TECHNICAL MANUAL UNIT MAINTENANCE FOR CONTAINER CRANE, 40-TON, ROUGH TERRAIN, MODEL RT875CC NSN

Transcription

1 TECHNICAL MANUAL UNIT MAINTENANCE FOR CONTAINER CRANE, 40-TON, ROUGH TERRAIN, MODEL RT875CC NSN This manual shall be used in place of the Unit maintenance portion of the GROVE Manufacturing Company Commercial Maintenance Manual No dated 1 Feb 89 and the PAT Equipment Corp. Troubleshooting Manual DS350M dated January 1989v that were originally overpacked with the crane. Approved for public release; distribution is limited H E A D Q U A R T E R S, D E P A R T M E N T O F T H E A R M Y 25 FEBRUARY 1993

2 * TECHNICAL MANUAL HEADQUARTERS No DEPARTMENT OF THE ARMY Washington D.C., 25 February 1993 UNIT MAINTENANCE MANUAL FOR CONTAINER CRANE, 40-TON ROUGH TERRAIN, MODEL RT875CC NSN REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in the back of this manual direct to: US Army Tank-Automotive Command, Attn: AMSTA-MB, Warren, MI A reply will be furnished to you. TABLE OF CONTENTS Page CHAPTER 1. INTRODUCTION Section I. General Information Scope Maintenance Forms, Records and Reports Destruction of Army Material to Prevent Enemy Use Preparation for Storage or Shipment Reporting Equipment Improvement Recommendations (EIR) Warranty Information Section II. Equipment Description and Data Equipment Characteristics, Capabilities and Features Location and Description of Major Components Equipment Data Safety, Care and Handling Section III. Principles of Operation Introduction Engine Lubrication System Fuel System Cooling System Electrical System Approved for public release; distribution Is unlimited. *This manual shall be used in place of the Unit maintenance portion of the GROVE Manufacturing Company Commercial Maintenance Manual No dated 1 Feb 89 and the PAT Equipment Corp. Troubleshooting Manual, DS350M dated January 1989 that were originally overpacked with the crane. i

3 Page CHAPTER 1. Section III. INTRODUCTION (Cont d) Principles of Operation (Cont d) Air System Hydraulic System CHAPTER 2. CRANE MAINTENANCE INSTBUCTIONS Section I. Repair Parts, Special Tools, TMDE, and Support Equipment Common Tools and Equipment Special Tools, Repair Parts, TMDE, and Support Equipment Section II. Service Upon Receipt Summary Unpacking Checking Unpacked Equipment Deprocessing Unpacked Equipment Preliminary Servicing and Adjustment Section III. Organizational Preventive Maintenance Checks and Services General Organizational Preventive Maintenance Checks and Services CHAPTER 3. TROUBLESHOOTING Introduction Symptom Index Engine Cooling System Electrical System Transmission/Torque Converter Brake System Steering System Hydraulic System Cab Heater STE/ICE ii

4 CHAPTER 4. ENGINE MAINTENANCE Page Section I. Rocker Arm Maintenance Valve Adjustment Valve Cover Replacement Section II. Engine Lubrication System Maintenance Engine Oil Filter Replacement Turbocharger Oil Return Lien Replacement CHAPTER 5. FUEL SYSTEM MAINTENANCE Section I. Air Cleaner Maintenance Air Cleaner and Piping Air Cleaner Assembly Section II. Fuel Tanks, Lines and Fittings Maintenance Fuel Tank Installation Fuel Line Replacement Fuel Supply and Return Lines Replacement Bleeding Fuel System Section III. Fuel Filter Maintenance In-Line Fuel Filter/Strainer Installation Fuel Water Separator/Filter Replacement Section IV. Engine Starting Aid Maintenance Quick Start Starting Fluid/Cylinder Service Quick Start Ether Valve and Tubing Replacement Section V. Fuel Pump Maintenance Fuel Pump Installation Idle Speed Adjustment CHAPTER 6. EXHAUST SYSTEM MAINTENANCE Muffler and Pipe Replacement iii

5 CHAPTER 7. COOLANT SYSTEM MAINTENANCE Section I. Radiator Maintenance Coolant Overflow Tank Radiator Fan and Fan Guard Replacement Radiator Hose and Tube Replacement Radiator, Mooring Bracket and Shroud Replacement Page Section II. Water Manifold, Headers, Thermostat and Gaskets Maintenance Coolant Filter Replacement Thermostat Replacement Turbocharger Aftercooler and Piping Replacement Water Pump Installation Section III. Fan Assembly Maintenance Belt Tensioner Replacement Fan Drive Belt Replacement CHAPTER 8. ELECTRICAL SYSTEM MAINTENANCE Section I. Alternator Maintenance Alternator Installation Section II. Starter Motor Maintenance Starter Motor Installation Section III. Instrument Panel Maintenance Blackout Light (Military) Switch Replacement Dual Air Pressure Gauge Replacement LED Alert Module Replacement Front Control Panel Left Console Harness Installation Right Console Harness Installation AV Harness Installation Gauge Replacement Pushbutton Switch Replacement Rotary Switch Replacement Side Console and Access Panel Replacement Side Console Panel Light (Bulb) Replacement Side Console Harness Installation iv

6 Page CHAPTER 8. ELECTRICAL SYSTEM MAINTENANCE (Cont d) Distribution Panel Wire Harness Installation Distribution Panel Installation Stop Light Switch Replacement Tachometer Replacement Toggle Switch Replacement Warning Buzzer Replacement Turn Signal Control Replacement Section IV. Beacon Light Assembly Replacement Vehicle Lights Maintenance Blackout Light Replacement Boom Floodlight Replacement Cab Floodlight Replacement Clearance Light Replacement Headlight Replacement Turn Signal Light Replacement Section V. Sending Units and Switches Maintenance Oil Pressure Sender Replacement Low Oil Pressure Switch Replacement Tachometer Magnetic Sensor Replacement Transmission Oil Temperature Sender Replacement Transmission Oil Temperature Switch Replacement DCA Fuel Pressure Transducer Replacement High Coolant Temperature Switch Replacement Coolant Temperature Sender Replacement DCA Pulse Tach Sender Replacement Cold Start Temperature Switch Replacement DC Power Relay Replacement DCA Pressure Differential Switch Replacement Fuel Shutoff Solenoid Installation Rear Wheels Not Centered Switch Installation Elevation Swing Warning Switch Installation Area Definition Switch Replacement Emergency Steer Oil Pressure Switch Replacement Hydraulic Oil Cooler Temperature Control Switch Replacement Back-Up Light Oil Pressure Switch Replacement Fuel Filter Cable Assembly Fuel Pressure Cable Assembly Pulse Tach Cable Assembly VTM Power Cable Harness Carrier Harness Installation Superstructure Harness Installation Blackout Light Harness Installation Floodlight Harness Installation Cab Interior Harness Installation v

7 PAGE CHAPTER 8. ELECTRICAL SYSTEM MAINTENANCE (Cont d) Section VI. Horn and Alarms Maintenance Backup Alarm Replacement Horn Replacement Section VII. Battery Maintenance Battery Replacement Battery Box Cover and Slave Receptacle Replacement Battery Box Replacement Emergency Steer Pump Box Replacement Emergency Steer Pump Cable(s) Replacement Battery Cable(s) Removal Ground Cable at Shunt Shunt Replacement CHAPTER 9. TRANSMISSION SHIFTER MAINTENANCE Transmission Shifter Replacement Transmission Shift Hydraulic Lines, Superstructure Transmission Shift Hydraulic Lines, Carrier Transmission Control Valve Replacement Transmission to Torque Converter Hydraulic Lines Torque Converter Oil Filter Assembly Installation Torque Converter Oil Filter Installation CHAPTER 10. PROPELLER SHAFT MAINTENANCE Propeller Shaft Replacement Propeller Shaft Repair CHAPTER 11. BRAKE AND AIR SYSTEM MAINTENANCE Section I. Service Brakes Maintenance Air System Purge Brake Chamber Installation Brake Chamber Assembly vi

8 PAGE CHAPTER 11. BRAKE AND AIR SYSTEM MAINTENANCE (Cont d) Section II. Air System Maintenance Air Dryer Replacement Air Dryer Desiccant Cartridge Replacement Air Governor Replacement Air Reservoir Replacement Air Valve Muffler Replacement Automatic Drain Valve Replacement Double Check Valve and Pressure Protection Valve Replacement Foot Brake Control Valve Replacement Low Pressure Indicator Switch Replacement Park Brake Control Valve and Pressure Indicator Switch Replacement Pressure Protection Valve Replacement R-12 Relay Valve Replacement Single Check Valve Replacement Spring Brake Control Valve Replacement Throttle Cylinder and Control Rod Replacement Tire Inflation Assembly Windshield Washer Valve Replacement Foot Throttle Control Valve Replacement Air Lines Replacement, Superstructure Carrier CHAPTER 12. WHEELS AND TRACKS MAINTENANCE Tire and Wheel Installation Tire and Wheel Assembly CHAPTER 13. STEERINC SYSTEM MAINTENANCE Section I. Steer Cylinder Maintenance Steer Cylinder Installation Section II. Front Steer Relief Valve Maintenance Front Steer Relief Valve Replacement Section III. Emergency Steering Pump Maintenance Emergency Steering Pump Replacement vii

9 CHAPTER 14. FRAME MAINTENANCE PAGE Section I. Pintle Hook Maintenance Pintle Hook Installation Pintle Hook Assembly Section II. Outrigger Float Maintenance Outrigger Float Assembly CHAPTER 15. BODY, CAB, HOOD AND HULL MAINTENANCE Section I. Cab Maintenance Cab Acoustical Foam Installation Window Glass Replacement Cab Protective Grill Replacement Door Assembly Replacement Door Latch Assembly Replacement Grabrails Cab Front Panel Replacement Cab Bottom Panel Replacement Section II. Engine Hood Maintenance Engine Access Doors Replacement Engine Hood Replacement Section III. Fender and Rear Decking Maintenance Fender and Rear Decking Replacement Section IV. Seat Assembly Maintenance Operator Seat and Pedestal Assembly Removal Operator Seat Assembly Section V. Accessory Maintenance Circulating Fan Replacement Cab Counterbalance Cylinder Replacement Cab Heater Fuel Tank Replacement Cab Heater/Defroster Assembly Replacement Domelight Replacement Fire Extinguisher Installation Skylight Wiper Motor Replacement viii

10 Page CHAPTER 15. BODY, CAB, HOOD AND HULL MAINTENANCE (Cont d) Steering Wheel Removal Rear View Mirror Replacement Windshield Wiper Motor Replacement Wiper Arm Replacement Decal Replacement CHAPTER 16. HYDRAULIC SYSTEM MAINTENANCE Section I. Hydraulic Control Valve Maintenance Hydraulic Control Valve Installation Integrated Outrigger Control Valve Installation Front and Rear Outrigger Control Valve Installation Swing Brake Valve and Pedal Installation Rear Axle Lockout Valve Two-Position Selector Valve Lift Cylinder Over-Center Valve Installation Section II. Filter and Lines Maintenance Axle Lockout Hydraulic Lines Free Swing Hydraulic Lines Front Steering Hydraulic Lines, Cab Front Steering Hydraulic Lines, Carrier Rear Steering Hydraulic Lines Hoist Hydraulic Lines Hydraulic Filter Replacement Lift Cylinder Hydraulic Lines, Cylinders Lift Cylinder Hydraulic Lines, Valves Outrigger Lines Supply, Pressure, and Return Lines, Carrier Supply, Pressure, and Return Lines, Superstructure Telescope Hydraulic Lines Section III. Hydraulic Reservoir Maintenance Emergency Hand Pump Installation Hydraulic Reservoir Replacement Section IV. Hydraulic System Maintenance Draining and Flushing Hydraulic System Bleeding Air from Hydraulic System Hydraulic Control Valve Relief Setting Checks and Adjustment ix

11 CHAPTER 17. BOOM MAINTENANCE Page Section I. Boom Assembly Maintenance17-2 Auxiliary Boom Nose Installation Overhaul Ball Installation Overhaul Ball Assembly Hook Block Installation Boom Alignment Section II. Hoist Maintenance Hoist Cable Idler Installation Main and Auxiliary Wire Rope Installation Section III. Turntable Maintenance Positive Swing Lock Control Cable Installation Swing Motor Installation CHAPTER 18. PREPARATION FOR STORAGE OR SHIPMENT Introduction Preservation, Packaging, Packing, Illustration, Marking, and Shipping Requirements Short Term Storage Long Term Storage APPENDICES... Appendix A References... A-1 Appendix B Maintenance Allocation Chart... B-1 Appendix C Expendable/Durable Supplies and Material List... C-1 Appendix D Illustrated List of Manufactured Items... D-1 Appendix E Torque Limits... E-1 ALPHABETICAL INDEX... INDEX-1 HYDRAULIC DIAGRAM... WIRING DIAGRAM... FO-1 FO-3 x

12 LIST OF TABLES Table Title1 Page 2-1 Organizational Preventive Maintenance Checks and Services Organizational Troubleshooting xi/xii Blank

13 CHAPTER 1 INTRODUCTION Section I. GENERAL INFORMATION SCOPE Type of Manual: Organizational Maintenance Model Number and Equipment Name: RT875CC - Container Crane, Rough Terrain Wheel Mounted, Hydraulic, Diesel Powered Purpose of Equipment: Provides for 360 degree boom travel and 80, 000 lbs (40 Tons) lifting capacity in rough terrain conditions. MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM , The Army Maintenance Management System. Accidents involving injury to personnel or damage to materiel will be reported on DA Form 285 (Accident Report) in accordance with AR Explosives and ammunition malfunctions will be reported in accordance with AR75-1. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Demolition of materiel to prevent enemy use will be in accordance with the requirement of TM (Procedures for Destruction of Equipment to Prevent Enemy Use for U.S. Army). PREPARATION FOR STORAGE OR SHIPMENT Before the Container Crane is stored for a long period of time, shipped to a distant location, or returned to service after a period of time, certain guidelines/procedures must be followed. Refer to Chapter 18, Preparation for Storage and Shipment. 1-1

14 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your RT875CC Container Crane needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don t like about your equipment. Let us know why you don t like the design. Put it on an SF 368 (Quality Deficiency Report). Mail it to us at U.S. Army Tank Automotive Command, Attn: AMSTA-QRT, Warren, MI We ll send you a reply. WARRANTY INFORMATION The RT875CC Rough Terrain Container Crane is warranted by Grove Manufacturing Company for 18 months. Warranty starts on the date found on DA Form 2410 or DA Form in the logbook. Report all defects in materiel or workmanship to your supervisor who will take appropriate action. Refer to Warranty Technical Bulletin TB

15 Section II. EQUIPMENT DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES RT875CC Rough Terrain Container Crane Axle steering accomplished by utilizing hydraulic steer cylinders Welded steel frame Engine mounted at rear of crane Superstructure Sliding beam outriggers are integral with carrier frame Remote mounted six speed transmission Four-wheel drive Capability and Features Automatic axle oscillation when superstructure travels more than 5 degrees from-travel position All crane functions controlled from cab Superstructure capable of 360 degree rotation in either direction Lifting is provided by main and auxiliary hoists Equipped with two section, trapezoidal boom Integral fifth wheel, to which rear axle is mounted, provides axle oscillation 1-3

16 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Counterweight. Bolted onto turntable to be part of turntable assembly. Weighs 12, 500 pounds. Hookblock. Provides lifting capability while boom is retracted. Capable of lifting 40 tons and utilizes one-piece pivot block with a safety latch. Overball Ball. Mounted on the auxiliary boom-nose. Ball can be stored during travel. Capable of lifting 5 tons. Hydraulic Tank. 165 gallon capacity. Supplies hydraulic oil to hydraulic valve banks. Located on right side of carrier frame. Uses a magnetized drain plug to collect metal particles in tank and a sight gauge to indicate oil level. Rear Outrigger. Mounted on rear stabilizer box. Extends when selector valve in outrigger control panel is operated. Stabilizes rear portion of crane during lifting operations. Diesel Engine. Cummins 6CTA8.3 turbo-charged diesel engine. Speed is controlled by a foot operated air throttle valve. Access to engine is gained through two side doors in hood assembly. 1-4