TM-5-3810-295-34 Crane Wheel Mounted: 20 Ton at 10 Foot Radius 2 Engines Diesel Engine Driven 4x4 Air Transportable Manual

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TM-5-3810-295-34

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
SAFETY PRECAUTIONS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS-CONT.
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS-CONT.
LIST OF ILLUSTRATIONS-CONT.
CHAPTER 1 INTRODUCTION
Section II. DESCRIPTION AND DATA
Section II. DESCRIPTION AND DATA
Table 1-1, General Torque Values (except Engines)
Table 1-2. General Torque Values for Engines
CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Table 2-1 Troubleshooting Continued
Figure 2-1. Crane sheet metal (sheet1I of 7)
Figure 2-1. Crane sheet metal (sheet 2 of 7).
Figure 2-1. Crane sheet metal (sheet 3 of 7).
Figure 2-1. Crane sheet metal (sheet 4 of 7).
Figure 2-1. Crane sheet metal (sheet 5 of 7).
Figure 2-1. Crane sheet metal (sheet 6 of 7).
Figure 2-1. Crane sheet metal (sheet 7 of 7).
Section III. GENERAL MAINTENANCE
Table 2-2. Current-Voltage Settings
Figure 2-2. Engine and reduction gear assembly, removal and installation
Figure 2-3. Crane engine mounting
Installation
Figure 2-4. Reduction gear and clutch assembly, removal and installation
Figure 2- Rear drumshaft assembly, removal and installation (sheet l of 2).
Figure 2-5. Rear drumshaft assembly, removal and installation (sheet 2 of 2).
Front Drumshaft Assembly
Figure 2-6. Front drumshaft assembly, removal and installation
Figure 2- Reversing shaft assembly removal and installation (sheet 1 of 2).
Figure 2-7. Reversing shaft assembly removal and installation (sheet 2 of 2).
Figure 2-8. Horizontal swing shaft assembly, removal and installation
Horizontal Swing Shaft Assemblies
Figure 2-9. Deleted.
Figures 2-10 through 2-13. Deleted.
Figure 2-14 deleted.
Figure 2-15. Control stand assembly, removal and installation.
Installation
CHAPTER 3 REPAIR OF CRANE ENGINE ACCESSORIES
Figure 3-1. Generator assembly-exploded view.
Inspection and Repair
Reassembly
Figure 3-2. Starting motor assembly--exploded view.
Inspection and Repair
Section III. REPAIR OF RADIATOR
Figure 3-3. Radiator assembly, exploded view
Figure 3-4. Water pump assembly, exploded view.
Disassembly
Figure 3-5. Oil cooler assembly-exploded view.
Section VI. REPAIR OF AIR INLET HOUSING
Figure 3-6. Air inlet housing assembly exploded view
Section VII. REPAIR OF AIR BLOWER
Figure 3-7. Air blower assembly--exploded view.
Figure 3-8. Blower rotor clearances.
Installation
Description
Disassembly
Section IX. REPAIR OF FUEL PUMP
Figure 3-10. Fuel pump assembly exploded view.
Reassembly
Figure 3-11. Governor mounting hardware-exploded view.
Disassembly
Figure 3-12. Governor assembly--exploded view.
Inspection and Repair
Section XI. REPAIR OF FUEL INJECTOR
Figure 3-13. Fuel injector mounting
Figure 3-14. Fuel injector assembly--exploded view
Inspection and Repair
Installation
CHAPTER 4 REPAIR OF CRANE ENGINE
Figure 4-1. Cylinder head, rocker arms, and valves--exploded view.
Figure 4-2. Checking bottom face of cylinder head for war page..
Figure 4-3. Exhaust valve installation specifications.
Figure 4-4. Water nozzle installation
Figure 4-5. Cam roller clearancre specifications.
Figure 4-7. Head bolt tightening sequence
Figure 4-8. Bridge positioning.
Figure 4-9. Flywheel assembly-exploded view.
Figure 4-11. Final tightening sequence of flywheel housing screws
Section IV. REPAIR OF UPPER FRONT COVER
Figure 4-12. Upper front cover assembly--exploded view
Section V. REPAIR OF FRONT COVER AND OIL PUMP
Section VI. REPAIR OF CAMSHAFT AND BALANCE SHAFT
Figure 4-14. Camshaft and balance shaft assembly - exploded view.
Figure 4-15. Camshaft and balance shaft bearing installation
Section VII. REPAIR OF OIL PAN
Figure 4-16. Oil pan and oil inlet screen assembly-exploded view
Section VIII. REPAIR OF CRANKSHAFT, PISTONS AND RODS
Figure 4-16A. Crankshaft connecting rod and piston assembly-exploded view.
Figure 4-17. Main bearing shell measurements.
Figure 4-18. Cylinder liner measurements.
Section IX. REPAIR OF CYLINDER BLOCK
Removal and Disassembly
Figure 4-19. Cylinder block assembly-exploded view.
Figure 4-20. Block bore measurement diagram.
Reassembly and Installation
CHAPTER 5 REPAIR OF CRANE DRIVE AND TRAIN
Removal
Figure 5-2. Reduction gear assembly-exploded view.
Cleaning, Inspection and Repair
Installation
Figure 5-3. Propeller shaft assembly - exploded view.
Section III. REPAIR OF CRANE WORM SHAFT
Figure 5-4. Worm shaft assembly-exploded view.
Section IV. REPAIR OF BOOM HOIST SHAFT
Figure 5-5. Boom hoist shaft assembly - exploded view.
Cleaning, Inspection and Repair
Section V. REPAIR OF REAR DRUMSHAFT
Figure 5-6. Rear drumshaft assembly--exploded view.
Cleaning, Inspection and Repair
Figure 5-7. Front and rear drum clutch assembly--exploded view
Section VI. REPAIR OF FRONT DRUMSHAFT
Disassembly
Section VII. REPAIR OF REVERSING SHAFT
Figure 5-9. Reversing shaft assembly--exploded view.
Figure 5-10. Reversing shaft and horizontal swing shaft clutch assemblies exploded view.
Section VIII. REPAIR OF HORIZONTAL SWING SHAFT
Figure 5-11. Horizontal swing shaft assembly--exploded view.
Section IX. REPAIR OF SWING BRAKE SHAFT
Figure 5-12. Swing brake shaft assembly exploded view.
Section X. REPAIR OF VERTICAL SWING SHAFT
Disassembly
Figure 5-13. Vertical swing shaft assembly--exploded view .
Figure 5-14. Checking vertical swingshaft bevel gear backlash
Figure 5-15. Checking gear tooth contact
Installation
CHAPTER 6 REPAIR OF THE CRANE LOCKS, BRAKES AND PAWLS
Figure 6-1. Pawls and swing lock assembly linkage.
Section II. REPAIR OF SWING LOCK
Section III. REPAIR OF CRANE LOCK
Figure 6-3. Crane lock assembly.
CHAPTER 7 REPAIR OF CRANE CAB COMPONENTS AND CONTROLS
Figure 7-1. Swing brake control stand assembly--exploded view
Section II. REPAIR OF MASTER CYLINDER
Section III. REPAIR OF CRANE HEATER AND LINES
Figure 7-3. Heater lines and drain valve
Figure 7-4. Heater assembly--exploded view.
Cleaning, Inspection and Repair
CHAPTER 8 REPAIR OF SAFETY DEVICES
Figure 8-1. Load moment safety device.
Figure 8-2. Safety device block and wiring diagram (sheet 1 of 2)
Figure 8-2. Safety device block and wiring diagram (sheet 2 of 2).
Table 8-1. Test Procedure
Table 8-1. Test Procedure-Continued
Table 8-1. Test Procedure-Continued
Testing-CONT.
Testing-CONT.
Figure 8-3. Cables schematic. (Sheet 1 of 2).
Figure 8-3. Cables schematic. (Sheet 2 of 2).
Calibration
Figure 8-4. Console and remote indicator.
Figure 8-5.
Figure 8-6.
Figure 8-7. Angle transducer
Figure 8-7. Angle transducer-CONT.
CHAPTER 9 REPAIR OF CAB AND WIRING HARNESS
CHAPTER 10 REPAIR OF CRANE GANTRY, SPREADER AND BOOM COMPONENTS
Figure 10-2. Gantry assembly exploded view.
Figure 10-3. Boom backstop assembly--exploded view
Section III. REPAIR OF HOOK BLOCK
Figure 10-4. Hook block assembly--exploded view.
Section IV. REPAIR OF BOOM, BOOM ROLLERS AND PULLEYS
Figure 10-5. Boom assembly.
Removal and Disassembly
CHAPTER 11 INTRODUCTION
CHAPTER 12 DIRECT SUPPORT AND GENERAL SUPPORT
Figure 12-1. Carrier engine mounting.
Figure 12-2. Carrier torque converter mounting.
Figure 12-3. Carrier transmission removal
Transmission System Testing
12-8. Carrier Drive Steer Axles
Figure 12-4. Carrier drive steer axle removal.
Figure 12-5. Transmission oil flow and test points.
CHAPTER 13 REPAIR OF CARRIER ENGINE ACCESSORIES
Figure 13-1.Starting motor--exploded view.
Inspection and Repair
Section II. REPAIR OF ALTERNATOR
Figure 13-2. Alternator--exploded view
Inspection and Repair
Figure 13-3. l cooler-exploded view.
Inspection and Repair
Figure 13-4. Water pump-exploded view.
Inspection and Repair
Figure 13-5. Fuel pump-exploded view.
Figure 13-6. Shutdown valve--exploded view.
Inspection and Repair
Table 13-1 Plunger Size and Color Code
Section VI. AIR COMPRESSOR AND REAR BEARING SUPPORT
Figure 13-7. Rear bearing support~exploded view.
Figure 13-8. Air compressor-exploded view
Cleaning
Figure 13-9. Top of unloader body.
Reassembly and Installation
Reassembly and Installation-CONT.
Figure 13-10. Bearing support torquing sequence
Figure 13-11. Fuel lines and fittings.
Figure 13-12. Fuel tank--exploded view.
Reassembly and Installation
Figure 13-13. Carrier radiator, and fan drive assembly removal and installation
Figure 13-14. Radiator assembly-exploded view.
Section IX. REPAIR OF HYDRAULIC FAN DRIVE MOTOR
Removal and Disassembly
Figure 13-15. Fan drive hydraulic motor-exploded view
Cleaning, Inspection and Repair
Reassembly and Installation
Figure 13-17. Battery box -exploded view.
Section XI. REPAIR OF INSTRUMENT BOARD ASSEMBLY
Figure 13-18. Instrument board assembly-exploded-view.
Cleaning, Inspection and Repair
CHAPTER 14 REPAIR OF CARRIER ENGINE
Figure 14-1. Intake manifold assembly exploded view.
Figure 14-2. Exhaust manifold assembly--exploded view.
Figure 14-4. Rockers levers cover-exploded view.
Figure 14-5. Rocker levers-exploded view
Reassembly
Figure 14-7. Cylinder head torquing sequence
Figure 14-8. Injectors, push rods and tappets-exploded view.
Cleaning, Inspection
Figure 14-10. Installing cup on barrel
Figure 14- 11. Checking open cup spray holes.
Figure 14-12. Cylinder head-exploded view
Figure 14-13. Valve spring compressor, typical
Figure 14-14. Valve seat insert cross section
Figure 14-16. Valve head rim thickness.
Table 14-2 Valve seat insert specification
Figure 14-17. Injector recess area.
Figure 14-18. Cylinder head-exploded view.
Section VI. FLYWHEEL, FLYWHEEL HOUSING, GEAR HOUSING AND OIL PAN
Figure 14-19. Oil pan-exploded view.
Figure 14-20. Flywheel-exploded view.
Figure 14-21. Flywheel housing exploded view.
Figure 14-22. Gear housing exploded view.
Figure 14-23. Flywheel adapter torquing sequence.
Figure 14-24. Run-out flywheel housing bore.
Figure 14-26. Oil pan torquing sequence.
Figure 14-27. Flywheel torquing sequence.
Figure 14-29. Camshaft and camshaft cover - exploded view.
Figure 14-30. Front cover exploded view.
Section VIII. LUBRICATING OIL PUMP
Figure 14-31. Lubricating oil pump exploded view.
Figure 14-32. Lubricating oil pump assembly dimensions.
Figure 14-33. Vibration damper-exploded view.
Figure 14-34. Connecting rod and piston--exploded view.
Figure 14-35. Connecting rod specifications.
Figure 14-36. Typical installation of pin bushing in rod
Section X. CRANKSHAFT AND CYLINDER BLOCK
Figure 14-38. Crankshaft and cylinder block-exploded view Change 1 14-38
Removal and Disassembly
Cleaning, Inspection
Figure 14-39. Cylinder block height
Figure 14-40. Main bearing or torquing sequence.
Figure 14-41. Side screw torquing sequence
CHAPTER 15 REPAIR OF CARRIER DRIVE TRAIN
Figure 15-1. Transmission assembly -exploded view (sheet 1 of 2)
Figure 15-1. Transmission assembly--exploded view (sheet 2 of 2).
Figure 15-2. Input, reverse, third and fourth clutch assembles--exploded view
Figure 15-3. Disconnect assembly-exploded view.
Figure 15-4. First and second clutch assemblies--exploded view.
Disassembly
Figure 15-5. Control valve assembly--exploded view.
Disassembly-CONT.
Figure 15-6. Transmission internal tubing.
Cleaning, Inspection and Repair
Cleaning, Inspection and Repair-CONT.
Cleaning, Inspection and Repair-CONT.
Section II. REPAIR OF PROPELLER SHAFTS AND UNIVERSAL JOINTS
Figure 15-8. Propeller shaft (converter to transmission) and (transmission to rear axle).
Section III. REPAIR OF CAB HYDRAULIC SHIFT CONTROL
Figure 15-10. Hydraulic shift control.
Cleaning, Inspection and Repair
Figure 15-11. Torque converter assembly-exploded view (sheet I of 2).
Figure 15-11. Torque converter assembly-exploded view (sheet 2 of 2).
Cleaning, Inspection and Repair
Reassembly and Installation
Service
CHAPTER 16 REPAIR OF AXLES
Section II. DRIVE STEER AXLES
Figure 16-2. Axle assembly--exploded view.
Disassembly
Reassembly
Section III. DIFFERENTIAL AND CARRIER ASSEMBLIES
Figure 16-3. Front differential and carrier assembly--exploded view.
Reassembly-CONT.
Figure 16-4. Rear differential and carrier assembly - exploded view.
Cleaning, Inspection and Repair
Reassembly
Figure 16-5. Differential gear contact chart
Section IV. BRAKE ASSEMBLY
Figure 16-6. Brake shoe assembly--exploded view..
Figure 16-7. Brake lining installation.
CHAPTER 17 REPAIR OF CARRIER STEERING SYSTEM
Removal and Disassembly
Figure 17-2. Steering column and gear box--exploded view.
Reassembly and Installation
Figure 17-3. Steering shafts and stub shaft gear box -exploded view.
Figure 17-4. Stub shaft gear box exploded view.
Section III. REPAIR OF STEERING GEAR BOX AND POWER STEERING CONTROL VALVE
Figure 17-5. Steering gear and adjustment points.
Figure 17-6. Steering gear assembly removal
Figure 17-7. Steering gear box-exploded view.
Steering Gear Adjustments
Figure 17-8. Power steering control valve-exploded view.
Figure 17-9. Filling ball nut circuits and guides
Reassembly and Installation
Section IV. REPAIR OF DUAL STEERING AND EMERGENCY STEERING PUMP ASSEMBLIES
Figure 17-11. Emergency steering pump mounting.
Figure 17-12. Dual steering hydraulic pump -exploded view.
Removal and Disassembly
Figure 17-13. Emergency steering hydraulic pump exploded view.
Cleaning, Inspection and Repair
Section V. REPAIR OF STEERING SELECTOR CONTROL VALVE
Figure 17-15. Steering selector control valve--exploded view
Figure 17-16. Hydraulic steering cylinders
Figure 17-17. Self-centering steering cylinder exploded view.
Figure 17-18. Tandem steering cylinder.
Figure 17-19. Steering cylinder - exploded view.
Cleaning, Inspection and Repair
Cleaning, Inspection and Repair-CONT.
CHAPTER 18 CARRIER AIR BRAKE SYSTEM
Figure 18-1. Air brake system.
Section II. REPAIR OF BRAKE CHAMBER
Figure 18-2. Brake air chamber assembly - exploded view.
Section III. REPAIR OF AIR TANKS
Figure 18-3. Alcohol evaporator assembly exploded view.
Figure 18-4. Governor assembly exploded view.
Section VI. REPAIR OF AIR PRESSURE INDICATOR ASSEMBLY
Figure 18-5. Air pressure indicator - exploded view.
Figure 18-6. Brake treadle valve assembly exploded view.
Treadle Valve Assembly
Figure 18-7. Brake actuating valve exploded view.
Check Valves
Figure 18-8. Single check valve assembly-exploded view.
Figure 18-9. Double check valve-exploded view.
Figure 18-10. Drain valve assembly - exploded view.
Figure 18-11. Reservoir exhaust control valve-exploded view.
Three Way Control Valve
Figure 18-12. Three way control valve-exploded view.
Park Release Control Valve
Figure 18-13. Park release control valve--exploded view.
Park Release Control Valve-CONT.
Drain Valve Assembly
Figure 18-14. Drain valve assembly-exploded view
Safety Valve Assembly
Figure 18-15. Safety valve assembly-exploded view
Pressure Valve Assembly
Figure 18-16. Pressure value assembly-exploded view.
Figure 18-17. Push pull control valve exploded view
Relay Valve Assembly
Figure 18-18. Relay valve assembly--exploded view.
Relay Valve Assembly-CONT.
CHAPTER 19 REPAIR OF CARRIER CAB, FRAME AND ACCESSORIES
Removal and Disassembly
Figure 19-2. Operator's seas assembly exploded view.]
Reassembly and Installation
Section III. REPAIR OF CARRIER CAB HEATER ASSEMBLY
Figure 19-3. Carrier cab heater assembly-exploded view.
Section IV. REPAIR OF CARRIER WIRING HARNESS
Figure 19-4. Carrier wiring harness (sheet 1 of 2).
Figure 19-4. Carrier wiring harness (sheet 2 of 2).
Section V. REPAIR OF OUTRIGGERS AND PADS
Figure 19-6. Float pad assembly--exploded view.
Figure 19-7. Front outrigger assembly--exploded view
Figure 19-8. Rear outrigger assembly-exploded view.
Section VI. REPAIR OF OUTRIGGER HYDRAULIC CYLINDERS
Figure 19-9. Outrigger hydraulic cylinder, removal and installation
Figure 19-10. Outrigger hydraulic cylinder-exploded view.
Section VII. REPAIR OF UTILITY BLADE ASSEMBLY
Figure 19-11. Utility blade assembly-exploded view.
Section VIII. REPAIR OF BLADE HYDRAULIC CYLINDER ASSEMBLY
Figure 19-12. Hydraulic blade cylinder--exploded view .
Figure 19-13. Control Valve, Outrigger
Section IX. REPAIR OF PINTLE HOOK ASSEMBLY
Section XI. REPAIR OF CARRIER FRAME ASSEMBLY
Figure 19-15. Carrier frame--exploded view.
Cleaning, Inspection and Repair
CHAPTER 20 REPAIR OF HYDRAULIC SYSTEM
Figure 20-1.Outriggers and front axle lock-out hydraulic pump--exploded view.
Cleaning, Inspection and Repair
Section IV. REPAIR OF HYDRAULIC CONTROL VALVES
Figure 20-2.Hydraulic shit control--exploded view.
Utility Blade Control
Figure 20-3.Utility blade control valveexploded view.
Figure 20-4.
Figure 20-5.
Section V. REPAIR OF HYDRAULIC RESERVOIR TANK
Figure 20-6.
Replacement
APPENDIX A REFERENCES
INDEX
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TM-5-3810-295-34
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