TM-5-3810-207-35 Crane-Shovel Basic Unit Truck Mtd 20 Ton 3/4 Cu.Yd. Gasoline Driven 6x6 (Quickway Model M-200) Non-Winterized Manual

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TM-5-3810-207-35

FIELD AND DEPOT MAINTENANCE MANUAL
SAFETY PRECAUTIONS
DIRECT SUPPORT, GENERAL SUPPORT AND DEPOT MAINTENANCE MANUAL
TABLE OF CONTENTS
TABLE OF CONTENTS-CONT.
TABLE OF CONTENTS-CONT.
CHAPTER 1 INTRODUCTION
Table I. Crane Engine Repair and Replacement Standards.
Table I. Crane Engine Repair and Replacement Standards.
Table II. Carrier Engine Repair and Replacement Standards.
Table II. Carrier Engine Repair and Replacement Standards-CONT.
Table II. Carrier Engine Repair and Replacement Standards-CONT.
Table III. Time Standards
Table III. Time Standards
Table III. Time Standards
Table III. Time Standards
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
Table III. Time Standards-CONT.
CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS
Section II. TROUBLESHOOTING
Carrier Engine Clutch Slips
Section III. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS OR AUXILLARIES
Figure 1. Crane cab assembly, removal and installation
Figure 2. Crane engine assembly, removal and installation
Figure 3. Carrier engine assembly, removal and installation
Chapter 3 CRANE ENGINE REPAIR INSTRUCTIONS
Figure 4. Crane engine carburetor assembly, exploded view
Section II. CRANE ENGINE SPEED GOVERNOR ASSEMBLY
Figure 5. Crane engine speed governor assembly, exploded view.
Section IV. CRANE ENGINE GENERATOR ASSEMBLY
Section V. CRANE INSTRUMENT PANEL AND WIRING HARNESS
Figure 7. Crane engine generator assembly, exploded view.
Section VII. CRANE ENGINE DISTRIBUTOR ASSEMBLY
Figure 8. Crane instrument panel and wiring harness, removal and installation.
Section VIII. CRANE ENGINE RADIATOR ASSEMBLY
Figure 9. Crane engine starter assembly, exploded views.
Section X. CRANE ENGINE CLUTCH ASSEMBLY
Figure 10. Crane engine distributor assembly, exploded view.
Figure 11. Crane engine radiator assembly, removal and installation.
Figure 12. Crane engine water pump assembly, exploded view.
Figure 13. Crane engine clutch assembly, removal and installation
Figure 13.-Continued
Section XI. CRANE ENGINE CYLINDER HEAD ASSEMBLY AND VALVES
Figure 14. Crane engine clutch assembly, exploded view
Section XII. CRANE ENGINE OIL PAN AND FILLER BLOCKS
Section XIII. CRANE ENGINE OIL PUMP ASSEMBLY
Section XIV. CRANE ENGINE PISTON AND CONNECTING ROD ASSEMBLIES
Figure 16. Crane engine valve assemblies, removal and installation
Figure 17. -Crane engine valve assemblies, exploded
Figure 18. Crane engine oil pan and filler block, removal and installation.
Figure 19. Crane engine oil pan and filler block, exploded view.
Section XV. CRANE ENGINE FLY WHEEL AND FLYWHEEL HOUSING
Figure 21. Crane engine oil pump assembly, exploded
Section XVI. CRANE ENGINE FRONT MOUNT AND PULLEY ASSEMBLY
Section XVII. CRANE ENGINE TIMING GEAR COVER AND TIMING GEARS
Figure 23. Crane engine piston and connecting rod assembly, exploded view.
Figure 24. Crane engine flywheel and flywheel housing, removal and installation
Figure 25. Crane engine flywheel, ring gear, and flywheel housing exploded view
Figure 26. Crane engine front mount and pulley assembly, removal and installation
Section XIX. CRANE ENGINE CRANKSHAFT ASSEMBLY
Figure 28. Timing gear cover and timing gears, removal and installation.
Timing gears, installed
Figure 29. Crane engine camshaft assembly, removal and installation.
Section XX. CRANE ENGINE BLOCK
Figure 31. Crane engine crankshaft assembly, exploded view.
Figure 32. Crane engine block, exploded view.
CHAPTER 4 CRANE HYDRAULIC SYSTEM REPAIR INSTRUCTIONS
Figure 33. Crane hydraulic master cylinder assemblies, exploded view.
Crane Clutch Hydraulic Cylinder Assembly Reassembly and Installation
CHAPTER 5 CRANE ROTATING FRAME BASE ASSEMBLY REPAIR INSTRUCTIONS
Figure 35. Crane main hoist shaft assembly, removal and installation.
Figure 36. Crane main hoist shaft assembly, exploded view
Section III. BOOM HOIST SHAFT AND GEARCASE ASSEMBLY
Figure 37. Jackshaft assembly removal and installation
Figure 38. Jackshaft assembly, exploded view
Section IV. CRANE CHAIN TIGHTENER
Section V. CRANE HORIZONTAL SWING SHAFT ASSEMBLY
Figure 40. Boom hoist shaft and gearcase assembly, exploded view.
Section VI. VERTICAL SWING SHAFT ASSEMBLY
Figure 41. Crane horizontal swing shaft assembly, removal and installation.
Figure 42. Crane horizontal swing shaft assembly, exploded view.
Section VII. CRANE ROTATING FRAME BASE ASSEMBLY
Figure 44. Vertical swing shaft assembly, exploded view
Section VIII. ROTATING FRAME RING GEAR
Section VIII. ROTATING FRAME RING GEAR-CONT.
CHAPTER 6 CRANE SHOVEL FRONT END ATTACHMENT REPAIR INSTRUCTIONS
Figure 47. Shipper shaft assembly, exploded view
Section II. CRANE GANTRY FRAME
Section II. CARRIER ENGINE HEATER
Figure 49. Crane cab and engine heater, partial exploded view
Section III. CARRIER CAB HEATER
Figure 50. Carrier cab heater, exploded view.
Section III. CARRIER CAB HEATER-CONT.
CHAPTER 8 CARRIER ENGINE REPAIR INSTRUCTIONS
Section III. CARRIER ENGINE GENERATOR ASSEMBLY
Figure 51. Carrier engine carburetor assembly, exploded view
Section V. CARRIER ENGINE ASSEMBLY
Figure 52. Carrier engine speed governor assembly, exploded view
Section VI. CARRIER ENGINE ACCESSORY DRIVE ASSEMBLY
Figure 53. Carrier engine accessory drive assembly, removal and installation
Figure 54. Carrier engine accessory drive assembly, exploded view.
Section VIII. CARRIER ENGINE WATER PUMP ASSEMBLY
Section IX. CARRIER ENGINE OIL FILTER BASE AND OIL COOLER ASSEMBLY
Figure 57. Carrier engine oil filter, base and oil cooler assembly, removal and installation.
Section X. CARRIER ENGINE ROCKER ARM AND PUSH RODS ASSEMBLY
Section XI. CARRIER ENGINE CYLINDER HEAD AND VALVES
Section XII. CARRIER ENGINE OIL PAN
Figure 59. Carrier engine rocker arm and push rod assembly, exploded view
Figure 60. Carrier engine cylinder head and valves, removal and installation
Figure 61. Carrier engine cylinder head and valves, exploded view
Section XIV. CARRIER ENGINE CONNECTING ROD AND PISTON ASSEMBLIES
Figure 63. Carrier engine oil pan, exploded view
Figure 64. Carrier engine oil pump assembly, removal and installation
Section XV. CARRIER ENGINE CLUTCH HOUSING
Section XVI. CARRIER ENGINE CLUTCH ASSEMBLY
Figure 67. Carrier engine piston and connecting rod, exploded view.
Section XVII. CARRIER ENGINE FLYWHEEL AND FLYWHEEL HOUSING
Figure 69. Carrier engine clutch housing, exploded view
Section XVIII. CARRIER ENGINE VIBRATION DAMPER AND PULLEY ASSEMBLY
Section XIX. CARRIER ENGINE TIMING GEARS
Figure 72. Carrier engine flywheel and flywheel housing, removal and installation
Figure 73. Carrier engine flywheel, ring gear, and flywheel housing, exploded view
Section XX. CARRIER ENGINE CAMSHAFT
Section XXI. CARRIER ENGINE CRANKSHAFT AND MAIN BEARINGS
Figure 76. Carrier engine timing gears, removal and installation
Carrier engine camshaft and bushing, removal and installation
Figure 78. Carrier engine camshaft, bushings, and valve lifters, exploded view.
Figure 79. Carrier engine crankshaft and main bearings, removal and installation
Section XXII. CARRIER ENGINE BLOCK
Carrier Engine Block Removal
CHAPTER 9 CARRIER CAB AND FENDER REPAIR INSTRUCTIONS
Section III. CARRIER CAB AND WIRING HARNESS
Figure 82. Carrier cab and wiring harness, removal and installation
Figure 83. Carrier left front fender, removal and installation
CHAPTER 10 CARRIER TRANSMISSION AND TRANSFER CASE REPAIR INSTRUCTIONS
Figure 85. Carrier engine transmission assembly and top cover, exploded view
Carrier Transmission Assembly Removal and Disassembly
Installation
Section II. CARRIER TRANSFER CASE ASSEMBLY
Figure 86. Carrier transfer case assembly, removal and installation
Carrier Transfer Case Assembly Reassembly and Installation
Figure 87. Carrier transfer case assembly, exploded view
Transfer case and cover
Figure 87. Continued
Idler shaft and gear
CHAPTER 11 CARRIER AIR BRAKE SYSTEM REPAIR INSTRUCTIONS
Figure 88. Carrier air compressor assembly, removal and installation
Figure 89. Carrier air compressor assembly, exploded view
Compressor governor assembly
Section II. CARRIER FRONT AIR BRAKE CHAMBER ASSEMBLY
Section III. CARRIER REAR AIR BRAKE CHAMBER ASSEMBLY
Section IV. CARRIER MOISTURE EJECTOR VALVE ASSEMBLY
Section V. CARRIER AIR BRAKE DOUBLE CHECK VALVE ASSEMBLY
CHAPTER 12 CARRIER BRAKES REPAIR INSTRUCTIONS
Figure 94. Carrier handbrake, removal and installation
Figure 95. Carrier emergency handbrake assembly, exploded view
Section III. CARRIER REAR SERVICE BRAKE ASSEMBLY
Section V. CARRIER TREADLE VALVE ASSEMBLY
Section VI. CARRIER AIR BRAKE QUICK RELEASE VALVE ASSEMBLY
Figure 98. Carrier air assist valve assembly, exploded view
Carrier Air Brake Quick Release Valve Cleaning, Inspection, and Repair
Section VII. CARRIER TRAILER BRAKE VALVE
Section VIII. CARRIER AIR BRAKE PROTECTION VALVE ASSEMBLY
Section IX. CARRIER AIR BRAKE PROTECTION CONTROL VALVE ASSEMBLY
Section X. CARRIER SAFETY VALVE ASSEMBLY
Section XI. CARRIER AIR BRAKE RELAY VALVE ASSEMBLY
Section XII. CARRIER LOW AIR PRESSURE WARNING SWITCH
Figure 105. Carrier air brake relay valve assembly, exploded view.
Figure 106. Carrier low air pressure warning switch, exploded view.
CHAPTER 13 CARRIER STEERING REPAIR INSTRUCTIONS
Section III. CARRIER STEERING HYDRAULIC CYLINDER ASSEMBLY
Figure 108. Carrier steering hydraulic control valve assembly, exploded view
Section IV. CARRIER STEERING COLUMN AND GEAR ASSEMBLY
Section V. CARRIER STEERING KNUCKLE AND SHAFT ASSEMBLY
Figure 110. Carrier steering gear assembly, removal and installation
Figure 111. Carrier steering gear assembly, exploded view
Figure 112. Carrie steering knuckle and shaft assembly, removal and installation.
Figure 113. Carrier steering knuckle and shaft, exploded view
CHAPTER 14 CARRIER FRONT AXLE ASSEMBLY REPAIR INSTRUCTIONS
Figure 115. Carrier front axle housing and differential assembly, exploded view
Figure 115.-Continued
Section II. CARRIER FRONT SPRING ASSEMBLY
Figure 116. Carrier front spring and axle assembly, removal and installation
Figure 117. Carrier front spring assembly, exploded view
CHAPTER 15 CARRIER REAR AXLE AND BOGIE ASSEMBLY REPAIR INSTRUCTIONS
Section III. CARRIER REAR, REAR AXLE DIFFERENTIAL ASSEMBLIES
Figure 119. Torque rod assembly, exploded view
Figure 120. Equalizing beam assembly, removal and installation
Figure 122. Carrier rear, rear axle differential assembly, removal and installation.
Figure 123. Carrier rear, rear axle differential assembly, exploded view
Figure 123.--Continued
APPENDIX I REFERENCES
APPENDIX I REFERENCES
INDEX
INDEX-CONT.
INDEX-CONT.
INDEX-CONT.
INDEX-CONT.
INDEX-CONT.
ORDER OF THE SECRETARIES OF THE ARMY AND THE AIR FORCE
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TM-5-3810-207-35
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