Grove Crane AP 308T WAREHOUSE CRANE 10,000 LB CAPACITY, M469 WHEELED DIESEL Parts Manual

TM 10-3950-672-24P TECHNICAL MANUAL Unit, Direct Support and General Support Maintenance REPAIR PARTS AND SPECIAL TOOLS LIST for WAREHOUSE CRANE 10,000 LB. CAPACITY, M469 WHEELED, DIESEL POWERED NSN 3950-01-412-5345 (Grove Model AP 308T)

Approved for public release: Distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY JUNE 1997

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TM 10-3950-672-24P Technical Manual No. 10-3950-672-24P

HEADQUARTERS, DEPARTMENT OF THE ARMY, Washington, DC, 15 June 1997 Unit, Direct Support and General Support Maintenance REPAIR PARTS AND SPECIAL TOOLS LIST for WAREHOUSE CRANE 10,000 LB. CAPACITY, M469 WHEELED, DIESEL POWERED NSN 3950-01-412-5345 (Grove Model AP 308T)

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 2028-2 located in the back of this manual direct to: Commander. US Army Tank-automotive and Armaments Command, ATTN: AMSTA-IM-OPIT, Warren. MI 48397-5000. In either case a reply will be furnished direct to you. Your may also provide DA Form 2028-2 information to TACOM via datafax or e.mail. TACOM's datafax number for AMSTA-IM-OPIT is: (810) 574-6323 and e.mail address is: tacom-techpubs@cc.tacom.army.mil.

TABLE OF CONTENTS

Section

I II Group 0100 0101 0101 0102 0103 0104 0105 0105 0105 0105 0105 0106 0106 0106 0106 0108 0108 0109

Page Introduction................................................................................................................. 1 Repair Parts List ...................................................................................................... 1-1 01 - ENGINE Engine Installation.................................................................................................... 1-1 Cylinder Head Assembly.......................................................................................... 2-1 Cylinder Block Installation........................................................................................ 3-1 Crankshaft Assembly ............................................................................................... 4-1 Flywheel and Housing.............................................................................................. 5-1 Pistons and Connecting Rods .................................................................................. 6-1 Valve Cover Installation ........................................................................................... 7-1 Rocker Levers and Push Rods ................................................................................. 8-1 Cam Follower Cover Assembly ................................................................................ 9-1 Camshaft and Valve Tappets................................................................................. 10-1 Front Gear Cover Installation ................................................................................. 11-1 Engine Oil Level Gage........................................................................................... 12-1 Engine Oil Cooler................................................................................................... 13-1 Engine Oil Pan Installation..................................................................................... 14-1 Engine Oil Pump Installation.................................................................................. 15-1 Air Intake Manifold and Gasket w/Heater Assy....................................................... 16-1 Exhaust Manifold Installation ................................................................................. 17-1 Front Gear Train Accessory Drive.......................................................................... 18-1 Approved for public release: Distribution is unlimited.

i

Illus/ Figure

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

TM 10-3950-672-24P TABLE OF CONTENTS - continued Section II - Continued

Group

Page

Illus/ Figure

03 - FUEL SYSTEM 0301 0302 0302 0302 0304 0306 0306 0306 0309 0311 0312 0401 0501 0501 0503 0503 0504 0505 0505 0601 0601 0603 0603 0607 0607 0607 0609 0609 0609 0610 0611 0612 0613 0613 0613 0613 0613 0613

Fuel Injectors ......................................................................................................... 19-1 Fuel Lift Pump and Lines ....................................................................................... 20-1 Fuel Injection Pump w/Shutoff Valve Inst............................................................... 21-1 Fuel Injection Pump Assembly............................................................................... 22-1 Air Cleaner Assembly and Inst ............................................................................... 23-1 Fuel Tank Installation............................................................................................. 24-1 Low Pressure Engine Fuel Lines ............................................................................ 25-1 High Pressure Engine Fuel Lines ........................................................................... 26-1 Fuel Filter/Water Separator.................................................................................... 27-1 Cold Start Installation............................................................................................. 28-1 Accelerator Pedal and Linkage............................................................................... 29-1 04 - EXHAUST SYSTEM Muffler Installation ................................................................................................. 30-1 05 - COOLING SYSTEM Fan Guard Installation............................................................................................ 31-1 Radiator Installation ............................................................................................... 32-1 Engine Water Inlet Connection............................................................................... 33-1 Thermostat and Housing ........................................................................................ 34-1 Water Pump Installation......................................................................................... 35-1 Engine Cooling Fan and Drive Assembly ............................................................... 36-1 Fan Belt and Tensioner.......................................................................................... 37-1 06 - ELECTRICAL SYSTEM Alternator Installation ............................................................................................. 38-1 Alternator Assembly............................................................................................... 39-1 Starter Installation.................................................................................................. 40-1 Starter Assembly.................................................................................................... 41-1 Cab Main Control Panel Assembly......................................................................... 42-1 Relay Panel Installation.......................................................................................... 43-1 Fuse Panel Assembly ............................................................................................ 44-1 Exterior Lights and Turnsignal Installation.............................................................. 45-1 Spotlight Inst.......................................................................................................... 46-1 Boom Lights Installation......................................................................................... 47-1 Engine Senders and Switches................................................................................ 48-1 Horn and Backup Alarm Installation ....................................................................... 49-1 Battery Installation ................................................................................................. 50-1 Carrier Harness Assembly...................................................................................... 51-1 Cab Harness Assembly.......................................................................................... 52-1 Front Console Harness Assembly .......................................................................... 53-1 Boom Harness Assembly ....................................................................................... 54-1 Boom Lights Harness Assembly............................................................................. 55-1 Relay Panel Harness Assembly ............................................................................. 56-1

ii

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

TM 10-3950-672-24P TABLE OF CONTENTS - continued Section II - Continued

Group 0705 0705 0710 0710 0710 0710 0900 1000 1000 1002 1100 1104 1202 1204 1204 1313 1401 1401 1411 1412 1412 1503 1507 1507 1507

Page 07 - TRANSMISSION Transmission Shifting Lever Installation ................................................................. 57-1 Transmission Shift Modulator................................................................................. 58-1 Transmission Installation........................................................................................ 59-1 Transmission Assembly ......................................................................................... 60-1 Park Brake Lever Installation ................................................................................. 61-1 Park Brake Installation ........................................................................................... 62-1 09 - PROPELLER AND PROPELLER SHAFTS Drive Line Assembly and Installation...................................................................... 63-1 10 - FRONT AXLE Front Axle Installation ............................................................................................ 64-1 Front Axle Assembly.............................................................................................. 65-1 Front Axle Differential ............................................................................................ 66-1 11 - REAR AXLE Rear Axle and Hub Installation............................................................................... 67-1 Steering Cylinder Assembly ................................................................................... 68-1 12 - BRAKES Front Brake Parts................................................................................................... 69-1 Master Cylinder Installation.................................................................................... 70-1 Service Brake Lines Installation ............................................................................. 71-1 13 - WHEELS AND TRACKS Tire Assembly and w/Lug Nuts............................................................................... 72-1 14 - STEERING Steering Wheel and Control Valve Inst................................................................... 73-1 Steering Control Valve Assembly........................................................................... 74-1 Steering Hydraulic Lines Installation....................................................................... 75-1 Steering Pump Installation ..................................................................................... 76-1 Steering Pump Assembly....................................................................................... 77-1 15 - FRAME, TOWING ATTACHMENTS, AND DRAWBARS Pintle Hook Assembly and Front Tiedown .............................................................. 78-1 Outrigger Installation.............................................................................................. 79-1 Outrigger Stabilizer Cylinder Assembly .................................................................. 80-1 Outrigger Stabilizer Cylinder Assembly .................................................................. 81-1

iii

Illus/ Figure 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

TM 10-3950-672-24P TABLE OF CONTENTS - continued Section II - Continued

Group 1507 1507 1801 1801 1801 1801 1801 1806 2201 2202 2207 2207 2210 2401 2401 2402 2402 2402 2402 2406 2406 2406 2406 2406 2406 2406 2406 2406 2407 2407 2407 2407 2407 2408 2408

Page 15 - FRAME, TOWING ATTACHMENTS, AND DRAWBARS - Continued Outrigger Selector Valves Installation .................................................................... 82-1 Outrigger Selector Valve Assembly........................................................................ 83-1 18 - BODY, CAB, HOOD, AND HULL Cab Top Installation ............................................................................................... 84-1 Cab Door Holder Installation .................................................................................. 85-1 Cab Acoustics Installation ...................................................................................... 86-1 Deck Covers w/Handle Installation......................................................................... 87-1 Frame Stud Installation .......................................................................................... 88-1 Seat Installation ..................................................................................................... 89-1 22 - BODY, CHASSIS, OR HULL ASSEMBLY ITEMS Windshield Wiper and Washer Installation............................................................. 90-1 Rearview Mirror w/Deck Post Installation ............................................................... 91-1 Cab Heater and Defroster Installation..................................................................... 92-1 Cab Circulating Fan Installation ............................................................................. 93-1 Decal Installation ................................................................................................... 94-1 24 - HYDRAULIC LIFT COMPONENTS Two-Section Pump Installation............................................................................... 95-1 Two-Section Pump Assembly................................................................................. 96-1 Hydraulic Lockout/Level Indicator Inst.................................................................... 97-1 Hydraulic Control Valves and Linkage.................................................................... 98-1 Two-Section Valve Assembly................................................................................. 99-1 Three-Section Valve Assembly ............................................................................ 100-1 Pressure Check Hydraulic Lines Installation......................................................... 101-1 Supply/Pressure/Return Hydraulic Lines .............................................................. 102-1 Hydraulic Return Line Filter Assembly.................................................................. 103-1 Lift Cylinder Hydraulic Lines Installation............................................................... 104-1 Telescope Cylinder Hydraulic Lines ..................................................................... 105-1 Swing Drive Hydraulic Lines Installation............................................................... 106-1 Hoist Hydraulic Lines Installation.......................................................................... 107-1 Outrigger Hydraulic Lines Installation................................................................... 108-1 Swivel Hydraulic Lines Installation ....................................................................... 109-1 Lift Cylinder Installation........................................................................................ 110-1 Lift Cylinder Assembly ......................................................................................... 111-1 Lift Cylinder Holding Valve Assembly................................................................... 112-1 Telescope Cylinder Assembly .............................................................................. 113-1 Telescope Cylinder Holding Valve Assembly ....................................................... 114-1 Hydraulic Tank Installation ................................................................................... 115-1 Hydraulic Oil Cooler Inst w/Fan Assembly............................................................ 116-1

iv

Illus/ Figure 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116

TM 10-3950-672-24P TABLE OF CONTENTS - continued Section II - Continued

Group 6801 7411 7411 7411 7411 7411 7417 7417 7417 7417 7417 7417 7419 7419 7419 7419 7419 7419 7419 7419 7419 7638

Section Section

III IV

Page 68 - WARNING, SCANNING, AND SIGNALING DEVICES Antitwo-Block Installation ..................................................................................... 117-1 74 - CRANES, SHOVELS, EARTH MOVING COMPONENTS Boom Assembly, 2 -Section ................................................................................. 118-1 Boom Nose Sheave and Cable Retainer .............................................................. 119-1 Boom Pivot Pin Installation .................................................................................. 120-1 Boom Angle Indicator Installation......................................................................... 121-1 Hook Block and Latch Assembly .......................................................................... 122-1 Hoist Installation .................................................................................................. 123-1 Hoist Assembly w/Wedge Socket......................................................................... 124-1 Hoist Primary and Secondary Carrier ................................................................... 125-1 Hoist Hydraulic Motor Assembly........................................................................... 126-1 Hoist Motor Control Valve .................................................................................... 127-1 Cable Follower Installation ................................................................................... 128-1 Turntable Bolt Installation..................................................................................... 129-1 Turntable Drive w/Breather Vent Installation ........................................................ 130-1 Swing Drive w/Valve Assembly............................................................................ 131-1 Swing Drive Gear Reducer Assembly .................................................................. 132-1 Swing Brake Assembly......................................................................................... 133-1 Swing Motor Assembly......................................................................................... 134-1 Electric/Hydraulic Swivel Installation.................................................................... 135-1 Hydraulic Swivel Assembly .................................................................................. 136-1 Electric Slip Ring Assembly ................................................................................. 137-1 76 - FIRE FIGHTING EQUIPMENT COMPONENTS Fire Extinguisher Installation ................................................................................ 138-1 Kits ...................................................................................................................... 139-1 Special Tools List - N/A Cross-Reference Indexes National Stock Number Index ................................................................................ I-1 Part Number Index............................................................................................... I-13 Figure and Item Number Index ............................................................................ I-62

v/(vi blank)

Illus/ Figure 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139

TM 10-3950-672-24P SECTION I INTRODUCTION 1. SCOPE This manual lists and authorizes spares and repair parts; special tools; special test, measurement, and diagnostic equipment (TMDE); and other special support equipment required for performance of unit, direct support and general support maintenance with depot maintenance of the 10K Warehouse Truck Crane, M469. It authorizes the requisitioning, issue, and disposition of spares, repair parts, and special tools as indicated by the source, maintenance, and recoverability (SMR) codes.

2. GENERAL This Repair Parts and Special Tools List is divided into the following sections: a. Section II. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance. This list also includes parts which must be removed for replacement of the authorized parts. Parts lists are composed of functional groups in ascending item number sequence, with the parts in each group listed in ascending item number sequence. Figure numbers are listed directly beneath the group header. Bulk materials are listed in item name sequence. Repair parts kits are listed separately in their own functional group within Section II. Repair parts for reparable special tools are also listed in this section.

Items listed are shown on the associated illustration. b. Section III. Special Tools List. A list of special tools, special TMDE, and other special support equipment authorized by this RPSTL as indicated by Basis of Issue (BOI) information (column (5)) for the performance of maintenance. c. Section IV. Cross-Reference Indexes. A list, in National Item Identification Number (NIIN) sequence, of all National stock numbered items appearing in the listing, followed by a list in alphanumeric sequence of all part numbers appearing in the listings. National stock numbers and part numbers are cross-referenced to each illustration figure and item number appearance. The figure number and item number index lists figure and item numbers in numeric sequence and cross-references National stock number. Commercial and Government Entity Code, and part numbers.

3. EXPLANATION OF COLUMNS (Sections II and III) a. Item No. (Column (1)). Indicates the number used to identify items called out in the illustrations.

1

TM 10-3950-672-24P 3. EXPLANATION OF COLUMNS (Sections II and III) - Continued b. SMR Code (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a five-position code containing supply/requisitioning information, maintenance category authorization criteria, and disposition instruction, as shown in the following breakout:

NOTE Complete repair: Maintenance capacity, capability, and authority to perform all corrective maintenance tasks of the "repair" function in a use/user environment in order to restore serviceability to a failed item.

(1) Source Code. The source code tells you how to get an item needed for maintenance, repair, or overhaul of an end item/equipment. Explanations of source codes follows: Code

Explanation Stocked items: use the applicable NSN to request/requisition items with these source codes. They are authorized to the category indicated by the code entered in the third position of the SMR code.

NOTE Items coded PC are subject to deterioration.

2

TM 10-3950-672-24P 3. EXPLANATION OF COLUMNS (Sections II and III) Continued Code

Explanation Items with these codes are not to be requested/requisitioned individually. They are part of a kit which is authorized to the maintenance category indicated in the third position of the SMR code. The complete kit must be requisitioned and applied.

Items with these codes are not to be requested/requisitioned individually. They must be made from bulk material which is identified by the part number in the description and usable on code (UOC) column and listed in the Bulk Material group of the repair parts list. If the item is authorized to you by the third position code of the SMR code, but the source code indicates it is made at a higher category, order the item from the higher category of maintenance.

Items with these codes are not to be requested/requisitioned individually. The parts that make up the assembled item must be requisitioned or fabricated and assembled at the category of maintenance indicated by the source code. If the third position code of the SMR code authorizes you to replace the item, but the source code indicates the item is assembled at a higher category, order the item from the higher category of maintenance.

3

TM 10-3950-672-24P 3. EXPLANATION OF COLUMNS (Sections II and III) - Continued Code XA XB XC XD -

Explanation Do not requisition an "XA" coded item. Order its next higher assembly.

If an "XB" item is not available from salvage, order it using the CAGEC and part number given.

Installation drawing, diagram, instruction sheet. field service drawing, that is identified by manufacturer's part number.

Item is not stocked. Order an "XD" coded item through normal supply channels using the CAGEC and part number given, if no NSN is available.

NOTE Cannibalization or controlled exchange, when authorized, may be used as a source of supply for items with the above source codes, except for those source coded "XA" or those aircraft support items restricted by requirements of AR 750-1.

(2) Maintenance Code. Maintenance codes tell you the category of maintenance authorized to USE and REPAIR support items. The maintenance codes are entered in the third and fourth positions of the SMR Code as follows: (a) The maintenance code entered in the third position tells you the lowest maintenance category authorized to remove, replace, and use an item. The maintenance code entered in the third position will indicate authorization to one of the following categories of maintenance.

Code COFHLD-

Application/Explanation Crew or operator maintenance done within organization or aviation unit maintenance.

Organizational or aviation unit category can remove, replace, and use the item.

Direct support or aviation intermediate category can remove, replace, and use the item.

General support category can remove, replace, and use the item.

Specialized repair activity can remove, replace, and use the item.

Depot category can remove, replace, and use the item.

4

TM 10-3950-672-24P 3. EXPLANATION OF COLUMNS (Sections II and III) - Continued (b) The maintenance code entered in the fourth position tells whether or not the item is to be repaired and identifies the lowest maintenance category with the capability to do complete repair (i.e., perform all authorized repair functions.) This position will contain one of the following maintenance codes.

NOTE Some limited repair may be done on the item at a lower category of maintenance, if authorized by the Maintenance Allocation Chart (MAC) and SMR codes.

Code OFHLDZB-

Explanation Organizational or aviation unit is the lowest category that can do complete repair of the item.

Direct support or aviation intermediate is the lowest category that can do complete repair of the item.

General support is the lowest category that can do complete repair of the item.

Specialized repair activity (designate the specialized repair activity) is the lowest category that can do complete repair of the item.

Depot is the lowest category that can do complete repair of the item.

Nonreparable. No repair is authorized.

No repair is authorized. (No parts or special tools are assigned for the maintenance of a "B" coded item). However, the item may be reconditioned by adjusting, lubricating, etc., at the user category.

(3) Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on unserviceable items. The recoverability code is entered in the fifth position of the SMR code as follows: Recoverability Code Application/Explanation ZNonreparable item. When unserviceable, condemn and dispose of the item at the category of maintenance shown in third position of SMR Code.

OReparable item. When uneconomically reparable, condemn and dispose of the item at organizational or aviation unit category.

FReparable item. When uneconomically reparable, condemn and dispose of the item at the direct support or aviation intermediate category.

5

TM 10-3950-672-24P 3. EXPLANATION OF COLUMNS (Sections II and III) - Continued Recoverability Code Application/Explanation HReparable item. When uneconomically reparable, condemn and dispose of the item at the general support category.

DReparable item. When beyond lower category repair capability, return to depot. Condemnation and disposal of item not authorized below depot category.

LReparable item. Condemnation and disposal not authorized below specialized repair activity (SRA).

AItem requires special handling or condemnation procedures because of specific reasons (e.g., precious metal content, high dollar value, critical material, or hazardous material). Refer to appropriate manuals/directives for specific instructions. c. CAGEC (Column (3)). The Commercial and Government Entity Code (CAGEC) is a five digit numeric code which is used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. d. Part Number (Column (4)). Indicates the primary number used by the manufacturer (individual, company, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications, standards, and inspection requirements to identify an item or range of items.

NOTE When you use a NSN to requisition an item, the item you receive may have a different part number from the part ordered. e. Description and Usable on Code (UOC) (Column (5)). This column includes the following information: (1) The Federal item name and, when required, a minimum description to identify the item.

(2) The physical security classification of the item is indicated by the parenthetical entry, e.g. Phy Sec C1 (C) - Confidential. Phy Sec C1 (S) - Secret, Phy Sec C1 (T) - Top Secret.

(3) Items that are included in kits and sets are listed below the name of the kit or set.

6

TM 10-3950-672-24P 3. EXPLANATION OF COLUMNS (Sections II and III) - Continued (4) Spare/repair parts that make up an assembled item are listed immediately following the assembled item line entry.

(5) Part numbers for bulk materials are referenced in this column in the line item entry for the item to be manufactured/fabricated.

(6) When the item is not used with all serial numbers of the same model, the effective serial numbers are shown on the last line of the description (before UOC).

(7) UOC, when applicable (see paragraph 5, Special Information).

(8) In the Special Tools section, the Basis of Issue (BOI) appears as the last line in the entry for each special tool, special TMDE, and other special support equipment. When density of equipments supported exceeds density spread indicated in the BOI, the total authorization is increased proportionately.

(9) The statement "END OF FIGURE" appears just below the last item description in Column (5) for a given figure in Sections II and III. f. QTY (Column (6)). Indicates the quantity of the item used in the breakout shown on the illustration figure, which is prepared for a functional group, subfunctional group, or an assembly. A "V" appearing in this column in lieu of a quantity indicates that the quantity is variable and the quantity may vary from application to application.

4. EXPLANATION OF COLUMNS (Section IV) a. National Stock Number (NSN) Index.

(1) Stock number column. This column lists the NSN by National Item Identification Number (NIIN) sequence.

The NIIN consists of the last nine digits of the NSN. When requisitioning items use the complete NSN (13 digits) sequence.

(2) Fig. column. This column lists the number of the figure where the item is identified/located. illustrations are in numerical sequence in Sections II and III.

The

(3) Item column. The item number identifies the item associated with the figure listed in the adjacent Fig. column. This item is also identified by the NSN listed on the same line. b. Part Number Index. Part numbers in this index are listed by part number in ascending alphanumeric sequence.

7

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