pushing the button on the bottom ofthe indicator. If it does not reset, notify mainte-nance.

Tires - Check for proper pressure before travel-ing. Tires should only be checked when cold(refer to Recommended Tire Pressure Chart,page 1-20). Check for severe cuts and foreignobjects imbedded in tread.

Cable and Blocks - Inspect hoist cable, hoistblock, hook latch and boom attachment forreadiness.

Boom Head - Inspect cable retention pins andhair pin totters at boom head for correct installa-tion.

CAUTION

Keep tension on cable to preventdamage from slack.

Cable - Reeve hoist cable as required.

Anti-Two Block System - Inspect anti-twoblock switch found on boom head for damage.Check for free movement of the counterweightattached to switch. Be sure counterweight issecured around correct line of hoisting cable inproper manner. Inspect all electrical connectionsand wires as well as the entire length of cable at-tached to the cable reel and its connections forevidence of excessive wear, damage or improperinstallation. Check cable reel for proper tensionand to insure that reel is free to rotate. Verifyvisual and audible warning devices operation bylifting counterweight.

CAUTION

If disconnects malfunction andhook block is drawn into theboom point, vehicle may bedamaged. Care should be takenwhen performing disconnect test.

NOTE

A warning light will appear onanti-two block panel and anaudible signal will be heard ifhorn switch is in ON position,

The LRT 110 Crane is equipped with disconnectson control linkage. A check of this systemshould be made prior to lifting. Hoist hook blockso that actual contact between block and anti-twoblock counterweight is made. If all functions areoperating properly, winch hoisting will cease andboom will not extend or lower. Should any ofthese functions continue, disconnects are notworking and a complete system check must bemade. Boom retract, boom raise and winchdown functions remain active and will be unaf-fected by anti-two block system.

Brake Fluid - Check reservoirs on front of dash.Fill to FULL line on reservoirs.

Safety Equipment - Check safety equipment,including tall lights, parking brake, hazard warn-ing devices and fire extinguisher.

Operator Observations

As the operator, it is your responsibility toobserve and report any unusual sounds, odors orother signs of abnormal performance that couldindicate trouble ahead. On a routine basis,during the days operations the following itemsshould be checked.

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TM5-3810-305-10

1. Visual inspection - Check complete vehiclefor any unusual condition.

2. Check for any leaks or damage to the hydrau-lic system.

3. Check engine compartment for:

● Tension and wear of belt.● Oil level.● Air cleaner restriction indicator.● Air intake piping condition.● Muffler and exhaust pipe condition.

4. Check dash gauges for proper operation.

5. Check hydraulic reservoir dipstick level.

6. Check crane boom for:

● Wear or damage to hook block.● Wear on cable retention pin at boom head.● Proper function of anti-two block system.● Proper cable spooling on winch.● Wear of cylinder pin connections.

7. Check tires, axles and drive lines for wear ordamage.

8. Check cab for:

●

●

●

●

●

●

Properly functioning instruments.Properly operating controls.Clean windows.Properly functioning safety equipment<

Properly working lights.Cleanliness - free of mud and debris.

Time Intervals - Unusual Conditions

The LRT 110 Crane will require extra serviceand care when operated under unusual condi-tions, High or low temperatures, long periods ofhard use and continued use in sand, water, mudor snow will break down lubricants. Add orchange lubricant more often under these condi-tions. However, during long periods when theLRT 110 Crane is not in use, the service intervalscan be lengthened.

CabIe lnspection

All cable in active service should be inspectedDAILY along with spooling, sheaves, wedgesockets and any other cable fittings for damage.A thorough cable inspection should be madeWEEKLY by a competent inspector.

Refer to Section V, Wire Rope Instructions, page4-28, for guidelines covering inspection, mainte-nance, repair and replacement of cable.

Incorrect cable type or size willnot function properly and may bedangerous when used. Failure tofollow this procedure could causeDEATH or serious injury.

Before installing a new or replacement cable,make certain cable is of the correct type and size.

Cable Specifications

The LRT 110 Crane is equipped with 180 ft(54.86 m) of 1/2 in. diameter 6x19 IWRC IPScable.

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TM5-3810-305-10

Preventive Maintenance Checks andServices (PMC)

The following Preventive Maintenance Checksand Semites (PMCS) should be followed regu-larly to maintain the LRT 110 Crane at peakoperating condition. Perform PMCS more oftento compensate for continuous operation or underabnormal conditions (i.e., extreme cold or heat;exposure to moisture or salt; operation in dust orsand).

Daily Check or Every 8 Hours of Service

Check hydraulic reservoir fluid level (refer tolubrication chart, Appendix B, and page 4-10).

Fill fuel tank (refer to page 4-10).

Check engine oil level (refer to page 4-10).

Check coolant level (refer to page 4-10).

Check air cleaner (refer to page 4-11).

Check hydraulic components.

Make overall visual inspection, includingground, for leakage.

Check brake fluid (refer to page 4-11).

Verify that tires are inflated properly (refer topage 1-20).

Check for dirt accumulation in outrigger box.

Drain fuel/water separator (refer to page 4-10).

CAUTION

If any gauge fails to operate, shutengine off and notify mainte-nance. Failure to follow thisprocedure could cause damage toequipment.

Check instruments, gauges and safety equipmentusing the following procedure :

1.

2.

3.

4.

Start engine. Check to see if all gauges areoperational.

Check all lights, warning horns, mirrors andturn signals.

Check all controls for proper operation. Con-trols should move smoothly, without bindingor excessive free play.

Check transmission oil level (refer to page 4-10).

Check anti-two block system (refer to page 4-11).

Check cable and related equipment (refer to page4-11).

Lubricate rear axle pivot and axle lockout cylin-ders. Raise crane on outriggers before greasing(refer to lubrication chart, Appendix B).

Lubricate turntable gear and pinion gear teeth(refer to lubrication chart, Appendix B).

Weekly Check or Every 40 Hours of Service

Perform the Daily Check.

Perform Daily and Weekly lubrication (refer tolubrication chart, Appendix B).

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TM5-3810-305-10

Check battery condition:

● Battery gases can explode. Donot smoke or allow sparks oropen flames near batteries.Wear safety glasses or goggleswhen checking the batteries.Failure to follow this procedurecould cause DEATH or seriousinjury.

● Sulfuric acid contained inbatteries can cause seriousburns. If battery corrosion orelectrolyte makes contact, takeimmediate action to stop theburning effects:

EYES: Flush with cold water forno less than 15 minutes and seekmedical attention immediately.

SKIN: Flush with large amountsof cold water until all acid isremoved. Seek medical attentionas required.

INTERNAL: If corrosion orelectrolyte is ingested, drinklarge amounts of water or milk.Follow with milk of magnesia,beaten egg or vegetable oil. Seekmedical attention immediately.

CLOTHING/EQUIPMENT:Wash area with large amounts ofcold water. Neutralize acid withbaking soda or household ammo-nia.

Failure to follow this procedurecould cause DEATH or seriousinjury,

1.

2.

3.

Check electrolyte level. Fill battery cells to0.75 in. (19. 1 mm) above the separator plateswith distilled water.

Check battery box. It should be clean and drywith no signs of leakage from batteries.

Check cables. Corroded cables must becleaned, tightened and coated with grease.Batteries should be clean and free of damage.

Check tire condition (refer to page 4-11).

Visually inspect the LRT 110 Crane. Inspectstructural members and welds for cracks, align-ment and wear.

Visually inspect hook block. Inspect hook blockfor damage and wear to sheaves and tubes.

Check hydraulic cylinders and rods. Inspectcylinders for damage and leaks. Inspect rods fornicks, burrs and scratches.

Lubricate control disconnects (refer to lubric-ation chart, Appendix B).

Lubricate sheaves Type II (refer to lubricationchart, Appendix B).

Two Week Check or Every 80-100 Hours ofService

Perform Daily and Weekly Checks.

Perform Daily, Weekly and Two Week lubrica-tion (refer to lubrication chart, Appendix B).

Verify that wheel nuts have been torqued to 450to 500 lb-ft (610 to 678 N ● m).

Check engine belt. Visually inspect belt forglazing, cracks and fraying.

4 - 1 4

TM5-3810-305-10

Visually check the condition of the hydraulic oil. Periodic testing of oil is the safest, most accurateThickening of oil or a change in its appearance, method of determining the condition of the oil.such as darkening, may serve as an indicator of An oil sample may be taken through the fittingwhen an oil change is needed. on inlet end of the reservoir return filter. Obtain

hydraulic oil sample for analysis every 100 hoursClean radiator exterior. Wash radiator with soap of service.and water to remove dirt and foreign materialfrom fins of radiator.

Operator Troubleshooting

1. Engine Does Not Crank

Problem

a. Ignition switch OFFb. Transmission shift not in neutralc. Loose battery cablesd. Low battery voltage

2. Engine Cranks But Does Not Start

Problem

a. Out of fuel

b. STE/ICE fuel switch OFFc. Temperature below 32 degrees F (O degrees C)d. No fuel at engine

3. Electrical Circuit Non-Functional

Problem

a. Turn ONb. Shift into neutralc. Refer to maintenanced. Refer to maintenance

a. Check guage and fill tank (refer to page4-l0)

b. Turn ONc. Use cold start assistd. Check fuel solenoid wire connection. If

loose refer to maintenance

Remedy

a. circuit breaker trippedb. Lights will not come onc. Low battery voltage (below 22 V)

d. High battery voltage (above 29.5 V)

a. Check and resetb. Check for blackout mode and correctc. Increase engine speed and observe

voltmeter. If no response, refer to main-tenance

d. Refer to maintenance

4-15

R e m e d y

Remedy

TM5-3810-305-10

4. Engine Overheating

Problem

a. Low coolant level

b. Broken fan beltc. Radiator fins plugged

5. Engine Oil Pressure

Problem

a. Low (below 10 psi [69 kPa])

b. High (above 90 psi [621 kpa])

6. Transmission Overheating

Problem

a. Too high a gear ratiob. Low oil level (oil below FULL line)c. High oil level (oil above FULL line)

a. Cool down and check radiator (refer topage 4-10)

b. Refer to maintenancec. Stop engine, check and clean

Remedy

a. Stop engine, check and add oil (refer topage 4-10)

b. Stop and refer to maintenance

Remedy

a. Stop, cool down and change gearsb. Check and refer to maintenancec. Stop and refer to maintenance

7. Control Lever(s) Inoperative or Erratic

Problem Remedy

a. Low hydraulic oil level a. Add hydraulic oil as required (refer topage 4-10)

b. Anti-two block system malfunction b. Refer to maintenancec. Lever or linkage damaged c. Refer to maintenance

8. Boom Hoist or Extend Cylinders Inoperative or Erratic

a. Low hydraulic oil level a. Add hydraulic oil as required (refer topage 4-10)

b. Load is too heavy b. Consult Capacity Chart for maximumloads and reduce as required

c. Anti-two block system malfunction c. Refer to maintenance

4-16

Remedy

P r o b l e m Remedy

TM5-3810-305-10

Section IllStart-Up

Starting the Engine Once the Checks, Inspections and Observationshave been completed, the engine maybe started.

Exhaust gases can producesymptoms of headache, dizzinessand loss of muscular control.DEATH, permanent brain dam-age or other serious injury maybe caused by exhaust gases.

If exhaust gases or exposuresymptoms are observed, ventilatethe area immediately and treataffected personnel:

● Administer artificialrespiration, if required.

● Expose affected personnel tofresh air.

● Keep affected personnel warm.

● Do not permit physicalexertion.

● Refer to FM21-11, First AidFor Soldiers for a more detaileddescription of treatmentprocedures.

1.

2.

3.

4.

5.

6.

7.

Make sure parking brake is on.

Move transmission shift lever to the neutralposition.

Set throttle to one-half speed.

Turn ignition switch to the ON position.

I CAUTION IDo not engage starter motor formore than 30 seconds at a time.Should engine fail to start within30 seconds, allow starter motorto cool for 2 minutes beforeattempting to start engine again.Failure to follow this procedurecould cause damage to equip-ment.

Push starter button to start engine. Releasestarter button as soon as engine starts. Ifengine stalls during start-up procedure, allowengine to stop revolving before re-engagingstarter.

Move throttle back to idle as soon as enginestarts. Idle speed range is 720 to 880 rpm.

With engine running, check oil pressuregauge. If gauge does not register minimumreadings of 10 psi (69 kpa) idle to 30 psi (207kPa) governed speed, no load, within 15 sec-onds, stop engine and refer to maintenance.

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Section IVOperation Under Normal Conditions

Operating the Engine

When engine reaches operating temperature of140 degrees F (60 degrees C), operations maybegin. While engine is running, check gauges atfrequent intervals and be alert for any abnormalengine sounds or faulty engine performance.

NOTE

Maintaining battery in a fullycharged state is important forstarting engine.

When idling engine for extended periods, main-tain an idle speed sufficient to prevent batteryfrom being discharged, a voltmeter reading of26+ V.

Before Moving the LRT 110 Crane

CAUTIONIf traveling more than 5 miles onimproved roads or 2 miles onrough terrain or unimprovedroads, remove anti-two blockweight and chain from the switchand secure it to the anchor pointof the wedge socket locatedeither on the boom head or hookblock, whichever is accessible.Failure to follow this procedurecould cause damage to the hookblock switch.

The LRT 110 Crane is capable of both off-roadand on-road travel. The kind of travel under-taken will determine how carrier is operated.Before moving the LRT 110 Crane around worksite or between sites, carefully consider type of

terrain, road conditions and any hazards likely tobe encountered enroute. Think the move throughin advance and carry it out safely.

Pre-Move Check List

Before moving vehicle to and from job sites,complete the following steps:

1.

2.

3.

4.

Secure hook block to hook block tieback.

Verify that tires are inflated properly (refer toRecommended Tire Pressure Chart, page 1-20).

Check to be sure rear wheels are centered,then switch to two-wheel steer.

Adjust seat and mirrors for clear vision.

Moving the Vehicle to a Job Site

The general procedure for moving the LRT 110Crane is as follows:

1.

2.

3.

4.

Buckle seat belt.

Start engine.

Check to be sure engine oil pressure is innormal operating range (30 psi [207 kPa]engine idling to 55 psi [380 kPa] governed noload).

Shift into two-wheel drive, 1st gear. This isrecommended for normal travel conditions.

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TM5-3810-305-10

Do not attempt to move thevehicle with the parking brakeengaged. Failure to follow thisprocedure could cause damage toequipment.

5. Release parking brake.

6. Shift into forward travel.

Good judgment in selection of gear range androute of travel is essential when operating off-road.

Though designed primarily for use in off-roadconditions, there may be instances when highwaytravel is necessary. In such instances, the LRT110 Crane is subject to the same regulationsgoverning the operation of other heavy equip-ment on public roads. Adequate lighting, flares,flags and safety equipment must be on the ve-hicle at all times.

7.

When operating on hard surfaces,use two-wheel drive only. Fail-ure to do so may result in severedrive line “wind-up” and compo-nent failure.

Accelerate engine by depressing acceleratorpedal until LRT 110 Crane starts to move.

CAUTION

Speed is not to exceed 25 mph(40 km/h). Failure to follow thisprocedure could cause damage toequipment.

The operator may start to travel from idle ineither forward or reverse, and in 1st gear.

In addition to conditions of terrain, gear selectionwhile traveling is also determined by transmis-sion temperature. Normal operating temperatureis 160 to 190 degrees F (71 to 88 degrees C).

CAUTION

Traveling with high transmissiontemperature (above 250 degreesF [121 degrees C]) can causedamage to vehicle. Do not shutengine off when transmission isoverheating.

If transmission temperature rises above 250degrees F (121 degrees C) while traveling, theLRT 110 Crane must be stopped and allowed tocool. Shift to neutral and run engine at 1,000 to1,200 rpm. The temperature should drop rapidlyto 160 to 190 degrees F(71 to 88 degrees C). Iftemperature does not drop, trouble is indicated,and should be determined before moving again.Overheating generally occurs due to working intoo high a gear ratio.

●

●

Never shift between forwardand reverse while the LRT 110Crane is in motion. Failure tofollow this procedure couldcause damage to equipment.

Downshifts should not bemade when vehicle speedexceeds maximum speed ofnext lower range.Downshifting at excessivespeeds will overspeed drivetrain components and causedamage to drive shafts.

Full power shifts under load may be made with-out endangering transmission or drive traincomponents.

4-19

CAUTION

C A U T I O N CAUTION

TM5-3810-305-10

CAUTION

Do not operate for extendedperiods with wide-open throttleat speeds below minimumsshown. Failure to follow thisprocedure could cause damage toequipment.

Upshifting and DownshiftingRecommendations

Shift from:

1 to 2 or from 2 to 1 at 2-3 mph (3-5 km/h)2 to 3 or from 3 to 2 at 3-6 mph (5-10 km/h)3 to40 or from 4 to 3 at 6-11 mph (10-18 km/h)

Use four-wheel drive only when greater tractionis necessary.

Four-wheel drive engagement is accomplishedby a mechanical coupling in transmission. Itmay be necessary to creep to get gears to align.

CAUTION

1.

2.

3.

4.

5.

6.

Put transmission in neutral.

Engage parking brake.

Turn off accessories.

Reduce engine speed.

Turn ignition switch OFF.

CAUTION

A dirty cab can result in damageto instruments and controls.

Keep cab clean.

Lift procedure on Outriggers

Never allow boom or load toswing into power lines. If thecrane must be operated in the vi-cinity of power lines, followthese safety precautions:

Under emergency or extremetraveling circumstances, it ispossible to stop the LRT 110Crane with the parking brake.However, this results in rapidbrake wear. After stopping 3 or4 times by this method, parkingbrake adjustment should bemade. Failure to follow thisprocedure could cause damage toequipment.

Stopping the Engine

Before stopping the engine, perform the follow-ing steps:

●

●

●

Contact the power companyand have all power lines andground wires turned off.

Never allow any portion of theequipment, including cable,hook block, lines and load,closer to power lines than thedistances shown on theElectrical Warning (Danger)Decal.

Know the maximum heightand reach of the crane and erecta suitable barricade around allpower sources.

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TM5-3810-305-10

● Warn all personnel in the workarea of the power source andelectrocution hazard.

● If contact with a power sourcedoes occur, DO NOT STEPOFF THE CRANE. Stay onthe vehicle until the power isturned off or the equipment islowered and clear of the powersource.

● If fire or other conditions forcethe operator to leave the crane,jump off and away, keeping allparts of the body clear of theequipment.

Failure to follow these proce-dures could cause DEATH orserious injury.

Keep all parts of body and toolsaway from moving cable. Fail-ure to follow this procedurecould cause DEATH or seriousinjury.

In making lifts, the operator must successfullycoordinate several functions. These include theboom raise/lower, boom extend/retract, loadhoist/flower and swing functions. Althoughexperienced operator tends to operate two ormore of these functions simultaneously, the liftprocedure can be broken down into the followingsequence of operations:

1.

The operator must exercisesound judgment in positioningoutriggers. The outriggersshould not be set near holes, onrocky ground or on extremelysoft ground. Setting outriggersin such locations may result invehicle tipping, causingDEATH or serious injury.

The LRT 110 Crane must belevel prior to extending boomor lifting loads. To achieve thiscondition, outriggers should beextended to lift carrier wheelsoff the ground. Use bubblelevel next to the operator’s seatto insure that vehicle is level.The bubble must be centered incircle. Failure to follow thisprocedure could cause DEATHor serious injury.

Set outriggers with boom over front of ve-hicle, not side. When a firm footing or levelground is not otherwise available, use sub-stantial timbers, solid blocking or otherstructural members for support. Distributeload so as not to exceed safe bearing capacityof underlying material and to enable levelingof the LRT 110 Crane.

While operating the LRT 110 Crane, frequentlycheck and level the crane. Proper positioning iscritically important to both safety and effective-ness of craning operations.

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TM5-3810-305-10

● Hook latch is intended to retainloose slings or devices underslack conditions. It is notintended to be an anti-foulingdevice. Caution should be usedto prevent the latch fromsupporting any of the load.Periodic inspection of latchmust be made to insure itsproper operating condition.Failure to follow this procedurecould cause DEATH or seriousinjury.

● Make certain slings, ties andhooks are of sufficientcapacity, properly set andsecure before performing anylift operation. Failure to followthis procedure could causeDEATH or serious injury.

I CAUTION IWhen removing hook block fromstorage bracket, pay out cablewhile raising boom to preventdamage to windshield.

Raise boom to a 50-degree elevation, keepinghook block in vertical position. Unhook hookblock from storage bracket. Lower boom tohorizontal position while raising hook block.Before making a LRT 110 Crane lift, be surehook is properly engaged with slings. The liftingdevice should be employed to make lift. Becertain hook latch is not supporting any of theload (refer to the warning decal on the hookblock).

An operator must be guided bythe Capacity Chart mounted onvehicle when considering loadweights. Rated loads must neverbe exceeded. Failure to followthis procedure could causeDEATH or serious injury.

2. Use the Capacity Chart attached to the LRT110 Crane to interpret conditions and limita-tions that exist when making a lift. The deter-mining factors are lifted load, radius, boomangle, working position and hoist linereeving.

Use load ratings from the Capacity Chart at-tached to the LRT 110 Crane when making alllifting calculations.

The intent of the followinginformation is to prevent anypossibility of either reversewinding of the rope on the winchdrum, causing breakage of winchcable, or the unseating of cablefrom winch drum, resulting inuncontrolled fall of the hookblock and load. Failure to followthis procedure could causeDEATH or serious injury.

Always consider, anticipate and/or determine bytrial, the maximum amount of cable that will bepayed off the winch drum to perform eachdifferent craning application of this vehicle.Provide for no less than three wraps of cableremaining on winch drum, as specified in allapplicable crane operating safety standards.

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TM5-3810-305-10

The increased possibility of inadequate wrapsremaining on winch drum occurs when operatingwith a higher number of line parts than arerequired for load being lifted, particularly atlonger boom lengths and high boom angles.

Sufficient cable is initially provided to allow thehook block to reach ground level when reevedfor the required parts of line indicated on theCapacity Chart for all given loads. Reeving withmore parts of line than required may result in allof the cable being payed off the winch drum.

CAUTIONKeep tension on cable to preventdamage from slack.

3. Raise boom to required angle, consulting theboom angle indicator for the boom angle.

The boom elevation is controlled by a hand lever.To LOWER boom, push lever forward. ToRAISE boom, pull lever back. Improved controlis obtained by operating engine at low speedwhile “metering” controls. Always operate andrelease controls slowly to minimize dynamiceffects of load. During a lift, where precisecontrol of load is required, do not attempt to usemore than one function at a time.

● Always use a qualifiedsignalman and observe loadwhile the equipment is inoperation.

● When spotting a load, it maybecome necessary to alter theboom angle or length. Ifadjustment is necessary,consult the LRT 110 CapacityChart before performing a lift.Failure to follow this procedurecould cause DEATH or seriousinjury.

CAUTIONAlways consider possible ob-structions which may be encoun-tered during swings when vary-ing boom height or length.Think swing through, consider-ing all obstacles, before makingswing. Failure to follow thisprocedure could cause damage toequipment.

When lifting with the LRT 110 Crane, a signal-man must always be used to direct the operation.Limited visibility to the rear is caused by upper-structure being in the operator’s line of vision.

I CAUTION INever hold controls in an “acti-vated’ position once hoist/lowercylinder or extend/retract cylin-der has reached its limit of travel.This can cause overheating ofhydraulic oil.

4. Swing boom over load. Upperstructure andboom swing is controlled by swing lever. Toswing boom to the RIGHT, push lever for-ward. To swing boom to LEFT, pull leverback. Swing speed increases as lever ismoved further forward or back. Swing speedalso varies with engine speed.

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TM5-3810-305-10

Never lift and swing a loaddirectly over operator’s compart-ment or over ground personnel inthe work area. Failure to followthis procedure could causeDEATH or serious injury.

CAUTION

ALWAYS START AND STOPSWINGS GRADUALLY.Stopping swing too abruptlycause load to oscillate andimpose side loads on boom.will cause damage to boom.

will

This

When ready, try for a smooth, controlled, safeswing. The swing should be SLOW. StartSLOWLY and allow load to buildup just enoughmomentum to carry it through to the point whereit is to be lowered. Begin slowing swing inadvance of point where load is to be lowered.Slow swing GRADUALLY, enabling it to“coast” to a stop over desired spot.

If properly executed, load will hang motionlesswhen swing is terminated. If load is oscillating,swing was made too rapidly and/or stopped tooabruptly.

5. . Extend boom to desired length (refer to theCapacity Chart). EXTEND boom by pushingextend/retract lever forward and RETRACTby pulling lever back.

CAUTION

Never pull to the side with acrane boom. Crane booms arenot designed for excessive sidepull and may collapse if sub-jected to excessive side loading.

6. Lower hook block to load and fasten hook.Make sure hook is properly engaged in slingsor lifting device employed to make the lift.Be certain hook latch is not supporting any ofthe load (refer to warning decal on hookblock).

Hoisting or lowering load with winch is con-trolled by winch lever. To LOWER load, pushlever forward. To RAISE load, pull lever back.Improved control is obtained by operating engineat low speed while “metering” control.. Alwaysactuate and release this lever slowly to minimizedynamic effects on load and to prevent “birdcaging” of cable on winch drum.

●

●

Never operate equipment withpersonnel on the hook or aload. Failure to follow thisprocedure could cause DEATHor serious injury.

Crane operators must alwaysbe prepared to take emergencyaction while a load issuspended in the air. Neverleave the operator’scompartment with a loadsuspended. Failure to followthis procedure could causeDEATH or serious injury.

7. Lift load to desired height. Do not lift higherthan necessary.

The LRT 110 Crane is equipped with an anti-twoblock system. If hook or block is raised too closeto boom head, a warning light appears on panel.If horn switch is activated, an audible warningwill sound. This vehicle is also equipped withcontrol disconnects to prevent winch fromraising load and boom from extending or lower-

4-24

TM5-3810-305-10

ing. To reactivate the system disconnects, retractor raise boom and/or lower hook.

CAUTION

Do not continue to pull block upafter contact has been made withboom head. This will result indamage to boom head andsheaves. The cable may also bebroken, causing load to drop.

If the operator needs to raise hook block beyondpoint at which the anti-two block is activated, hemay override the system by using anti-two blockBY-PASS switch (refer to page 4-7).

8.

9.

CAUTION

When spotting load, it may benecessary to alter boom length orboom angle. In making theseadjustments, the operator mustguard against exceeding ratedload as determined by the Capac-ity Chart. Failure to follow thisprocedure could cause damage toequipment.

Swing and spot load over the location where itis to be placed. When lowering light loads,be sure to maintain sufficient cable tension,preventing cable from becoming loose oncable drum. Loose cable can slip and bindsuddenly, causing “jerky” lowering and shockloading of boom. Loose wraps may formloops which can be overlaid when cable iswound onto winch drum. These conditionsmay result in personal injury or propertydamage.

Lower load and unfasten hook.

CAUTION

When attaching hook block tohook block tieback, take up cableslowly while lowering boom toprevent damage to windshield.

10. Center boom over cab and raise boom to a50-degree angle. Lower hook block down farenough to hook it into hook block tieback onfront of the LRT 110 Crane. Lower boom totravel position while taking up slack in cable.

Lift Procedu er “ On Tires**

CAUTION

● Insufficient tire pressurereduces the “On Tires”capacity. Attempts to pickrated capacity without properlyinflated tires may cause vehicleto tip and/or result in damageto tires and rims.

● The following precautions arenecessary to prevent a“pendulum” effect of aswinging load. Failure tofollow these precautions canresult in vehicle tipping over.

Listed below are special precautions for “OnTires” lifts. Load Ratings shown in the “OnTires” portion of the Capacity Chart are based onthe following conditions:

1.

2.

3.

Boom shall be carried straight over front ofvehicle.

Travel speed shall be reduced to suit condi-tions.

Specified tire pressure shall be maintained.

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TM5-3810-305-10

4.

5.

6.

Sudden starts and stops shall be avoided.

Tag or restraint lines shall be provided to snubswinging of load.

CAUTION

Traveling over uneven terrainwith rear axle oscillation lockedout can result in instability.Excessive boom length can alsocause instability depending onterrain and wind pressure.

Load shall be carried as near to ground aspossible with necessary minimum boomlength. Carry straight over front since rearaxle oscillation is locked out when boommoves off center more than 5 degrees.

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TM5-3810-305-10

Hand S _ignals for the LRT 110 Crane Operation

The following are hand signals and their meaning for the operation of the LRT 110 Crane. Both opera-tor and person indicating the necessary movement of the LRT 110 Crane must be familiar with all handsignals and their interpretation (Figure 4-16).

HAND SIGNALS FOR CRANE OPERATIONS

Figure 4-16. Hand Signals for Crane Operation

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TM5-3810-305-10

Section VWire Rope Instructions

Rope Identification andConstruction

Wire rope is identified not only by its componentparts, but also by its construction, i.e., by the waythe wires have been laid to form strands, and bythe way the strands have been laid around thecore.

The following illustration is a comparison oftypical wire rope lays (Figure 4-17):

D

E

Figure 4-17.

d. Left Lang Lay e. Right Alternate Lay.

In Figure 4-17, illustrations (A) and (C) showstrands as normally laid into the rope to the right,in a fashion similar to the threading in a right-hand bolt, Conversely, the “left lay” rope strandsillustrations (B) and (D) are laid in the oppositedirection.

Again in Figure 4-17, the first two illustrations(A) and (B) show regular lay ropes. Followingthese are the types known as lang lay ropes.Note that the wires in regular lay ropes appear toline up with the axis of the rope; in lang lay ropethe wires form an angle with the axis of the rope.

This difference in appearance is a result ofvariations in manufacturing techniques: regularlay ropes are made so that the direction of thewire lay in the strand is opposite to the directionof the strand lay in the rope; lang lay ropes (C)and (D) are made with both strand lay and ropelay in the same direction. Finally, the last ropeillustrated (E), called alternate lay, consists ofalternating regular and lang lay strands.

Wire rope nomenclature also defines: length, size(i.e., diameter), type, direction of lay, grade ofrope, type of core and whether it is preformed(p/f) or non-preformed (rip/f). If the directionand type of lay are omitted from the rope de-scription, it is presumed to be a right regular lay.In addition, if no mention is made as to pre-forming, this will be presumed as a requirementfor preforming. On the other hand, an order forelevator rope requires an explicit statement sincep/f and rip/f ropes are used extensively.

An example of a complete description wouldappear thus:

600 ft 3/4 in. 6x25 FW Left lang layImproved plow IWRC.

(Rope described above would be made PRE-FORMED.)

There are four basic constructions around whichstandard wire ropes are built (Figure 4-18):

6x21 SEALE 6x31 WARRINGTONWITH IWRC SEALE WITH IWRC

6x43 FILLER WIRE SEALE 6x46 SEALE FILLERWITH FIBER CORE WIRE WITH IWRC

Figure 4-18. Basic Design Construction

4-28

a.Right Regular Lay b. Left Regular Lay c. Right Lang Lay

TM5-3810-305-10

Illustrated below are a few combinations of basic design constructions (Figure 4- 19). Wire rope is iden-tified by reference to its number of strands, as well as the number and geometric arrangement of wires inthe strand (Figure 4-20).

6x7 6x9 WARRINGTON 6X19 SEALE 6X25 FW

Figure 4-19. Basic Constructions Figure 4-20. A Single Wire Rope Strand

Table 1. Wire Rope ClassificationBased on the normal number of wires in each strand

Classification

6x7

6x19

6x37

6X61

6x91

6x127

8x19

19x7and18x7

Description

Containing 6 strands that are made up of 3 through 14 wires, ofwhich no more than 9 are outside wires.

Containing 6 strands that are made up of 15 through 26 wires, ofwhich no more than 12 are outside wires.

Containing 6 strands that are made up of 27 through 49 wires, ofwhich no more than 18 are outside wires.

Containing 6 strands that are made up of 50 through 74 wires, ofwhich no more than 24 are outside wires.

Containing 6 strands that are made up of 75 through 109 wires, ofwhich no more than 30 are outside wires.

Containing 6 strands that are made up of 110 or more wires, ofwhich no more than 36 are outside wires.

Containing 8 strands that are made up of 15 through 26 wires, ofwhich no more than 12 are outside wires.

Containing 19 strands, each strand is made up of 7 wires. It ismanufactured by covering an inner rope of 7x7 left Iang layconstruction with 12 strands in right regular lay. (The rotation-resistant property that characterizes this highly specializedconstruction is a result of the counter torques developed by thetwo layers.) When the steel wire core strand is replaced by afiber core, the description becomes 18x7.

When a center wire is replaced by a strand, it is considered as a single wire, and the rope classificationremains unchanged. There are, of course, many other types of wire rope, but they are useful only in alimited number of applications and, as such, are sold as specialties. They are usually designated accord-ing to their actual construction.

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Wire Rope Installation

Checking The Diameter

It is most important to check the diameter of the delivered rope before installation. This is to makecertain that the rope diameter meets the specified requirements for the given machine or equipment.With an undersize diameter rope, stresses will be higher than designed for and the probability of break-ing the rope will be increased; an oversize diameter rope will wear out prematurely. This happensbecause of abuse to the rope caused by pinching in the grooves of the sheave and drum. In checking,however, the “true” rope diameter must be measured. And this is defined as the diameter of the circum-scribing circle, i.e., its largest cross-sectional dimension. To insure accuracy, this measurement shouldbe made with a wire rope caliper using the correct method (B, Figure 4-21). For measuring ropes withan odd number of outer strands, special techniques must be employed.

Design specifications for wire rope are such that the diameter is slightly larger than the nominal size,according to the allowable tolerances shown in Table 2.

Table 2. 0versize Limits of Wire Rope Diameters*Nominal Rope Diameter Allowable Limits

Over 1/4 in. and larger (6.35 mm and larger) -o +5%

*These limits have been adopted by the Wire Rope Technical Board (WRTB), and are being consideredfor inclusion in the forthcoming revised edition of “Federal Standard RR-W-410.” In the case of certainspecial purpose ropes, such as aircraft cables and elevator ropes, each has specific requirements.

In measuring a wire rope correctly, always measure the larger dimension. The “true” diameter (A) lieswithin the circumscribed circle (B). Avoid using incorrect measurement position (C, Figure 4-21).

Figure 4-21. How to Measure (or caliper) a Wire Rope

4 -30

TM5-3810-305-10

Unreeling and Uncoiling

Wire rope is shipped in cut lengths, either incoils or on reels. Great care should be takenwhen the rope is removed from the shippingpackage since it can be permanently damaged byimproper unreeling or uncoiling. Looping therope over the head of the reel or pulling the ropeoff a coil while it is lying on the ground, willcreate loops in the line. Pulling on a loop will, atthe very least, produce imbalance in the rope andmay result in open or closed kinks (Figure 4-22).Once a rope is kinked, the damage is permanent.To correct this condition, the kink must be cutout, and the shortened pieces used for some otherpurpose.

Improper handling will help create open (A) orclosed (B) kinks. The open kink will open therope lay; the closed kink will close it. Do notallow the rope to form a small loop. If, however,a loop forms and is removed at the point shown(C), a kink will be avoided. When the loopedrope is put under tension (D), a kink will form.The rope is then permanently damaged and is oflittle value.

Unwinding wire rope from its reel also requirescareful and proper procedure. There are threemethods to perform this procedure correctly:

1. Method A: The reel is mounted on a shaftsupported by two jacks or a roller payoff(Figure 4-23). Since the reel is free to rotate,the rope is pulled from the reel by a workman,holding the rope end and walking away fromthe reel as it unwinds. A braking deviceshould be employed so that the rope is kepttaut and the reel is restrained from over-running the rope. This is necessary particu-larly with powered de-reeling equipment.

Figure 4-22. Wire Rope Kinking

Figure 4-23. Mounted Unreeling

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TM5-3810-305-10

2.

3.

Figure 4-24. On Vertical Unreeling&

Method B: Mount the reel on an unreelingstand (Figure 4-24). It is then unwound in thesame manner as described in Method A. Inthis case, however, greater care must beexercised to keep the rope under tensionsufficient to prevent the accumulation of slack- a condition that will cause the rope to dropbelow the lower reel head.

Method C: Hold the end of the rope while thereel itself is rolled along the ground. Withthis procedure the rope will pay off properly;however, the end being held will travel in thedirection the reel is being rolled. As thedifference between the diameter of the reelhead and the diameter of the wound ropeincreases, the speed of travel will increase.

When re-reeling wire rope from a horizontallysupported reel to a drum, it is preferable for therope to travel from the top of the reel to the topof the drum (Figure 4-25). Re-reeling in thismanner will avoid putting a reverse bend in therope as it is being installed. If a rope is installedinducing a reverse bend, it may cause the rope tobecome livelier and, consequently, harder tohandle.

When unwinding wire rope from a coil, there aretwo suggested methods for carrying out thisprocedure in a proper manner: -

1.

Figure 4-25. Horizontal Re-reeling

Method A: Place the coil on a vertical unreel-ing stand. The stand consists of a base with afixed vertical shaft. On this shaft there is a“swift,” consisting of a plate with inclinedpins positioned so that the coil may be placedover them. The whole swift and coil thenrotate as the rope is pulled off. This methodis particularly effective when the rope is to bewound on a drum.

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2. Method B (the most common as well as theeasiest uncoiling method): Hold one end ofthe rope while rolling the coil along theground like a hoop (Figure 4-26).

Incorrect methods of unreeling and uncoilingwire rope will most likely result in kinks (Figures4-27 and 4-28). Such improper proceduresshould be strenuously avoided in order to preventthe occurrence of loops. These loops, whenpulled taut, will inevitably result in kinks. Nomatter how a kink develops, it will damagestrands and wires, and the kinked section must becut out. Proper and careful handling will keepthe wire rope free from kinks.

Figure 4-27. Incorrect Method of Unreeling Wire ROPe. .

Figure 4-26. Correct Method of Uncoiling Wire Rope

u

Figure 4-28. Incorrect Method of Uncoiling Wire Rope

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Seizing Wire Rope

While there are numerous ways to cut wire rope,in every case certain precautions must be ob-served. Proper seizings are always applied onboth sides of the place where the cut is to bemade, In a wire rope, carelessly or inadequatelyseized, ends may become distorted and flattened,and the strands may loosen. Subsequently, whenthe rope is put to work, there may be an unevendistribution of loads to the strands. This condi-tion will significantly shorten the life of the rope.

There are two widely accepted methods ofapplying seizing.

1.

2.

Figure 4-29. Seizing Wire Rope - Method A

Method A: Lay one end of the seizing wire inthe groove between two strands; wrap theother end tightly in a close helix over aposition of the groove using a seizing iron (around bar 1/2 to 5/8 in. diameter by 18 in.long) (Figure 4-29). Both ends of the seizingwire should be twisted together tightly, andwith a finished appearance. Seizing widthsshould not be less than the rope diameter.

Method B: The second of two accepted meth-ods for placing seizing on wire rope is illus-trated in Figure 4-30. The seizing itselfshould be a soft or annealed wire or strand.The seizing wire diameter and the length ofthe seize will depend on the diameter of thewire rope. But the length of the seizingshould never be less than the diameter of therope being seized. For preformed ropes, oneseizing on each side of the cut is normallysufficient. But for those that are not pre-formed, a minimum of two seizings is recom-mended (Figure 4-3 1). Seizings should bespaced six rope diameters apart.

Figure 4-30. Seizing Wire Rope - Method A

NONPREFORMED

BEFORE CUTTING

AFTER CUTTING

PREFORMED

AFTER CUTTINGFigure 4-31. Se izinG Applied Before Cutting

4-34

TM5-3810-305-10

Table 3 lists seizing lengths and seizing wire diameters suggested for use with some commonly usedwire ropes.

Table 3. Seizing: Sugges edt Diameters and Lengths

Rope Diameters Seizing Wire Diameters Seizing Lengthsin. mm in. mm in. mm

3/8-9/1 6 9.5-14.3 0.048 1.2 0.5 13

Cu tting Wire Rope

Using an axe or hatchet to cutwire rope may be dangerous. Ifnecessary to use, proceed withgreat caution. Failure to followthis procedure could causeSERIOUS INJURY. Portablehydraulic and mechanical ropecutters are available. In remoteareas, however, it may at timesbe necessary to use less desirablecutting methods.

Wire rope is cut after being properly seized(Figure 4-3 1). Cutting is a reasonably simpleoperation provided appropriate tools are used.There are several types of cutters and shearscommercially available. These are specificallydesigned to cut wire rope.

End Fittings and/or Attachments

There are many available designs of end fittingsand attachments, some of which were developedfor particular applications. The most commonones are illustrated in Figure 4-32.

NONPREFORMED

BEFORE CUTTING

AFTER CUTTING

PREFORMED

BEFORE CUTTING

AFTER CUTTING

Figure 4-31. Seizing Applied Before Cutting

WIRE ROPE SOCKET - SPELTER OR RESIN Attachment

WIRE ROPE SOCKET - SWAGED

MECHANICAL SPLICE - LOOP OR THIMBLE Attachment

WEDGE SOCKET

CLIPS - NUMBER OF CLIPS VARIES WITH ROPE SIZE

LOOP OR THIMBLE SPLICE - HAND TUCKED

Figure 4-32. End Fittings and Attachments

4-35

TM5-3810-305-10

Table 4. Terminal Efficiencies (Approximate)

Efficiencies are based on nominal strengthsMethod of attachment Efficiency

Rope with IWRC* Rope with FC**

Socket-Spelter or 100% 100%

Swagged Socket 95% (Not Established)

Mechanical Spliced Sleeve1 in. (25.40 mm) Diameterand Smaller 95% 92.5%—

ILoop or Thimble SpliceHand Spliced (Tucked)(Carbon Steel Rope)1/2 in. (12.70 mm) 86% 86%

Loop or Thimble SpliceHand Spliced (Tucked)(Stainless Steel Rope)

1/2 in(12.70 mm) 76%

Wedge Sockets***(Depending on Design) 75 to 95% 75 to 95%

Clips***(Number of Clips Varieswith size of Rope) 80% 80%

*IWRC. - Independent Wire Rope Core , .

**FC - Fiber Core

Socketinq

***Typical values wnen applied properly.Refer to fittings manufacturers for exactvalues and method.

All wire rope elements must be held securely bythe terminal. If this is not accomplished, the

Improperly attached wire rope strands will “loaf on the job” and there is everyterminals lead to serious or likelihood that a strand will become “high”

possibly unsafe conditions. (Figure 4-33). Selective abrasive wear of theFailure to follow this procedure loose strand will necessitate early removal of thecould cause DEATH or serious rope.injury.

Figure 4-33. A "High" Strand

4-36

Wire Rope

Resin Attachment

TM5-3810-305-10

To avoid many dangerous prac-tices, play it safe by followingcorrect procedures. Failure tofollow these procedures couldcause loads to fall causingDEATH or serious injury.

When preparing a wire rope for socketing, it is ofextreme importance to follow recommendedprocedures (refer to page 4-40). Proceduresother than those stipulated here may develop therequired strength but this cannot be predeter-mined without destructive tests. It is far saferand ultimately less costly to follow well-estab-lished practices.

There are many ways to go wrong in socketingprocedures. Some of the more common PIT-FALLS THAT SHOULD BE GUARDEDAGAINST include:

1.

2.

3.

4.

5.

Turning back the strands, inward or outward,before the “broom” is inserted into the socket.

Turning back the strands and seizing them tothe body of the rope.

Turning back the strands and tucking theminto the body of the rope.

Tying a knot in the rope.

Driving nails, spikes, bolts and similar objectsinto the socket after the rope is in, so as to“jam” it tight; this is particularly dangerousand ruinous.

Wire Rope Clips

Wire rope clips are widely used for attachingwire rope to haulages, mine cars and hoists, andfor joining two ropes,

Clips are available in two basic designs: the U-bolt and fist grip (Figure 4-34). The efficiencyof both types is the same.

U-BOLT FIST GRIP

Figure 4-34. Basic Designs of Wire Rope Clips

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TM5-3810-305-10

U-Bolt Clips

Refer to Table 5 and Figure 4-35 for specifica-tions of U-bolt clips.

The recommended method of applying U-boltclips to get maximum holding power of the clipis as follows:

2.

3.

Apply the next clip as near the loop as pos-sible. Turn nuts firmly, but do not tighten.

Space additional clips, if required, equallybetween the first two. Turn nuts, take up ropeslack and tighten all nuts evenly on all clips torecommended torque.

● When using U-bolt clips,extreme care must be exercisedto make certain that they areattached correctly. Failure tofollow this procedure couldcause DEATH or seriousinjury.

● Failure to make a terminationin accordance with thefollowing instructions, orfailure to periodically checkand retighten to therecommended torque, willcause a reduction in efficiencyrating which could causeDEATH or serious injury.

1. Turn back the specified amount of rope fromthe thimble. Apply the first clip one basewidth from the dead end of the wire rope (U-bolt over dead end; live end rests in clipsaddle). The U-bolt must be applied so thatthe “U” section is in contact with the dead endof the rope (Figure 4-36). Tighten nutsevenly to recommended torque.

Figure 4-35. Attaching U-bolts

RIGHT WAY FOR MAXIMUMROPE STRENGTH

WRONG WAY: CLIPS STAGGERED

WRONG WAY: CLIPS REVERSED

Figure 4-36. U-bolt Clip Dimensions

Table 5.* U-Bolt Clip Specifications

Min. AmountClip no. of of rope to Torque WeightSize A B c D E F G H clips turn back1/2 in, 0,50 in. 1.88 in. 1.00 in. 1.19 in. 1.13 in. 0.88 in. 1.91 in. 2.28 in. 3 11.5 in. 65 lb-ft 75 lb/100

12,7 mm 47,8 mm 25,4 mm 30,2 mm 28.7 mm 22,4 mm 48,5 mm 57.9 mm 292 mm 88 N ● m 34 kg/100

*From the Crosby Group

4-38

TM5-3810-305-10

4.

NOTE

Rope will stretch and shrink indiameter when loads are applied,

Apply the initial load and retighten nuts to therecommended torque. Inspect periodicallyand retighten.

A termination made in accordance with theabove instructions, and using the number ofclips shown, has an approximate 80% effi-ciency rating. This rating is based upon thecatalog breaking strength of wire rope. If apulley is used in place of a thimble for turningback the rope, add one additional clip.

NOTE

The following information isbased upon the use of U-boltclips on new rope.

The number of clips shown is based uponusing right regular or lang lay wire rope, 6x19class or 6x37 class, fibre core or IWRC, IPSor XIPS. If Scale construction or similarlarge outer wire type construction in the 6x19class is to be used for sizes 1 in. and larger,add one additional clip.

The number of clips shown also applies toright regular lay wire rope, 8x19 class, fibrecore, IPS size 1-1/2 in. and smaller; and rightregular lay wire rope, 18x7 class, fibre core,IPS or XIPS, sizes 1-3/4 and smaller.

For other classes of wire rope not mentionedabove, it may be necessary to add additionalclips to the number shown.

If a greater number of clips are used thanshown in the table, the amount of ropeturnback should be increased proportionately.

Fist Grip Clips

Failure to make a termination inaccordance with the followinginstructions, or failure to periodi -tally check and retighten to therecommended torque, will cause

a reduction in efficiency rating,which could cause DEATH orserious injury.

Refer to Figure 4-37 and Table 6 (page 4-40) forspecifications of fist grip clips.

The recommended method of applying fist gripclips is as follows:

1. Turn back the specified amount of rope fromthe thimble. Apply the first clip one basewidth from the dead end of the wire rope.Tighten nuts evenly to recommended torque.

2. Apply the next clip as near the loop as pos-sible. Turn nuts firmly but do not tighten.

3. Space additional clips, if required, equallybetween the first two. Turn nuts, take up ropeslack, and tighten all nuts evenly on all clipsto recommended torque.

Figure 4-37. Fist Grip Clip Dimensions

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TM5-3810-305-10

Table 6.* Fist Grip Clip Specifications

Min . AmountClip L no. of rope to TorqueSize A

WeightB c D E F G H approx M N clips turn back

1/2 in. 0.50 in. 1.88 in. 0.56 in. 1.25 in. 0.50 in. 1.00 in. 2.19 in, 0.28 in. 2,75 in, 0.88 in. 2.19 in. 3 11 in. 65 lb-ft 60 lb/10012.7 mm 47.8 mm 14.2 mm 31.8 mm 12.7 mm 25.4 mm 55,6 mm 71. mm 69.9 mm 22.4 mm 55.6 mm 279 mm 88 N ● m 27 kg/100

*From the Crosby Group

NOTEIf a greater number of clips are used than shown

Rope will stretch and shrink in in the table, the amount of rope turnback shoulddiameter when loads are applied. be increased proportionately.

4.recommended torque. Inspect periodicallyand retighten.

A termination made in accordance with theabove instructions, and using the number ofclips shown, has an approximate 80$% effi-ciency rating. This rating is based upon thecatalog breaking strength of wire rope. If apulley is used in place of a thimble for turningback the rope, add one additional clip.

The number of clips shown is based uponusing right regular or lang lay wire rope, 6x19class or 6x37 class, fibre core or IWRC, IPSor EIPS. If Scale construction or similar largeouter wire type construction in the 6x19 classis to be used for sizes 1 in. and larger, add oneadditional clip.

NOTE

The following information isbased upon the use of fist gripclips on new rope.

The number of clips shown also applies to rightregular lay wire rope, 8x19 class, fibre core, IPS,sizes 1-1/2 in. and smaller; and right regular laywire rope, 18x7 class, fibre core, IPS or EIPS,sizes 1-1/2 and smaller.

One of the more popular end attachments forwire rope is the wedge socket. For field or on-the-job attachment, it is easily installed andquickly dismantled.

Failure to install wedge socketsin accordance with the followinginstructions could cause DEATHor serious injury.

The recommended method for the installation ofwedge sockets is as follows:

1. Inspect the wedge and socket. All roughedges or burrs that might damage the ropeshould be removed.

2. If the end of the rope is welded, the weldedend should be cut off. This will allow the dis-tortions of the rope strands, caused by thesharp bend around the wedge, to adjustthemselves at the end of the line. If the weldis not cut off, the distortions will be forced upthe working line. This may result in thedevelopment of high strands and wavy rope.

For other classes of wire rope not mentionedabove, it may be necessary to add additional clipsto the number shown.

4-40

Wedge SocketsApply the initial load and retighten nuts to the

TM5-3810-305-10

3.

4.

5.

6.

Place the socket in an upright position andbring the rope around in a large, easy-to-handle loop. Care must be taken to makecertain that the live-loaded-side of the rope isin line with the ears (Figure 4-38).

Clamp the dead end close to thesocket to prevent the rope andwedge from disengaging fromthe socket. Failure to follow thisprocedure could cause DEATHor serious injury.

Clamp the dead end of the rope (Figure 4-39)(refer to page 2-3).

Secure the ears of the socket to a sturdysupport and carefully take a strain on the liveside of the rope. Pull the wedge and rope intoposition with tension sufficiently tight to holdthem in place.

After final pin connections are made, increasethe loads gradually until the wedge is prop-erly seated. Avoid sudden shock loads.

RIGHT WRONG

Figure 4-38. Installing the Wedge Sock et

Figure 4-39. Clamping the Dead End of the Wire Rope

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TM5-3810-305-10

Drums. Plain (Smooth)

Installation of a wire rope on a plain (smooth)face drum requires a great deal of care. Thestarting position should be at the drum end sothat each turn of the rope will wind tightlyagainst the preceding turn (Figure 4-40). Closesupervision should be maintained all duringinstallation. This will insure the following:

1. The rope will be properly attached to thedrum.

USE RIGHT LAY ROPE RIGHT LAY OVERWOUND

3.

4.

Each turn will be guided as close to the pre-ceding turn as possible, so that there are nogaps between turns.

There will beat least two dead turns on thedrum when the rope is fully unwound duringnormal operating cycles.

By holding the right or left hand with indexfinger extended, palm up or palm down, theproper procedure for installing left and right layrope on a smooth drum can be easily determined.

OVERWIND RIGHT TO LEFTUSE LEFT LAY ROPE

UNDERWIND RIGHT TO LEFTUSE RIGHT LAY ROPE

LEFT LAY OVERWOUND

ROPE ATFLANGE

L

RIGHT LAY UNDERWOUNDFigure 4-40 Drum Winding and Appropriate Hand Signals

Flexibility of Wire Ropeflexible fiber core rope. The reason for this lies

The term flexibility is frequently thought of as in the ability of IWRC rope to retain its round-being synonymous with resistance to bending ness and freedom of internal movement. Underfatigue. This is not true. Flexibility refers to the the same conditions, a fiber core rope will flattencapability of flexing or bending. While a high and inhibit free internal adjustment, therebydegree of fatigue resistance may sometimes leading to early failure.accompany the flexibility characteristic, it doesnot necessarily follow that this is so. A fiber As noted earlier, a design choice is almostcore rope, for example, is more flexible than an invariably the result of compromise. Ultimately,IWRC rope. Yet, when the IWRC rope is bent what is sought is an efficient, economical solu-around undersize sheaves at relatively high loads, tion; hence, whatever the compromise, it mustit will usually perform better than the more help achieve this goal.

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TM5-3810-305-10

Breaking in a New Wire Rope

A new wire rope requires careful installation andclose adherence to all the appropriate procedurespreviously noted. After the rope has been in-stalled and the ends secured in the correct man-ner, the mechanism should be started carefullyand then permitted to run through a cycle ofoperation at very slow speed. During this trialoperation, a very close watch should be kept onall working parts - sheaves, drums, rollers - tomake certain that the rope runs freely, andwithout any possible obstructions as it makes itsway through the system. If no problems appearin running the rope, the next step should includeseveral run-throughs of the normal operationalcycle under light load and at reduced speed. Thisprocedure allows the component parts of the newrope to make a gradual adjustment to the actualoperation conditions.

Wire Rope and Operations Inspection

To insure a high level of safety while keeping theannual cost of wire rope at a reasonably lowlevel, it is essential to maintain a well-plannedprogram of periodic inspection. Frequently,there are statutory and/or regulatory agencieswhose requirements must be adhered to, butwhether or not these exist in a given locale, thewire rope user can be guided by the suggestedprocedures that follow,

Abrasion, bending and crushing represent theABC’s of wire rope abuse, and it is the primarygoal of good inspection practice to discover suchconditions early enough so that corrections canbe made or ropes replaced safely and with mini-mum effort. When any degradation indicates aloss of original rope strength, a decision must bemade quickly as to allowing the rope to remain inservice. But such a decision can only be madeby an experienced inspector. And this determi-nation will be based on:

1.

2.

3.

4.

5.

Details of the equipment’s operation: Willthe rope break?

Frequency of inspection: Will it be safeuntil the next scheduled inspection?

Maintenance history: How rapid is thedegradation?

Consequences of failure: Will it presenthazards to personnel?

Historical records of similar equipment.

To make certain that sufficient information isobtained, following are guidelines that should beadhered to:

The groove size is evaluated on the basis of howthe gage leaf fits the groove. Daylight under thegage is not tolerable when using the worn groovegage. If a full oversize gage is used, somedaylight may be acceptable, but this really mustbe judged by relating the measurement to theactual size of the rope.

For new rope, extra caution should be observedas to its fit in the groove. Characteristically,ropes become smaller in diameter immediatelyafter being placed in service. As a result, theywould operate satisfactorily in a “worn” groove;one that was gaged OK by the” worn” groovegage. Nonetheless, in some cases, a rope maynot “pull down,” and if this happens, abnormalwear may occur.

It is important to remember that a tight groovenot only pinches and damages the rope, but thatthe pinching prevents the necessary adjustmentof the wires and strands. On the other hand, agroove that is too large will not provide suffi-cient support; in this case, the rope will flattenand thereby restrict the free sliding action of thewires and strands.

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The size of the groove is not the only criticalitem to be examined closely. The condition ofthe groove is also an important factor of concern.Is it smooth or imprinted? If the groove isimprinted, then it must be re-machined or, if it isimprinted too deeply, it means that sheave, rolleror drum must be replaced. If replacement isindicated, a larger sheave or drum should beinstalled if possible, or a harder material shouldbe specified for the replacement

Groove examination should also concern itselfwith how the groove is wearing. If it is worn off-center, thereby forcing the rope to undercut or torub against the flange, it then becomes necessaryto correct the alignment of the reeving system,and to specify a harder material.

When checking the grooves, the bearings of thesheaves and rollers should also be examined.They should turn easily. If not, each bearingmust be properly lubricated. “Wobble” in thesheave, from broken or worn bearings, is notacceptable. Bad bearings will set up vibrationsin the wire rope that can cause rapid deteriorationunless the condition is remedied. Bad bearingsalso increase the force on the rope that is neededto move a given load, since friction forces will begreatly increased.

Sheaves with broken flanges may allow the ropeto jump from the sheave and become fouled inthe machinery. When this happens, the rope iscut, curled, and the crowns of the wires in thestrands are burred. There is ample evidence tosupport the rule that sheaves with broken flangesmust be replaced immediately.

A sheave or drum with a flat spot can induce a“whip” into the line. This whip, or wave, travelsuntil it is stopped by the end terminal, at whichpoint the rope may bend severely. This conditionhelps to accelerate the fatigue breakage of wires.Sometimes the reeving is such that the whip or

wave is arrested by a sheave, or the drum itself.In these circumstances, the whipping will causewire breaks along the crowns of the strands.Obviously, sheaves or drums that excite vibra-tions of this sort must be repaired or replaced.

Guideline to Inspections and Reports forEquipment. wire Rope and Wire RopeSlings

1.

2.

3.

Maintain all inspection records and reports forthe length of time deemed appropriate.

Prior to each daily use, the following proce-dure should be followed:

a.

b.

c.

d.

Check all equipment functions.

Lower load blocks and check hooks fordeformation or cracks.

During lowering procedure and the follow-ing raising cycle, observe the rope and thereeving. Particular notice should be paid tokinking, twisting or other deformities.Drum winding conditions should also benoted.

Check wire rope and slings for visual signsof anything that can cause them to beunsafe to use, i.e., broken wires, excessivewear, kinking or twisting, and markedcorrosion. Particular attention should begiven to any new damage during operation.

Monthly Inspections are recommended with asigned report by an authorized competent in-spector. The Monthly Reports should includeinspection of the following:

a. All functional operation mechanisms forexcessive wear of components, brakesystem parts and lubrication.

b. Limit switches.

4-44

T M 5 - 3 8 1 - 3 0 5 - 1 0

c.

d.

e.

f.

Crane hooks for excess throat opening ortwisting along with a visual for cracks.

Wire rope and reeving for conditionscausing possible removal.

Wire rope slings for excessive wear,broken wires, kinking, twisting and me-chanical abuse.

All end connections such as hooks, shack-les, turnbuckles, plate clamps, sockets, etc.for excessive wear and distortion.

4. An Annual Inspection with a signed reportmust be made for the following:

a.

b.

c.

d.

Crane hook for cracks.

Hoist drum for wear or cracks.

Structural members for cracks, corrosionand distortion.

For loose structural connections such asbolts, rivets and weldments.

Wire Rope Inspection

The following is a fairly comprehensive listing ofcritical inspection factors. It is not, however,presented as a substitute for an experiencedinspector. It is rather a user’s guide to the ac-cepted standards by which ropes must be judged.

1. Abrasion: Rope abrades when it movesthrough an abrading medium or over drumsand sheaves. Most standards require that ropeis to be removed if the outer wire wear ex-ceeds 1/3 of the original outer wire diameter.This is not easy to determine and discoveryrelies upon the experience gained by theinspector in measuring wire diameters ofdiscarded ropes.

2. Rope stretch: All ropes will stretch whenloads are initially applied. As rope deterio-rates from wear, fatigue, etc. (excludingaccidental damage), continued application ofa load of constant magnitude will producevarying amounts of rope stretch. A “stretch”curve plotted for stretch vs. time (Figure 4-41) displays three discrete phases:

a.

b.

c.

Initial stretch, during the early (beginning)period of rope service, caused by the ropeadjustments to operating conditions (con-structional stretch).

Following break-in, there is a long period -the greatest part of the rope’s service life -during which a slight increase in stretchtakes place over an extended time. Thisresults from normal wear, fatigue, etc. Onthe plotted curve - stretch vs. time - thisportion would almost be a horizontalstraight line, inclined slightly upward fromits initial level.

Thereafter, the stretch begins to increase ata quicker rate. This means that the rope isreaching the point of rapid deterioration; aresult of prolonged subjection to abrasivewear, fatigue, etc. This second upturn ofthe curve is a warning indicating that therope should soon be removed.

Figure 4-41. S tretch vs. Time

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TM5-3810-305-10

3. Reduction in rope diameter: Any markedreduction in rope diameter indicates degrada-tion. Such reduction may be attributed to:

a. Excessive external abrasion.

b. Internal or external corrosion.

c. Loosening or tightening of rope lay.

d. Inner wire breakage.

e. Rope stretch.

f. Ironing or milking of strands.

In the past, whether or not a rope was allowedto remain in service depended to a greatextent on the rope’s diameter at the time ofinspection. Currently this practice has under-gone significant modification.

Previously, a decrease in the rope’s diameterwas compared with published standards ofminimum diameters. The amount of changein diameter is, of course, useful in assessing arope’s condition. But, comparing this figurewith a fixed set of values is, for the most part,useless. These long-accepted standards arenot, in themselves, of any serious significancesince they do not take into account suchfactors as:

a. Variations in compressibility betweenIWRC and Fiber Core.

b. Differences in the amount of reduction indiameter from abrasive wear, or from corecompression, or a combination of both.

c. The actual original diameter of the roperather than its nominal value.

As a matter of fact, all ropes will show a sig-

nificant reduction in diameter when a load isapplied. Therefore, a rope manufacturedclose to its nominal size may, when it issubjected to loading, undergo a greater reduc-tion in diameter than that stipulated in theminimum diameter table. Yet, under thesecircumstances, the rope would be declaredunsafe although it may, in actuality, be safe.

As an example of the possible error at theother extreme, we can take the case of a ropemanufactured near the upper limits of allow-able size. If the diameter has reached areduction to nominal or slightly below that,the tables would show this rope to be safe.But it should, perhaps, be removed.

Today, evaluations of the rope diameter arefirst predicated on a comparison of the orig-inal diameter - when new and subjected to aknown load - with the current reading underlike circumstances. Periodically, throughoutthe life of the rope, the actual diameter shouldbe recorded when the rope is under equivalentloading and in the same operating section.This procedure, if followed carefully, revealsa common rope characteristic: after an initialreduction, the diameter soon stabilizes. Later,there will be a continuous, albeit small,decrease in diameter throughout its life.

Core deterioration, when it occurs, is revealedby a more rapid reduction in diameter andwhen observed it is time for removal.

Deciding whether or not a rope is safe is notalways a simple matter. A number of differ-ent but interrelated conditions must be evalu-ated. It would be dangerously unwise for aninspector to declare a rope safe for continuedservice simply because its diameter had notreached the minimum arbitrarily establishedin a table if, at the same time, other observa-tions lead to an opposite conclusion.

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TM5-3810-305-10

4.

5.

6.

7.

Because criteria for removal are varied, andbecause diameter, in itself, is a vague crite-rion, the table of minimum diameters hasbeen deliberately omitted from this manual.

Corrosion: Corrosion, while difficult toevaluate, is a more serious cause of degrada-tion than abrasion. Usually, it signifies a lackof lubrication. Corrosion will often occurinternally before there is any visible externalevidence on the rope surface. Pitting of wiresis a cause for immediate rope removal. Notonly does it attack the metal wires, but it alsoprevents the rope’s component parts frommoving smoothly as it is flexed. Usually, aslight discoloration because of rusting merelyindicates a need for lubrication.

Severe rusting, on the other hand, leads topremature fatigue failures in the wires, neces-sitating the rope’s immediate removal fromservice. When a rope shows more than onewire failure adjacent to a terminal fitting, itshould be removed immediately. To retardcorrosive deterioration, the rope should bekept well lubricated. In situations whereextreme corrosive action can occur, it may benecessary to use galvanized wire rope.

Kinks: Kinks are permanent distortionscaused by loops drawn too tightly. Ropeswith kinks must be removed from service.

“Bird caging”: Bird caging results from tor-sional imbalance that comes about because ofmistreatments such as sudden stops, the ropebeing pulled through tight sheaves, or woundon too small a drum. This is cause for ropereplacement unless the affected portion can beremoved.

Localized conditions: Particular attentionmust be paid to wear to the equalizingsheaves. During normal operations this wear

8.

9.

is not visible. Excessive vibration or whipcan cause abrasion and/or fatigue. Drumcrossover and flange point areas must be care-fully evaluated. All end fittings, includingsplices, should be examined for worn orbroken wires, loose or damaged strands,cracked fittings, worn or distorted thimblesand tucks of strands.

Heat Damage: After a fire or the presence ofelevated temperatures, there may be metaldiscoloration or an apparent loss of internallubrication; fiber core ropes are particularlyvulnerable. Under these circumstances, therope should be replaced.

Protruding Core: If, for any cause, the ropecore protrudes from an opening between thestrands, the rope is unfit for service.

10. Damaged End Attachments: Cracked, bent,or broken end fittings must be eliminated.The cause should be sought out and cor-rected. In the case of bent hooks, the throatopenings - measured at the narrowest point -should not exceed 15% over normal norshould twisting be greater than 10%.

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TM5-3810-305-10

11. Peening: Continuous pounding is one of thecauses of peening. The rope strikes againstan object such as some structural part of themachine, or it beats against a roller, or it hitsitself. Often, this can be avoided by placingprotectors between the rope and the object itis striking. Another common cause of peen-ing is continuous passage, under high ten-sion, over a sheave or drum. Where peeningaction cannot be controlled, it is necessary tohave more frequent inspections and to beready for earlier rope replacement.

The external appearance of two ropes are il-lustrated, one of which has been abraded andthe other peened (Figure 4-42). Also shownare the cross-section of both wires in theseconditions. Note that a crack has formed as aresult of heavy peening.

12. Scrubbing: Scrubbing refers to the displace-ment of wires and strands as a result ofrubbing around or against an object. This, inturn, causes wear and displacement of wiresand strands along one side of the rope.Corrective measures should be taken as soonas this condition is observed.

13, Fatigue Failure: Wires that break with squareends and show little surface wear haveusually failed as a result of fatigue. Such

failures can occur on the crown of thestrands, or in the valleys between the strandswhere adjacent strand contact exists. Inalmost all cases, these failures are related tobending stresses or vibration.

If the diameter of the sheaves, rollers or drumcannot be increased, a more flexible ropeshould be used. But, if the rope in use isalready of maximum flexibility, the onlyremaining course that will help prolong itsservice life is to move the rope through thesystem by cutting off the dead end. Bymoving the rope through the system, thefatigued sections are moved to less fatiguingareas of the reeving. This technique is mostfrequently used in rotary drilling.

14. Broken Wires: The number of broken wireson the outside of a wire rope are consideredan index of its general condition, and whetheror not it must be considered for replacement.Frequent inspection will help determine theelapsed time between breaks. Ropes shouldbe replaced as soon as the wire breakagereaches the numbers given in Table 7. Suchaction must be taken without regard to thetype of fracture.

On occasion, a single wire will break shortlyafter installation. However, if no other wires

Table 7. When to Replace Wire Rope. Based on Number of Broken Wires

Number Broken Wires Number Broken WiresIn Running Ropes In Standing Ropes

ANSI In One In One In One At EndNo. Equipment Rope Lay Strand Rope Lay Connection

B30.5 Crawler. Locomotive & Truck Cranes 6 3 3 2

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TM5-3810-305-10

break at that time, there is no need for con-cern. On the other hand, should more wiresbreak, the cause should be carefully investi-gated.

On any installation, valley breaks - i.e.,where the wire ruptures between strands -should be given serious attention. When twoor more such conditions are found, the ropeshould be replaced immediately.

It is well to remember that once broken wiresappear - in a normal rope operating undernormal conditions - a good many more willshow up within a relatively short period.Attempting to squeeze to the last measure ofservice from a rope beyond the allowablenumber of broken wires (Table 7) will createan intolerably hazardous situation.

A diagnostic guide to some of the mostprevalent rope abuses is given in Table 8. Onthe following pages these abuses are illus-trated and described.

A wire that has broken under a tensile load inexcess of its strength is recognized by the“cup and cone” configuration at the fracturepoint (A, Figure 4-43). The necking down ofthe wire at point of failure shows that failureoccurred while the wire retained its ductility.A fatigue break is usually characterized bysquared-off ends perpendicular to the wireeither straight across or Z-shaped (B) and(c).

PEENING

ABRASION

Figure 4-42. Effects of Abrasion and Peening

Figure 4-43. Types of Breaks in Wire Rope

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TM5-3810-305-10

Table 8. Diagnostic Guide to Common Wire Rope Abuses

Abuse Symptoms Possible Causes

Fatigue Wire break is transverse - either straight across Check for rope bent around too small a radius;or Z-shaped. Broken ends will appear grainy, vibration or whipping; wobbly sheaves; rollers too

small; reverse bends; bent shafts; incorrect ropeconstruction; improper installation; poor endattachments. All running rope if left in service longenough will fail by fatigue.

Tension Wire break reveals predominantly cup and cone Check for overloads; sticky, grabby clutches;fracture with some 45-degree shear breaks. jerky conditions; loose bearing on drum; fast

starts, fast stops; broken sheave flange; wrongrope size and grade; poor end attachments.Check for too great a strain on rope after factorsof deterioration have weakened it.

Abrasion Wire break mainly displays outer wires worn Check for change in rope or sheave size; changesmooth to knife-edge thinness. Wire broken in load; overburden change; frozen or stuckby abrasion in combination with another factor sheaves; soft rollers, sheaves, or drums;will show a combination break. excessive fleet angle; misalignment of sheaves;

kinks; improperly attached fittings; grit and sand;objects imbedded in rope; improper grooving.

Cut or Gouged Wire ends are pinched down, mashed and/or Check on all the above conditions for mechanicalor Rough Wire cut in a rough diagonal shear-like manner. abuse, or either abnormal or accidental forces

during installation.

Torsion or Wire ends show evidence of twist and/or cork- Check on all the above conditions for mechanicalTwisting screw effect. abuse, or either abnormal or accidental forces

during installation.

Mashing Wires are flattened and spread at broken ends. Check on all the above conditions for mechanicalabuse, or either abnormal or accidental forcesduring installation.

Corrosion Wire surfaces are pitted with break showing Indicates improper lubrication or storage.evidence either of fatigue tension or abrasion.

Abrasion plus Reduced cross-section is broken off square A long-term condition normal to the operatingFatigue thereby producing a chisel shape. process.

Abrasion plus Reduced cross-section is necked down as A long-term condition normal to the operatingTension in a cup and cone configuration. Tensile break process.

produces a chisel shape.

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TM5-3810-305-10

STRANDIllustrated Examples of Possible WireRope Damage

1. Interstrand and core-to-strand nicking: Astrand has been removed from the rope toshow the equivalent lines of nicking wherestrands are in contact with one another, aswell as with the core (Figure 4-44).

Figure 4-44. Interstrand and Core-to-Strand

2. Cork-screwed rope: This condition resultsfrom rope being pulled around an objecthaving a small diameter (Figure 4-45).

Figure 4-45. Cork-Screw Rope

3. Damaged reel: When a reel has been dam-aged in transit, it is a safe assumption that ir-reparable damage has been done to the rope(Figure 4-46).

Figure 4-46. Damaged Reel

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TM5-3810-305-10

4. Shipping damage: Wire rope abuses during 6. Incorrect handling results indifferent types ofshipment create serious problems (Figure 4-47). One of the more common causes isimproper fastening of rope end to reel, e.g.,nailing through the rope end. These illustra-tions show two acceptable methods:

a.

b.

Figure 4-47. Shipping Damage

One end of a wire “noose” holds the ropeand the other end is secured to the reel(A).

The rope end is held in place by a J-bolt orU-bolt that is fixed to the reel (B).

5. “High strand” wire rope: The excessive wearof a single strand is caused by improper sock-eting (Figure 4-48).

Figure 4-48. “High Strand” Wire Rope

damage to wire rope (Figure 4-49):

a. Rope damaged by being rolled over somesharp object (A).

b. Damage resulting from bad drum winding(B).

c. Drum crushing is evidence of bad windingconditions (C).

d. Damage resulting from a deeply corru-gated sheave (D).

A

c

Figure 4-49. Damage From Incorrect Handling

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TM5-3810-305-10

7. There are different types of wire rope damage(Figure 4-50):

a.

b.

c.

d.

e.

f.

Dog leg (A).

Popped core (B).

Bird caging (C).

Snagged strand wires (D).

Spiraling that is brought about when ropejumps from the sheave (E).

A tension break resulting from overload-ing (F).

B

D

E

FFigure 4-50. Typ es of Wire Rove Damage

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TM5-3810-305-10

8. There are different types of wearing of wirerope (Figure 4-5 1):

a.

b.

c.

d.

From excessive bending (A).

Localized wear brought about by poor cut-off practice (B).

Rope slides over or against itself (C).

Flexing the rope exposes broken wireshidden in valleys between strands. This isknown as valley-type fatigue breaks (D).

B

c

DFigure 4-51. Wearing of Wire Ropes

Rope Inspection Summary

Any wire rope that has broken wires, deformedstrands, variations in diameter or any changefrom its normal appearance must be consideredfor replacement. It is always better to replace arope when there is any doubt concerning itscondition or its ability to perform the requiredtask. The cost of wire rope replacement is quiteinsignificant when considered in terms of injuriesto personnel, the cost of down time or the cost ofreplacing broken structures.

Wire rope inspection includes examination ofbasic items such as:

1. Rope diameter reduction.

2. Rope lay.

3. External wear.

4. Internal wear.

5. Peening.

6. Scrubbing.

7. Corrosion.

8. Broken wires.

Some sections of rope can breakup without anyprior warning. Already discussed in some detailas to cause and effect, sections where this occursare ordinarily found at the end fittings, and at thepoint where the rope enters or leaves the sheavegroove of boom hoists, suspension systems orother semi-operational systems. Because of the“working” that takes place at these sections, noappreciable wear or crown breaks will appear.Under such an operation, the core fails therebyallowing the strands to notch adjacent strands.However, when this happens, valley breaks willappear. As soon as the first valley break isdetected, the rope should be removed immedi-ately.

If preventive maintenance, previously described,is diligently performed, the rope life will beprolonged and the operation will be safer. Cut-ting off a given length of rope at the end attach-ment before the core deteriorates and valleybreaks appear, effectively eliminates thesesections as a source of danger.

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TM5-3810-305-10

Equipment lnspection

Any undetected fault on a sheave, roller or drum,be it of relatively major or minor significance,can cause a rope to wear out many times fasterthan the wear resulting from normal operations.As a positive means of minimizing abuses andother-than-normal wear, the procedures here setforth should be adhered to. Every observationand measurement should be carefully recordedand kept in some suitable and accessible file.

1.

2.

3.

4.

Give close examination to the method bywhich the rope is attached both to the drumand to the load. Make certain that the propermeans of attachment is applied correctly, andthat any safety devices in use are in satisfac-tory working order.

Carefully check the groove and workingsurface of every sheave, roller and drum todetermine whether each (groove and surface)is as near to the correct diameter and contouras circumstances will permit, and whether allsurfaces that are in contact with the rope aresmooth and free of corrugations or otherabrasive defects.

Check sheaves and rollers to determinewhether each turns freely, and whether theyare properly aligned with the travel of therope. All bearings must be in good operatingcondition and furnish adequate support to thesheaves and rollers. Sheaves that are permit-ted to wobble will create additional forcesthat accelerate the deterioration rate of therope.

If starter, filler and riser strips on drums areused, check their condition and location.Should these be worn, improperly located orbadly designed, they will cause poor winding,dog legs and other line damage.

5. Whenever possible, follow the path that therope will follow through a complete operatingcycle. Be on the lookout for spots on theequipment that have been worn bright or cutinto by the rope as it moves through thesystem. Ordinarily, excessive abrasive wearon the rope can be eliminated at these pointsby means of some type of protector or roller.

Refer to Appendix B, page B-2 for completeinformation regarding lubrication of the cable.

4 -55

Cable Lubrication

TM5-3810-305-10

Section VIOperation Under Emergency or Abnormal Conditions

Emergency Load Lowering Procedure.

In the event that lowering a suspended load bythe normal means is impossible due to enginefailure, pump failure or a hydraulic line failure, ahydraulic hand pump is provided. The followingprocedures will restore the vehicle to a normaltraveling or towing attitude.

During the execution of thisprocedure, the danger exists ofuncontrollably dropping a load.Rotate the upperstructure to asafe position. Failure to followthis procedure could causeDEATH or serious injury.

NOTE

Swing the Boom Mechanically

1.

2.

3.

Remove three nuts (1), bolt (2), three washers(3), five bolts (4), washers (5), deck plate (6),and pinion cover (7, Figure 4-52).

NOTE

Move swing lever in same swingdirection to relieve oil pressureas the upperstructure is beingturned.

Attach a wrench to the protruding shaft of theswing box drive. Turn swing box drive shaftclockwise to swing boom to the right andcounterclockwise to swing boom to the left.

Rotate the upperstructure and the load to asafe area.

Two men are required to performthis task.

Figure 4-52. Swing Drive Box

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TM5-3810-305-10

Prepare Equipment

The hand pump is mounted in the left side tool box. The pump supply and pressure hose with a connec-tor tee is also located in this box.

The pump is used from this location by inserting the pin in the pump handle,

Attach Supply Hose

Attach the quick disconnect on the pump supply hose to the nipple on the reservoir side of the filtermanifold (Figure 4-53).

Figure 4-53. Quick Disconnect on Supply Hose

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TM5-3810-305-10

Lower Load with Winch

1.

2.

3.

4,

5.

6.

7.

NOTE

If there is no load on hookproceed to Retract Boom.

Bring hand pump pressure hose up to winchand remove smallest cap on the connector tee.

Disconnect the brake hose from the tee in thelowering port on the winch motor.

Entry of air into lowering portwill cause winch motor to cavi-tate. The winch motor loweringport tee must be capped to pre-vent load from free falling whenhand pump pressure is applied.Failure to follow this procedurecould cause DEATH or seriousinjury.

Install cap on winch motor lowering port tee.

Connect connector tee to winch brake hose.

When working the hand pump,clear all personnel from the area.Failure to follow this procedurecould cause DEATH or seriousinjury.

Close pressure release lever on pump. Pumpslowly until winch brake is released. Theload will lower slowly to the ground.

With the load safely down, open pressurerelease lever on hand pump.

Disconnect brake hose from connector tee andreattach to lowering port tee. Install cap onconnector tee.

8. Using a wrench on the swing box, rotate up-perstructure back to the travel position.

Retract Boom

1.

2.

3.

4.

5.

Never disconnect hydraulic linesor fittings before venting pres-sure. Turn dipstick cap 1/4 turnto safety notch to relieve pres-sure. Failure to follow thisprocedure could cause SERIOUSINJURY.

Turn dipstick 1/4 turn to safety notch torelieve pressure.

Locate counterbalance valve on top of boomextend cylinder at base of boom.

Loosen jam nut on counterbalance valve ex-tending up from valve block and turn theadjusting screw in until it bottoms (Figure 4-54). Keep track of number of turns requiredto bottom out screw.

Figure 4-54. Holding Valve (Adjusting Screw)

Turn ignition switch ON and pull back onboom telescope lever until boom is fully re-tracted.

NOTE

If boom retracts, proceed to step12.

Remove hose from retract port adapter oncontrol valve extend/retract section (firstsection from the left side) (refer to Figure 4-53).

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TM5-3810-305-10

6.

7.

8.

Take cap off largest adapter on connector tee,and put it on valve adapter.

Attach connector tee to the retract hose.

NOTE

Another person is required in thecab to pull back on boom tele-scope lever to open valve andallow oil to flow thru valve whilepumping is taking place.

Pull back on boom telescope lever.

9. Close pressure release lever on hand pumpand pump until boom is fully retracted.

10. When boom is retracted, open pressurerelease lever on pump and disconnect con-nector tee from retract hose.

11. Connect retract hose to boom retract cylinderport adapter.

12. Back out adjusting screw on extend cylindercounter balance valve to its exact original ad-justment (turns) and tighten jam nut.

13. Turn ignition switch OFF.

Figure 4-53. Quick Disconnect on Supply Hose

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TM5-3810-305-10

Lower Boom

1.

2.

When lowering boom to a hori-zontal position, work from sideof upperstructure, not underboom. Failure to follow thisprocedure could cause DEATHor serious injury.

With a 5/ 16 in. hex allen wrench, remove plugfrom the hold valve cartridge protruding upon bottom side of hoist cylinder (Figure 4-55).

With the same wrench, back-out internal plugcounterclockwise until wire retaining ringstops it. Do not force plug beyond this point.It cannot be removed because approximately0.5 in. (13 mm) of threads remain at stop.

3.

4.

5.

6.

Everyone must be clear of thearea before moving hoist controllever. Failure to follow thisprocedure could cause DEATHor serious injury.

Turn ignition switch ON. Push forward onboom hoist control lever in cab until boom islowered to horizontal position.

Turn ignition switch OFF.

Swing boom mechanically over one side(refer to page 4-56).

Tighten internal plug on hold valve cartridge

7.

until it bottoms out in the original position.Replace plug.

Swing boom mechanically over cab (refer topage 4-56).

Figure 4-55. Internal Plug

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TM5-3810-305-10

Lower the LRT 110 Crane Off the 2.Outriggers

3.

Never disconnect hydraulic linesor fittings before venting pres- 4.sure. Turn dipstick cap 1/4 turnto safety notch to relieve pres-sure. Failure to follow thisprocedure could cause SERIOUSINJURY. 5.

1. Turn dipstick 1/4 turn to safety notch torelieve pressure.

Remove reducer -6 to -4 and cap -4 fromconnector tee on pressure hose (Figure 4-56).

Remove single return hose and adapter fromtee and connect connector tee to tee.

Use reducer -6 to -4 and cap -4 to cap adapteron single return hose removed from tee instep 3.

Remove appropriate extend hose from outrig-ger solenoid.

Figure 4-56. Lowering the LRT Crane off the Outriggers

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TM5-3810-305-10

6. Remove plug and place elbow and female 7. Close pressure release lever on hand pump.quick disconnect on one end of emergency Pump to retract outrigger to travel position.return hose and connect hose to disconnectport on top of hydraulic reservoir. Remove 8. Repeat steps 5 thru 7 for each outrigger ascap and connect other end of emergency necessary.return hose to outrigger extend hose (Figure4-56).

Figure 4-56. Lowering the LRT Crane off the Outriggers

4 - 6 2

TM5-3810-305-10

9. Remove pressure hose, emergency return hose 11. Remove pin from pump handle and store inand pump supply hose, replace caps and place tool box.in tool box.

12. Install pinion cover (7), deck plate (6), five10. Connect outrigger hoses. washers (5), bolts (4), three washers (3), bolt

(2), and three nuts (1, Figure 4-52).

Figure 4-52. Swing Drive Box

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TM5-3810-305-10

Secure Hook Block

1. If cable and hook block are lying on theground after completing these emergency pro-cedures, tighten cable and install wood blockon winch to retain tension on cable. Removecable from hook block socket and securecable to vehicle.

Weight of the hook block isapproximately 235 lb (107 kg).Use adequate hoist and sling tolift hook block. Do not lift overpersonnel or let personnel walkunderneath suspended load.Failure to follow this procedurecould cause DEATH or seriousinjury.

2. Using hoist and sling, lift hook block to toolbox for carrying purposes.

Unus ual Operating ConditionS

Special problems in maintenance and operationare caused by unusual conditions such as ex-tremes in heat, cold, humidity, high altitude, saltwater and dusty or sandy work sites. Whenoperating under such conditions, special precau-tions must be taken to prevent vehicle damage,minimize wear and avoid component deteriora-tion.

Extreme Cold

In periods of extreme cold, problems of freezedamage, adequate lubrication and battery failuremay become particularly troublesome. With theonset of very cold weather, it is advisable to“winterize” the LRT 110 Crane by servicing thecooling system and switching to the lubricantrecommended for cold weather usage. Followrecommendations in this manual when operating

the LRT 110 Crane under very extreme condi-tions.

1.

2.

Prevent freeze damage. To prevent freezedamage to the cooling system and cracking ofengine block or head, drain and flush coolingsystem. Clean radiator exterior, makingcertain all air passages through core andcooling fins are free of foreign matter.

CAUTION

Never use a chromate-base corro-sion inhibitor when coolantcontains ethylene glycol. Useonly nonchromate-base inhib-itors. Chromate-base inhibitorsreacting with ethylene glycol canproduce chromium hydroxide,commonly known as “greenslime.” This substance reducesthe heat transfer rate and cancause serious engine overheating.

Refill cooling system. Add an antifreeze so-lution as recommended in the amount andstrength appropriate to anticipated tempera-tures. A corrosion inhibitor is recommended.

Inspect clamps, radiator hoses and radiator.Replace or repair any cooling system compo-nent found to be defective.

Condensation in fuel tank contaminates thefuel supply with water. This can freeze infuel lines and block fuel flow to engine. Tominimize this possibility, keep tank as full aspossible during cold weather. This may entailrefilling tank more frequently than usual, butthe inconvenience is small compared toclearing a blocked fuel line.

Check and drain the fuel/water separator. Ifwater is found in fuel tank, drain tank andrefill it with uncontaminated fuel.

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TM5-3810-305-10

3.

4.

Lubricate with correct lubricants. For tem-peratures below -10 degrees F (-23 degreesC), service the LRT 110 Crane with Arcticdiesel fuel in fuel tank and Arctic lubricatingoil MIL-L-46167 in the engine. To aid coldweather start below O degrees F (-18 degreesC), service hydraulic system and transmissionwith Arctic lubricating oil MIL-L-46167(refer to Lubrication chart, Appendix B).

5.

6.

Idle vehicles must be properly stored (refer tomaintenance). At the end of work period, orwhenever vehicle is to be left idle for ex-tended periods, park it on a wood, concrete,asphalt or mat surface. This will prevent itfrom being frozen to the ground.

For cold weather starting, use the cold startdevice.

CAUTION

Water added to battery can freezebefore it mixes with electrolyte.During very cold weather, addwater to battery just prior to, orduring operation of, vehicle. Ifvehicle is not to be run, connectan external charger to battery ifadding water.

Battery care is needed. The battery is morelikely to sustain freeze damage if not keptfully charged. Its electrolyte will freeze at ahigher temperature than a fully chargedbattery. Be certain battery is charging whenengine is running. Use an external charger torestore full charge when the vehicle is notbeing operated.

The battery can discharge if snow or ice shortcircuits the terminals. Keep battery posts andcable connectors clean and dry. Remove anycorrosion with a solution of baking soda andwater.

During extremely cold weather, when thevehicle is to remain idle overnight or for anyextended period, it is advisable to remove andstore battery in a heated area.

For cold start at -25 degrees F (-32 degreesC), the batteries have sufficient charge foronly one start attempt.

Starting fluid is toxic and highlyflammable. Container is pressur-ized to act as an expellent. Donot heat container and do notdischarge starting fluid in con-fined areas or near an openflame. Failure to follow thisprocedure could cause SEVEREINJURY.

It is recommended that the cold start devicebe used for starting the LRT 110 Crane in am-bient temperatures below 32 degrees F (O de-grees C) and required at temperatures of 10degrees F (- 12 degrees C) and below.

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TM5-3810-305-10

a.

To install cold start cylinder:

Remove cylinder from tool box and removecap from top of cylinder (Figure 4-57).

b.

c.

Figure 4-57. Cold Start Cylinder

Remove protector cap from valve or, ifempty cylinder is in place, loosen clampand unscrew cylinder.

Invert cylinder and thread into cold startmounting valve.

d. Secure cylinder with clamp.

Before starting engine using the cold startdevice, be sure to inspect engine oil andtransmission oil filters for bulges and rup-tures. The applicable Preventive MaintenanceChecks and Services are also to be completed(refer to page 4-13).

If temperature is below O degrees F (- 18degrees C), briefly turn ignition switch ON tocheck battery voltage. If battery voltage isbelow 24 volts, the LRT 110 Crane willrequire a slave start (refer to page 4-68).Headlights are to be turned on for 3 minutesto warm the batteries, then all switches andaccessories are to be turned off.

To use the cold start device:

a .

b.

c.

d.

e.

f.

g .

Pull cold start knob out and wait 3 to 5seconds for ether to fill charging valve.(Omit this step if temperature is above Odegrees F [- 18 degrees C]).

Push cold start knob in and wait 3 to 5seconds for ether to spray into intakemanifold. (Omit this step if temperature isabove 0 degrees F [-18 degrees C]).

Repeat steps a and b. (Omit this step iftemperature is above O degrees F [- 18degrees C]).

CAUTION

Do not crank engine for periodslonger than 30 seconds if tach-ometer indicates less than 250rpm and no longer than 1 minuteif tachometer indicates over 250rpm. Failure to follow this pro-cedure could cause damage toequipment.

Pull cold start knob out and wait 3 to 5seconds. Turn ignition switch ON andpress start button. Then push cold startknob in while holding start button. Holdaccelerator pedal all the way down whilecranking engine.

Pull cold start knob out and wait 3 to 5seconds for ether to fill charging valve.

Push cold start knob in and wait 3 to 5seconds for ether to spray into intakemanifold.

Inject additional ether as necessary toattain and then maintain a minimum of500 rpm.

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TM5-3810-305-10

h. Continue to hold start button until tach-

i.

j .

k.

1.

ometer indicates 500 rpm or 1 minute oftime is reached.

Check oil pressure gauge for 10 psi (69kPa), or higher at idle 720 to 880 rpm.

Operate engine at 1,000 to 1,500 rpm, untilengine temperature reaches 120 to 140degrees F (49 to 60 degrees C).

NOTE

Minor oil leakage of filters isnormal and can be as much as 3tablespoons per minute for thefirst 5 minutes of operation.

Inspect engine oil filter and transmissionoil filter for leaks. There should be noleaks present after 5 minutes of operation.Close engine hood.

Attempt to move the LRT 110 Crane for-ward and backward to check for frozenbrakes and tires.

m. Check brakes and steering functionsbefore exceeding 5 mph (8 km/h).

ALLOW THE ENGINE TO WARMUP SO

7.

that optimum engine power is obtained atlow speed for the protection of the hydrau-lic system.

Special attention must be given to the hy-draulic oil.

CAUTION

BE ALERT FOR SIGNS OFPUMP CAVITATION. Thehydraulic oil provides lubricationfor pumps. When too heavy orstiff, it will not flow fast enoughto meet pump demand and avacuum or “cavitation” will becreated. A “screaming” noiseindicates inadequate pumplubrication, and, if allowed tocontinue for more than a shortperiod, will result in seriousdamage to pumps.

If cavitation noise is noticed, hydraulic oilmust be warmed. To do this, actuate a func-tion, allow the cylinders involved to reach thelimits of their travel and hold control inengaged position for 10 minutes. Whenrunning hydraulic oil over relief to warm it,be sure to restrict flow by turning engine at asslow a speed as possible.

Increase engine speed gradually, allowingsufficient time for oil to run through thesystem before commencing operation. Ifcavitation noise is still noticed, repeat theprocedure listed above. Refer to the lubrica-tion chart, Appendix B, for recommended oilviscosity for the winter season.

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TM5-3810-305-10

8. Slave start engine when necessary. Maintainbatteries at full 24-volt charge. The slavereceptacle on side of battery compartmentmay be used for charging batteries or slavestarting engine from an external power source(Figure 4-58).

Turn ignition switch ON and engage starteruntil engine starts.

After starting, allow engine speed to return toidle for engine warm-up and remove slavepower cable connection.

Cold weather shutdown procedure. Park theLRT 110 Crane on prepared surface, if pos-sible, free of snow, ice and water, to preventtires from freezing to surface. Be sure slavereceptacle is accessible. Remove all ice and/or snow accumulations from the vehicle andproceed as follows:

If slave starting, make sure when connectingslave start cables that ignition switch is OFF,transmission is in neutral and parking brake isapplied.

Connect external power source cable plug toslave receptacle. The LRT 110 Crane is a 24-volt negative ground system.

CAUTION

Do not crank engine for periodslonger than 30 seconds if ta-chometer indicates less than 250rpm, and no longer than 1 minuteif tachometer indictes over 250rpm. Failure to follow thisprocedure could cause damage toequipment.

a.

b.

c.

d.

e.

Turn off all accessories, i.e., heater, fan,etc.

Check transmission fluid level.

Check voltmeter. If voltmeter reads below24 volts, indicating insufficient charge inbattery for unassisted start, notify organ-izational maintenance.

Perform vehicle shutdown (refer to page4-71).

Drain water from fuel separator by open-ing drain valve and pumping handle on liftpump. Close drain valve when procedureis completed.

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TM5-3810-305-10

f. Restart engine and check to insure allcontrols are properly positioned for starting.Run engine for 3 to 5 minutes to chargebattery.

g. Turn ignition switch OFF and servicevehicle.

Emergency Window Removal

If it is necessary to rescue an operator that istrapped in the cab, remove the front glass. Usingany available pointed object such as a knife,screwdriver or stick, pry out the seal lip of theweatherstripping. Pry in under the glass to raiseit so that it can be removed. This same methodcan be used on any of the side or rear windowsfor emergency purposes.

An able and conscious operator can also exit thecab by placing his feet against the glass and withmoderate force, push the glass out of front or rearwindows.

Extreme Heat

Like extreme cold, extreme heat requires thatprecautions be taken with respect to the coolingsystem, battery and lubrication. Protect thevehicle by performing the following recom-mended procedures:

1. Lubricate with correct lubricants. High tem-peratures necessitate the use of lubricantswhich are both higher in viscosity and resistdeterioration at higher operating tempera-tures. Refer to the Lubrication section,Appendix B and use the lubricants recom-mended for the expected temperatures.

2.

Crankcase oil is particularly important be-cause it helps dissipate heat. Check the oillevel frequently and add oil as required tomaintain the correct level. Low oil willhinder heat dissipation.

The cooling system is pressur-ized. Use extreme caution andproper protection when removingradiator cap after operating tem-perature is reached. Whenremoving cap, loosen it slowly tothe left, then pause a moment.Steam and hot gases will beescaping through the radiatorcap; avoid being burned by thesegases. Continue to turn cap untilit can be removed. Failure tofollow this procedure could causeSERIOUS INJURY.

Prevent overheating. To insure proper cool-ant circulation, drain and flush the coolingsystem. Clean any foreign matter from theradiator cooling fins and core air passages.Replace defective hoses and tighten hoseclamps. Eliminate any leaks detected and fillthe system with a 5070 solution of ethyleneglycol and water. A corrosion inhibitor isalso recommended.

Engine overheating due to loss of coolant willmost often be corrected by SLOWLY replac-ing the lost coolant with engine idling.

Water containing larger than normal concen-trations of salt or minerals should not be usedin the cooling system. Salt will cause corro-sion and mineral deposits will collect on thecoolant passage walls. Both processes inhibitproper cooling.

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TM5-3810-305-10

3.

4.

Check the battery. Increased evaporationrates will cause the battery electrolyte level tofall more rapidly during very hot weather.Check the level frequently and add distilledwater as required to maintain the proper level.

Keep air circulation free. Air circulation

1.

around the engine and battery must not berestricted. Keep air intake and exhaustopenings clear of leaves, paper and otherforeign matter which may restrict air flow.

Keep the engine clean of dirt, grease andother substances which inhibit heat dissipa-tion.

Use sound judgment in operating the engine.Avoid the two extremes of racing and lug-ging.

Advance the throttle only enough to handlethe load, yet be certain that the engine speedis high enough to maintain adequate fan speedfor cooling.

Run the engine only when engaged in workoperations or when traveling the vehicle.Avoid prolonged periods at idling and shutthe engine down if operations are interrupted.

Sandy or Dusty Work Sites

The presence of large amounts of sand or dust atthe work site can contribute to acceleratedcomponent wear. Either substance will act as anabrasive when deposited on moving parts. Theproblem is combated by more frequent lubrica-tion and by the servicing of breathers and filtersat shorter intervals. Follow the recommendationsbelow when operating in sand or dust on aregular basis:

2.

Check the filler caps, filters, breathers, aircleaner and grease fittings.

Keep sand and dust out of the hydraulicsystem by keeping the reservoir filler captight and servicing the hydraulic system filtersfrequently.

The fuel system should be kept free of sandand dust by keeping the tank filler cap tightand servicing the fuel filters frequently.

When lubricating, thoroughly clean eachgrease fitting before attaching the grease gun.Pump generous amounts of grease into alllubrication points, using the fresh grease topump out the old grease. The increasedfrequency of lubrication and service notedabove should be determined by observationsmade at work site. Inspection will indicatehow long it takes for lubricants, breathers andfilters to accumulate unacceptable amounts ofsand or dust. The frequency of lubricationand service should be adjusted accordingly.

The engine and air cleaner should also beserviced frequently to prevent sand and dustfrom entering the engine. The engine oil andoil filter should be changed at shorter thannormal intervals to insure a clean oil supply tothe engine’s moving parts.

Adequate ground bearing supportmust be provided for the outrig-ger when operating on softsurface. Be alert for signs ofLRT 110 Crane movementduring operations. Failure tofollow this procedure could causeDEATH or serious injury.

Insure that the terrain is adequate to supportthe crane’s weight.

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TM5-3810-305-10

High Humidity or Saltwater

In some locations, such as coastal areas, the LRT110 Crane may be exposed to the deterioratingeffects of salt, moisture or both. To protectexposed metallic surfaces, wiring, hoist rope,paint and other items, keep them dry and welllubricated. Follow the recommendations belowwhen operating in these conditions:

Where paint may not be applied, such as onpolished or machined surfaces, coat the area withgrease to repel water.

Keep bearings and their surrounding surfaceswell lubricated to prevent the entry of water.

Cable must be kept well lubricated to preventmoisture and salt from penetrating the cablestrands.

Check for deterioration.Fording

Make frequent inspections for rust and corrosion.Remove them as soon as they are detected. Dryand paint exposed surfaces after rust and corro-sion have been removed.

There are no special preparation or maintenancevehicle requirements to ford up to 30 in, (762mm) of water.

Section VllShutdown

Vehicle Shutdown Procedu esr

Before securing the LRT 110 Crane, make sure 2. Secure hook block to hook block tieback.of the following:

3. Lower boom to travel position.1. Fully retract boom and center it over the front

of the LRT 110 Crane. 4. Make certain all outriggers are in the up

CAUTION

position.

5. Place transmission shift lever in neutral.When attaching hook block tohook block tieback, take up cable 6. Apply parking brake.slowly while lowering boom toprevent damage to windshield. 7. Turn ignition switch OFF.

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TM5-3810-305-10

Section VlllTransportability

As required by the procurement specification,provisions are included on the LRT 110 Cranefor highway, air, marine and rail transportation.Figure 4-60 illustrates the weight distribution andlocation of slinging eyes, tiedown lugs andtowing lugs.

Land Transport

The LRT 110 Crane may be driven on publicroads (refer to Vehicular Operation, page 4-18),Normal transport over highways should beaccomplished by hauling on a flatbed truck ortrailer.

LRT 110 Crane Towing Procedure forEmergency Recovery Only Figure 4-59. Driveshaft

This towing procedure is to be used for emer-gency recovery only, such as a dead engine orany other breakdown unabling the LRT 110crane to be moved under its own power. Refer topage 4-56 of this manual for “Emergency LoadLowering” to return the LRT 110 Crane to atravel mode for towing purposes. Do not tow theLRT 110 Crane in any convoy or troop move-ment by this procedure. For convoy or troopmovement, transport on a flatbed truck or trailer.

To prepare the vehicle for towing:

1. Position the boom over the front in the travelposition to prevent engagement of rear axlelockout.

2. Attach the hook block to the hook blocktieback with enough tension to take the slackout of cable.

C A U T I O N

If the LRT 110 Crane is to betowed a distance of more than 1mile (1.6 km) and/or at speedsgreater than 3 mph (4.8 km/h),the front drive shaft must be dis-connected from the front axle.As an alternative to disconnect-ing the drive shaft, if the engineis operable, the engine may bestarted and allowed to idle duringthe towing process. This will cir-culate lubricant in the transmis-

C A U T I O Nsion, lubricating the clutchesduring the towing operation.

When attaching hook block to Failure to disconnect the drive

hook block tieback, take up cable shaft or to run the engine will

slowly while lowering boom to cause internal damage to the

prevent damage to windshield. transmission as the vehicle istowed.

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TM5-3810-305-10

3.

4.

Disconnect the drive shaft by removing fourcapscrews and two caps (Figure 4-59). Thedriveshaft must be disconnected from thefront axle and secured to a frame crossmem-ber to prevent it from contacting the rotatingaxle input yoke or the ground while thevehicle is being towed. The spider bearingcaps must be taped or wired together toprevent them from falling off and being lost.

Place the two-wheel/four-wheel drive shiftlever, located at the right of the operator’sseat, in the two wheel drive position to pre-vent damage to the transmission duringtowing.

CAUTION

The tow bar MS500048 is theonly tow bar to be used on thisvehicle. If not available, see or-ganizational maintenance. Fail-ure to follow this procedurecould cause damage to equip-ment.

5.

6.

Attach tow bar to the lugs on the outriggerand to towing vehicle.

Release the parking brake in the operator’scab by pulling the lever up to release it. If thevehicle’s electrical power is available, turn onthe emergency four-way flashers.

The crane may now be towed at speeds up to20 mph (32 km/h) (depending on existingconditions) for whatever distance is neces-sary. When making turns, make them as wideas possible (no sharp turns) at no more than 5mph (8 km/h).

Figure 4-60. Preperation for Travel

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TM5-3810-305-10

Air Transport 2. Use the link in the tool box to connect thehook block to the pintle hook on the rear outrig-

The overall height of the LRT 110 Crane allows ger. With the winch, take up the slack in thefor transport without disassembly by C-5, C- 141, cable.and C-130 aircraft. Prepare the LRT 110 Craneas follows:

3. Refer to TM55-3810-165-14 . T ranspor tab i l i t y

1. Retract the boom and lower it over the rear ofGuidance for the Crane. 7.5 Ton. RoughTerrain. Koehring. Type 1, {NSN 3810-01-

the carrier (Figure 4-61 ). 165-0646}, Type 2, {NSN 3810-01-165-0467}and the sh ipp ing da ta p la tes fo r t i edown

CAUTIONrequ i rements .

Apply only enough tension to thecable to take up the slack. Fail-ure to follow this procedurecould cause damage to equip-ment.

OVERALL LENGTH 342 in. (8.69 m) SHIPPING CUBAGE 1767 cu. ft (50.04 cu. m)OVERALL HEIGHT 93 in. (2.36 m) OVERALL WIDTH 96 in. (2.44 m)

Figure 4-61. Air Transport Tiedowns

4-74

TM5-3810-305-10

Rail Transport

Weight of hook block is approxi-mately 235 lb (107 kg). Use ade-quate lifting equipment andalways properly support hookblock. Do not lift over personnelor let personnel walk underneathsuspended load. Failure tofollow this procedure could causeDEATH or serious injury.

1. Using hoist and sling, remove the hook blockfrom the cable. Store it in the tool box andblock it to prevent it from moving.

2.

3.

4 .

5.

6.

Retract the boom and lower it over the front.Wind the cable back on the winch drum, andwire the socket down to prevent the cablefrom loosening on the winch drum.

Install a 1/2 in. 6x19 IWRC cable around theload sheave and the hook block tieback.

Refer to TM55-3810-01-165-14, Transpor-

t a b i l i t y G u i d a n c e for the Crane. 7.5

Ton, Rough Terrain, Koehr ing, Type 1,{NSN 3810-01-165-0646}, Type 2 {NSN3810-01-165-0467} and the shipping datap la tes fo r t i edown requ i rements .

Place the fuel shut-off on the rear wall of thecab in the off position. Put the transmissionshift lever in the center (neutral) position, andrelease the parking brake.

Remove all loose tools and equipment fromthe operators cab. Stow and secure all toolsand equipment in the tool box.

7. Band the tool and battery box lids shut.

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Transport For LRT 110 Crane

For loading aboard ship, the LRT 110 Crane may be slung in a horizontal attitude from the lifting eyeson the ends of the outrigger boxes. Figure 4-66 shows the slinging geometry, indicating the sling apexof the vehicle’s center of gravity. If provisions exist, the LRT 110 Crane may be driven aboard the shipin a forward or backward direction. Once aboard, the LRT 110 Crane may be maneuvered into tightquarters by using the crab steering capability. Tie down the vehicle as required using the tiedown lugsprovided.

Figure 4-66. Marine Transport

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TM5-3810-305-10

CHAPTER 5TYPE II SUPPLEMENT

Section Tit le Page

SectionalizationPreparation for and Sectionalization of the LRT 110 5-2

Type II Crane for External Air Transport (EAT)Preparation for and Assembly of Sectionalized LRT 110 5-26

Type II Crane After External Air Transport (EAT)

TransportabilityLand Transport 5-46Air Transport 5-48Rail Transport 5 - 4 9Marine Transport 5 - 5 0

Helicopter Transport 5 - 5 0

5-1

TM5-3810-305-10

Section ISectionalization

The LRT 110 Type II Crane is equipped with a nents are stored on the LRT 110 Crane withsectionalization kit complete with all components pinned connections in storage locations A thru Eand tools necessary to disassemble it into two (Figure 5-l). All tools, extension hoses andseparate loads for transport, and reassemble it on accessories required are stowed in carrier toolanother site. All of the sectionalization compo- box on left side of vehicle.

TOOL BOX

Preparation for and Sectionalization ofthe LRT 110 Type II Crane for External AirTransport (EAT).

Preparation for Separating Upperstruc-ture from Carrier

The LRT 110 Crane should be positioned on asuitable unobstructed location for disassemblyprocedure.

Vehicle must be level to preventpossible loss of control of upper-structure when lifting off ofcarrier. DEATH or seriousinjury may result if upperstruc-ture gets out of control.

1. Start engine and with boom lowered over cab,retracted and in travel position, proceed asfollows:

5-2

Figure 5-1. Storage Locations

TM5-3810-305-10

a.

b.

Set outriggers by extending beams andlowering outrigger pads to the ground.Lift the LRT 110 Crane off ground andlevel it, using bubble level on right side ofconsole.

CAUTION

When removing hook block fromstorage bracket, pay out cablewhile raising boom to preventdamage to windshield.

Raise boom to a 50-degree elevation,keeping hook block in vertical position.Unhook hook block from storage bracket.Lower boom to horizontal position while raising hook block.

c. Shut engine off.

2. Remove anti-two block counterweight (Figure5-2) as follows:

a.

b.

c.

d.

Using 6 mm hex allen wrench, open andsplit the anti-two block counterweighthanging down from boom tip around hoistcable.

Separate and remove counterweight halvesfrom cable. Using capscrews, reassemblecounterweight halves after removal. Figure 5-2.

Remove counterweight from anti-twoblock switch by removing thumbscrewfrom clevis holding chain to anti-twoblock switch.

Remove counterweight and chain. Stowin tool box. Reinstall clevis on anti-twoblock switch with thumbscrew.

Anti-Two Block Counterweight. Switch andHook Block

5-3

TM5-3810-305-10

3.

4.

5.

Observe length of cable endprotruding from cable socket andclamp. If cable end extendsmore than 2 in. (51 mm), adjustcable so no more than 2 in. (51mm) protrude. Excessive cableprotrusion can push cable out ofsocket when hook block ishoisted with plate to boom head.Failure to follow this procedurecould cause DEATH or seriousinjury.

NOTE

When counterweight has beenremoved from anti-block switch,the switch is shut off and LRT110 Crane control disconnectsystem has been deactivated.Functions of raising winch, andextending and lowering boomwill not operate. To use any ofthese functions for the followingprocedures, turn on anti-twoblock BY-PASS switch. This isto be done only as required.

Prepare to raise hook block up to boom headby removing plate ( 1, Figure 5-3) from toolbox and place over dead end bracket on top ofhook block. The LRT 110 Crane should bereeved with a two-part line for this procedure.

Start engine and swing upperstructure andboom around to right side of carrier to 2o’clock position.

Shut engine off.

Figure 5-3.Preparation for Raising the Hook Block

5 -4

TM5-3810-305-10

6.

7.

Weight of mast is approximately98 lb (44 kg). Use two people toproperly support and lift mast.Failure to follow this procedurecould cause DEATH or seriousinjury.

Remove two pins (2) and mast (3) from stor-age location D (Figure 5-4) on left side of up-perstructure. Lay mast (3) on carrier deck forfuture assembly and store two pins (2) in toolbox for future use.

Start engine. Swing upperstructure to left sideof the LRT 110 Crane to an approximate 10o’clock position.

Figure 54. Storage Location D

5-5

TM5-3810-305-10

8.

9.

Lower hook block to ground, positioning it onits side (Figure 5-5). Maintain tension on

cable and continue to pay out 3 ft (914 mm)of cable. Insert wedge block between winchcable and winch brace at counterweight side(Figure 5-6).

Shut engine off.

Figure 5-5. Hook Block

Figure 5-6. Wedge Block in Winch Drum

Figure 5-7. Storage Location C

5 - 6

T M 5 - 3 8 1 0 - 3 0 5 - 1 0

10. Install toggle sheave brackets on top of boomas

a.

b.

c.

d.

e.

f.

follows:

Remove two right side attaching links (4)and toggle sheave brackets (5) fromstorage location C (Figure 5-7) on rightfront side of carrier frame.

Remove two sheave pins (6) from togglesheave brackets (5).

Attach two toggle sheave brackets (5) andattaching links (4, Figure 5-8) to studs ontop of boom. The cable should lay overtwo toggle sheave brackets (5), betweenears. Secure two attaching links (4) andtoggle sheave brackets (5) with two lynchpins (7) tethered to attaching links (4).

Remove two sheaves (8) from tool boxand install on toggle sheave brackets (5)with sheave pins (6). Make sure hex headof sheave pin (6) is aligned with key stockon toggle sheave bracket (5).

With anti-two block safetyfeature not functional, do notapply excessive line pull to cable.This can cause serious damage tocable, hook block, boom headand winch.

Start engine. Hold on anti-two block BY-PASS switch (Figure 5-9).

Maintain tension on cable and removewedge block from winch drum. Usingwinch control lever, pull hook block andplate up to and in contact with boom head.Stop as soon as contact is made.

Figure 5-8. Installing Sheaves

Figure 5-9. Anti-Two Block Panel

5 -7

TM5-3810-305-10

11. Shut engine off.

Be aware of limited work areawhile lifting, reaching andassembling the mast and lift arm.The deck and fender surface issmall and can become slippery ininclement weather. Failure tofollow this procedure could causeDEATH or serious injury.

12. Install mast (3) on carrier as follows:

Figure 5-10. Assembling the Masta. With the aid of another person, raise mast

b<

c.

(3) from deck, and lower it over squarepivot bearing (9, Figure 5-10), located onright side of frame, behind operator’s cab.Position stop on mast (3) towards centerline of vehicle between stops. Mast base ears should be over fender. Align ears ontop of mast with support ears on frame.

Remove two truss rods (10), adjustabletruss rod (11 ) and six pins (12) from stor-age location A (Figure 5:11) on right sideof upperstructure.

Figure 5-11. Storage Locations A and BInstall two truss rods (10) to top of carrierframe, one on left side, behind cab, and theremaining one on right side of cab. Installfour pins (12, Figure 5-11 A) in connectingpoints.

Figure 5A. Installing the Truss Rods

5-8

TM5-3810-305-10

13. Install lift arm (16) as follows:

a.

b.

c.

d.

With lift arm (16) still in storage locationB on right side of boom, pull out sheavepin (13) and remove sheave (14) fromsheave bracket (15, Figure 5-11 ).

Temporarily lay sheave (14) aside.

Weight of the lift arm isapproximately 95 lb (43 kg).Use two people to properlysupport and lift the lift arm.Failure to follow this procedurecould cause DEATH or seriousinjury.

Remove lift arm (16) and pins (17) and(18) from storage brackets. Place pin (18)in tool box for future use.

With sheave bracket (15) down, connectlift arm (16) to base of mast (3) with pin(17, Figure 5-12).

e.

f.

Using two pins (12), attach adjustabletruss rod (11) to top of mast (3) and top oflift arm (16). The mast and arm assemblyis now complete.

Temporarily swing mast and arm assemblyout of the way.

14. Start engine. Raise boom until a minimumboom angle of 45 degrees is observed onboom angle indicator.

15. Shut engine off.

The crane winch is used to hoist and separateupperstructure from carrier. Extension hoses areadded to winch hydraulic circuit, supplyingpower to winch to hoist upperstructure off carrierand lower it to ground.

The rotary manifold is located internally incenter of upperstructure. Access to rotary mani-fold is through opening under boom and throughcutout on sides of upperstructure.

Figure 5-12. Assembling the Mast

5-9

TM5-3810-305-10

16. Prepare crane winch for hoisting as follows:

a.

b.

Never disconnect hydraulic linesor fittings before venting pres-sure. Turn dipstick 1/4 turn tosafety notch to relieve pressure.Failure to follow this procedurecould cause SERIOUS INJURY.

Turn dipstick 1/4 turn to safety notch torelieve pressure.

Disconnect two winch hoses, tagged H-10and H-11 (Figure 5-13), attached to rotarymanifold with quick disconnect fittings.These hoses come down from winch on

c.

right side of upperstructure and run inthrough hole to rotary manifold. Reach inand release attaching disconnects on thesehoses.

Remove two coiled extension hoses (Fig-ure 5-14) from tool box. Their ends areconnected together by quick disconnects,and are marked with ID tags reading H-10and H-11. Take them to right side ofvehicle.

Figure 5-14. Extension Hoses

Figure 5-13. Rotary Manifold Hoses

5-10

TM5-3810-305-10

NOTE of earner. Remove protective dust capsand connect male connectors of extension

Be sure to keep the hoses and hose H-10 to H- 10 winch hose and exten-their quick disconnect ends clean sion hose H-11 to H-11 winch hose (Fig-during this procedure. ure5-15).

d. Disconnect ends and uncoil hoses. f. Connect loose ends of H- 10 and H- 11 ex-tension hoses to respective tagged fittings.

e. Locate the two quick disconnect fittings The winch hoses are now attached fromthat extend down from two tees on winch valve to original winch hoses with thesevalve next to frame, underneath right side extensions.

Figure 5-15. Quick Disconnect Fittings

5-11

TM5-3810-305-10

CAUTION

DO NOT use a torque wrench forremoval purposes. Failure tofollow this procedure could causedamage to equipment.

17. Remove 10 upperstructure mounting cap-screws and 20 washers from inside upper-structure, by using a 36 mm socket, twoadapters, torque multiplier, short and long ex-tensions, breaker bar, and extension bar(Figure 5-16). All these tools are found intool box (refer to Tools for Sectionalization,page 5-45). Set mounting capscrews andwashers aside where they will not be kickedoff deck, as they will be reinstalled shortly.

R E A R

wF R O N T

Location TOOLS REQUIRED BY TOOL NUMBERRef (REFER TO PAGE 5-45)

1 6 2 8 4 15 25 52 6 2 8 4 15 253 6 3 2 8 4 15 25 54 6 2 8 4 15 25 513 6 3 2 8 4 15 25 514 6 3 2 8 4 15 25 515 6 4 2 8 15 25 516 6 2 8 4 15 25 517 6 4 2 8 15 25 518 6 3 2 8 4 15 25 5

Figure 5-16. Tools Used for Remo al of Mouv nting Capscrews

5-12

5

TM5-3810-305-10

18. With a 36 mm socket, remove stop pin andlockwasher from torque arm bracket on sideof rotary manifold. Stem stop pin and lock-washer in tool box.

19. Disconnect wire harness (Figure 5-17) con-nected to electrical collector ring.

20. Relieve pressure in extend-retract valvecircuit by turning ignition switch ON, hold-ing on anti-two block BY-PASS switch andoperating boom telescope lever in both direc-tions several times until pressure is released.Turn ignition switch OFF and proceed as fol-lows:

a.

b.

c.

Disconnect boom extend-retract hosequick disconnects from rotary manifold.

Remove two plugs size 12 from tool boxand plug hoses.

Roll both hoses back to rear opening andhang the right extend hose over lip of

opening. Hang left retract hose over rightextend hose and under tab (Figure 5-18).

NOTE

Make sure that all capscrews andstop pin are removed from insideupperstructure and wire harnessis disconnected from electricalcollector ring.

21. Start engine. Lower hook block 12 in. (305mm) from boom head and proceed as fol-lows:

a. Lower boom to horizontal position.

b. Shut engine off.

Figure 5-18 L ocation of Boom Extend-Retract HosesAfter Disconnection

5-13

TM5-3810-305-10

22. Relieve pressure in boom hoist circuit byturning ignition switch ON, holding on anti-two block BY-PASS switch and operatingboom hoist lever in both directions severaltimes until pressure is released. Turn ignitionswitch OFF and proceed as follows:

a. Disconnect two boom hoist cylinder hoses(Figure 5-19) from manifold. Access isthrough cutout in front of upperstructure.

b. After disconnecting, pull hose ends outthrough front hole to keep them out of theway. Remove two plugs size 10 from toolbox and plug hose ends (Figure 5-20).

Figure 5-20 Location of Boom Hoist Cylinder HosesAfter Disconnection

Figure 5-19 Rotary Manifold Hoses

5-14

TM5-3810-305-10

Preparation for Removing Upperstructurefrom Carrier

1.

2.

3.

Swing mast and lifting arm around frombeside cab and position it over lifting point ofboom, between toggle sheaves (Figure 5-21).

Start engine. Lower hook block to groundand begin paying out cable to form slack fromtoggle sheaves up to clevis on lift arm. Main-tain tension on cable to prevent unspooling.

Insert wedge block between winch cable andwinch brace at counterweight (Figure 5-6). Figure 5-6 Wedge Block in Winch Drum

Figure 5-21 Positioning of Mast and Lifting Arm

5-15

TM5-3810-305-10

4.

5.

Take loose sheave (14, Figure 5-22) that wasremoved from lift arm (16) in step 13.a ofPreparation for Separating Upperstructurefrom Carrier and insert it in slack of cable.

Raise sheave (14) and cable up into clevis onlift arm (16) and using sheave pin (13), installsheave (14) in place in clevis.

CAUTION

Make sure three sheaves andcable are in alignment withboom. Failure to follow thisprocedure could cause damage toequipment.

6. Remove wedge block and raise hook block toboom head and draw cable tight. Maintaintension on cable to prevent unspooling. Thetightened cable will help support boom andupperstructure while removing remainingcapscrews.

7. Shut

Figure 5-22 Lifting the Upperstructure

5-16

TM5-3810-305-10

8. Remove 8 remaining mounting capscrews and16 flat washers on outside of upperstructure,using a 36 mm socket, two adapters, torquemultiplier, short and long extensions, breakerbar and extension bar (Figure 5-23).

R E A R

F R O N T

Location TOOLS REQUIRED BY TOOL NUMBERRef. (REFER TO PAGE 5-45)

5 6 3 2 8 15 25 56 6 3 2 8 15 25 57 6 3 2 8 4 15 25 58 6 2 8 4 15 25 59 6 4 2 8 15 25 510 6 4 2 8 15 25 511 6 3 2 8 15 25 512 6 3 2 8 15 25 5

Figure 5-23 Tools Used for Removal of Mounting Capscrews

5-17

TM5-3810-305-10

Removing Upperstructure from Carrier 3. Swing upperstructure around and lower it to

Two personnel are required onthe deck next to upperstructure,one on each side, to observe up-perstructure separation. Anotherperson is required on the groundto handle the tether rope.

2. Start engine. Hold on anti-two block BY-PASS switch and slowly hoist upperstructureoff carrier. Be sure that, while it is raising, itis clearing rotary manifold and electrical col-lector ring cover. It will not be necessary toclear manifold cover by more than 1 to 2 in.(25 to51 mm). Stop hoisting at this point.

ground as follows:

a.Alert all personnel that theupperstructure is to be lifted offthe carrier. Keep all uninvolvedpersonnel clear of the vehiclewhile hoisting and removal aretaking place. Check all pinconnections, cable alignment andmachine bubble level before pro-ceeding with the lift. Failure tofollow this procedure could causeDEATH or serious injury.

1. Remove tether rope from tool box and knotrope to boom head quick reeving pin (Figure5-24).

NOTE

Using one person pushing on lift arm andmast assembly, one person guidingcounterweight end of upperstructure andone person holding the tether rope, swingupperstructure around to right side ofcarrier.

Figure 5-24 Attached Tether Rope

5-18

TM5-3810-305-10

b.

c.

Align upperstructure parallel to carrierwith boom tip to rear and counterweight tofront (Figure 5-25).

Keep arms and hands from underupperstructure. Failure to followthis procedure could causeSERIOUS INJURY.

d.Install canvas bag, located in tool box,around and under base plate of upperstruc-ture. Pull drawstring tight and tie.

I CAUTION

Keep all hoses out of the waywhen lowering upperstructure.Make sure the winch extensionhoses are not pinched against theoutrigger beam as the upperstruc -ture is lowered. This could resultin damage to the extension hoses.

Lower upperstructure until just short oftouching ground.

Figure 5-25 Lowering the Upperstructure

5-19

TM5-3810-305-10

e. Remove posts (19), (20), (21) and (22) andsix pins (23) from storage locations A, Dand E (Figures 5-26, 5-27 and 5-28). Twopins (2) and tube (24) are located in toolbox. Connect one end of posts (19) and(20) to ends of post (21) with two pins(23). Swing remaining ends of posts (19)and (20) up and attach to ears on side of

Figure 5-26 Storage Location D

Figure 5-27 Storage L ocation E

boom with two pins (23, Figure 5-29).Connect one end of post (22) to center ofpost (21) with pin (23); then swing otherend of post (22) up and attach to earsunderneath boom with pin (23). Attachtube (24) to posts (21) and (20) with twopins (2).

Figure 5-28 Storage Location A

Figure 5-29 Support for Front of Boom

5-20

TM5-3810-305-10

NOTE 4.

Make sure hook is turned side-ways, and trunnion rotated sothat bottom of hook block setslevel on ground. Use tether ropearound hook to hold hook inplace while lowering.

Lower upperstructure on to front supportbetween outriggers. Position of lift arm (16)should be straight out from side of carrierframe (Figure 5-30).

Figure 5-30 Lowering Upperstructure on Support

5-21

TM5-3810-305-10

Removing and Stowing Parts Used forSeparation

1.

2.

3.

4.

When upperstructure is down, continue to payout approximately 18 ft (5.49 m) to removetension on hoist cable.

Shut engine off.

Block cable at winch drum with a wooden b.wedge (Figure 5-6) to prevent cable from un-winding.

c.Dismantle and restow lift arm ( 16) as follows:

a. Remove hoist line from lift arm (16) by re- d.moving pin (12) connecting adjustabletruss rod (11 ) to top of mast (3, Figure 5-31). e.

Figure 5-6. Wedge Block in Winch Drum

Weight of the lift arm is approxi-mately 95 lb (43 kg), Use twopeople to properly support the liftarm. Failure to follow thisprocedure could cause DEATHor serious injury.

Manually lower lift arm (16) down towardboom.

Remove sheave (14) from clevis on liftarm (16). This will leave the cable slack.

Remove adjustable truss rod (11 ) by re-moving pin (12) from top of lift arm (16).

Remove bottom pin (17) and lift arm (16)from mast (3, Figure 5-3 1). Restow instorage location B (Figure 5-11) on rightside of boom.

Figure 5-31 Assembling the Mast

5-22

TM5-3810-305-10

f.

g.

h.

i.

Install sheave (14) back in clevis on liftarm (16). Index sheave pin (13) and locksheave bracket (15) to side of lift arm ( 16).

Maintain tension on cable and removewooden wedge from winch drum.

Start engine. Hold on anti-two block BY-PASS switch and use winch to pull loosecable down snug against boom, fromboom head to winch. Stop as soon as allslack is removed from cable.

Shut engine off.

5. Remove and stow mast (3) as follows:

a. Remove two truss rods (10) from mast (3, Figure 5-11.

Figure 5-11A). Stow truss rods (10) andadjustable truss rod (11) in storage loca-tion A (Figure 5-11) on upperstructure.

Storage Locations A and B

Figure 5-11A. Installing the Truss Rods

5-23

TM5-3810-305-10

b.

c.

d.

Weight of mast is approximately98 lb (44 kg). Use two people toproperly support and lift mast.Failure to follow this procedurecould cause DEATH or seriousinjury.

Lift mast (3) up off pivot bearing and stowin storage location D (Figure 5-4) onupperstructure.

Disconnect H-10 and H-11 winch exten-sion hoses from both upperstructure andunderneath carrier. Install dust caps ondisconnect fittings at winch valve on rightside of carrier.

Roll up hoses H- 10 and H- 11 and connect

e.

f.

g.

Remove dust caps and plugs from tool box(three sizes, two of each). Plug or capopen hose ends and all open fittings onrotary manifold (Figure 5-20). Lock dip-stick cap on hydraulic tank.

Maintain normal rear axle oscillation withrotary manifold disconnected from upper-structure. Remove wrench from tool boxand, using two mounting capscrews andfour washers, install wrench (Figure 5-32)with pin end engaged in hole of torquearm bracket on rotary manifold. Usebreaker bar and 36 mm socket to tightentwo mounting capscrews.

Thread remaining 16 mounting capscrewsand 32 washers back into threaded holes ofswing bearing.

ends together (Figure 5-14). Return themto tool box.

Figure 5-14. Extension Hoses

Figure 5-4. Storage Location D

5-24

TM5-3810-305-10

Preparation of Carrier for Transport

1. Lower carrier to ground, using the followingprocedure:

a.

b.

Start engine. Raise outrigger beams. Liftoutrigger pads that are underneath boomjust enough to clear ground.

CAUTION

Do not allow outrigger beam,located under upperstructure, tocontact winch hoses. Failure tofollow this procedure could causedamage to equipment.

Using swing lever, rotate swing bearing tounlocked position with cam roller on axlelockout valve, located at rear, bottom ofrotary manifold, centered in notch.

Figure 5-20 Location of Boom Hoist Cylinder HosesAfter Disconnection

2.

3.

NOTE

This position will permit oscilla-tion of rear axle when maneuver-ing carrier away from upperstruc-ture.

Use crab steering and short forward-reversemovements to move the carrier until it is clearof upperstructure.

Prepare outriggers for travel, using the fol-lowing procedure:

a.

b.

c.

Raise outrigger beams to travel position.

Shut engine off.

Remove nuts, washers, bolts and padsfrom ends of outrigger beams. Reinstallbolts, washers and nuts after pads areremoved.

Figure 5-32 Rear Axle Oscillation

5-25

TM5-3810-305-10

4.

5.

6.

d. Stow pads in hanger brackets on right sideof boom toward tip. Secure with rod (25)and two cotter pins (26, Figure 5-33) lo-cated on boom.

Clean and stow all remaining items and tools,used for sectionalization disassembly, in toolbox.

Check fuel tank. Add diesel fuel to bring levelup to the 3/4 full mark.

NOTE

Prior to air lifting carrier, rearaxle must be in locked position.

Start engine. Rotate swing bearing 10 ormore degrees from unlocked position (refer tostep 1 b). Cam roller on valve must be out ofnotch on rotary manifold. Shut engine off.The vehicle is now “sectionalized.”

Preparation for and Assembly ofSectionalized LRT 110 Type II Crane AfterExternal Air Tranport (EAT)

Preparation for Assembly

Carrier is to be positioned parallel to upperstruc-ture on operator’s right side, with boom tip torear and counterweight to front. Front outriggerbeam is to be positioned approximately evenwith upper hose clamp (Figure 5-34).

1. Install pads on outrigger beams.

a.

b.

Remove two cotter pins (26) and rod (25)that stow pads on right side of boom(Figure 5-33). Remove pads for installa-tion and reinstall rod (25) and pins (26) onside of boom.

Remove nuts, washers and bolts from endsof outrigger beams and install pads.Reinstall bolts, washers and nuts to endsof outrigger beams. Torque nuts to 240 lb-ft (325 N ● m).

Figure 5-33 Secure Pads on Boom

5-26

TM5-3810-305-10

2. Start engine. Position carrier next to upper-structure as follows:

a.

b.

c.

d.

Extend outrigger beams and pads downclose to ground.

Using swing lever, rotate swing bearing tounlocked position with cam roller on axlelockout valve, located at rear, bottom ofrotary manifold, centered in notch.

Maneuver carrier over toward upperstruc-ture, positioning right front outrigger beamin under upperstructure (Figure 5-34).

Vehicle must be level to preventpossible loss of control of upper-structure when lifting off ofground. DEATH or seriousinjury may result if upperstruc-ture gets out of control

Figure 5-34 P o s i t i o n i n g O u t r i g g e r

With carrier in place, extend outriggerbeams, raising carrier off ground at allfour corners. Level carrier, using bubblelevel on right side of console.

5-27

TM5-3810-305-10

e.

f.

g.

h.

Align left edge of wrench (Figure 5-32)with right side of lockout valve. Using a36 mm socket and breaker bar, removetwo capscrews and four washers attachingwrench to swing bearing and rotary mani-fold. Remove wrench and stow in toolbox. Capscrews and washers will beinstalled at a later time.

Shut engine off.

Remove remaining 16 capscrews and 32washers from top of swing bearing. Setthem aside, for reinstallation at a latertime.

Check and clean top of swing bearing, ifnecessary, where upperstructure will bebolted down.

i. Remove all dust caps and plugs from con-nectors on hoses and rotary manifold incenter of swing bearing (Figure 5-20).Stow caps and plugs in tool box.

3. Attach winch extension hoses as follows:

a.

b.

Remove two coiled extension hoses (Fig-ure 5-14) from tool box. Their ends areconnected together by quick disconnects,and are marked with ID tags reading H-10and H-11. Take them to right side ofcarrier.

NOTE

Be sure to keep the hoses andtheir quick disconnect ends cleanduring this procedure.

Disconnect ends and uncoil hoses.

Figure 5-32 Rear Axle OscillationFigure 5-20 Location of Boom Hoist Cylinder Hoses

After Disconnection

5 -28

TM5-3810-305-10

c.

d.

● Never disconnect hydrauliclines or fittings before ventingpressure. Turn dipstick cap 1/4turn to the safety notch torelieve pressure. Failure tofollow this procedure couldcause SERIOUS INJURY.

● Turn the face during thefollowing procedure to avoidhaving hydraulic oil splash inface or eyes. Failure to followthis procedure could causeSERIOUS INJURY.

NOTEDuring reconnection of hydraulicquick disconnects, pressurebuild-up may prevent reconnec-tion. Striking the cone at thecenter of the disconnect willrelieve the pressure.

Figure 5-14. Extension Hoses

Turn dipstick cap 1/4 turn to safety notchto relieve pressure.

Locate two quick disconnect fittings thatextend down from two tees on winch valvenext to frame, underneath right side ofcarrier. Remove protective dust caps andconnect male connectors of extension hoseH-10 to H-10 winch hose and extensionhose H-11 to H- 11 winch hose (Figure 5-35). Attach female connectors of exten-sion hose H-10 to H-10 valve fitting andextension hose H-11 to H-11 valve fitting.Stow plugs in tool box.

Winch hoses are now attached from valve to Figure 5-35 Quick Disconnet Fittings

original winch hoses with these extensions.

5-29

TM5-3810-305-10

a.

Be aware of limited work areawhile lifting, reaching andassembling mast and lift arm.Deck and fender surface is small b.

and can become slippery ininclement weather. Failure tofollow this procedure could causeDEATH or serious injury.

4. Install mast (3) on carrier as follows:

Weight of the mast is approxi-mately 98 lb (44 kg). Use twopeople to properly support andlift mast. Failure to follow thisprocedure could cause DEATHor serious injury.

Remove two pins (2) and mast (3) fromstorage location D (Figure 5-4) on left sideof upperstructure. Store two pins (2) intool box for future use.

With the aid of another person, raise mast(3) and lower it over square pivot bearing(9, Figure 5-10), located on right side offrame, behind operator’s cab. Positionstop on mast (3) towards center line ofvehicle between stops. Mast base earsshould be over fender. Align ears on topof mast with support ears on frame.

Figure 5-4. Storage Location D

Figure 5-11. Storage Locations A and B

5-30

Figure 5-10. Assembling the Mast

TM5-3810-305-10

c. Remove two truss rods (10), adjustabletruss rod (11 ) and six pins (12) fromstorage location A (Figure 5-11) on rightside of upperstructure. Install two trussrods (1 O) to top of carrier frame, one onleft side, behind cab, and the remainingone on right side of cab. Install four pins(12) in connecting points (Figure 5-11A).

5. Install lift arm (16, Figure 5-12) as follows:

a. With lift arm (16) still in storage locationB on right side of boom, pull out sheavepin (13) and remove sheave (14) fromsheave bracket (15, Figure 5-11 ).

b. Temporarily lay sheave (14) aside.

Weight of the lift arm is approxi-mately 95 lb (43 kg). Use twopeople to properly support andlift the lift arm. Failure to followthis procedure could causeDEATH or serious injury.

Figure 5-11A. Installing the Truss Rods

c.

d.

e.

f.

Remove lift arm (16) and pins (17) and(18) from storage brackets. Place pin (18)in tool box for future use.

With sheave bracket (15) down, connectlift arm (16) to base of mast (3) with pin(17, Figure 5-12).

NOTE

Adjustable truss rod (11) hasbeen permanently adjusted forthe LRT 110 Crane and shouldnever require adjustment.

Using two pins (12), attach adjustabletruss rod (11) to top of lift arm (16) andthen to top of mast (3). Mast and arm as-sembly is now complete.

Swing assembly around and position overrear fender.

Figure 5-12. Assembling the Mast

5-31

TM5-3810-305-10

Preparing the Upperstructure for Lift

1. Remove wedge block from tool box andlocate it near winch.

2. Start engine. Lower hook block to ground.Pay out a loop of cable approximately 18 ft(5.49 m) from winch to reach up to sheaveclevis at top of lift arm (16, Figure 5-36).Using wedge block, wedge cable to preventcable unspooling (Figure 5-6).

3. Take loose sheave (14, Figure 5-36) that wasremoved from lift arm (16) in step 5.a ofPreparation for Assembly and insert it inslack of cable.

4.

5.

Check that all pins and pinlocksare installed and secured prop-erly. DEATH or serious injurymay result if upperstructurecomes loose.

Raise sheave (14) and cable up into clevis onlift arm (16) and using sheave pin (13), installsheave (14) in clevis. Swing lift arm (16)over upperstructure.

Maintain tension on end of cable and removewedge block from cable spool. Operatewinch until hook block is secured to boomhead.

Figure 5-6. Wedge Block in Winch Drumr

Figure 5-36 Preparing Upperstructure for Lift

5-32

TM5-3810-305-10

6.

7.

8.

9.

Remove tether rope from tool box and knotrope to boom head quick reeving pin (Figure5-24).

Hold on anti-two block BY-PASS switch anduse winch to slowly hoist upperstructure untilsupport bracket clears ground.

Remove three pins (23, Figure 5-37) fromboom support that connects it to upperstruc-ture and remove boom support. Set aside forlater disassembly and storage.

Remove protective bag from base plate of up-perstructure and place in tool box.

Lifting Upperstructure onto Carrier

Stay clear of hoisted upperstruc-ture while it is being positionedover carrier. Failure to followthis procedure could causeDEATH or serious injury.

1. With one person handling the tether rope,raise upperstructure high enough to checkbottom of mounting base plate to see if it isclean. Remove any foreign material that mayhave accumulated on mounting base plate.

Figure 5-24 Attached Tether Rope Figure 5-37 Boom Support Removal

5-33

TM5-3810-305-10

NOTE

Two personnel are required onthe deck next to the upperstruc-ture, one on each side, to observethe upperstructure alignment.Another person is required on theground to handle the tether rope.

2. Continue to hoist assembly high enough toclear rotary manifold and electrical collectorring cover (1 to 2 in. [25.4 to 50.8 mm] issufficient).

3. By pushing on lift arm and pulling with tetherrope, manually swing upperstructure intomounting position with boom pointing in a 10o’clock direction on left side of carrier (Figure5-38).

Keep hands and arms clear of allpinch points while checking thealignment of the upperstructureand the carrier mounting surface.Failure to follow this procedurecould cause SERIOUS INJURY.

CAUTION

Make sure the base plate openingclears the connections on therotary manifold, Failure tofollow this procedure could causedamage to equipment.

4. Slowly lower the upperstructure over rotarymanifold to within 0.5 in. (13 mm) of rotarymanifold.

Figure 5-38 Installing Upperstructure

5 - 3 4

TM5-3810-305-10

Installing Upperstructure on Carrier

1.

2.

3.

Align the upperstructure and swing bearing bymanually starting four mounting capscrewsand eight washers into the outside comerholes 6, 8, 9 and 11 (Figure 5-38). Lowerupperstructure to swing bearing.

Align torque arm on rotary manifold andanchor ear on inside of upperstructure frameby swinging the upperstructure.

With alignment correct, install four mountingcapscrews and eight washers in remainingoutside mounting holes. Tighten eightmounting capscrews. The final torquing willbe done after remaining mounting capscrewsare installed on inside of upperstructure.

Removing and Stowing Parts Used forAssembly

1. Remove hoist cable from lift arm (16) as fol-lows:

a.

b.

c.

Remove tether rope from boom head andstow in tool box.

Lower hook block to ground and pay outcable 12 in. (305 mm) while maintainingtension on cable. Insert wedge block inwinch drum (Figure 5-6).

Remove sheave (14) and cable from liftarm (16) by removing pin (13) from theclevis that retains sheave (14, Figure 5-39). Temporarily lay pin (13) and sheave(14) aside.

Figure 5-39 Lifting the Upperstructure

5-35

Figure 5-6. Wedge Block in Winch Drum

TM5-3810-305-10

d. Swing lift arm and mast out of the way.

e. Shut engine off.

2. Disconnect winch extension hoses as follows:

a. Relieve pressure in winch circuits byturning ignition switch ON, holding onanti-two block BY-PASS switch and oper-ating winch lever in both directions sev-eral times until pressure is released. Turnignition switch OFF.

Turn the face during the follow-ing procedure to avoid havinghydraulic oil splash in face oreyes. Failure to follow thisprocedure could cause SERIOUSINJURY.

b. Disconnect winch extension hoses H-10and H-11 (Figure 5-15) from both upper-structure and underneath carrier. Do notconnect winch lines to rotary manifold atthis time. Install dust caps on quickdisconnect fittings on valve under carrier.

WINCHHOSES

Figure 5-14. Extension Hoses

EXTENSIONHOSES

Figure 5-15. Quick Disconnect Fittings

5-36

TM5-3810-305-10

c. Roll up hoses H-10 and H-11 and connectends together (Figure 5-14). Return themto tool box.

3. Relieve pressure in extend-retract and boomhoist circuits by turning ignition switch ON,holding on anti-two block BY-PASS switchand operating extend-retract and boom hoistlevers several times in both directions untilpressure is released. Turn ignition switchOFF.

4. Push the boom hoist cylinder hoses, stickingout through cutout in front of upperstructure,back inside and attach to fittings on rotarymanifold (Figure 5-19).

5. Remove toggle sheave brackets (5) and at-taching links (4) from boom (Figure 5-8) asfollows:

a. Remove two pins (6) and sheaves (8) fromtoggle sheave brackets (5). Stow sheaves(8) in tool box. Remove cable frombracket (5) and restow pins (6) in brackets(5).

b. Remove lynch pins (7) and attaching links(4) from studs on top of boom.

c. Remove cable from between ears andremove toggle sheave brackets (5).

Figure 5-8 Sheaves

Figure 5-19 Rotary Manifold Hoses

5-37

TM5-3810-305-10

d. Stow toggle sheave brackets (5)withattaching links (4) in storage location C,on bracket on right-hand front of earner(Figure 5-7). Secure with pins (6) con-nected to the attaching links (4).

Completion of Upperstructure Assembly

1. Install anti-two block counterweight (Figure5-2) as follows:

a.

b.

c.

Remove clevis from anti-two block switchon boom head. Hook the weight chain onclevis and reinstall on anti-two blockswitch.

Using a 6 mm hex allen wrench, opencounterweight halves.

Install weight halves around hoist linehanging down over boom head sheave.Secure halves with thumbscrews.

2. Raise boom and install mounting capscrewsinside upperstructure using the followingprocedure:

a.

b.

c.

Swing mast and arm assembly out of theway.

Start engine. Raise boom to a minimumof 45-degree angle.

Shut engine off.

Figure 5-7. Storage Location C

Figure 5-2. Anti-Two Block Counterweight, Switch andHook Block

5-38

TM5-3810-305-10

d. Remove stop pin and lockwasher fromtool box and install in upperstructuretorque arm bracket. Make sure end of stoppin goes down through ear on side ofrotary manifold. Tighten stop pin with a36 mm socket and breaker bar (Figure 5-40).

Figure 5-40 Rotary Manifold Hoses

TM5-3810-305-10

e.

f.

Install 10 mounting capscrews and 20washers inside of upperstructure (Figure 5-41).

Tighten all 18 capscrews. Refer to Figure5-41 for torquing sequence and tool re-quirements for each mounting capscrew.Set the torque wrench to 205 lb-ft (278N ● m). Using torque multiplier in conjunc-tion with torque wrench, the actual torqueon the capscrew is 722 lb-ft (979 N ● m).

REAR

F R O N T

Location TOOLS REQUIRED BY TOOL NUMBERRef. (REFER TO PAGE 5-45)

1 6 2 8 4 13 7 25 52 6 2 8 4 13 7 25 53 6 3 2 8 13 7 25 54 6 2 8 4 13 255 6 3 2 8 4 13 7 25 56 6 3 2 8 13 257 6 3 4 2 13 7 25 58 6 3 4 2 13 7 25 59 6 3 4 2 13 7 25 510 6 3 4 2 7 25 511 6 3 2 7 25 512 6 3 2 7 2 513 6 3 2 8 4 13 7 25 514 6 3 2 8 13 7 25 515 6 4 2 7 25 516 6 4 2 7 25 517 6 4 2 7 2518 6 3 2 8 4 13 7 25 5

Figure 5-41 Tools Used for Tightening of Capscrews

5 -40

4

4

13

4

5

5

7

7

5

5

TM5-3810-305-10

3. Connect hoses and wiring harness to rotary c.manifold using the following procedure:

a.

b.

Relieve pressure in extend-retract valvecircuit by turning ignition switch ON,holding on anti-two block BY-PASS d.switch and operating boom extend-retractlever in both directions several times untilpressure is released. Turn ignition switchOFF. e.

Connect extend-retract hoses, hookedunder tabs (Figure 5-13), onto rotarymanifold. f.

Remove plugs from winch hoses and stowin tool box. Connect winch hoses H-10and H-11 to connectors on rotary mani-fold.

Reconnect wiring harness on collectorring. The anti-two block system is nowoperable.

Check to make sure the torque arm stoppin, hoses and wiring harness are all inplace and connected to rotary manifold.

Turn hydraulic reservoir cap 1/4 turnclockwise to close reservoir.

Figure 5-13. Rotary Manifold Hoses

5-41

TM5-3810-305-10

Removal and Stowage of RemainingParts Used in Assembly

1. Lower boom to horizontal position using thefollowing procedure:

a. Remove wedge from winch and stow intool box.

b. Start engine. Lower boom to a horizontalposition while raising hook block.

c. Remove plate (1) from top of hook block(Figure 5-3) and stow in tool box.

d. Shut engine off.

2. Remove and stow lift equipment as follows:

a.

b.

Weight of lift arm is approxi-mately 95 lb (43 kg). Use twopeople to properly support andlift the lift arm. Failure to followthis procedure could causeDEATH or serious injury.

Remove pin (12) from adjustable truss rod(11) at top of mast (3) and lower lift arm(16) to deck. Remove pin (12) fromadjustable truss rod (11 ) and set adjustabletruss rod (11 ) aside temporarily. Removepin (17) from lift arm (16) at base of mast(3, Figure 5-42).

Remove lift arm (16) and stow in locationB using one pin from tool box. Installsheave (14) back in clevis on lift arm (16)with pin (13). Index sheave pin (13) andlock sheave bracket to side of lift arm (16,Figure 5-11 ).

Figure 5-3. Preparation for Raising the Hook Block Figure 5-42 Disassembling the Mast

5-42

TM5-3810-305-10

c.

d.

Remove two truss rods (10) from mast (3, e.Figure 5-42) and stow two truss rods (10)and adjustable truss rod (11, Figure 5-11)in location A on upperstructure.

Weight of mast is approximately98 lb (44 kg). Use two people toproperly support and lift themast. Failure to follow thisprocedure could cause DEATHor serious injury.

Remove mast (3, Figure 5-42) and lay ondeck.

Disassemble and stow boom support thatwas removed in step 8 of Preparing theUpperstructure for Lift. Remove two pins(2) and tube (24, Figure 5-29) and store intool box. Remove three remaining pins(23) that connect posts (19), (20) and (22)to post (21). Using pins (23), stow post(19) at storage location D (Figure 5-26) onupper structure, post (20) at storage loca-tion A (Figure 5- 11) on upperstructure andposts (21) and (22) at storage location E(Figure 5-27) on frame.

Figure 5-11 Storage Locations A and B Figure 5-26 Storage Location D

Figure 5-29 Support for Front of Boom Figure 5-27 Storage Location E

5-43

TM5-3810-305-10

f.

g.

h.

Start engine.

Swing boom to 2 o’clock position andstow mast (3) on upperstructure storagelocation D (Figure 5-4) using additionalpin from tool box.

Shut engine off.

3. Account for and clean all tools used in assem-bly procedures. Put away all tools in toolbox.

Lower the LRT 110 Crane to the Ground

1.

2.

3.

CAUTION

When attaching hook block tohook block tieback, take up cableslowly while lowering boom toprevent damage to windshield.

Start engine. Center boom over cab and raiseboom to a 50-degree angle. Lower hookblock down far enough to hook it into hookblock tieback on front of the LRT 110 Crane.Lower boom to travel position while takingup slack in cable.

Raise outriggers, lowering the crane toground. Retract outrigger beams up to travelposition. Shut engine off.

Recheck stowage of all items used for assem-bly of the LRT 110 Crane, The crane is nowready for normal operation.

Figure 5-4. Storage Location D

5-44

TM5-3810-305-10

REF

12

345678910111213141516171819202122232425

2627

TOOLS AND PARTS FOR SECTIONALIZATION

TOOL

HOSE H-10, H-11TORQUE MULTIPLIERw/reaction bar, 3/4 drive,1/2 inputSHORT EXTENSION, 3/4 driveLONG EXTENSION, 3/4 driveEXTENSION BAR36 mm SOCKETTORQUE WRENCH, 1/2 driveREDUCER, 3/4 f to 1/2 mHAMMERTAPERED PUNCHPLIERSROPEADAPTER, 1/2 f to 3/4 mWOODEN WEDGEBREAKER BAR, 3/4PLASTIC CAP -10PLASTIC PLUG -10PLASTIC CAP -12PLASTIC PLUG -12PLASTIC CAP -16PLASTIC PLUG -16BAGWRENCHPLATEPIN, HAIR

ALLEN WRENCH -6 mmTUBE

USE

Winch extension hoses4 to 1 mechanical advantagefor torquing swing bearing capscrews

Use with torque multiplierUse with torque multiplierUse with breaker bar and torque wrenchSwing bearing capscrewsTorquing swing bearing capscrewsAdapt extension to torque multiplierAll purpose useAll purpose useAll purpose useTether boom tipAdapt torque wrench to extensionsWedge winch cableRemoving swing bearing capscrewsCap hoist connectors on manifoldPlug hoist hoses

QTY

21

111111111111122

Cap extend-retract connectors on manifoldPlug extend-retract hosesCap winch connectors on manifoldPlug winch hosesBase plate protectorAxle oscillationHook blockSecure extension bar to breaker bar/torque wrenchAnti-two block counterweightBoom support assembly

22221111

11

Also use the basic issue tools as required from pages 1-25 and 1-26 of this manual.

5-45

TM5-3810-305-10

Section IITransportability

As required by the procurement specification,provisions are included on the LRT 110 Cranefor land, air, marine and rail transportation.Figure 5-44 illustrates the weight distribution andlocation of slinging eyes, tiedown lugs andtowing lugs.

Land Transport

The LRT 110 Crane may be driven on publicroads (refer to Vehicular Operation, page 4- 18).Normal land transport should be accomplishedby hauling on a truck or trailer.

LRT 110 Crane Towing Procedure forEmergency Recovery Only

This towing procedure is to be used for emer-gency recovery only, such as a dead engine orany other breakdown unabling the LRT 110Crane to be moved under its own power. Referto page 4-56 for “Emergency Load Lowering” toreturn the LRT 110 Crane to a travel mode fortowing procedures. Do not tow the LRT 110Crane in any convoy or troop movement by thisprocedure. For convoy or troop movement,transport on a flatbed truck or trailer. To preparethe vehicle for towing:

1. Position the boom over the front in the travelposition to prevent engagement of the rearaxle lockout.

C A U T I O N

When attaching hook block tohook block tieback, take up cableslowly while lowering boom toprevent damage to windshield.

2. Attach the hook block to the hook blocktieback with enough tension to take the slackout of cable.

3.

Figure 5-43 Drive Shaft

CAUTION

If the LRT 110 Crane is to betowed a distance of more than 1mile (1.6 km) and/or at speedsgreater than 3 mph (4.8 km/h),the front driveshaft must be dis-connected from the front axle.As an alternative to disconnect-ing the driveshaft, if engine isoperable, engine may be startedand allowed to idle during thetowing process. This will circu-late lubricant in the transmission,lubricating the clutches duringthe towing operation. Failure todisconnect the driveshaft or torun engine will cause internaldamage to the transmission as thevehicle is towed.

Disconnect the driveshaft by removing fourcapscrews and two caps (Figure 5-43). Thedriveshaft must be disconnected from thefront axle and secured to a frame cross-member to prevent it from contacting the

5-46

TM5-3810-305-10

4.

rotating axle input yoke or ground while thevehicle is being towed. The spider bearingcaps must be taped or wired together toprevent them from falling off and being lost.

Place the two-wheel/four-wheel drive shift

CAUTIONThe tow bar MS500048 is theonly tow bar to be used on thisvehicle. If not available, see or-ganizational maintenance. Fail-

lever, located at right of operator’s seat, in thetwo-wheel drive position to prevent damageto the transmission during towing.

5.

ure to follow this procedurecould cause damage to equip-ment.

Attach tow bar to lugs on outrigger and totowing vehicle.

Figure 5-44 Preparation for Travel

5-47

TM5-3810-305-10

6. Release the parking brake in the operator’scab by pulling up lever to release it. If thevehicle’s electrical power is available, turn onemergency four-way flashers.

The vehicle may now be towed at speeds upto 20 mph (32 km/h) (depending on existingconditions) for whatever distance is neces-sary. When making turns, make them as wideas possible (no sharp turns) at no more than 5mph (8 km/h).

Air Tranport

The overall height of the LRT 110 Crane allowsfor transport without disassembly by C-5, C-141and C-130 aircraft. Prepare the LRT 110 Craneas follows:

1. Retract the boom and lower it over the rear ofcarrier (Figure 5-45).

C A U T I O N

2.

3.

Apply only enough tension to thecable to take up the slack. Fail-ure to follow this procedurecould cause damage to equip-ment.

Use the link in the tool box to connect thehook block on the rear outrigger. With thewinch, take up the slack in cable.

Refer to TM55-3810-01-165 -14, Transpor-tability Guidance for the Crane, 7-5Ton, Rough Terrain, Koehring, Type 1,{NSN 3810-01-165-0646}, Type 2 {NSN3810-01-165-0467} and the shipping dataplates for tiedown requirements.

Figure 5-45 Air Transport Tiedowns

5-48

TM5-3810-305-10

Rail TransportPrepare

the LRT 110 Crane for rail transport as follows:

1.

2.

3.

4 .

Weight of the hook block isapproximately 235 lb (107 kg).Use adequate lifting equipmentand properly support the hookblock. Do not lift over personnalor let personnel walk underneathsuspended. Failure to follow thisprocedure could cause DEATHor serious injury.

Using hoist and sling, remove the hook blockfrom cable. Store it in the tool box and blockit to prevent it from moving.

Retract the boom and lower it over the front.Wind cable back on drum, and wire socketdown to prevent cable from loosening onwinch drum.

Install a 1/2 in. 6x19 IWRC cable around loadsheave and hook block tieback.

Refer to TM55-3810-165-14 TransportabilityGuidance for the Crane, 7.5 Toni RoughTerrain. Koehring, Type 1, {NSN 3810=01-165-0646}, Type 2, {NSN 3810-01-165-0467}and the shipping data plates for tiedownrequirements.

5. Place the fuel shut-off on the rear wall of cab

6.

7.

in the off position. Put the transmission shiftlever in center (neutral) position, and releasethe parking brake

Remove all loose tools and equipment fromthe operator’s cab. Stow and secure all toolsand equipment in the tool box.

Band the tool and battery box lids shut.

5-49

TM5-3810-305-10

Marine Transport Helicopter Transport

For loading aboard ship, the LRT 110 Crane may 1.be slung in a horizontal attitude from lifting eyeson ends of outrigger boxes. Figure5-46 showsslinging geometry, indicating sling apex of thevehicle’s center of gravity. If provisions exist, 2.the LRT 110 Crane may be driven aboard theship in a forward or backward direction. Onceaboard, the LRT 110 Crane may be maneuveredinto tight quarters by using the crab steering ca- 3.

pability. Tie down the vehicle as required usingtiedown lugs provided.

The LRT 110 Crane must be “sectionalized’in two sections according to the instructionsfound in Chapter 5, Section 1.

Attach the slings to the lifting eyes providedon the outrigger beams of the carrier, and onthe boom and upperstructure.

After delivery, reassemble the LRT 110Crane, following instructions found in Chap-ter 5, Section I.

Figure 5-46 Marine Transport

5-50

TM5-3810-305-10

APPENDIX A

Preparation of a New LRT 110 Crane for

Conduct the following checks before putting anew crane into operation (Figure A-1 ):

Engine: Check the oil level, coolant level andthat all clamps on the air intake system are tight.Check that all filters are installed. Look for oilleaks around the engine. Oil level is to be main-tained between ADD and FULL as indicated onthe dipstick.

Transmission: Check transmission oil level dip-stick. Oil level is checked with the enginerunning at idle speed, transmission in neutral andoil warm (160 to 190 degrees F [71 to 88 degreesC]). Oil should be at FULL line on dipstick.

Drive Shafts: Visually check the connectingcapscrews and drive shafts for damage. Examinethe parking brake disc and brake pack. Checkthe function of the brake.

Axles: Visually check all attaching bolts. Checkthe differentials and hub drives for lubricantlevels. Visually check the steering cylinders andtie rods for damage. Check to be sure the torqueon all wheel nuts is 450 to 500 1b-ft (610 to 678N ● m). Visually check tires for damage, andverify tire pressure. Tire pressure should be 90psi (620 kPa).

Swing Gear Box: Check lubricant level in theswing gear box.

Winch: Check oil level, and that the vent is freeto open.

Figure A-1. Loaction of check Points

A-1

TM5-3810-305-10

Check fuel in the fuel tank.

Check hydraulic oil level in the reservoir.

Check all hydraulic components and fittings foroil leaks.

Check batteries for electrolyte level and that allbattery connections are tight and not corroded.

Check brake fluid in brake reservoir.

Lubricate the LRT 110 Crane according to thelubrication chart found in Appendix B up to andincluding the two weeks (80 to 100 hours).

Start the engine and check the gauges whilerunning at low idle rpm. When engine tempera-ture reaches the operating temperature of 190degrees F (88 degrees C), increase the rpm andcontinue to monitor the gauges, making sureeverything is functioning properly. Shut engineoff!

If not already on the LRT 110 Crane, install thecable, hook block and anti-two block counter-weight according to the instructions found inChapters 2 and 4. When all checks are com-pleted and the LRT 110 Crane is reeved, theoperator should familiarize himself with thecontrols and operate the LRT 110 Crane at halfthrottle to gain experience.

Special Break in Requirements for NewLRT 110 Cranes.

These requirements are to be performed afterindicated hours of service.

8 hours: Torque wheel nuts to 450 to 500 lb-ft(610 to 678 N ● m) for a 2-week period.

20 hours: Drain, change filter and refill thetransmission with new fluid.

40 hours: Make an initial replacement of the hy-draulic return line filter.

100 hours: Do the following:

1.

2.

Drain and change winch lubricant.

Tighten the swing bearing capscrews. The 18capscrews in the outer race hold the upper-structure to the bearing. The 22 capscrews inthe inner race hold the bearing to the carrier.Torque all 40 capscrews to 722 lb-ft (979N ● m). Torque winch base mounting cap-screws to 249 lb-ft (338 N ● m). Torque cap-screws of counterweight to 845 lb-ft (1,146N ● m).

A-2

TM5-3810-305-10

APPENDIX B

Lubrication Instructions

Oil levels are to be checked with the LRT 110Crane parked on a level surface in transport posi-tion. Check while the oil is cold, unless other-wise specified.

On plug-type check points, the oil levels are tobe at the bottom edge of the check port. Over-lubrication of nonsealed fittings will not harm thefittings or components. Under-lubrication willlead to a shorter lifetime.

On sealed U-joints, care must be exercised toprevent rupturing seals, Fill only until expansionof the seals becomes visible.

Items not equipped with grease fittings, such aslinkages, pins, and levers, should be lubricatedwith lubricating oil MIL-L-2104 once a week.Oil, applied sparingly, will provide the necessarylubrication and help prevent the formation ofrust. Grease fittings that are worn and will nothold the grease gun, or those that have a stuckcheck ball, must be replaced. Where slide padsare used, cycle the boom and relubricate to insurecomplete lubrication of the entire wear area.

All lubrication and check time intervals are basedon hours of operation under average workingconditions:

●

●

●

●

Daily or 8 hours, whichever comes first.

Weekly or 40 hours, whichever comes first.

Two weeks or 80 to 100 hours, whichevercomes first.

Three months or 250 hours, whichever comesfirst.

● Four months or 500 hours, whichever comesfirst.

● Six months or 1,000 hours, whichever comesfirst.

● Yearly or 1,500 to 2,000 hours, whichevercomes first.

Time Intervals - Unusual Conditions

The LRT 110 Crane will require extra serviceand care when operated under unusual condi-tions. High or low temperatures, long periods ofhard use and continued use in sand, water, mudor snow will break down the lubricants. Add orchange lubricants more often under these condi-tions. However, during long periods when thecrane is not in use, the service intervals can belengthened.

Turntable Gear and Pinion Gear Teeth

Never apply grease to turntablegear while the upperstructure isin motion. Failure to follow thisprocedure could cause DEATHor serious injury.

Gear teeth must be lubricated with a saturatedbrush or swab. Grease a segment; stand clear,swing the upperstructure 10 degrees and greaseanother segment. Repeat until entire ring gear iscoated.

B-1

TM5-3810-305-10

No personnel are permitted onthe deck while rotating upper-structure. Failure to follow thisprocedure could cause DEATHor serious injury.

Lubricate swing bearing through the greasefitting on the inside of cab while rotating theupperstructure.

Cable Lubrication

During fabrication, ropes receive lubrication; thekind and amount depending on the rope’s size,type, and anticipated use. This in-process treat-ment will provide the finished rope with ampleprotection for a reasonable time if it is storedunder proper conditions. But, when the rope isput into service, the initial lubrication may beless than needed for the full useful life of therope. Because of this possibility, periodic appli-cations of a suitable rope lubricant are necessary.The important characteristics of a good wire ropelubricant are as follows:

1. It should be free from acids and alkalis.

2. It should have sufficient adhesive strength toremain on the ropes.

3. It should be of viscosity capable of penetrat-ing the interstices between wires and strands.

4, It should not be soluble in the medium sur-rounding it under the actual operating condi-tions.

5. It should have a high film strength.

6. It should resist oxidation.

● Dry cleaning solvent P-D-680

●

used to clean parts is toxic andflammable. Use only in wellventilated areas and avoidcontact with eyes, skin orclothing. Do not breath vapors.Wear the proper protectiveclothing and equipment:goggles or safety glasses, faceshield and gloves. Do not usenear sparks or open flames anddo not smoke while using it.Failure to follow theseprocedures could causeSERIOUS INJURY.

Compressed air used forcleaning purposes must notexceed 30 psi (207 kPa).Safety glasses must be usedwhen cleaning parts. Failure tofollow this procedure couldcause SERIOUS INJURY.

Before applying lubrication, accumulations ofdirt or other abrasive material should be removedfrom the rope. Cleaning is accomplished with astiff wire brush and dry cleaning solvent P-D-680, and dried with compressed air. Immediatelyafter it is cleaned, the rope should be lubricated.When it is normal for the rope to operate in dirt,rock or other abrasive material, the lubricantshould be selected with great care to makecertain that it will penetrate and, at the sametime, will not pick up any of the material throughwhich the rope must be dragged. As a generalrule, the most efficient and most economicalmeans to do cable lubrication/protection is byusing some method or system that continuouslyapplies the lubricant while the rope is in motion.Many techniques are used, including the continu-ous bath, dripping, pouring, swabbing, painting,and where circumstances dictate, automatic sys-tems can be used to apply lubricants either by adrip or pressure spray method (Figure B- 1 ).

B-2

TM5-3810-305-10

The arrows in the illustration indicate the direction in which the rope is moving.

Figure B-1. Methods of Applying Lubrication

B-3

TM

5-3

81

0-3

05

-10

Figure B

-2. Lubrication

Points

B-4

APPENDIX C TM5-3810-305-10

PUBLICATION REFERENCES

PUBLICATION INDEXES

DA Pam 25-30 . . . . . . . . . . . Consolidated Index of Administration Publications

FORMS

Refer to DA Pam 738-750, The Army Maintenance Management System (TAMMS), forinstructions on the use of maintenance forms pertaining to the vehicle.

PUBLICATION REFERENCES

General

AR 310-2 . . . . . . . . . . . . . . .

CTA 50-970 . . . . . . . . . . . . .

DA Pam738-750 . . . . . . . . . .FM 5-20 . . . . . . . . . . . . . . . .FM 9-207 . . . . . . . . . . . . . . .

FM 20-22 . . . . . . . . . . . . . . .FM 21-11 . . . . . . . . . . . . . . .FM 21-60 . . . . . . . . . . . . . . .FM 31-70 . . . . . . . . . . . . . . .FM 31-71 . . . . . . . . . . . . . . .FM 90-3(HTF) . . . . . . . . . . .FM 90-6(HTF) . . . . . . . . . . .MIL-M-63042C(TM) . . . . . . . .

TC 25-7 . . . . . . . . . . . . . . . .TM 5-331 A . . . . . . . . . . . . . .

TM 9-238 . . . . . . . . . . . . . . .TM 43-0139 . . . . . . . . . . . . . .

Vehicle

FM 21-306 . . . . . . . . . . . . . .LO 5-2350-262-12 . . . . . . . . .

TB 750-651 . . . . . . . . . . . . . .

TM 5-2350-262-10-HR . . . . . .

TM 55-3810 -01-165 -14....

TB 5-3810-305-15 . . . . . . .

Identification and Distribution of DA Publications and Issueof Agency and Command and Administrative PubIications.Expendable/Durable Items (Except Medical, Class V. Repair

Parts, and Heraldic Items)The Army Maintenance Management System (TAMMS)CamouflageOperation and Maintenance of Army Materiel in Extreme

Cold Weather 0 to -65° F (TO 36-1-40)Vehicle Recovery OperationsFirst Aid for SoldiersVisual SignalsBasic Cold Weather ManualNorthern OperationsDesert Operations (How to Fight)Mountain Operations (How to Flight)Manuals, Technical:Procedures for Obstruction of Equipment to PreventEnemy Use

Training Management Skills, Unit DevelopmentUtilization of Engineer Construction Equipment: Volume A:

Earthmoving, Compaction, Grading and DitchingEquipment

Deepwater Fording of Ordnance MaterielPainting Instructions for Field Use

Manual for Tracked Combat Vehicle DriverLubrication Order for Armored Combat Earthmover (ACE),

M9Use of Antifreeze Solutions and Cleaning Compounds in

Engine Cooling SystemsHand Receipt Manual Covering End hem/Components ofEnd Item (COEl), Basic Issue hems (Bll), and AdditionalAuthorization List (AAL) for Armored Combat Earthmover(ACE), M9

Transportability Guidance For The Crane,7.5 Ton, Rough Terrain, Koehring Type 1,(NSN 3810-01-165-0646), Type 2 (NSN 3810-01-165-0647) .Warranty Technical Bulletin For: Crane,7.5 Ton, Rough Terrain, Koehring Type1 and 2. C-1

TM5-3810-305-10APPENDIX C

TM 9-6140-200-14 . . . . . . . . . . .Operator’s Organizational, Direct Support and GeneralSupport Maintenance Manual for Lead-Acid Storage Bat-teries: 4HN, 24 V, MS75047-1; 2HN, 12 V; 6 TN, 12 V

TM 55-2350-262-14 . . . . . . . . . .Technical Manual Transportability Guidance ArmoredCombat Earthmover. M9

Night Vision Equipment

TM 11-5855-236-10 . . ...”... . . Operator’s Manual for Night Vision Goggles, AN/PVS-5 andAN/PVS-5A

TM 11-5855-238-10-HR . . . . . . Hand Receipt Manual Covering End Item/Componentsof End Item (COEI), Basic Issue Items (Bll), and Addi-tional Authorization List (AAL) for Night Vision GogglesAN/PVS-5 and AN/PVS-5A

Chemical, Biological, and Nuclear

FM 3-4 . . . . . . . . . . . . . . . . . . . . . .. NBC ProtectionFM 3-5 . . . . . . . . . . . . . . . . . . . . . . NBC DecontaminationFM 3-6 . . . . . . . . . . . . . . . . . . . . . . . Field Behavior of NBC Agents (Including Smoke and

Incendiaries)TF 3-4899 . . . . . . . . . . . . . . . . . . . CBR Decontamination, Unit Level, MCB ProficiencyTM 3-4230-214-12&P . . . . . . . . Operator’s and Organizational Maintenance Manual Includ-

ing Repair Parts and Special Tools Lists: DecontaminatingApparatus, Portable DS2, 1 1/2 Quart. ABC M 11

TM 34240-280-10. . . . . . . . . . . . . Operator’s Manual: Mask. Chemical-Biological, Aircraft,ABC-M24 and Accessories: Mask. Chemical-Biological.Tank, M25 and Accessories: Mask. Chemical-Biological.Tank, M25A1 and Accessories

TM 34240-282-L . . . . . . . . . . . . List of Applicable Publications (LOAP) 12 and 20 CFMGas-Particulate Filter Units

TM 36910-227-10 . . . . . . . . . . .Operator’s Manual: Training Set, Chemical Agent Identifi-cation: Simulants, M72A2

TM 43-0001 -26-1 . . . . . . . . . . . .Army Equipment Data Sheets, Chemical Defense Equip-ment

Communications

SB 11-131 . . . . . . . . . . . . . . . . . . .Vehicular Radio Sets and Authorized InstallationsTM 11-5820-498-12 . . . . . . . . . . Operator’s and Organizational Maintenance Manual:

Radio Sets AN/VRC-53. AN/VRC 64. AN/VRC-125,AN/GRC-160

and

TM 11-5820-498-12-HR . . . . . . Hand Receipt Manual Covering End Item/Componentsof End Item (COEI), Basic Issue Items (Bll), and Addi-tional Authorization List (AAL) for Radio Sets AN/VRC-53,AN/VRC-64, AN/GRC-125, and AN/GRC-160

C-2

TM5-3810-305-10

APPENDIX D

BASIC ISSUE ITEMSTYPE I TYPE II

D-1

TM5-3810-305-10

APPENDIX D

COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST

Crane. Wheel Mounted. NSN 3810-01-165-0646-Non-Sectionalized

Type 1&2

ILLUST. NO. NSN DESCRIPTION/CAGEC and PART NO. USABLE ON CODE

1.

2 .

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

5120-01-145-7452

5120-00-277–8301

5120-00-240-5609

5120-00-264-3796

5120-00-293–1289

5120-00-266-1927

4730-00-079-8814

5310-01-212–6134

4730-00-706-8711

4730-00-203-5266

4730-01–271–3751

4730-01-247–2611

5365-01-280-6488

4730-01–270-9651

ratchet wrench/55719/P/N R2428

3/4"X7/8"

open end wrench/55719/P/N S2022 B

9/16”X5/8”

wrench/55719/P/N V020225X8"x 11/16"

Open end wrench/19207/P/N 11655789-4

3/4”X7/8”

adj. wrench/55719/P/N DA21212"

socket wrench/09386/P/N 18806

straight adapter/90906/P/N MS51500A6-83

8 to -6

plain nut/01276/P/N 210292-4S- 4

tube reducer/01276/P/N 221501-6-4S-6 to -4

pipe tee/01276/P/N 2090-8-8S- 8

tube plug ftg./01276/900599-6S

–6

machine plug/17335/P/N 2408-10– lo

tube plug ftg./57760/P/N 03CP-12

coupling half/01276/P/N FD(90-1021–04-04

105-106

105-106

1 05- I 06

105-106

105-106

105-106

1 05- I 06

105-106

105-106

105-106

105-106

105-106

105-106

105-106

105-106

105-106

QTY.

1

1

1

1

1

1

1

1

1

1

3

2

D-2

1

1

1

1

TM5-3810-305-10

17.

18.

19.

20.

21.

23

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

4730-(00-955- 1559

4720-01-267-4258

4730-00-781–6089

5310-00-257-6177

4730-00-647-3311

4730-01-297-9072

5120-00-198-5409

5120-00-198–5392

4720-01–262–5215

5315-01-267-2927

4720-01–266-4240

4320-01-126-0014

4720-01-262-5211

4730-00-812-7999

4730-01-266-1369

5340-01-269-1701

2590-01-267-1359

3040-01–285–2914

2910-00-646-9727

straight:adapter/96906/P/N MS51500A6–6 to -4

hose assy./81495/709 1272–166

tube nipple/96906/P/N MS51501A65–6 to –6

plain nut/01276/P/N 210292-6S

tube cap/87373/P/N 306CP–12–12

straight adapter/57760/P/N 0103-8-12-12 to -8

socket key wrench/57719/P/N ALW105/16”

socket key wrench/16786/P/N P8480002105/32’’–hex

hose assy./81495/P/N709 1270-78

retaining pin)96652/P/N 1200-03125-02000

hosea assy./81495/P/N 709 1270-142

hyd. ram pump/19184/P/N HP-121-DA-TL

adapter/57760/0203-4-6

hose assy./81495/P/N 709–1272–18

pipe to tube elbow/81343/P/N 6-4070202

pipe plug/81492/P/N 1219–137-4

protective cap plug/23540/P/N 249–2

special adapter/81495/709-4227

link/81495/P/N 37881

engine cartridge/53203/P/N 020030

105-106

105-106

105-106

105– 106

105-106

I 05-106

105-106

105–106

105–106

105-106

105–106

105-106

105– 106

105-106”

105-106”

105-106”

105-106”

105-106

105–106

105-106

3

1

2

2

2

1

1

1

1

1

1

1

1

1

D-3

24.

1

1

2

1

1

1

22

TM5-3810-305-10

D-4 T y p e I I Sec t iona l i za t ion T o o l K i t

. ,

A p p e n d i x D

TM5-3810-305-10

Appendix D

Basic Issue Items

Crane, Wheel Mounted, Hydraulic

NSN 3810–01–165-0647 Sectionalized. Type II

Type II Basic Issue Items (BII) . include the BII for the Type I LRT 110 in addition to the below listed BII.

2

3.

4.

5.

6 .

7.

8.

9 .

1 0.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Illust. No. NSN

1 . 4720-01-274-1841A. 9905-01-268-7581

B. 9905-01-268-7582

5120-00-509–9092

5120–01-030-1187

5120-00-227–8079

5120-01–278–7281

5120–01-119-4806

5120-01-276-7016

5120-01-133-8880

5120-00-272-8985

5120-00-223–7396

4020-01-28-6173

5120-00–144-5207

5510-01-276-9242

8105-01-286-0935

5315-01-284-9813

3020-01-26l–6856

5365-01-276-7509

Description/CAGEC and Part No. Usable on Code Qty

hose,extension, h–11, h–11h–10 label

h–11 label

torque multiplier/55719/P/N GA184A

5" extesion.drive/55719/P/N GA184A

36MM socket/55719/P/N LDHM362

torque wrench. 1/2" drive/81495/P/N TQR250

adapter 3/4f to 1/2 MM/55719/GLA62

hammer 55719)/P/N BPN 16B

tapered punch/55719/P/N 1816A

pliers/1495/P/N 1226-3

rope/8149/P/N 12178–144

adapter. 1/2f to 3/4 M/55719/P/N GLA12

wooden wedge/81495/P/N 709 1985

extension bar/81495/P/N 709 1977

metal bar/81495/P/N 709 1977

wrench.6MM/81495/P/N610 1039

bag/81495/P/N 709 4324

lock pin/3942 8/P/N 9017A114

space plate/81495/P/N 709 1998

106106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

106

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

D-5

2

groove pulley/81495/P/N 709A1565

16" extension, 3/4" drive/55719/P/N LI22

breaker bar 3/4" drive/55719/P/N 1226-57

22.

23.

25.

26.

27.

28.

3040-01-273-9314

5340-00-071-3836

4730-01-128-5831

5340-00-071-3834

5354-01-013-1040

4730-01-246-8511

5340-01-239-8742

Appendix D

connecting link/81495/P/N 709 1877 106 1

protective cap/01276/P/N 5657-10 106 1

protective plug/01276/P/N5659-10 106 1

protective cap/01276/P/N 5657-12 106 1

protective plug/01276/P/N 5659-12 106 1

protective cap/01276/P/N 5657–16 106 1

protective plug/01276/P/N 5659-16 106 1

D-6

24.

TM5-3810-305-10

TM5-3810-305-10

Appendix E

Additional Authorized List(AAL)

Description NSN U/M Qty

1.Helmut,Construction 8415-00-889-3767 Ea 2

2.Gogles,Protective 4240-00–252-3776 Pr 2

3.Grease Gun 4930-00-253-2478 Ea 1

4. Adapter,Grease Gun Flex 4930-00-288-1511 Ea 1

5. Bag,Pamphlet 7520-00-559-9618 Ea 1

6.Fire Extinguisher 4215-00-555-8837 Ea 1

7. Kit,Sign Vehicle 9909-00-565-6267 Ea 1

8. Kit,First Aid 6545-00-922-1200 Ea 1

WARNING

The pintle hook, NSN 2450-00-835-9093, is authorized for use on Aviation Support Unit Cranes only.

The towing capacity of this pintle hook is 30,000 lbs.. This capacity is 10,000 lbs. less than the standard

cranes pintle hook capacity of 40,000 lbs.. Failure to consider the lower capacity may result in death,in–

jury, or damage to equipment.

NOTE

The smaller pintle hook, adapter aand capscrews are all required to support the Aviation Support Unit Crane.

9. Hook, Pintle 2540-00-835-9093 Ea 1

10.Adapter 2540-01–332-0108 Ea 1

11.Capscerws 5305-00-042-6417 Ea 4

E-1

APPENDIX F

OPERATOR/CREW TM5-3810-305-10

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS )

GENERAL

Your Preventive Maintenance Checks andinspections and care of your equipmentgood operating condition.

Services Table lists therequired to keep it in

Record all deficiencies and shortcomings along with correctiveaction taken on DA Form 2404.

OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES

1. The number column of your PMCS is the source for the numberused on the TM Number Column on DA Form 2404.

2. The interval column of your PMCS Table tells your when to doa certain check of service.-

a.keep in

b.keep in

c.

3. The

While you operate, perform yourmind the WARNINGS and CAUTIONS.

While you operate, perform yourmind the WARNINGS and CAUTIONS.

Before (B) PMCS. Always

During (D) PMCS. Always

Right after you operate, perform your After (A) PMCS.

procedure column of your PMCS Table tells you how to dothe required checks and services. Carefully follow theseinstructions. If you do not have the tools, or if the proceduretells you to, have unit maintenance do the work.

4. If your equipment does not perform as required, refer to thetroubleshooting section in this manual for possible problems.Report any malfunctions or failures on the proper DA Form 2404 orrefer to DA Pamphlet 738-750.

NOTE

The terms ready\available and mission capablerefer to the same status: Equipment is on handand is able to perform listed combat missions (seeDA Pamphlet 738-750).

5. Equipment is not ready/available if column. This columntells you when and why your equipment cannot be used.

6. Always do your PMCS in the same order so it gets to be ahabit. Once you’ve had some practice, you will spot anythingwrong in a hurry.

7. When you do your PMCS, take along a rag or two.

8. While performing PMCS, observe WARNINGS and CAUTIONSpreceding those operations which could endanger your safety orcould result in damage to equipment.

F-1

APPENDIX F

TM5-3810-305-10

Dry cleaning solvent, P-D-680 is toxic andflammable. Wear protective goggles and glovesand use only in well ventilated area. Avoidallowing solvent to contact skin, eyes, andclothes, and do not breathe vapors. Do notuse near open flame or excessive heat. Ifyou become dizzy while using cleaning solvent,get fresh air immediately and get medical aid.If solvent comes in contact with skin orclothing; wash with water. If solvent getsin your eyes, flush with water and get medicalaid immediately. Flash point of solvent is138°F (59°C).

a. Keep it clean. Dirt, grease, oil and debris only get inthe way and may cover up a serious problem. Clean as you workand as needed. Use dry cleaning solvent (P-D-680) to clean metalsurfaces. Use soap and water when you clean rubber or plasticmaterial.

b. Bolts, nuts, and screws. Check that they are not loose,missing, bent or broken. You can’t try them all with a tool, orcourse, but look for chipped paint, bare metal or rust aroundbolt heads. Tighten any bolt, nut, or screw that you find loose.

c Welds. Look for loose or chipped paint, rust or gapswhere parts are welded together. If you find a bad weld, reportit to unit maintenance.

d. Electric wires and connectors. Look for cracked orbroken insulation, bare wires and loose or broken connectors.Report damaged or loose wiring to unit maintenance.

Hoses and fluid lines. Look for wear, damage and leaks.Makeesure clamps and fittings are tight. Wet spots show leaksbut a stain around a fitting or connector can also mean a leak.If leakage comes from a loose fitting or connector, tighten thefitting or connector. If something is broken or worn out, reportit to unit maintenance.

f. Vehicle must be on level ground in order to get correctfluid level measurement.

9. It is necessary for you to know how fluid leaks affect thestatus of your equipment. The following are definitions of thetypes/classes of leakage you need to know to be able to determinethe status of your equipment. Learn and be familiar with them andREMEMBER - when in doubt, notify your supervisor.

Class I Seepage of fluid (as indicated by wetness ordiscoloration) not great enough to form drops.

Class II Leakage of fluid great enough to form drops, but notenough to cause drops to drip from the item beingchecked/inspected.

F-2

WARNING

APPENDIX F TM5-3810-305-10

Class I I I Leakage of fluid great enough to form drops and fallfrom the item being checked/inspected.

CAUTION

Equipment operation is allowable with minor leakages(Class I or I I ) . Of course, consideration must begiven to the fluid capacity in the item/system beingchecked/inspected. When operating with Class I or IIleaks, continue to check fluid levels as required onyour PMCS. Class III leaks should be reported toyour supervisor or unit maintenance. Equipment isnot ready/available if any gasoline leak is present,whether Class I, II, or III (Reference AR 385-55).

F-3

TM5-3810-305-10 APPENDIX F

F-4

APPENDIX F

F-5

T M 5 - 3 8 1 0 - 3 0 5 - 1 0

TM5-3810-305-10

F-6

APPENDIX F

APPENDIX FTM5-3810-305-10

OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES

B . BEFORE D - DURING A - AFTER W - WEEKLY M - MONTHLY

F-7

M5-3810-305-10 APPENDIX F

F-8

TM5-3810-305-10

A

Accelerator PedalAir Cleaner, Checks and

InspectionsAir Transport-Type IAir Transport-Type IIAnti-Two Block PanelAnti-Two Block System,Checks and Inspections

Attachments for Wire Rope,End Fittings and/or

Axle, Theory of OperationAxles

4-8

4-114-725-484-7

4-11

4-353-21-7,A-1

Boom 1-9Boom Angle Indicator 1-24Boom Angle Indicator 4-8Boom Cable Retention Pins, Checksand Inspections 4-11

Boom Cylinder 1-9Boom Hoist Lever 4-6Boom Length Markers 1-24,

4-9Boom Telescope Lever 4-6Brake Fluid, Checks and

Inspections 4-11Brake Pedal 4-8Brakes 1-7Break-In Requirements forNew Cranes A-1

Breaking in New Wire Rope 4-43Bubble Level 4-6

INDEX

c

Cable:Inspection

Installing on WinchItems FurnishedLubricationSpecificationsSpooling on Drums

CapabilitiesCapacitiesCautions, GeneralCenterline of RotationChart, Radius from

Characteristics,Performance

Check List, Pre-MoveChecks and Inspections:

Air CleanerAnti-Two Block SystemBoom PinBrake FluidCableCable and BlockscoolantEngine OilFuelFuel/Water SeparatorHydraulic SystemLeakageLubricationSafety EquipmentTiresTransmission Oil

Checks and Services,Preventive Maintenance

Circuit BreakersClips, Wire Rope:

Fist GripU-Bolt

4-11,4-432-41-24B-14-122-31-51-151-36

1-22

1-54-18

4-114-114-114-114-114-114-104-104-104-104-104-104-104-114-114-10

4-134-64-374-394-38

INDEX-1

TM5-3810-305-10

Cold Start

Cold, ExtremeCompletion ofUpperstructure Assembly

Construction of Wire Rope,Identification and

Control and InstrumentIdentification

Control Settings, InitialAdjustments and

Converter, TorqueCoolant, Checks and

InspectionsCounterweightCranes, New, Break-In

RequirementsCutting Wire RopeCylinder, Boom

D

Dash LightsDash Light SwitchDecals, SafetyDecible Level ChartDefinition of Load RatingReferencesFreely Suspended LoadOperating RadiusSide LoadWorking Arc

Defroster FanDiagnostic Connector PanelDiagnostic Guide to Common

Wire Rope AbusesDimensions, Equipment

SpecificationsDimensions, GeneralDrawbarDrive ShaftsDrums-Plain (Smooth) for

Wire Rope

4-4,4-664-64

5-38

4-28

4-3

4-101-7

4-101-10

A-14-351-9

4-44-51-411-10

1-161-181-181-181-184-84-7

4-50

1-111-121-8A-1

4-42

E

Electrical SystemEmergency Load Lowering

Procedure:Attach Supply HoseLower the BoomLower the Crane off theOutriggers

Lower the Load with theWinch

Prepare the EquipmentRetract the BoomSecure the Hook BlockSwing the CraneMechanically

Emergency Window RemovalEnd Fittings and/or

Attachments for Wire RopeEngine Oil Pressure GaugeEngine Oil, Checks and

Inspections

Engine Temperature GaugeEngine:OperatingStartingStopping

Environmental RequirementsEquipment Inspection, Wire

RopeDimensionsLoad Rating on OutriggersLoad Rating on TiresMaximum Permissible Hoist

Line Load ChartRadius from Centerline of

Rotation ChartWeightsWorking Area Diagram

Extreme HeatExtreme Cold

1-6

4-564-574-60

4-61

4-584-574-584-64

4-564-69

4-354-4

4-10,A-14-4

4-184-174-201-24

1-111-191-20

1-21

1-221-111-234-694-64

INDEX-2

4-55

TM5-3810-305-10

F

Fire ExtinguisherFlexibility of Wire RopeForward-Neutral-ReverseLever

Fuel GaugeFuel, Checks and

InspectionsFuel/Water Separator,

Checks and Inspections

G

Gear RangesGeneral Theory of Operation:General:

CautionsDimensionsWarnings

Guidelines to Inspectionsand Reports of Equipment,Wire Rope and Wire RopeSlings

H

Hand Signals for CraneOperation

Heat, ExtremeHeater:

Shut-OffSwitch

Helicopter Transport-Type II

High Humidity or SaltwaterHoist Line Load Chart,Maximum Permissible

Hoist Line ReevingHook BlockHook, PintleHornHydraulic System

4-84-42

4-64-4

4-10

4-10

1-63-2

1-361-121-27

4-44

4-274-69

4-84-8

5-504-71

1-212-21-241-84-4)-8

Hydraulic System, Checksand Inspections

I

Identification andConstruction of Wire Rope

Ignition SwitchInitial Adjustments andControl Settings

Inspection Summary of WireRope

Inspection, Cable

Inspections, Checks andInstalling:Cable on WinchUpperstructure on CarrierWedge Socket on Cable

Instrument Identification,Control and

Items Furnished, List ofItems Required, List of

J

Job Site, Moving to a

L

Land Transport-Type ILand Transport-Type IILeakage, Checks and

InspectionsLift Procedure:

on Outriggerson Tires

Lift, PreparingUpperstructure for

Lifting Upperstructure ontoCarrier

4-10

4-284-5

4-10

4-544-11,4-454-10

2-45-352-3

4-31-241-24

4-18

4-725-46

4-10

4-204-25

5-32

5-33

INDEX-3

TM5-3810-305-10

List of Items Furnished:Boom AngleBoom Length MarkersCableHook Block

List of Items RequiredLoad Chart:on Outriggerson Tires

Load Lowering Procedure,Emergency

Load Rating References,Definition of

Load Rating:on Outriggerson Tires

Lowering the LRT 110 Craneto the Ground

Lubrication ChartLubrication InstructionsLubrication Points,

IllustratedLubrication, CableLubrication, Checks and

Inspections

M

Major Components:LocationNomenclature

Marine Transport-Type IMarine Transport-Type IIMaximum Permissible Hoist

Line Load ChartMinimum Safety Requirements

for Work PlatformsSuspended from Load Lineor Rigidly Mounted on Boom

Moving the LRT 110 Crane,Before

Moving to a Job Site

1-241-241-241-241-24

1-191-20

4-56

1-16

1-191-20

5-44B-4B-1

B-4B-2

4-10

1-31-44-765-50

1-21

1-42

4-184-18

New Cranes, Break-InRequirements

Nomenclature, MajorComponent

o

Operating Instructions andFunctions:Initial Adjustments andControl Settings

Operation Under Emergencyand Abnormal Conditions

Operation Under NormalConditions

Shut Downstart-upTransportabilityUse of Operator’s Controls

and IndicatorsOperations Inspection,

Wire Rope andOperation:

Under Emergency andAbnormal Conditions

Under Normal ConditionsOperator ObservationsOperator TroubleshootingOutriggers:

Control LeverLift ProcedureLoad ChartLoad RatingPerformance CharacteristicsSwitch (Front)Switch (Rear)

Oversize Limits of WireRope Diameters

A-1

1-4

4-1

4-10

4-56

4-184-714-174-72

4-3

4-43

4-544-184-114-15

4-54-201-191-191-54-54-5

4-30

INDEX-4

N

TM5-3810-305-10

P

Parking Brake LeverParts Used for Assembly,Removing and Stowing

Parts Used for Separation,Removing and Stowing

Performance,Characteristics:Electrical SystemEngineOutriggersTorque ConverterTransmission

Pintle HookPower and Utility

RequirementsPre-Move Check ListPrecautions, SafetyPreparation for Use:Hoist Line ReevingInstalling Cable on WinchInstalling Wedge Socketon Cable

Spooling Cable on DrumsPreparation:for and Assembly of Carrier

and Upperstructureof Carrier for Transportfor Removing Upper-

structure from Carrierfor Separating Upper-structure from Carrier

of Upperstructure forLift

of New Crane forOperation

Preventive MaintenanceChecks and Services(PMCS)

Purpose and Function:GeneralMajor ComponentNomenclature

4-8

5-35

5-22

1-61-51-91-71-61-8

1-244-181-27

2-22-4

2-32-3

5-265-25

5-15

5-2

5-32

A-1

4-131-31-4

1-4

R

Radius from Centerline ofRotation Chart

Rail Transport-Type IRail Transport-Type 11Rail Transport MaterialsList-Type I

Rail Transport MaterialsList-Type II

Rear Axle CenteringIndicator

Reeving, Hoist LineRemoval and Stowage:

of Parts Used forAssembly

of Parts Used forSeparation

of Remaining Parts Usedin Assembly

Removing Upperstructurefrom Carrier, Preparationfor

Replacement of Wire RopeRequirements, Environmental

s

Safety DecalsSafety Equipment, Checks

and InspectionsSafety Precautions:General CautionsGeneral WarningsIntroductionMinimum SafetyRequirements for WorkPlatforms Suspendedfrom Load Line orRigidly Mounted on Boom

Safety DecalsSaltwater, High Humidity orSandy or Dusty Work Sites

1-224-755-49

4-78

5-52

4-42-2

5-35

5-22

5-42

5-154-481-24

1-41

4-11

1-361-271-27

1-421-414-714-70

INDEX-5

TM5-3810-305-10

Seat Adjust LeverSectionalization:Preparation for andSectionalization ofLRT 110 Crane,Type II, for ExternalAir Transport (EAT)

Preparation for andAssembly ofSectionalized LRT 110Crane, Type II, AfterExternal Air Transport(EAT)

Seizing Wire RopeSeparating Upperstructurefrom Carrier, Preparation

Shut DownSocketing Wire RopeSpecial Break-InRequirements for NewCranes

Specifications, EquipmentSpeedometerSpooling Cable on Drumsstart-upStarter ButtonStarting the EngineSteeringSteering SelectorStopping the EngineStorage DataStowage:of Parts Used for

Assemblyof Parts Used for

Separationof Remaining Parts Used

in AssemblySuspension

4-8

5-2

5-264-34

4-714-36

A-11-114-82-34-174-54-171-74-54-201-24

5-35

5-22

5-421-7

Swing Gear BoxSwing LeverSwing SystemSystems:ElectricalHydraulicSwing

T

Tachometer/Hour MeterTerminal Efficiencies

(Approximate) for WireRope

Test Equipment, Tools andTime Intervals-UnusualConditions

Tires:Checks and InspectionsLift ProcedureLoad ChartLoad Rating

Tools and Test EquipmentTorque ConverterTowing Procedure for

Emergency Recovery Only-Type I

Towing Procedure forEmergency Recovery Only-Type II

TransmissionTransmission Oil, Checks

and Inspections

Transmission Speed ShiftLever

Transmission TemperatureGauge

TransmissionTheory of Operation

Transport, Preparation ofCarrier for

Transportability-Type I:Air Transport

A-14-51-8

1-61-81-8

4-4

4-361-25

B-1

4-114-251-201-201-251-7

4-72

5-461-6

4-10A-1

4-6

4-4

3-2

5-25

4-74

INDEX-6

TM5-3810-305-10

Land TransportMarine TransportRail Transport

TowingTransportability-Type II:

Air TransportHelicopter TransportLand TransportMarine TransportRail Transport

TowingTroubleshooting, Operator:

Electrical Circuit Non-Functional

Engine Cranks but DoesNot Start

Engine Does Not CrankEngine Oil Pressure-High

or LowEngine OverheatingTransmission Overheating

Turn SignalsTwo Wheel/Four Wheel Drive

Lever

u

Unreeling and UncoilingWire Rope

Unusual Conditions, TimeIntervals

Upperstructure:Completion of AssemblyInstalling on CarrierLifting onto CarrierPreparing for Lift

Use of Operator’s Controlsand Indicators

4-724-764-75

4-72

5-485-505-465-505-49

5-46

4-15

4-154-15

4-164-164-164-7

4-6

4-31

B-1

5-385-355-335-32

4-3

Utility Requirements, Powerand

v

Vehicle Lights SwitchVehicle ShutdownProcedures

Voltmeter

w

Warnings, GeneralWarranty InformationWedge Socket on Cable,

InstallingWedge Sockets for Wire RopeWeights, Equipment

SpecificationsWheelsWinch

Winch LeverWinch, Theory of OperationWindow Removal, EmergencyWindshield Wiper SwitchWire Rope ClassificationsWire Rope Clips:Fist GripU-Bolt

Wire Rope Damage,Illustrated Examples

Wire Rope Identificationand Construction

Wire Rope Inspection for:AbrasionBird CagingBroken WiresCorrosionDamaged End AttachmentsFatigue FailureHeat DamageKinksLocalized Conditions

1-24

4-5

4-714-4

1-271-27

2-34-40

1-111-71-9A-14-63-34-694-54-284-374-394-38

4 - 5 1

4-28

4-454-474-484-474-474-484-474-474-47

INDEX 7

TM5-3810-305-10

PeeningProtruding CoreReduction in Rope

DiameterScrubbingStretched Rope

Wire Rope InstallationWire Rope Instructions

Breaking in a New WireRope

Cable LubricationClassificationsClipsCutting Wire RopeDiagnostic Guide toCommon Wire Rope Abuses

Drums-Plain (Smooth)End Fittings and/or

AttachmentsEquipment InspectionFlexibility of Wire RopeGuidelines to

Inspections and Reportsfor Equipment, WireRope and Wire RopeSlings

Identification andConstruction

Illustrated Examples ofPossible Wire RopeDamage

InspectionInspection SummaryInstallationOperations InspectionOversized Limits of Wire

Rope DiametersSeizing Wire RopeSocketingTerminal Efficiencies

(Approximate)Unreeling and UncoilingWedge SocketsWhen to Replace Wire Rope

4-484-47

4-464-484-454-304-28

4-43B-14-294-374-35

4-504-42

4-354-554-42

4-44

4-28

4-514-454-544-304-43

4-304-344-36

4-364-294-404-43

Wire Rope Slings 4-44Work Lights Switch 4-5Work Platforms Suspended

from Load Line or RigidlyMounted on Boom, MinimumSafety Requirements for 1-42

Work Sites, Sandy or Dusty 4-70Working Area Diagram 1-23Working Positions 1-23

INDEX-8

By Order of the Secretary of the Army:GORDON R. SULLIVAN

General, United States ArmyChief of Staff

official:

PATRICIA P. HICKERSONBrigadier General, United States Army

The Adjutant General

Distribution:To be distributed IAW DA Form 12-25-E (Block No. 5737) Operator’s maintenance require-

ments for TM 5-3810-305-10.

U.S. GOVERNMENT PRINTING OFFICE : 1994-300-421 (03207)

THE METRIC SYSTEM AND EQUIVALENTS

PIN: 068527-001

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Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it. Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it... They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends?

I am setting this document FREE. This document was made by the US Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on.

I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines:

<A HREF=http://www.liberatedmanuals.com/>Free Military and Government Manuals</A>

– SincerelyIgor Chudovhttp://igor.chudov.com/

– Chicago Machinery Movers