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*TM 5-3810-305-23
TECHNICAL MANUAL
FIELD MAINTENANCE MANUALFOR
CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON
(ROUGH TERRAIN CRANE)LRT 110
TYPE I GENERAL PURPOSE
NSN 3810-01-165-0646TYPE II AIRBORNE/AIRMOBILE
NSN 3810-01-165-0647
*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24
dated 3 December 1991 including all changes.
DISTRIBUTION STATEMENT A: - Approved for public release;
distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY14 SEPTEMBER 2012 03 /15 /20
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WARNING SUMMARY
This warning summary contains general safety warnings and
hazardous materials warnings that must be understoodand applied
during operation and maintenance of this equipment. Failure to
observe these precautions could resul
in serious injury or death to personnel. Also included are
explanations of safety and hazardous materials icons usedwithin the
technical manual.
FIRST AID
For first aid information, refer to FM 4-25.11, First Aid.
EXPLANATION OF SAFETY WARNING ICONS
EAR PROTECTION - Headphones over ears shows that noise level
will harm ears.
ELECTRICAL - Electrical wire to arm with electricity symbol
running through human body shows thashock hazard is present.
EYE PROTECTION - Person with goggles shows that the material
will injure the eyes.
FLYING PARTICLES - Arrows bouncing off face with face shield
show that particles flying throughthe air will harm face.
HEAVY OBJECT - Human figure stooping under heavy object shows
physical injury potential fromimproper lifting techniques.
HEAVY PARTS - Hand with heavy object on top shows that heavy
parts can crush and harm.
HEAVY PARTS - Foot with heavy object on top shows that heavy
parts can crush and harm.
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WARNING SUMMARY - Continued
EXPLANATION OF SAFETY WARNING ICONS - Continued
HEAVY PARTS - Heavy object on human figure shows that heavy
parts present a danger to life orlimb.
HEAVY PARTS - Heavy object pinning human figure against wall
shows that heavy, moving partspresent a danger to life or limb.
HOT AREA - Hand over object radiating heat shows that part is
hot and can burn.
MOVING PARTS - Hand with fingers caught between gears shows that
the moving parts of theequipment present a danger to life or
limb.
MOVING PARTS - Human figure with an arm caught between gears
shows that the moving parts ofthe equipment present a danger to
life or limb.
GENERAL SAFETY WARNING DESCRIPTIONS
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed
15 psi (103 kPa)
nozzle pressure when drying parts with compressed air. Use a
maximum of 30 psi (207 kPa)when cleaning components. DO NOT direct
compressed air against human skin. Failure tofollow this warning
may result in injury. Make sure air stream is directed away from
user andother personnel in the area. To prevent injury, personnel
must wear protective goggles orface shield.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Compressed air used for cleaning purposes must not exceed 30 psi
(207 kPa). Safety glassesmust be used when cleaning parts. Failure
to follow this warning may result in injury or deathto
personnel.
WARNING
Before performing this test, turn the crane power off then on
again to ensure that an
existing two block warning and/or motion cut has not been
overridden.
During this test, DO NOT use the cancel alarm button to clear
audible warnings ormotion cuts.
During this test, DO NOT winch the hook block into the boom tip,
in case the system doesnot cut the crane motions.
Slowly raise the hook block until it lifts the anti-two block
weight and deactivates the anti-two block switch.
Failure to follow these warnings may result in damage to
equipment or injury or deathto personnel.
WARNING
Keep hands out of path of spring-loaded tensioner.
Keep fingers from between belt and pulley.
Failure to follow these warnings may cause serious injury if
tensioner slips.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Wear protective gloves when handling hot gear. Failure to follow
this warning may causeinjury or death to personnel.
WARNING
Weight of crankshaft is approximately 80 lbs (36 kgs). Use
adequate lifting equipment to liftand support crankshaft. Keep
hands out of component. DO NOT lift over personnel or letpersonnel
walk underneath suspended load. Failure to follow this warning may
cause injuryor death to personnel.
WARNING
Weight of cylinder head is approximately 80 lbs (36 kgs). Use
adequate lifting equipment tolift and support cylinder head. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may result in injury or death to
personnel.
WARNING
Wear eye protection when driving ring gear from flywheel.
Serious injury to personnel mayresult from flying metal fragments.
DO NOT use a steel drift pin.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Wear protective gloves when installing ring gear. Serious injury
to personnel may result if hotgear contacts skin.
WARNING
Weight of engine and transmission assembly is approximately
1,800 lbs (816 kgs). Useadequate lifting equipment to lift and
support engine/transmission assembly. DO NOT lift overpersonnel or
let personnel walk underneath suspended load. Failure to follow
this warningmay cause injury or death to personnel.
WARNING
Weight of transmission is approximately 1,100 lbs (499 kgs). Use
adequate lifting equipmentto lift and support transmission. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may cause injury or death to
personnel.
WARNING
Weight of engine is approximately 700 lbs (318 kgs). Use
adequate lifting equipment to liftand support engine. DO NOT lift
over personnel or let personnel walk underneath suspendedload.
Failure to follow this warning may cause injury or death to
personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of radiator and oil cooler assembly is approximately 300
lbs (136 kgs). Use adequatelifting device to lift and support
radiator and oil cooler. DO NOT lift over personnel or letpersonnel
walk underneath suspended load. Failure to follow this warning may
cause injuryor death to personnel.
WARNING
Weight of converter assembly is approximately 60 lbs (27 kgs).
Use adequate liftingequipment to lift and support converter
assembly. DO NOT lift over personnel or let personnelwalk
underneath suspended load. Failure to follow this warning may cause
injury or death topersonnel.
WARNING
Weight of output disconnect group is approximately 67 lbs (30
kgs). Use adequate liftingequipment to lift and support output
disconnect group. DO NOT lift over personnel or letpersonnel walk
underneath suspended load. Failure to follow this warning may cause
injuryor death to personnel.
WARNING
Weight of front cover is approximately 226 lbs (103 kgs). Use
adequate lifting equipment tolift and support front cover. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may cause injury or death to
personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of clutch group is approximately 139 lbs (63 kgs). Use
adequate lifting equipment tolift and support clutch group. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may cause injury or death to
personnel.
WARNING
Wear protective gloves when handling hot bearing. Serious injury
to personnel may result ifhot bearing contacts skin.
WARNING
Parts are under spring tension. Serious injury to personnel may
result from flying parts.Always wear eye protection.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Never reinflate a tire that has been run flat or seriously
underinflated without removing
and checking for tire tube or rim damage.
Never exceed 3 psi (21 kPa) inflation prior to placing tire and
wheel assembly into inflationsafety cage or mounting on a tire
change machine that has a positive lockdown device.
Always inflate tires that are mounted on rims with demountable
side ring flanges or lockrings in an inflation safety cage.
When inflating tires in an inflation cage, always use extension
air hose and pneumatictire inflator-gage.
Improperly seated side ring flanges or lock rings may fly off
during inflation. Never attemptto seat a side ring flange or lock
ring during inflation or after inflation.
Never inflate tires over 40 psi (276 kPa) to seat tire beads. If
beads do not seat, deflate,demount, and check the tire/rim match.
Mount and lubricate according to instructions.
When inflating tires mounted on the vehicle, all personnel must
remain a minimum of10 ft (3.1 m) away from tire and not in possible
path of lock ring or rim flange. Should theyfly off, serious injury
or death may result.
Failure to follow these warnings may cause injury or death to
personnel.
WARNING
Weight of axle assembly is approximately 1,323 lbs (600 kgs).
Use adequate lifting equipmentto lift and support axle assembly. DO
NOT lift over personnel or let personnel walk underneathsuspended
load. Failure to follow this warning may cause injury or death to
personnel.
WARNING
Weight of differential assembly is approximately 120 lbs (54
kgs). Use adequate liftingequipment to lift and support
differential assembly. DO NOT lift over personnel or letpersonnel
walk underneath suspended load. Failure to follow this warning may
cause injuryor death to personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Heating differential mounting bolts to a temperature of 300F
(149C) may be required tobreak down thread sealing compound. Wear
protective equipment while heating and handlingdifferential
mounting bolts. Failure to follow this warning may cause injury or
death topersonnel.
WARNING
Wear protective equipment while heating and handling bearing
cone. Failure to follow thiswarning may cause injury or death to
personnel.
WARNING
Weight of pivot and spindle assembly is approximately 69 lbs (30
kgs). Use adequate liftingequipment to lift and support pivot and
spindle assembly. DO NOT lift over personnel or letpersonnel walk
underneath suspended load. Failure to follow this warning may cause
injuryor death to personnel.
WARNING
Weight of housing assembly is approximately 631 lbs (286 kgs).
Use adequate liftingequipment to lift and support housing assembly.
DO NOT lift over personnel or let personnelwalk underneath
suspended load. Failure to follow this warning may cause injury or
death topersonnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of brake drum is approximately 81 lbs (37 kgs). Use
adequate lifting equipment
to lift and support brake drum. DO NOT lift over personnel or
let personnel walkunderneath suspended load.
The brake linings contain asbestos. Wear a protective breather
respirator whenperforming maintenance on the brake assembly and
brake drum.
Care must be taken when cleaning the brake assembly. Clean the
assembly as a whole
by using a solution of hot soapy water. Go over the assembly
three times or enough tobe sure it is completely clean to prevent
the asbestos fibers from being released into theair and circulated
in the maintenance area.
DO NOT use compressed air to dry the brake assembly. Let it air
dry.
Failure to follow these warnings may cause injury or death to
personnel.
WARNING
Weight of hub and studs is approximately 79 lbs (36 kgs). Use
adequate lifting equipment tolift and support hub and studs. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may result in injury or death to
personnel.
WARNING
Wear protective equipment while heating and handling seal
runner. Failure to follow thiswarning may cause serious injury to
personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of boom is approximately 3,100 lbs (1,406 kgs). Use
adequate lifting equipment to liftand support boom. DO NOT lift
over personnel or let personnel walk underneath suspendedload.
Failure to follow this warning may result in injury or death to
personnel.
WARNING
Weight of boom hoist cylinder is approximately 507 lbs (230
kgs). Use adequate liftingequipment to lift and support boom hoist
cylinder. DO NOT lift over personnel or let personnelwalk
underneath suspended load. Failure to follow this warning may cause
injury or deathto personnel.
WARNING
Heating nut to a temperature of approximately 300F (149C) may be
required to break downthread sealing compound. Wear protective
equipment while heating and handling parts.Failure to follow this
warning may cause injury or death to personnel.
WARNING
Stay clear of boom hoist cylinder rod while extending and
retracting to remove air.Serious injury to personnel may result if
rod jumps unexpectedly.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of hydraulic reservoir is approximately 190 lbs (86 kgs).
Use adequate liftingequipment to lift and support hydraulic
reservoir. DO NOT lift over personnel or let personnelwalk
underneath suspended load. Failure to follow this warning may cause
injury or death topersonnel.
WARNING
Weight of outrigger cylinder assembly is approximately 125 lbs
(57 kgs). Use adequate liftingequipment to lift and support
outrigger cylinder assembly. DO NOT lift over personnel or
letpersonnel walk underneath suspended load. Failure to follow this
warning may cause injuryor death to personnel.
WARNING
Weight of manifold is approximately 200 lbs (91 kgs). Use
adequate lifting equipment to liftand support manifold. DO NOT lift
over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may cause injury or death to
personnel.
WARNING
Weight of cab is approximately 250 lbs (113 kgs). Use adequate
lifting equipment to lift andsupport cab. DO NOT lift over
personnel or let personnel walk underneath suspended load.Failure
to follow this warning may cause injury or death to personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of fender is approximately 99 lbs (45 kgs). Use adequate
lifting equipment to supportfender. DO NOT lift over personnel or
let personnel walk underneath suspended load. Failureto follow this
warning may cause injury or death to personnel.
WARNING
Weight of toolbox is approximately 180 lbs (82 kgs). Use
adequate lifting equipment to supporttoolbox. DO NOT lift over
personnel or let personnel walk underneath suspended load.
Failureto follow this warning may cause injury or death to
personnel.
WARNING
Weight of beam is approximately 129 lbs (59 kgs). Use adequate
lifting equipment to lift andsupport beam. DO NOT lift over
personnel or let personnel walk underneath suspended load.Failure
to follow this warning may cause injury or death to personnel.
WARNING
Weight of swing bearing is approximately 187 lbs (85 kgs). Use
adequate lifting equipmentto lift and support swing bearing. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may cause injury or death to
personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of swing gearbox is approximately 125 lbs (57 kgs). Use
adequate lifting equipmentto lift and support swing gearbox. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may cause injury or death to
personnel.
WARNING
Weight of counterweight is approximately 2,200 lbs (998 kgs).
Use adequate lifting equipmentto lift and support counterweight. DO
NOT lift over personnel or let personnel walk underneathsuspended
load. Failure to follow this warning may cause injury or death to
personnel.
WARNING
Weight of upperstructure is approximately 6,000 lbs (2,722 kgs).
Use adequate lifting
equipment to lift and support upperstructure. DO NOT lift over
personnel or let personnelwalk underneath suspended load.
Upperstructure must be properly supported when lowering to
ground.
Failure to follow these warnings may cause injury or death to
personnel.
WARNING
Weight of boom tip section is approximately 1,500 lbs (680 kgs).
Use adequate liftingequipment to lift and support boom tip section.
DO NOT lift over personnel or let personnelwalk underneath
suspended load. Failure to follow this warning may cause injury or
death topersonnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of boom extend cylinder is approximately 415 lbs (188
kgs). Use adequate liftingequipment to lift and support boom extend
cylinder. DO NOT lift over personnel or letpersonnel walk
underneath suspended load. Failure to follow this warning may
causeinjury or death to personnel.
WARNING
Weight of hook block is approximately 235 lbs (107 kgs). Use
adequate lifting equipment tolift and support hook block. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may cause injury or death to
personnel.
WARNING
Make sure snapring is seated in groove in splined bore of cam.
Snapring will keep brakeclutch assembly correctly positioned in
center of friction brake pack. Brake may bind or failif snapring is
not correctly installed. Failure to follow this warning may cause
injury or deathto personnel.
WARNING
Weight of winch is approximately 300 lbs (136 kgs). Use adequate
lifting equipment to lift andsupport winch. DO NOT lift over
personnel or let personnel walk underneath suspended load.Failure
to follow this warning may cause injury or death to personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Remove jewelry and disconnect battery negative ground cable
before performingmaintenance on this equipment. Failure to follow
these warnings may result in injury or deathto personnel.
WARNING
Particles blown by compressed air are hazardous. Use a maximum
of 30 psi (207 kPa) whencleaning components. DO NOT exceed 15 psi
(103 kPa) nozzle pressure when drying partswith compressed air. DO
NOT direct compressed air against human skin. Make sure airstream
is directed away from user and other personnel in the area. User
must wear protectivegoggles or face shield.
WARNING
DO NOT release cord as cable reel will pull harness rapidly.
Rapidly moving harness mayresult in serious injury or death if it
hits personnel.
WARNING
Safety glasses or face protection must be used when working with
compressed air.Failure to follow this warning may result in serious
injury to personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Weight of brake drum is approximately 81 lbs (37 kgs). Use
adequate lifting equipmentto lift and support brake drum. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may result in serious injury or
death topersonnel.
WARNING
If necessary, heat differential mounting bolts to a temperature
of 300F (149C) to break downsealant. Hot surface may cause burns or
injury. Wear protective equipment while heating andhandling
differential mounting bolts. Failure to follow this warning may
result in serious injuryto personnel.
WARNING
Wear protective equipment while heating and handling spacer.
Failure to follow this warningmay result in serious injury to
personnel.
WARNING
When deflating tires, always ensure tire is completely deflated
before removing from rim.Failure to follow this warning may result
in serious injury or death to personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
When inflating tires, always ensure tires are properly seated.
Improperly seated tires can
burst with explosive force.
DO NOT mix one type of wheel with a different type of tire.
Improper seating of thesecomponents can cause tire and wheel to fly
apart with explosive force.
Failure to follow these warnings may result in serious injury or
death to personnel.
WARNING
Remove jewelry and disconnect battery negative ground cable
before performing
maintenance on this equipment.
Wear protective eye covering. Serious injury to personnel may
result from flying metalfragments.
Wear protective gloves when handling hot parts.
Failure to follow these warnings may result in injury or death
to personnel.
WARNING
Keep all personnel away from winch and hook block area. Failure
to follow this warning mayresult in death or serious injury to
personnel.
WARNING
Use extreme caution when handling heavy parts. Provide adequate
support and useassistance during procedure. Ensure any lifting
device used is in good condition and ofsuitable load capacity. Keep
clear of heavy parts supported only by lifting device. Failure
tofollow this warning may result in injury or death to
personnel.
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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Ensure to tag all cables and valve body properly before
disconnecting. Failure to follow thiswarning may result in injury
or death to personnel.
WARNING
Weight of brake drum is approximately 81 lbs (37 kgs). Use
adequate lifting equipmentto lift and support brake drum. DO NOT
lift over personnel or let personnel walk underneathsuspended load.
Failure to follow this warning may result in serious injury or
death topersonnel.
WARNING
Do not use outriggers to support vehicle. Failure to follow this
warning may result in seriousinjury or death to personnel.
WARNING
Do not remove lifting device until hydraulic pressure has been
built up. Failure to follow thesewarnings may result in damage to
equipment or injury or death to personnel.
EXPLANATION OF HAZARDOUS MATERIALS ICONS
BIOLOGICAL - Abstract bug symbol shows that a material may
contain bacteria or viruses thapresent a danger to life or
health.
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WARNING SUMMARY - Continued
EXPLANATION OF HAZARDOUS MATERIALS ICONS - Continued
CHEMICAL - Drop of liquid on hand shows that the material will
cause burns or irritation to humanskin or tissue.
FIRE - Flame shows that a material may ignite and cause
burns.
HYDRAULIC FLUID PRESSURE - Hydraulic fluid spraying human hand
shows that fluid escaping
under great pressure can cause injury or death to personnel.
RADIOACTIVE - Identifies a material that emits radioactive
energy and can injure human tissue ororgans.
VAPOR - Human figure in a cloud shows that material vapors
present a danger to life or health.
HAZARDOUS MATERIALS DESCRIPTIONS
WARNING
ADHESIVES AND SEALANTS
Use caution when using adhesives and sealants. Prolonged
inhalation of vapors can causelung irritation. Contact with skin
can cause dermatitis. Wear gloves and safety goggles anduse product
in a well-ventilated area away from open flame. If ingested, keep
individual calmand seek medical attention. DO NOT induce vomiting.
If contact with skin or eyes is made,flush thoroughly with water.
Dispose of cleanup rags IAW local policy and ordinances.Failure to
follow this warning may cause injury to personnel.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
BATTERIES
Battery gases can explode. DO NOT smoke or allow sparks or open
flames nearbatteries. Wear safety glasses or goggles when checking
the batteries.
To avoid injury, eye protection and acid-resistant gloves must
be worn when workingaround batteries. DO NOT smoke, use open flame,
make sparks, or create otherignition sources around batteries. If a
battery is giving off gases, it can explode and
cause injury to personnel. Remove all jewelry such as rings, ID
tags, watches, andbracelets. If jewelry or a tool contacts a
battery terminal, a direct short will result ininstant heating,
damage to equipment, and injury or death to personnel.
Sulfuric acid contained in batteries can cause serious burns. If
battery corrosion orelectrolyte makes contact with skin, eyes, or
clothing, take immediate action to stopthe corrosive burning
effects. Seek medical attention in the event of an injury.
a. Eyes. Flush with cold water for no less than 15 minutes and
seek medicalattention immediately.
b. Skin. Flush with large amounts of cold water until all acid
is removed. Seekmedical attention as required.
c. Internal. If corrosion or electrolyte is ingested, drink
large amounts of wateror milk. Follow with milk of magnesia, beaten
egg, or vegetable oil. Seekmedical attention immediately.
d. Clothing/Equipment. Wash area with large amounts of cold
water. Neutralizeacid with baking soda or household ammonia.
Failure to follow these warnings may cause injury or death to
personnel.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL!
Carbon monoxide is a colorless, odorless, deadly poison which,
when breathed,deprives the body of oxygen and causes suffocation.
Exposure to air containingcarbon monoxide produces symptoms of
headache, dizziness, loss of muscularcontrol, apparent drowsiness,
and coma. Permanent brain damage or death topersonnel can result
from severe exposure.
Carbon monoxide occurs in exhaust fumes of internal combustion
engines. It alsooccurs in exhaust fumes of engine coolant heater
(arctic vehicle only). Carbonmonoxide can become dangerously
concentrated under conditions of inadequateventilation. The
following precautions must be observed to ensure safety of
personnelwhen engine of crane is operated.
1. DO NOT operate engine in enclosed areas without adequate
ventilation.2. DO NOT idle engine without adequate ventilation.3.
DO NOT drive vehicle with inspection plates or cover plates
removed.4. BE ALERT for exhaust poisoning symptoms. They are:
Headache
Dizziness
Sleepiness
Loss of muscular control
5. If you see another person with exhaust poisoning
symptoms:
Remove person from area.
Expose person to fresh air.
Keep person warm.
DO NOT permit physical exercise.
Administer cardiopulmonary resuscitation (CPR), if
necessary.
Notify a medic.
6. BE AWARE. The field protective mask for
Nuclear-Biological-Chemical (NBC)protection will not protect you
from carbon monoxide poisoning.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
CBRN EXPOSURE
If Chemical, Biological, Radioactive and Nuclear (CBRN) exposure
is suspected, personnelwearing protective equipment must handle all
air cleaner media. Contaminated filters mustbe handled using
adequate precautions and must be disposed of by trained
personnel.Consult your CBRN Officer or CBRN NCO for appropriate
handling or disposal procedures.Failure to follow this warning may
cause injury or death to personnel. Seek medical attention.
To order this CBRN decal use:
National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN)
- 1709220 Commercial and Government Entity Code (CAGEC) - 11083
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an
environmentally compliant and lowtoxicity material. However, it may
be irritating to the eyes and skin. Use protective gloves
andgoggles. Use in well-ventilated areas. Keep away from open
flames and other sources ofignition. Failure to follow this warning
may cause injury to personnel.
WARNING
If vehicle is parked indoors during performance of Preventive
Maintenance Checks andServices (PMCS), DO NOT run engine unless
exhaust fumes are vented to the outside.Failure to follow this
warning may cause injury or death to personnel due to carbon
monoxidepoisoning.
WARNING
Diesel fuel and other combustible materials are used in
operation and maintenance of thisequipment. DO NOT smoke or allow
open flames in areas where combustible materials arestored or used.
Failure to follow this warning may cause injury or death to
personnel.
WARNING
Never disconnect hydraulic lines or fittings before venting
pressure. Turn dipstick cap 1/4 turnto safety notch to relieve
pressure. Failure to follow this warning may cause death or
injuryto personnel.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
Never perform fan hub bearing end play check with the engine
running. Failure to follow thiswarning may cause death or injury to
personnel.
WARNING
Cooling system is pressurized. Use extreme caution and proper
protection when removingradiator cap after operating temperature is
reached. Steam and hot gases will be escapingthrough the radiator
cap; avoid being burned by these escaping gases. When removing
cap,loosen it slowly to the left, then pause a moment. Continue to
turn cap until it can be removed.Failure to follow this warning may
cause death or injury to personnel.
WARNING
DO NOT disconnect or remove any hydraulic system lines or
fitting unless engine
is shut down and hydraulic system pressure has been relieved.
Tighten allconnections before applying pressure. Escaping hydraulic
fluid under pressure canpenetrate the skin.
At operating temperature, hydraulic oil is hot. Allow hydraulic
oil to cool beforeremoving any hydraulic fitting.
Wear protective eye covering.
Avoid sudden movement of vehicle.
Use a container to catch any fluid that may drain from hoses or
system. Dispose offluid IAW local policy and ordinances. Ensure all
spills are cleaned up.
Failure to follow these warnings may result in injury or death
to personnel.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an
environmentally compliant
and low-toxic material. However, it may be irritating to the
eyes and skin. Useprotective gloves and goggles. Use in
well-ventilated areas. Keep away from openflames and other sources
of ignition.
Improper cleaning methods and use of unauthorized cleaning
solvents may injurepersonnel and damage equipment.
Fire extinguishers should be placed nearby when using solvent
cleaning compound. Cloths or rags saturated with solvent cleaning
compound must be disposed of IAW
authorized facilities procedures.
Eye shields must be worn when cleaning with a wire brush.
Particles blown by compressed air are hazardous. Use a maximum
of 30 psi(207kPa) when cleaning components. DO NOT exceed 15 psi
(103 kPa) nozzlepressure when drying parts with compressed air. DO
NOT direct compressed airagainst human skin. Make sure air stream
is directed away from user and otherpersonnel in the area. User
must wear protective goggles or face shield.
Failure to follow these warnings may result in injury or death
to personnel.
WARNING
When servicing equipment, performing maintenance, or disposing
of materials such
as engine coolant, hydraulic fluid, lubricants, battery acids or
batteries, or ChemicalAgent Resistance Coating (CARC) paint,
consult your unit/local hazardous wastedisposal center or safety
office for local regulatory guidance.
Wear protective eye covering.
Dispose of contaminated drained fluids in accordance with the
Standard OperatingProcedures (SOP) of your unit.
Failure to follow these warnings may result in injury or death
to personnel.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
The brake linings contain asbestos. Wear protective breather
respirator when
performing maintenance on the brake assembly and brake drum.
Care must be taken when cleaning the brake assembly. Clean the
assembly as awhole by using a solution of hot soapy water. Go over
the assembly three times orenough to be sure it is completely clean
to prevent the asbestos fibers from beingreleased into the air and
circulated in the maintenance area.
DO NOT use compressed air to dry the brake assembly. Let it air
dry. Failure to follow these warnings may cause injury or death to
personnel.
WARNING
Liquid nitrogen is extremely cold, having a temperature of -320F
(-195C). Wear protectivegloves that will not absorb liquid
nitrogen. Excess liquid nitrogen must be disposed of promptlysince
liquid nitrogen will condense oxygen from the atmosphere. The
mixture of liquid nitrogenand liquid oxygen is a powerful oxidizer
and may react violently with easily oxidizablesubstances. Failure
to follow this warning may cause injury or death to personnel.
WARNING
Remove jewelry and disconnect battery negative ground cable
before performing
maintenance on this equipment.
Hot coolant and alkali contained in cooling system can burn
severely. Even withcooling system drained, residual coolant remains
in system lines and fittings.Wear protective goggles, face shield,
and clothing when handling cooling systemcomponents. If coolant
contacts eyes, skin, or clothing, flush with large amounts ofcold
water and seek medical attention, if required.
Failure to follow these warnings may result in injury or death
to personnel.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed
15 psi (103 kPa)nozzle pressure when drying parts with compressed
air. Use a maximum of 30 psi(207 kPa) when cleaning components. DO
NOT direct compressed air againsthuman skin. Failure to follow this
warning may result in injury. Make sure air streamis directed away
from user and other personnel in the area. To prevent
injury,personnel must wear protective goggles or face shield.
Solvent cleaning compound MIL-PRF-680 Type III is an
environmentally compliantand low toxicity material. However, it may
be irritating to the eyes and skin. Useprotective gloves and
goggles. Use in well-ventilated areas. Keep away from openflames
and other sources of ignition. Failure to follow this warning may
cause injuryto personnel.
WARNING
Weight of differential assembly is approximately 120 lbs (54
kgs). Use adequate liftingequipment to lift and support
differential assembly. DO NOT lift over personnel or letpersonnel
walk underneath suspended load.
Use caution when using adhesives and sealants. Prolonged
inhalation of vapors can
cause lung irritation. Contact with skin can cause dermatitis.
Wear gloves and safetygoggles and use product in a well-ventilated
area away from open flame. If ingested,keep individual calm and
seek medical attention. DO NOT induce vomiting. If contactwith skin
or eyes is made, flush thoroughly with water. Dispose of cleanup
rags IAWlocal policy and ordinances. Failure to follow this warning
may cause injury topersonnel.
Failure to follow these warnings may result in serious injury or
death to personnel.
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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
Never disconnect hydraulic lines or fittings before venting
pressure. Turn dipstick cap 1/4 turnto safety notch to relieve
pressure. Failure to follow this warning may result in serious
injuryor death to personnel.
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NOTE: This manual supersedes TM 5-3810-305-24 dated 3 December
1991 including all changes. Zero in the
"Cha nge No." column indica tes an origina l page or work
package .
Date of iss ue for the origina l manua l is:
Original 14 September2012TOTAL NUMBER OF PAGES FOR FRONT AND
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HEADQUARTERS DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 14 SEPTEMBER 2012
TECHNICAL MANUAL
FIELD MAINTENANCE MANUAL
FOR
CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON(ROUGH TERRAIN
CRANE)
LRT 110
TYPE I GENERAL PURPOSE
NSN 3810-01-165-0646
TYPE II AIRBORNE/AIRMOBILE
NSN 3810-01-165-0647
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any errors,
or if you would like to recommend anyimprovements to the procedures
in this publication, please let us know. The preferred method is
tosubmit your DA Form 2028 (Recommended Changes to Publications and
Blank Forms) through the
Internet on the TACOM Unique Logistics Support Applications
(TULSA) Web site. The Internet addressis
https://tulsa.tacom.army.mil. Access to all applications requires
CAC authentication, and you must
complete the Access Request form the first time you use it. The
DA Form 2028 is located under theTULSA Applications on the
left-hand navigation bar. Fill out the form and click on
SUBMIT.
Using this form on the TULSA Web site will enable us to respond
more quickly to your comments andto better manage the DA Form 2028
program. You may also mail, e-mail, or fax your comments orDA Form
2028 directly to the U.S. Army TACOM Life Cycle Management Command.
The postal mail
address is U.S. Army TACOM Life Cycle Management Command, ATTN:
AMSTA-LCL-MPP/TECHPUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI
48397-5000. The e-mail address is
[email protected]. The fax number is DSN 786-1856
or
Commercial (586) 282-1856. A reply will be furnished to you.
*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24
dated 3 December 1991 including all changes.
DISTRIBUTION STATEMENT A: - Approved for public release;
distribution is unlimited.
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TABLE OF CONTENTS
Page NoWP Sequence No
HOW TO USE THIS MANUAL
.........................................................................................................................
xlvii
Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND
THEORY OF
OPERATION
GENERAL
INFORMATION..........................................................................................................................
WP 0001
EQUIPMENT DESCRIPTION AND
DATA...................................................................................................
WP 0002
Figure 1. Major
Components...............................................................................................................
0002-2
Figure 2. Major
Components...............................................................................................................
0002-4
Figure 3. Major
Components...............................................................................................................
0002-5
Figure 4. Major
Components...............................................................................................................
0002-6
Table 1. Gear Range
Values............................................................................................................
0002-13
Figure 5. General
Dimensions...........................................................................................................
0002-14
Figure 6. General
Dimensions...........................................................................................................
0002-15
Figure 7. Radius from Centerline of
Rotation....................................................................................
0002-16
Figure 8. Crane Working
Positions....................................................................................................
0002-17
Figure 9. Lift Capacity (on
Outriggers)..............................................................................................
0002-17
Figure 10. Lift Capacity (on
Tires).......................................................................................................
0002-18
Figure 11. Maximum Permissible Hoist Line
Load..............................................................................
0002-18
THEORY OF
OPERATION..........................................................................................................................
WP 0003
Chapter 2 - TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING SYMPTOM
INDEX..................................................................................................
WP 0004
TROUBLESHOOTING PROCEDURES
ENGINE........................................................................................
WP 0005
TROUBLESHOOTING PROCEDURES
HYDRAULICS..............................................................................
WP 0006
TROUBLESHOOTING PROCEDURES SWING
CIRCUIT..........................................................................
WP 0007
TROUBLESHOOTING PROCEDURES BOOM HOIST
CIRCUIT...............................................................
WP 0008
TROUBLESHOOTING PROCEDURES BOOM EXTEND
CIRCUIT...........................................................
WP 0009
TROUBLESHOOTING PROCEDURES OUTRIGGER
CIRCUIT................................................................
WP 0010
TROUBLESHOOTING PROCEDURES STEERING
CIRCUIT...................................................................
WP 0011
TROUBLESHOOTING PROCEDURES
PUMPS.........................................................................................
WP 0012
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TABLE OF CONTENTS - Continued
Page No.WP Sequence No.
TROUBLESHOOTING PROCEDURES RELIEF
VALVES..........................................................................
WP 0013
TROUBLESHOOTING PROCEDURES
BRAKES.......................................................................................
WP 0014
TROUBLESHOOTING PROCEDURES ELECTRICAL
SYSTEM...............................................................
WP 0015
TROUBLESHOOTING PROCEDURES ANTI-TWO BLOCK
SYSTEM....................................................... WP
0016
TROUBLESHOOTING PROCEDURES
TRANSMISSION..........................................................................
WP 0017
TROUBLESHOOTING PROCEDURES AXLE
ASSEMBLY........................................................................
WP 0018
TROUBLESHOOTING PROCEDURES
WINCH.........................................................................................
WP 0019
MSD-ICE TROUBLESHOOTING AND TEST
PROCEDURE......................................................................
WP 0020
Figure 1. Remove Cap from DCA
Receptacle.....................................................................................
0020-3
Figure 2. Schematics and
Diagrams...................................................................................................
0020-7
Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(PMCS)
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INTRODUCTION............................. WP 0021
Table 1. Leakage Definitions for
PMCS.............................................................................................
0021-2
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
(PMCS)......................................................... WP
0022
Table 1. Preventive Maintenance Checks and Services
(PMCS)......................................................
0022-2
Figure 1. Winch Lubrication Level Access
Plug..................................................................................
0022-3
Figure 2. Air Cleaner Element
Maintenance........................................................................................
0022-5
Figure 3. Engine Oil and Filter
Change...............................................................................................
0022-6
Figure 4. Fuel Tank Drain
Plug............................................................................................................
0022-7
Figure 5. Hydraulic Suction Filter
Removal.........................................................................................
0022-9
Figure 6. Transmission Fluid
Change................................................................................................
0022-10
Figure 7. Check Antifreeze
Concentration.........................................................................................
0022-11
Figure 8. Check Axle Differential and Hub Oil
Levels........................................................................
0022-12
Figure 9. Check Axle Differential and Hub Oil
Levels........................................................................
0022-12
Figure 10. Check Fan Hub Bearing End
Play......................................................................................
0022-13
Figure 11. Winch Oil
Change..............................................................................................................
0022-14
Figure 12. Add Hydraulic
Oil................................................................................................................
0022-16
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TABLE OF CONTENTS - Continued
Page NoWP Sequence No
Figure 13. Bleed Air from Hydraulic
Reservoir....................................................................................
0022-17
Figure 14. Swing Reduction Unit Oil
Change......................................................................................
0022-18
Figure 15. Differential Oil
Filter............................................................................................................
0022-19
Figure 16. Engine Coolant
Change.....................................................................................................
0022-20
Figure 17. Engine Coolant
Change.....................................................................................................
0022-21
Figure 18. Check Hydraulic Pressure Relief
Valves............................................................................
0022-22
Figure 19. Relief Valve
Adjustment.....................................................................................................
0022-24
Chapter 4 - MAINTENANCE INSTRUCTIONS
SERVICE UPON
RECEIPT.........................................................................................................................
WP 0023
Figure 1. Vehicle Check
Points...........................................................................................................
0023-3
POWER PACK ASSEMBLY
MAINTENANCE.............................................................................................
WP 0024
Figure 1. Power Pack
Removal...........................................................................................................
0024-2
Figure 2. Power Pack
Removal...........................................................................................................
0024-3
Figure 3. Power Pack
Removal...........................................................................................................
0024-4
Figure 4. Power Pack
Removal...........................................................................................................
0024-4
Figure 5. Power Pack
Removal...........................................................................................................
0024-5
Figure 6. Power Pack
Removal...........................................................................................................
0024-6
Figure 7. Power Pack
Removal...........................................................................................................
0024-7
Figure 8. Power Pack
Removal...........................................................................................................
0024-8
Figure 9. Power Pack
Removal...........................................................................................................
0024-9
Figure 10. Power Pack
Removal...........................................................................................................
0024-9
Figure 11. Power Pack
Removal.........................................................................................................
0024-10
Figure 12. Power Pack
Removal.........................................................................................................
0024-10
Figure 13. Power Pack
Removal.........................................................................................................
0024-11
Figure 14. Power Pack
Removal.........................................................................................................
0024-12
Figure 15. Power Pack
Removal.........................................................................................................
0024-13
Figure 16. Transmission from Engine
Removal..................................................................................
0024-14
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Page No.WP Sequence No.
Figure 17. Transmission from Engine
Removal..................................................................................
0024-15
Figure 18. Transmission from Engine
Removal..................................................................................
0024-16
Figure 19. Transmission to Engine
Installation....................................................................................
0024-17
Figure 20. Transmission to Engine
Installation....................................................................................
0024-18
Figure 21. Transmission to Engine
Installation....................................................................................
0024-19
Figure 22. Transmission to Engine
Installation....................................................................................
0024-20
Figure 23. Power Pack
Installation......................................................................................................
0024-21
Figure 24. Power Pack
Installation......................................................................................................
0024-22
Figure 25. Power Pack
Installation......................................................................................................
0024-22
Figure 26. Power Pack
Installation......................................................................................................
0024-23
Figure 27. Power Pack
Installation......................................................................................................
0024-23
Figure 28. Power Pack
Installation......................................................................................................
0024-24
Figure 29. Power Pack
Installation......................................................................................................
0024-24
Figure 30. Power Pack
Installation......................................................................................................
0024-25
Figure 31. Power Pack
Installation......................................................................................................
0024-25
Figure 32. Power Pack
Installation......................................................................................................
0024-26
Figure 33. Power Pack
Installation......................................................................................................
0024-26
Figure 34. Power Pack
Installation......................................................................................................
0024-27
Figure 35. Power Pack
Installation......................................................................................................
0024-27
Figure 36. Power Pack
Installation......................................................................................................
0024-28
ENGINE ASSEMBLY
MAINTENANCE........................................................................................................
WP 0025
ENGINE MOUNT
MAINTENANCE..............................................................................................................
WP 0026
Figure 1. Engine Mount
Removal........................................................................................................
0026-1
Figure 2. Engine Mount
Installation.....................................................................................................
0026-2
CYLINDER HEAD
MAINTENANCE.............................................................................................................
WP 0027
Figure 1. Cylinder Head
Removal.......................................................................................................
0027-2
Figure 2. Cylinder Head
Removal.......................................................................................................
0027-3
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Figure 3. Cylinder Head
Installation....................................................................................................
0027-4
Figure 4. Cylinder Head
Installation....................................................................................................
0027-5
CRANKSHAFT PULLEY
MAINTENANCE...................................................................................................
WP 0028
Figure 1. Crankshaft Pulley
Removal..................................................................................................
0028-1
Figure 2. Crankshaft Pulley
Installation...............................................................................................
0028-2
FLYWHEEL AND FLYWHEEL HOUSING
MAINTENANCE........................................................................
WP 0029
Figure 1. Flywheel
Removal................................................................................................................
0029-1
Figure 2. Flywheel
Removal................................................................................................................
0029-2
Figure 3. Flywheel
Installation.............................................................................................................
0029-3
Figure 4. Flywheel
Installation.............................................................................................................
0029-3
Figure 5. Flywheel
Installation.............................................................................................................
0029-4
Figure 6. Flywheel
Installation.............................................................................................................
0029-5
Figure 7. Flywheel
Installation.............................................................................................................
0029-6
Figure 8. Flywheel
Installation.............................................................................................................
0029-6
REAR CRANKSHAFT SEAL
MAINTENANCE............................................................................................
WP 0030
Figure 1. Rear Seal
Removal..............................................................................................................
0030-2
Figure 2. Rear Seal
Removal..............................................................................................................
0030-2
Figure 3. Rear Seal
Removal..............................................................................................................
0030-3
Figure 4. Rear Seal
Installation...........................................................................................................
0030-4
Figure 5. Rear Seal
Installation...........................................................................................................
0030-5
ROCKER LEVERS AND PUSH RODS
MAINTENANCE............................................................................
WP 0031
Figure 1. Cylinder Head
Removal.......................................................................................................
0031-2
Figure 2. Rocker Lever and Push Rods
Removal...............................................................................
0031-2
Figure 3. Rocker Lever and Push Rods
Disassembly.........................................................................
0031-3
Figure 4. Rocker Lever and Push Rods
Disassembly.........................................................................
0031-3
Figure 5. Rocker Lever and Push Rods
Inspection.............................................................................
0031-4
Figure 6. Rocker Lever and Push Rods
Inspection.............................................................................
0031-4
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Figure 7. Rocker Lever and Push Rods
Inspection.............................................................................
0031-5
Figure 8. Rocker Lever and Push Rods
Assembly..............................................................................
0031-5
Figure 9. Rocker Lever and Push Rods
Assembly..............................................................................
0031-6
Figure 10. Rocker Lever and Push Rods
Installation............................................................................
0031-6
Figure 11. Cylinder Head
Installation....................................................................................................
0031-7
FRONT GEAR COVER AND GASKET
MAINTENANCE............................................................................
WP 0032
Figure 1. Tachometer Drive
Removal..................................................................................................
0032-2
Figure 2. Front Cover
Removal...........................................................................................................
0032-3
Figure 3. Front Gear Train
Installation.................................................................................................
0032-4
Figure 4. Front Cover
Installation........................................................................................................
0032-5
Figure 5. Tachometer Drive
Installation...............................................................................................
0032-6
TIMING PIN ASSEMBLY
MAINTENANCE..................................................................................................
WP 0033
Figure 1. Timing Pin Assembly
Removal.............................................................................................
0033-1
Figure 2. Timing Pin Assembly
Removal.............................................................................................
0033-2
Figure 3. Timing Pin Assembly
Installation..........................................................................................
0033-3
TAPPET COVER AND GASKET
MAINTENANCE......................................................................................
WP 0034
Figure 1. Tappet Cover
Installation.....................................................................................................
0034-3
VALVE COVERS AND GASKET
MAINTENANCE......................................................................................
WP 0035
Figure 1. Valve Covers
Removal.........................................................................................................
0035-1
Figure 2. Valve Covers
Installation......................................................................................................
0035-2
FRONT CRANKSHAFT SEAL
MAINTENANCE..........................................................................................
WP 0036
Figure 1. Front Seal
Removal..............................................................................................................
0036-2
Figure 2. Front Seal
Installation...........................................................................................................
0036-4
LUBE OIL COOLER AND FILTER HEAD ASSEMBLY
MAINTENANCE.................................................... WP
0037
Figure 1. Lube Oil Cooler
Removal.....................................................................................................
0037-2
Figure 2. Lube Oil Cooler
Removal.....................................................................................................
0037-2
Figure 3. Lube Oil Cooler
Removal.....................................................................................................
0037-3
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Figure 4. Lube Oil Cooler
Disassembly...............................................................................................
0037-3
Figure 5. Lube Oil Cooler
Disassembly...............................................................................................
0037-4
Table 1. Pressure Regulator Spring
Limits.........................................................................................
0037-4
Figure 6. Lube Oil Cooler
Inspection...................................................................................................
0037-5
Figure 7. Lube Oil Cooler
Assembly....................................................................................................
0037-6
Figure 8. Lube Oil Cooler
Installation..................................................................................................
0037-6
Figure 9. Lube Oil Cooler
Installation..................................................................................................
0037-7
Figure 10. Lube Oil Cooler
Installation..................................................................................................
0037-7
LUBE OIL PUMP
MAINTENANCE..............................................................................................................
WP 0038
Figure 1. Lube Oil Pump
Removal......................................................................................................
0038-1
Figure 2. Lube Oil Pump
Removal......................................................................................................
0038-2
Figure 3. Lube Oil Pump
Installation...................................................................................................
0038-3
OIL PAN AND SUCTION TUBE
MAINTENANCE.......................................................................................
WP 0039
Figure 1. Oil Pan and Suction Tube
Removal.....................................................................................
0039-2
Figure 2. Oil Pan and Suction Tube
Removal.....................................................................................
0039-3
Figure 3. Oil Pan and Suction Tube
Installation..................................................................................
0039-5
Figure 4. Oil Pan and Suction Tube
Installation..................................................................................
0039-6
OIL LEVEL GAGE
MAINTENANCE............................................................................................................
WP 0040
Figure 1. Oil Level Gage
Removal......................................................................................................
0040-1
Figure 2. Oil Level Gage
Removal......................................................................................................
0040-2
Figure 3. Oil Level Gage
Installation...................................................................................................
0040-3
INTAKE MANIFOLD COVER AND GASKET
MAINTENANCE...................................................................
WP 0041
Figure 1. Manifold Cover Plate
Removal.............................................................................................
0041-1
Figure 2. Manifold Cover Plate
Installation..........................................................................................
0041-2
EXHAUST MANIFOLD AND GASKETS
MAINTENANCE...........................................................................
WP 0042
Figure 1. Exhaust Manifold
Removal...................................................................................................
0042-1
Figure 2. Exhaust Manifold
Removal...................................................................................................
0042-2
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Figure 3. Exhaust Manifold
Installation................................................................................................
0042-2
FUEL INJECTOR
MAINTENANCE..............................................................................................................
WP 0043
Figure 1. Injector Nozzles
Removal.....................................................................................................
0043-2
Figure 2. Injector Nozzles
Removal.....................................................................................................
0043-2
Figure 3. Lube Oil Injector Nozzles
Installation...................................................................................
0043-3
Figure 4. Injector Nozzles
Installation..................................................................................................
0043-4
FUEL INJECTION PUMP
MAINTENANCE.................................................................................................
WP 0044
Figure 1. Injection Pump
Removal......................................................................................................
0044-2
Figure 2. Injection Pump
Removal......................................................................................................
0044-3
Figure 3. Injection Pump
Removal......................................................................................................
0044-3
Figure 4. Injection Pump
Removal......................................................................................................
0044-4
Figure 5. Injection Pump
Removal......................................................................................................
0044-4
Figure 6. Injection Pump
Removal......................................................................................................
0044-5
Figure 7. Injection Pump
Disassembly................................................................................................
0044-6
Figure 8. Injection Pump
Disassembly................................................................................................
0044-7
Figure 9. Injection Pump
Disassembly................................................................................................
0044-7
Figure 10. Injection Pump
Disassembly................................................................................................
0044-8
Figure 11. Injection Pump
Disassembly................................................................................................
0044-8
Figure 12. Injection Pump
Disassembly................................................................................................
0044-9
Figure 13. Injection Pump
Disassembly................................................................................................
0044-9
Figure 14. Injection Pump
Disassembly..............................................................................................
0044-10
Figure 15. Injection Pump
Disassembly..............................................................................................
0044-11
Figure 16. Injection Pump
Disassembly..............................................................................................
0044-11
Figure 17. Injection Pump
Disassembly..............................................................................................
0044-12
Figure 18. Injection Pump
Assembly...................................................................................................
0044-13
Figure 19. Injection Pump
Assembly...................................................................................................
0044-14
Figure 20. Injection Pump
Assembly...................................................................................................
0044-15
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Figure 21. Injection Pump
Assembly...................................................................................................
0044-15
Figure 22. Injection Pump
Assembly...................................................................................................
0044-16
Figure 23. Injection Pump
Assembly...................................................................................................
0044-16
Figure 24. Injection Pump
Assembly...................................................................................................
0044-17
Figure 25. Injection Pump
Assembly...................................................................................................
0044-17
Figure 26. Injection Pump
Assembly...................................................................................................
0044-18
Figure 27. Injection Pump
Assembly...................................................................................................
0044-18
Figure 28. Injection Pump
Assembly...................................................................................................
0044-19
Figure 29. Injection Pump
Installation.................................................................................................
0044-19
Figure 30. Injection Pump
Installation.................................................................................................
0044-20
Figure 31. Injection Pump
Installation.................................................................................................
0044-20
Figure 32. Injection Pump
Installation.................................................................................................
0044-21
Figure 33. Injection Pump
Installation.................................................................................................
0044-21
Figure 34. Injection Pump
Installation.................................................................................................
0044-22
FUEL LIFT PUMP
MAINTENANCE.............................................................................................................
WP 0045
Figure 1. Lift Pump
Removal...............................................................................................................
0045-2
Figure 2. Lift Pump
Installation............................................................................................................
0045-3
AIR CLEANER ASSEMBLY
MAINTENANCE.............................................................................................
WP 0046
Figure 1. Air Cleaner
Removal............................................................................................................
0046-2
Figure 2. Air Cleaner
Removal............................................................................................................
0046-3
Figure 3. Air Cleaner
Maintenance......................................................................................................
0046-5
Figure 4. Air Cleaner
Installation.........................................................................................................
0046-5
Figure 5. Air Cleaner
Installation.........................................................................................................
0046-6
FUEL TANK
MAINTENANCE......................................................................................................................
WP 0047
Figure 1. Fuel Tank
Removal..............................................................................................................
0047-1
Figure 2. Fuel Tank
Removal..............................................................................................................
0047-2
Figure 3. Fuel Tank
Disassembly........................................................................................................
0047-3
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Figure 4. Fuel Tank
Disassembly........................................................................................................
0047-3
Figure 5. Fuel Tank
Assembly.............................................................................................................
0047-4
Figure 6. Fuel Tank
Assembly.............................................................................................................
0047-5
Figure 7. Fuel Tank
Installation...........................................................................................................
0047-6
Figure 8. Fuel Tank
Installation...........................................................................................................
0047-7
FUEL LINES
MAINTENANCE.....................................................................................................................
WP 0048
Figure 1. Fuel Lines
Removal..............................................................................................................
0048-1
Figure 2. Fuel Lines
Removal..............................................................................................................
0048-2
Figure 3. Fuel Lines
Installation...........................................................................................................
0048-3
Figure 4. Fuel Lines
Installation...........................................................................................................
0048-3
Figure 5. Fuel Lines
Installation...........................................................................................................
0048-4
FUEL INJECTION TUBES
MAINTENANCE................................................................................................
WP 0049
Figure 1. High-Pressure Tubes
Removal............................................................................................
0049-2
Figure 2. High-Pressure Tubes
Removal............................................................................................
0049-3
Figure 3. High-Pressure Tubes
Removal............................................................................................
0049-4
Figure 4. Low-Pressure Tubes
Removal.............................................................................................
0049-5
Figure 5. Low-Pressure Tubes
Removal.............................................................................................
0049-6
Figure 6. Low-Pressure Tubes
Removal.............................................................................................
0049-7
Figure 7. Fuel Drain Tubes
Removal...................................................................................................
0049-8
Figure 8. Fuel Dr