TM-5-3810-206-12
TM 5-3810-206-12
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
Operator and Organizational Maintenance Manual
CRANE-SHOVEL, BASIC UNIT, CRAWLER MOUNTED, 40 TON
2 CU YD, DIESEL DRIVEN (W/HARNISCHFEGER ENGINE
MODEL 687C-18-ES) (W/CATERPILLAR ENGINE MODEL
D333TA)
(HARNISCHFEGER MODEL 855BG)
(FSN 3810-606-8569)
This copy is a reprint which includes current
pages from Changes 1 through 4.
HEADQUARTERS, DEPARTMENT OF THE ARMY
JANUARY 1969
SAFETY PRECAUTIONS
BEFORE OPERATION
Always provide a metallic contact between container, or nozzle, and fuel tank during fueling operations. This will
prevent sparks from jumping between nozzle and filler neck and lessen fire hazard.
Before starting engine, assure that all operating levers and controls are in neutral position.
Keep revolving frame floor free from mud, grease, or ice to prevent injury by falling.
Replace all guards and shields immediately completing adjustment.
DURING OPERATION
Stop the crane-shovel unit before maintenance is to be performed around gears, sheaves, drums, or other moving
parts.
Do not attempt to get on or off of the unit while it is in motion.
Do not give the operator a signal to raise a load until you are sure it is properly secured.
When the hook is not clearly visible by operator, use an intermediate signal man. Lift loads vertically to avoid
swinging.
Always keep within maximum working radius for load being lifted.
Be sure there is adequate clearance before attempting to move under low objects. Keep the boom at least 10 feet
from all electrical power lines. Assure that there is adequate clearance around unit before attempting to swing a load.
Do not travel unit with boom at high angle, or w hen carrying close to maximum load. Do not exceed capacity
rating.
To move capacity loads beyond radius of unit, pick up the load, swing it ahead, set it down, then move around it.
Repeat as often as necessary.
When traveling with a suspended load, secure load to the unit and prevent load from swinging out beyond boom
point.
Keep lift height to a minimum when handling close to maximum load. Never leave the unit while dipper, bucket, or
crane load, is in raised position. Lower to ground and disengage the engine clutch.
Always start or stop revolving frame swing s lowly and smoothly to avoid tilting the unit.
When operating as a shovel and digging from a bank, always inspect cut carefully for loose rock, frozen chunks of
sand, or other evidence of conditions which might lead to slides or rock falls. Use all necessary precautions to insure
safety of personnel. Avoid all careless operating habits which cause accidents to personnel.
When dumping into trucks, always spot truck s so swing will be over tailgate. Never swing a load over the cab, for
a brake may loosen enough to allow load to fall on personnel.
Stop all operation before cleaning, adjusting, o r lubricating the crane-shovel unit.
If the boom contacts high tension wires, stay on the unit until boom is cleared or current is shut off, and keep all
ground crew away from the unit.
Keep all ground personnel away from swinging area when making lifts, to avoid injury should clutch, brake, or
slings fail.
Never operate with worn or frayed cables. Install new cables when wear or frayed condition indicates failure is
imminent.
Assure that all hooks, slings, or ties, are in good condition, properly placed, and secure before lifting loads.
Never operate a shovel under overhanging embankments.
Stop operations at first sign of a slipping clutch or brake, and make proper adjustments to avoid dropping a load, or
injury to personnel.
Always be alert to unusual noises, investigate immediately.
AFTER OPERATION
Always lower a crane load, bucket, dipper, or hoe to ground before stopping operations.
When stopping operations, disengage engine clutch and assure that all operating levers are in neutral.
Use extreme caution when removing radiator cap when engine is hot, to avoid a scalding injury.
TM 5-3810-206-12
C4
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D.C., 19 July 1991
NO. 4
OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
CRANE-SHOVEL, BASIC UNIT, CRAWLER MOUNTED, 40 TON,
2 CU YD, DIESEL DRIVEN (W/HARNISCHFEGER ENGINE MODEL 687C-18-ES)
(W/CATERPILLAR ENGINE MODEL D333TA)
(HARNISCHFEGER MODEL 855BG)
NSN 3810-00-606-8569
TM 5-3810-206-12, 12 January 1969, is changed as
follows:
Inside front cover. Add the following WARNING to the
inside front cover:
WARNING
If NBC exposure is suspected, all air
filter media should be handled by
personnel wearing protective equipment. Consult your unit NBC Officer
or NBC NCO for appropriate handling
or disposal Instructions.
Page 2-30. Add the following paragraph at the bottom
of the page:
2-13. AIR CLEANER/AIR FILTER NBC WARNING
DECAL
A decal has been developed that warns of NBC
exposure. It is to be positioned in a noticeable place on
or near the air filter housing or air cleaner. You may
order the decal using part number 12296626, CAGE
19207. Refer to TB 43-0219 for further information.
(See Figure 3-2; Figure 3-3; Figure 3-9: Figure 3-45; and
Figure 3-46).
Figure 2-11.1. NBC Warning Decal
Add the following WARNING preceding paragraph 34d
on page 3-1; after paragraph 3-6 on page 3-19;
preceding paragraph 3-11 on page 3-23; preceding
Table 3-3 on page 3-42; and preceding paragraph 3-57
on page 3-65:
WARNING
If NBC exposure is suspected, all air
filter media should be handled by
personnel wearing protective equipment. Consult your unit NBC Officer
or NBC NCO for appropriate handling
or disposal Instructions.
Page I-1. Add the entry "Air Cleaner/Air Filter NBC
Warning Decal, paragraph 2-13, page 2-30" after the
entry "Aids, cold weather starting".
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
PATRICIA P. HICKERSON
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed IAW DA Form 12-25-E (Block No.
maintenance requirements for TM 5-3810-206-12.
0532) Unit, Direct Support and General Support
TM 5-3810-206-12
C3
Changes in force: C 1, C 2, and C 3
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D.C., 2 August 1990
No.3
OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
CRANE-SHOVEL, BASIC UNIT, CRAWLER MOUNTED, 40-TON,
2 CU YD, DIESEL DRIVEN (W/HARNISCHFEGER ENGINE MODEL 687C-18-ES)
(W/CATERPILLAR ENGINE MODEL D333TA)
(HARNISCHFEGER MODEL 855BG)
NSN 3810-00-606-8569
TM 5-3810-206-12, 30 January 1969, is changed as
follows:
hold each tag line to prevent the
leads from swinging. Front and rear
ground guides will be used when
moving the equipment.
Cover and title page (page i).The manual title is
changed to read as shown above.
Inside front cover. Add the following WARNINGs to the
inside front cover:
WARNING
When the leads are set over a pile,
raise the outriggers 2-3 inches off the
ground before driving the pile. Reset
the outriggers on the ground before
raising the leads.
WARNING
Travel over flat, level, solid surfaces
when moving the crane with the
leads in the raised position. Never
exceed 1-2 mph. Secure the leads to
the crane before moving the
equipment.
WARNING
Personnel not directly involved with
moving the crane and leads will
remain at least 50 feet from the
leads/equipment.
WARNING
Do not move the crane in high winds
(15-20 mph) when the leads are in the
raised position.
WARNING
Always use the load chart to
determine the boom angle, length,
and radius.
WARNING
Do not move the crane under
overhead obstacles (e.g., trees,
powerlines, bridges, etc.) with the
leads in a raised position.
WARNING
Set the swing lock brake before
attaching the boom to the leads.
WARNING
Raise the outriggers (if equipped) 2-3
inches off the ground when moving
the crane with the leads in the raised
position.
Page 1-1, paragraph 1-b, is superseded as follows: 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 or DA Form 2028
(Recommended Changes to Publications and Blank
Forms) direct to: Commander, U.S.
Army TankAutomotive Command, ATTN: AMSTA-MB, Warren, MI
48397-5000. A reply will be furnished to you.
WARNING
Attach tag lines to the leads before
moving the crane. One person will
1
By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
THOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25-E (Blocks 0532, 0533) Operator and Unit maintenance requirements
for TM5-3810-206-12.
TM 5-3810-206-12
C2
Change
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington. D.C., 7July 1972
No. 2
Operator and Organizational Maintenance Manual
CRANE-SHOVEL, BASIC UNIT, CRAWLER MOUNTED,
40 TON 2 CU. YD., DIESEL DRIVEN (W/HARNISCHFEGER
ENGINE MODEL 687C-18-ES) (W/CATERPILLAR
ENGINE MODEL D333TA)
(HARNISCHFEGER MODEL 855BG)
FSN 3810-606-8569)
TM 5-3810-206-12, dated 30 January 1969, is changed as follows:
Page ii. Change title of Appendix B as follows:
APPENDIX B. BASIC ISSUE ITEM LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED
Page B-1. Appendix B is superseded as follows:
APPENDIX B
BASIC ISSUE ITEM LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED
Section I. INTRODUCTION
1. Scope
This appendix lists basic issue items, items troop
installed or authorized which accompany the CraneShovel, and required by the crew/operator for operation,
installation, or operator's maintenance.
2. General
This basic issue items, items troop installed or
authorized list is divided into the following sections:
a. Basic Issue Items List-Section II.
"Not
Applicable".
b. Items Troop Installed or Authorized List-Section
III. A list, in alphabetical sequence of items which at the
descretion of the unit commander may accompany the
end item, but are NOT subject to be turned in with the
end item.
3. Explanation of Columns
The following provides an explanation of columns in the
tabular list of Basic Issue Items List, Section II, and
Items Troop Installed or Authorized, Section III.
a. Source, Maintenance, and Recoverability
Code(s) (SMR):
(1) Source code, indicates the source for the
listed item. Source code is:
Code
Explanation
P
Repair parts. special tools and test
equipment supplied from GSA/DSA or
Army supply system and authorized for
use at indicated maintenance levels.
(2) Maintenance code, indicates the lowest
level of maintenance authorized to install the listed item.
The maintenance level code is:
Code
C
Explanation
Crew/Operator
(3) Recoverability code, indicates whether
unserviceable items should be returned for recovery or
salvage.
Items not coded are non-recoverable.
Recoverability codes are:
Code
R
1
Explanation
Applied to repair parts (assemblies and
components), special tools and test
equipment which are considered
Code
S
Explanation
economically reparable at direct and
general support maintenance levels.
Repair Parts.
special tools, test
equipment and assemblies which are
economically reparable at DSU and
GSU activities and which normally are
furnished by supply on an exchange
basis.
d. Unit of Measure, (U/M). A 2character alphabetic
abbreviation indicating the amount or quantity of the
item upon which the allowances are based, e.g., ft, ea,
pr, etc.
e. Quantity Furnished With Equipment (BIIL only).
This column indicates the quantity of an item furnished
with the equipment.
f. Quantity Authorized (Items Troop Installed or
Authored Only). This column indicates the quantity of
the item authorized to be used with the equipment.
g. Illustration (BIIL only). This column is divided as
follows:
(1) Figure Number.
Indicates the figure
number of the illustration in which the item is shown.
(2) Item Number.
Indicates the callout
number used to reference the item in the illustration.
b. Federal Stock Number. This column indicates
the Federal stock number assigned to the item and will
be used for requisitioning purposes.
c. Description. This column indicates the Federal
item name and any additional description of the item
required.
Section Ill. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
(1)
SMR
CODE
PC
PC
PC
(2)
FEDERAL
STOCK
NO.
2590-045-9611
7720-559-9618
4210-889-2221
(3)
DESCRIPTION
REF. NO. & MFR
CODE
USABLE
ON CODE
CASE ASSEMBLY: RIFLE
CASE, MAINTENANCE AND OPERATIONAL MANUAL
EXTINGUISHER. FIRE
(4)
UNIT
OF
MEAS
(5)
QTY AUTH
EA
EA
EA
1
1
1
By Order of the Secretary of the Army:
BRUCE PALMER, JR.
General, U.S. Army
Acting Chief of Staff
Official:
VERNE L. BOWERS
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25B, (qty rqr block No.
requirements for Crane-Shovel Crawler: 40 Ton.
2
350) Organizational maintenance
TM 5-3810-206-12
C1
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 2 January 1970
NO. 1
Operator and Organizational Maintenance Manual
CRANE-SHOVEL, BASIC UNIT, CRAWLER MOUNTED,
40 TON, 2 CU YD, DIESEL DRIVEN (W/HARNISCHFEGER
ENGINE MODEL 687C-18-ES) (W/CATERPILLAR ENGINE MODEL
D333TA) (HARNISCHFEGER MODEL 855BG) FSN 3810-606-8569
Page 1-11. Figure 1-7, change caption to read:
"Figure 1-6. Shovel working ranges."
Page 1-12. Figure 1-8, change caption to read:
"Figure 1-7. Backhoe working ranges."
After figure 1-7, add figure 1-8 as follows:
Page 3-97. Figure 3-88, change caption to read:
"Figure 3-89. Swing brake hydraulic control, removal
and installation."
TM 5-3810-206-12, 30 January 1969, is changed as
follows:
Page 1-9. Delete figure 1-4.
Figure 1-5, Change caption to read: "Figure 1-4.
Clamshell working ranges."
Page 1-10. Figure 1-6, change caption to read:
"Figure 1-5. Dragline working ranges."
1
Figure 1-8. Piledriver clearance diagram.
By Order of the Secretary of the Army:
W. C. WESTMORELAND,
General United States Army,
Chief of Staff.
Official:
KENNETH G. WICKHAM,
Major General United States Army,
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25, Section II, (qty rqr block No.
maintenance requirements for Crane-Shovels, Crawlers, 40 Ton.
2
350) Organizational
*TM 5-3810-206-12
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D. C., 30 January 1969
No. 5-3810-206-12
OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
CRANE-SHOVEL, BASIC UNIT, CRAWLER MOUNTED, 40 TON,
2 CU YD, DIESEL DRIVEN (W/HARNISCHFEGER ENGINE
MODEL 687C-18-ES) (W/CATERPILLAR ENGINE MODEL D333TA)
(HARNISCHFEGER MODEL 855BG)
(FSN 3810-606-8569)
Paragraph
Page
CHAPTER 1. INTRODUCTION
Section
I. General.......................................................................................................... 1-1, 1-2
II. Description and data ...................................................................................... 1-3 - 1-5
1-1
1-1
CHAPTER 2. INSTALLATION AND OPERATING INSTRUCTIONS
Section I.
II.
III.
IV.
V.
VI.
Service upon receipt of material.....................................................................
Movement to a new worksite ..........................................................................
Controls and Instruments ...............................................................................
Operations under usual conditions..................................................................
Operation under unusual conditions ...............................................................
Operation of auxiliary material used in conjunction with crane-shovel ............
2-1 - 2-4
2-5, 2-6
2-7, 2-8
2-9 - 2-12
2-13 - 2-22
2-23 - 2-34
2-1
2-20
2-21
2-28
2-31
2-33
CHAPTER 3. OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
XV.
XVI.
XVII.
XVIII.
XIX.
XX.
XXI.
XXII.
XXIII.
Operator's and organizational maintenance repair parts, tools, and equipment
Lubrication .....................................................................................................
Preventive maintenance checks and services ................................................
Operator's maintenance .................................................................................
Troubleshooting .............................................................................................
Field expedient repairs...................................................................................
Radio interference suppression ......................................................................
Organizational 'maintenance procedures........................................................
Engine cylinder head and valve mechanism...................................................
Engine lubricating system ..............................................................................
Fuel system ...................................................................................................
Electrical system ............................................................................................
Exhaust system..............................................................................................
Cooling system ..............................................................................................
Engine clutch .................................................................................................
Power transfer................................................................................................
Hydraulic system............................................................................................
Rotating base (revolving frame) .....................................................................
Tracks............................................................................................................
Instruments and controls ................................................................................
Counterweights ..............................................................................................
Cabs, panels, doors, windows and seats.........................................................
Lights, light enclosure, and components.........................................................
3-1, 3-2
3-3, 3-4
3-5, 3-6
3-7 - 3-39
3-40 - 3-41
3-42 - 3-47
3-48 - 3-51
3-52, 3-53
3-54 - 3-56
3-57 - 3-62
3-63 - 3-73
3-74 - 3-89
3-90 - 3-93
3-94 - 3-99
3-100 - 3-102
3-103 - 3-108
3-109 - 3-116
3-117 - 3-132
3-133 - 3-138
3-139 - 3-153
3-154, 3-155
3-156 - 3-168
3-169 - 3-176
*Supersedes TM 5-3810-206-10, 3 September 1963, C1, 28 April 1965, and TM 5-3510-206-20, 27 January 1964, C1, 21 April 1965.
i
3-1
3-1
3-19
3-23
3-41
3-44
3-45
3-47
3-47
3-49
3-55
3-68
3-80
3-82
3-88
3-89
3-91
3-100
3-116
3-118
3-122
3-123
3-129
Paragraph
Page
4-1 - 4-10
4-11 - 4-23
4-24 - 4-31
4-32 - 4-37
4-38 - 4-40
4-1
4-10
4-22
4-30
4-33
CHAPTER 4. MATERIAL USED IN CONJUNCTION WITH CRANE-SHOVEL
Section I.
II.
III.
IV.
V.
Shovel front end attachment ..........................................................................
Clamshell, crane, and dragline front end attachment......................................
Backhoe front end attachment........................................................................
Piledriver front end attachment ......................................................................
Accessories....................................................................................................
CHAPTER 5. SHIPMENT AND LIMITED STORAGE AND DEMOLITION TO PREVENTENEMY USE
Section I. Shipment and limited storage......................................................................... -5-1 - 5-3
II. Demolition of material to prevent enemy use ................................................. -5-4 - 5-3
5-1
5-1
APPENDIX A. REFERENCES ................................................................................................................
A-1
B. BASIC ISSUE ITEMS LIST ..............................................................................................
B-1
C. MAINTENANCE ALLOCATION CHART...........................................................................
C-1
INDEX..........................................................................................................................................................
ii
I-1
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-2. Forms and Records
1-1. Scope
a. These instructions are published for the use of
personnel to whom the Crane-Shovel is issued. They
provide information on the operation and organizational
maintenance of the equipment. Also included are
descriptions of main units and their functions in
relationship to other components.
b. Numbers in parentheses following nomenclature
callouts on illustrations indicate quantity. Numbers
preceding nomenclature callouts indicate preferred
maintenance sequence of removal or disassembly, and
reassembly or installation should be performed in
reverse order.
c. Report all Equipment Improvement Recommendations as prescribed in TM 38-750.
a. DA Forms and records used for equipment
maintenance will be only those prescribed in TM 38-750.
b. Report
of
errors,
omissions,
and
recommendations for improving this publication by the
individual user is encouraged. Reports should be
submitted on DA Form 2028 (Recommended Changes
to DA Publications.) and forwarded direct to
Commanding General, U.S. Army Mobility Equipment
Command, ATTN: AMSMEMPP, 4300 Goodfellow
Boulevard, St. Louis, MO. 63120.
Section II. DESCRIPTION AND DATA
steel frame work and panels. Several hinged doors and
sliding panels provide access for removal of engine or
machinery.
Framed glass windows in operator's
compartment can be opened for ventilation or additional
visibility. Hand levers and foot pedals in operator's
compartment control all motions of revolving frame
operating machinery (para 2-8), and are easily within
reach of the operator from his adjustable seat.
d. Crawler Mounting. Crawler mounting (fig. 1-2)
consists of two crawler tracks and the carbody. Each
crawler track consists of forged steel side bars, (pinned
together), with track shoes bolted on. Tracks are chain
driven by the tread sprocket, and supported by a large
idler roller and numerous track rollers. The carbody
houses the propelling and steering mechanism.
e. Engine. The crane-shovel units are powered by
six-cylinder diesel engines, which operates both deck
machinery and crawlers, and are equipped with
electrical starting motors. The engine may be either a
Harnischfeger Model 687C 18-ES or a Caterpillar Model
D333TA, therefore in this manual the component
1-3. Description
a. General.
The Harnischfeger Model 855BG
Crane-Shovel is a crawler mounted, two cubic yard, 40
ton capacity, diesel engine driven unit. The booms are
interchangeable, enabling conversion to shovel, crane,
clamshell, dragline, backhoe, or piledriver operation.
b. Revolving Frame. The revolving frame (fig. 1-1)
upon which are mounted the engine, upper machinery,
and gantry, revolves around a center gudgeon and a
live roller circle mounted on the crawler. It carries four
hook rollers (two in front and two at rear), which ride on
the underside of the roller path, and prevents tipping of
the rotating base. A counterweight is fastened at rear of
revolving frame. A gantry frame which contains gantry
sheaves and harness, is mounted on the revolving
frame along with a collapsible high gantry which is
provided for use in crane, clamshell, dragline, or
piledriver service.
c. Cab. The cab (fig. 1-1) completely encloses all
machinery on the revolving frame. It consists of rigid
1-1
Figure 1-1. Crane-shovel basic unit, right 3/4 rear view, and shipping dimensions.
position on engine will be described in relation to
radiator as front end, or flywheel as the rear end. As an
example, on Model 687C-18-ES the starting motor is at
rear on left side, the generator at front on right side. On
Model D333TA, the alternator is. at front on left side,
and starting motor at rear on right side. The cylinders
are numbered from front to rear.
major identification plates which this paragraph locates
and describes. Data contained on them is listed in b
below.
(1) Corps of engineers identification plate.
This plate is mounted at right of the transportation data
plate ((7) below). It specifies the class, nomenclature,
stock number, model number, manufacturer's name.
and serial number.
(2) Manufacture’s identification plate. This
plate is mounted on right front of operator compartment
1-4. Identification and Tabulated Data
a. Identification. The crane-shovel basic unit has seven
1-2
Figure 1-2. Crane-shovel basic unit, with crane boom installed.
directly below the front window.
It gives the
manufacturer's name, and the unit serial number.
(3) Engine identification plate.
(a) The model 687C-18ES engine
identification plate is mounted on upper left side of
flywheel housing and gives the manufacturer's name,
model number, engine number, bore, stroke,
horsepower, revolutions per minute, and firing order.
(b) The
model
D333TA
engine
identification plate is mounted on left hand side of No. 6
cylinder wall and gives manufacturer's name and engine
serial number.
(4) Engine specification plate.
(a) The model 687C-18-ES engine
specification plate is mounted on right side of valve
cover, and gives engine model number, number of
cylinders, displacement in cubic inches, valve lash, type
of fuel, injection pump timing, and cooling system
capacities.
(b) The
model
D333TA
engine
specification plate is mounted on fuel filter and gives
model No., No. of cylinders, bore, stroke, high
1-3
idle engine rpm, full load engine rpm, rack setting, hp rating
at sea level, and warning of turbocharger setting and altitude
above sea level.
(5) Rated load capacity identification plate. This
plate is mounted inside operator's compartment and is
located on panel to right of cab door. It specifies operating
radius, angles, boom lengths, and lifting capacity in pounds.
(6) Loading identification plate.
This plate is
located on right front side of revolving frame cab. It specifies
position of slings for loading.
(7) Transportation data plate. This plate is located
directly below the loading identification plate ((6) above). It
specifies dimensions, cubage, tonnage, height, length, and
weights of the crane-shovel unit.
b. Tabulated Data.
(1)General.
Manufacturer
Harnischfeger Corp.
Model
855BG
Designed for use as
Backhoe, clamshell, crane,
dragline, piledriver, and
shovel
(2)Engines.
(a)Model 687C-1 8-ES.
Manufacturer
P&H Diesel Division, Harnischfeger Corp.
Model
687C-18-ES
Cycle
2
Compression ratio
16 to 1
Displacement
522 cu in. (cubic inches)
Number of cylinders
6
Cooling
Liquid
Horsepower
190 HP (horsepower) at
1,700 rpm (revolutions
per minute)
Idle speed
500 rpm
Rotation at flywheel end
Counterclockwise
Firing order
1-6-24-3-5
Governed full load speed 1,800 rpm
Weight
1 900 lbs (pounds)
Valve lash
0.012 in. cold
Injection pump timing
16 degrees below top center
(b) Model D333TA.
Manufacturer
Caterpillar Corp.
Model
D333TA
Bore
4.5 in (inch)
Stroke
5.5 in.
Number of cylinders
6
Displacement
522 cu in.
Horsepower (HP)
190 w/o (without) fan
Idle speed
600 rpm
Governed full load speed 2,000 rmp
(3)Dimensions and weights.
(a) Overall length.
(Less boom)
19 ft 6 in.
(With 50 ft crane boom)
67 ft 5 in.
(With 50 ft crane boom
and 15 ft jib)
80 ft 4 in.
1-4
(With 50 ft dragline
boom)
67 ft 5 in.
(With 50 ft clamshell
boom)
67 ft 5 in.
(With 24 ft shovel boom)
47 ft 7 in.
(With 23 ft backhoe boom) 41 ft 1 in.
(b)Overall width.
(27% in. shoes)
11 ft 38½ in.
(c)Overall height.
(Less boom and gantry) 12 ft 9½ ,i in.
(With 23 ft backhoe boom) 21 ft
(d)Shipping cubage.
(Basic unit)
2,738 cu ft
(With 50 ft boom)
9,675 cu ft
(With 50 ft boom and 15
ft jib)
11,600 cu ft
(With 50 ft dragline
boom)
9,675 cu ft
(With 50 ft clamshell
boom)
9.675 cu ft
(With 24 ft shovel boom)
6,775 cu ft
(With 23 ft backhoe boom)
9,725 cu ft
(e) Operating Weights (approximate).
(Basic unit)
101,025 lbs
(Backhoe)
119,290 lbs
(Crane)
106,400 lbs
(Shovel)
118,600 lbs
(Clamshell)
107,000 lbs
(Dragline)
107,500 lbs
(Piledriver)
. 118,600 lbs
(4) Personnel heater.
Manufacturer
Hupp Corp., Detroit,
Michigan
Model
H901-24V
Voltage
24 vdc (volts direct current)
(5)Capacities.
(a) Engine, model 687C-18-ES.
Crankcase
32 qt (quart)
Fuel filters:
Primary
% pt (pint)
Secondary
1 pt
Cooling system
36 qt
Air cleaner
4% qt
Oil filters
2 qt
(b) Engine, Model D333TA.
Crankcase
22 qt
Cooling system
33.6 qt
(c) Crane capacities.
Fuel tank
90 gal (gallons)
Swing gear box (oil)
20 qt
Chain case
8 qt
12 Hydraulic cylinders
4 qt
7 Hydraulic cylinders
2 qt
Hydraulic tank
22 qt
Power transfer reduction
gear case
8 qt
Horizontal vertical drive
gear case
12 qt
(6) Starter.
(a) For Model 687C-18-ES.
Manufacturer
Delco Remy
Model
Volts
Rotation
1113757
24 VDC
Counterclockwise at drive
end
New brush spring tension 24 to 28 oz (ounce(s))
(b) For model D333TA.
Manufacturer
Delco Remy
Model
1113771 or 1113818
Volts
24 VDC
Rotation at drive end
Clockwise
No load test:
Volts
23.0
Maximum amps
(amperes)
82.5 for 1113771 and 90 for
1113818
Minimum rpm
7,000
Lock test:
Volts
3.5
Maximum amps
500
Minimum torque
26 ft lb (food pounds)
Minimum brush spring
tension
80 oz
(7) Generator (model 687C-18-ES).
Manufacturer
Delco Remy
Model
1117497
Volts
24 VDC
Ground polarity
Shunt
Ground polarity control
Current-voltage regulator
Rated output
25 amps (amperes)
New brush spring tension 28 oz
Rotation
Clockwise (viewed from
transmission end)
(8) Alternator (model D333TA).
Manufacturer
Delco Remy
Model
1117072
Brush spring tension
10 oz
Rotation (viewing drive
end)
Clockwise
Circuit
A or B (normally B)
Field Current (80°F):
Volts
24 VDC
Amps
3.6 to 4.0
Output (cold):
Volts
28 VDC
Amps
61 amps
Approximate RPM
2,500
(9) Generator regulator (model 687C-1 8-ES)
Manufacturer
Delco Remy
Model
1118629
Volts
24 VDC
Circuit
B
Amperes
40
Ground
Negative
(10) Alternator regulator (model D333TA).
Manufacturer
Delco Remy
Model
9000591
Circuit
A or B (normally B)
Polarity
Either
(A circuit for positive
ground, B circuit for
negative ground)
Voltage setting range
27.5 to 28.5 VDC (with
adjusting screw at "O")
(11) Fuel filter (primary).
(a) For model 687C-1 8-ES.
Manufacturer
Zenith
Model
F471-2X712
(b) For model D333TA.
None used
(12) Fuel filter (secondary).
(a) For model 687C-18-ES.
Manufacturer
Fram
Type
Cartridge element
Model
F1125APBT4
Cartridge element
C1125PBT4
(b) For model D33STA.
Manufacturer
Caterpillar
Model
9H4729
(13) Air cleaner.
(a) For model 687C-18-ES.
Manufacturer
Donaldson
Type
Oil bath
Model
A14111
(b) For model DS3STA.
Manufacturer
Caterpillar
Type
Dry
Model
5L7680
(14) Engine lubricating oil filter.
(a) For model 687C-18-ES.
Manufacturer
Purolator
Model
WF500 (Assembly 64776)
Filter element
PC500 (Heavy duty senior
type)
(b) For model D333TA.
Manufacturer
Caterpillar
Model
9M530
Filter element
5S484 (disposable type)
(15) Batteries (2).
Manufacturer
Unspecified
Volts (each battery)
12 (hook up in series for 24
VDC electrical system)
(16) Specific nut and bolt torque dam
(a) For model 687C-18-ES.
Starter motor mounting
71-75 ft-lbs
Generator mounting
35-39 ft-lbs
Exhaust manifold nut
50 ft-lbs
Fuel injector mounting nut 15-20 ft-lbs
Fuel injector stud
15 ft-lbs
Muffler mounting
83-93 ft-lbs
Pulley mounting
3035 ft-lbs
Fan mounting
15-19 ft-lbs
Water manifold mounting -35-39 ft-lbs
(b) For model D33STA.
Fuel line nut torque
25-35 lbs
Valve cover retaining nut 12-18 ft-lbs
Glow plug
8-12 ft-lbs
(17) General torque data. The following
general torque values are to be used unless otherwise
specified.
1-5
TORQUE
TORQUE
TORQUE
TORQUE
FT-LBS, FOR
FT-LBS FOR
FT-LBS, FOR
PT-LBS FOR
STD. HEAT
SPECIAL HEAT
STD. HEAT
SPECIAL HEAT
TREATED
TREATED SAS
TREATED
TREATED SAE
SAE GRADE E
GRADE 8
SAE GRADE 5
GRADE
MIN-TENSILE
MIN-TENSILE
MIN-TENSILE
MIN-TENSILE
THREADS
STRENGTH
STRENGTH
THREADS
STRENGTH
STRENGTH
SIZE PER INCH
120,000 P.S.I.
150,000 P.S.I.
SIZE PER INCH
110,000 P.S.I.
150,000 P.S.I.
1/4
20
6-8
9-11
9/16
12
85-100
103-123
28
8-10
10-12
18
100-120
122-146
5/16
18
16-18
17-20
5/8
11
117-140
164-192
24
17-20
19-23
18
134-160
193-226
5/6
16
26-32
36-43
3/4
10
180-210
284-325
24
3S-40
41 49
16
216-250
337-385
7/16
14
42-60
54-65
(18) Specific gravity temperature corrections
20
50-60
64-77
for bottles. Refer to table 1-1 for battery temperature
1/2
13
67-80
81-97
corrections.
20
83-100
96-116
Table 1-1. Specific Gravity Temperature Correction for Batteries
Cranking
Temperature in
power
degrees F
available
-65°
-40° -20°
-10°
0°
+20°
+40°
+80°
+100°
+110° +120°
50%
1.277 1.267 1.259
1.255
1.251
1.243
1.236
1.220
1.213
1.209
1.205
58.3%
1.287 1.277 1.269
1.265
1.261
1.253
1.246
1.230
1.223
1.219
1.215
66.6%
1.297 1.287 1.279
1.275
1.271
1.263
1.256
1.240
1.233
1.229
1.225
75%
1.307 1.297 1.289
1.285
1.281
1.273'
1.266
1.250
1.243
1.239
1.236
83.3%
1.317 1.307 1.299
1.295
1.291
1.283
1.276
1.260
1.252
1.248
1.245
91.6%
1.82,7 1.317 1.309
1.305
1.301
1.294
1.286
1.270
1.262
1.258
1.256
100%
1.338 1.328 1.320
1.316
1.312
1.304
1.296
1.280
1.272
1.268
1.265
Operating radius (bin 450 boom angle)................. 40 ft
(19) Cable lengths, diameters, and use. Refer
Operating radius (stockpile) (45' boom angle) 40 ft
to table 1-2 for cable lengths for front end attachment to
Height from top of stock pile to boom point .......... 15 ft
be used.
Height of stock pile............................................... 25 ft
(20) Crane and jib working ranges. Refer to
Width of stock pile (approximate)......................... 60 ft
figure 1-3 for various crane and jib working ranges.
Height of bin......................................................... 24 ft
(21) Clamshell working ranges.
Clamshell
Half width of bin ................................................... 12 ft
working ranges are illustrated in figure 14 and dimension
Boom length......................................................... 60 ft
of ranges are listed below.
Table 1-2. Cable Lengths, Diameter, and Use
For
Boom length
Ft.
Boom
Hoist
Cable type and size
In.
50
0
No. 4
60
0
No. 4
65
0
No. 4
66
0
No. 4
60
0
No. 4
60
0
No. 4
65
0
No. 4
65
0
No. 4
70
0
No. 4
70
0
No. 4
76
0
No. 4
75
0
No. 4
80
0
No. 4
80
0
No. 4
85
0
No. 4
90
0
No. 4
95
0
No. 4
100
0
No. 4
Hoist
50
0
No. 4
*See footnotes At end of table.
In. Ft In.
3/4 x 290-0
3/4 x 190-0
3/4 x 310-0
3/4 x 180-0
3/4 x 390-0
3/4 x 240-0
3/4 x 420-0
3/4 x 240-0
3/4 x 450-4
3/4 x 240-0
3/4 x 450-0
3/4 x 240-0
3/4 x 270-0
3/4 x 240-0
3/4 x 240-0
3/4 x 240-0
3/4 x 240-0
3/4 x 240-0
7/8 x 130-0
Main guy cable
In. Ft In.
Intermediate guy
cable
In. Ft In.
2-13/4 x 28-0
2-13/4 x 33-0
2-1 1/4 x 38-0
2-1 1/4 x 43-0
2-1 1/4 x 48-0
2-1 1/4 x 53-0
2-1 1/4 x 58-0
2-1 1/4 x 63-0
2-1 1/4 x 68-0
2-1 1/4 x 73-0
2-1 1/4 x 78-0
1-6
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
2-3/4 x 20-0
Dragline
Clamshell
Crane
X
X
X
x
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Piledriver
X
Table 1-2. Cable Lengths, Diameter, and Use - Continued
For
Hoist
Digging
Closing
Holding
Holding
Tagline
Hammer
Pile
Line Hoist
20 Ft Jib Guy
Line 20 Ft
Dump Cable
Shovel
Hoist Cable
Boom Hoist Cable
Dipper Trip Cable
Trip Cable
Back hoe
Hoist Cable
Boom Hoist Cable
Digging Cable
Boom
length
Ft.
In.
50
0
55
0
55
0
60
0
60
0
65
0
65
0
70
0
70
0
75
0
75
0
80
0
80
0
85
0
90
0
95
0
100
0
50
0
56
0
60
0
65
0
70
0
75
0
80
0
50
0
55
0
60
0
65
0
70
0
75
0
50
0
65
0
60
0
65
0
70
0
75
0
50
0
55
0
60
0
65
0
70
0
60
0
60
0
100
0
100
0
Cable type and size
No. 4
In. Ft In.
1 X 175-0
7/8 X 140-0
1 X 190-0
7/8 X 150-0
1 X 205-0
7/8 X 160-0
1 X 220-0
7/8 X 170-0
1 X 235-0
7/8 X 180-0
1 X 250-0
7/8 X 185-0
1 X 265-0
1 X 280-0
1 X 296-0
1 X 310-0
1 X 325-0
1 X 60-0
1 X 65-0
1 X 70-0
1 X 75-0
1 X 80-0
1 X 85-0
1 X 904-0
7/8 X 165-0
7/8 X 175-0
7/8 X 186-0
7/8 X 195-0
7/8 X 206-0
7/8 X 215-0
7/8 X 130-0
7/8 X 140-0
7/8 X 104-0
7/8 X 160-0
7/8 X 170-0
7/8 X 180-0
3/8 X 854-0
3/8 X 854-0
3/8 X 850-0
3/8 X 850-0
3/8 X 861-0
7/8 X 145-0
7/8 X 175-0
7/8 X 280-0
2-3/4 X 22-0
2-3/4 X 100-0
3/4 X 18-0
No. 4
No. 4
No. 12
No. 12
1 X 95-0
3/4 X 145-0
5/16 X 35-0
5/16 X 13-0
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 4
No. 12
No. 12
No. 12
No. 12
No. 12
No. 4
No. 4
No. 11
No. 4
Main guy
cable
In. Ft In.
Intermediate
guy cable
In. Ft In.
Dragline
Clamshell
Crane
Piledriver
X*
X
X*
X
X*
X
X*
X
X*
X
X*
X
X*
X
X*
X*
X*
X*
X*
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
No. 4
No. 4
No. 4
*Represents two part line
Note
Quantities Indicated on this chart are indicated only to define those cable used with various
attachments and are not Intended to show quantity as reflected by the basic issue items list.
1-7
Figure 1-3. Crane and jib working ranges. ME 3810-201-12/1-4
Height
13 ft 6 in.
(22) Dragline working ranges.
Dragline
Boom
length
50 ft
working ranges are illustrated in figure 1-5 and
Boom
angle
456
dimensions are listed below.
(23)
Shovel
working
ranges.
Shovel working
Radius of boom point sheave
ranges
are
illustrated
in
figure
16
and
dimensions are
clearance (456 boom angle) 41 ft
listed below.
Height of boom point sheave
clearance (45°boom angle)
42 ft
Digging radius (boom at 46°
Casting clearance (approximate)
15 ft
angle)
834 ft
Depth of end or side cut (apDigging radius (boom at 600
proximate)
25 ft
angle)
31 ft
Digging reach (approximate
65 ft
Clearance radius of boom point
Center of rotation to center of
sheave (456 angle)
22 ft
dump (approximate)
40 ft
Clearance radius of boom point
Dumping height
26 ft 6 in.
sheave (60°angle)
17 ft
1-8
Figure 1-4. Clamshell Working ranges
Figure 1-5. Dragline working range".
1-9
Figure 1-6. Shovel working ranges. ME 3810-201-12' )6
Radius at end of dump (maxiDumping radius (boom at 450
mum)
28 ft
angle)
29 ft 3 in.
Clearance dumping height (maxDumping radius (boom at 600
mum)
29 ft
angle)
26 ft 9 in.
Dumping height at end of dump
26 ft 6 in.
Dumping height (boom at 456
Dumping height at start of dump-l4 ft
angle)
18 ft 6 in.
Digging reach (maximum)
40 ft
Dumping. height (boom at 60°
Digging depth (maximum)
27 ft
angle)
24 ft
Hoe stick length
9 ft
Depth below floor lever (45°
Boom length
28 ft
boom angle)
7 ft
Depth below floor lever (60°
(25) Piledriver clearances. Piledriver clearances are
boom angle)
6 ft 6 in.
illustrated in figure 1-8 and dimensions are listed below.
Floor lever radius (45°boom
Boom length
50 ft
angle)
22 ft
Distance
from
ground
to
hammer
47
ft 3 in. (maximum)
Floor lever radius (60°boom
Centerline of boom point sheave
45 ft (minimum)
angle)
20 ft
to bottom of leads
48 ft
Digging radius at height of 8 ft
Width of leads
3 ft
(45°boom angle)
34 ft
Height from ground to center
51 ft 9 in. (minimum)
Digging radius at height of 8 ft
of boom point sheave
55 ft (Maximum)
(60°boom angle)
31 ft
Height
from
ground
to
boom
tip
55 ft 3 in.
Height of cut (45°boom angle)
27 ft 3 in.
Distance from boom foot pin-to
15 ft 3 in. (minimum)
Height of cut (60°boom angle)
33 ft 6 in.
center line of leads
-21 ft 3 in.
Clearance height of boom point
(maximum)
sheave (45°boom angle)
24 ft 9 in.
(26) General information. Listed below are weights
Clearance height of boom point
of materials per two cubic yards, in pounds, commonly
sheave (60°boom angle)
28 ft 6 in.
Dipper handle length
17 ft
handled with the clamshell bucket.
These weights are
Boom length
24 ft
approximate and should only be used as a general guide. Be
Boom angle
45°or 60°
sure to add bucket weight to determine total load lift.
(24) Backhoe working ranges.
Backhoe Ash, dry
1,890 lbs
working ranges are illustrated in figure 1-7 and Cinders
2,971 lbs
Clay, compact
5,886 lbs
dimensions are listed below.
Clay, dry, in lumps
8,503 lbs
Radius at beginning of dump
- 11 ft
1-10
Figure 1-7. Backhoe working ranges.
Coal, anthracite
3,024 lbs
(28) Maintenance and operating supplies.
Coal, bituminous
2,971 lbs
Maintenance and operating supplies are listed in
Coke
1,458 lbs
appendix B of this manual.
Concrete, ready to pour
7,992 lbs
Earth, dry, loose
4,061 lbs
1-5. Difference in Models
Earth, dry, packed
6,131 lbs
Earth, wet, mud
5,942 lbs
a. General.
This
manual
covers
the
Gravel, loose, dry
5,942 lbs
Harnishchfeger crane-shovel unit model 855BG with
Gravel, wet, packed
6,480 lbs
serial number range from 21,426 through 21,550. No
Gypaum, crashed
5,131 lbs
known differences exist between units of this model.
Iron ore (50% iron)
13,503 lbs
b. Engines. All crane-shovel units will be equipped
Limestone, 1 1/2-2 In. grade
4,589 lbs
Limestone, ruin of crusher
5,11 lbs
with a model D333TA caterpillar engine, replacing the
Sand, dry, loose
6,131 lbs
Harnishchfeger model 687C18-ES as that engine
Sand, wet, packed
6,480 lbs
becomes unserviceable.
(27) Wiring diagrams. Refer to views A and B
of figure 1-9 for wiring diagrams of electrical functions.
1-11
Figure 1-8 Piledriver clearance diagram.
1-12
LEGEND
½ GROUND
8 WIRE SIZE
CL CAB LIGHTS
3/0 WIRE SIZE
A,B,ETC.TERMINALS
+ POSITIVE TERMINAL
TF UPPER FLOODLIGHTS
12 WIRE SIZE HSW HORN SWITCH
- NEGATIVE TERMINAL
JUNCTION BOX
14 WIRE SIZE PRC OIL PRESSURE INDICATOR LIGHT
SF LOWER FLOODLIGHTS
H HEATER
A. WITH ENGINE MODEL 687C-18NES
ME 3810-206-12/1.9 0
1-13
Figure 1-9. Wiring diagram (sheet 2 of 2).
1-14
CHAPTER 2
INSTALLATION AND OPERATING INSTRUCTIONS
Section I. SERVICE UPON RECEIPT OF MATERIEL
Caution
Provide a metallic contact between
service vehicle and fuel tank during
fueling operation.
Never operate
engine while in refueling process
Have serviceable fire extinguisher
available while refueling .
(3) Fill the fuel tank.
(4) Fill engine crankcase with oil as specified
in current lubrication order.
(5) Batteries may be shipped separately (para
2-2) or installed dry charged, with electrolyte shipped
separately. Install batteries (para 3-75) if necessary,
then fill with electrolyte until acid stands at least % inch
above plates. For further service to batteries refer to
TM 9-614w 200.
(6) Service cooling system (TB ORD 651)
with water, or proper mixture of anti-freeze solution. For
cold weather operation requirements see paragraph 214.
2-1. Inspecting and Servicing the Equipment
a. General. When a crane-shovel unit is received
by the organization, and after it has been unloaded from
the carrier (para 2-3), it must be thoroughly inspected
and serviced to insure that it is in good operating
condition.
b. Visual Inspection.
(1) Inspect for damage that might have
occurred during shipment.
(2) Inspect all components for loose mounting
hardware or connections.
(3) Inspect all controls for freedom of
movement through operating range, and that all handles
or knobs are in place.
(4) Inspect engine compartment for loose or
missing parts, or damage to air cleaner, manifold,
muffler, fuel injection pump, or fuel lines.
(5) Inspect fuel tank for dents, cracks, or
other damage. Insure removal of all preservative or
barrier material.
(6) Inspect battery installation for tightness of
cables and level of electrolyte.
(7) Inspect instruments for cracked or broken
glass, and security of mounting.
(8) Inspect cab for broken windows or door
glass.
(9) Inspect flood lights for serviceability, and
test operation of switches on control panel.
(10) Report all discrepancies to proper
authority.
c. Servicing the Equipment. After the equipment
has been unpacked (para 2-4) and separately packed
components have been installed (para 2-2), the
equipment must be serviced as follows:
(1) Lubricate the crane-shovel in accordance
with current lubrication order and paragraph 34.
(2) Perform all preventive maintenance
checks and services (para 3-6).
2-2. Installation of Separately Packet Components
a. General. Components packed separately are
boxed, crated, or secured on or about the basic unit on
carrier. After unloading (para 248b) and unpacking has
been accomplished, these components are installed as
follows:
b. Floodlights. Insure packing material has been
removed, then install a floodlight in single mounting
bracket on left or right front of cab (fig. 1-2) by
removing one locknut, inserting stud through bracket
and reinstalling locknut.
Install remaining floodlights in a similar manner.
c. Batteries. After batteries and electrolyte have
been unpacked (para 2-48), install batteries in box (para
375).
(1) Remove vent plugs (caps) from battery
cells and fill each cell with electrolyte, until it stands at
least 8/8 inch above plates. Install caps after checking
that vent holes are clear of any obstruction.
2-1
Warning
Avoid spilling of electrolyte. Wash
off all spilled electrolyte with fresh
water, from battery, skin, or clothing.
Serious burns may result, if this
warning is ignored.
Caution
Avoid flash currents when installing
battery cables by installing ground
cable first.
Serious damage to
instruments can occur, should this
caution be ignored.
(2) Install ground cable to negative post on
battery, then secure remaining end to stud on engine
mounting frame.
(3) Install battery cable to positive post on
battery, then secure remaining end to positive terminal
of starting motor solenoid. For further service to
batteries refer to paragraph 3-75, and TM 9-6140-20015 (Operation and Organizational, Field and Depot
Maintenance of Storage Batteries, Lead Acid type).
Note
After batteries have been installed for
about three or four hours, recheck
electrolyte level in all cells. Add
electrolyte, if necessary, until it
stands at least % inch above plates.
(4) Place cover on battery box and secure
with two catches (para 3-75).
d. Front End Attachments. Not all of the front end
attachment components will be boxed or crated. Most
will be secured to carrier with blocking, cribbing, and
hold-down bolts (para 2-3).
After unloading, the proper front end attachment will be
installed (para 2-4).
2-3. Installation or Setting Up Instructions
a. General. Crane-shovels are shipped partially
disassembled and processed for limited storage.
Definite services described below are required before
they can be put into operation. The operator and crew
requires assistance from organizational maintenance
personnel in performing these services.
b. Unloading the Equipment.
(1) Preparation for unloading. Remove all
blocking, hold-down cables, supports, or cribbing, from
front end attachments, accessories, or crane-shovel unit
(fig. 2-1 through 2-3).
Figure 2-1. Crane-shovel basic unit, and accessories loaded and blocked for shipment, front view.
2-2
Figure 2-2. Crane-shovel basic unit, and accessories loaded and blocked for shipment, rear view.
Warning
(2) Unpacking the equipment.
When
Keep
all
personnel
not engaged in
craneshovel unit is to be set up for immediate operation
remove anti-rotation bars (para 2-5); protective paneling
unloading procedure well back from
from cab windows and openings; barrier materials;
working area to avoid possible
preservatives; pressure sensitive tape from instruments
injury.
or engine components, and unpack crates or boxes
(c) Lift crane-shovel unit (on signal),
containing components of front end attachment to be
swing it away from carrier, and lower to level ground.
installed.
(d) Remove lifting slings from eyes of
Caution
crane-shovel unit and hook of lifting device.
Always use a nail puller to open
(4) Unloading by drive off method.
boxes, or crates, and avoid damage
(a) Position flatcar on a siding with an
to contents.
end ramp, preferably earthen, or where a suitable ramp
(3) Unloading by lifting.
(fig. 2-5) may be constructed.
(a) Position lifting device capable of
(b) Block all flatcar wheels to prevent
lifting 109,00 0 pounds along side carrier.
car moving away from ramp.
(b) Assure that all hold-down bolts and
(c) Perform steps (1) and (2) of b
tiedown. cables have been removed; position suitable
above.
slings in lifting eyes of crane-shovel; over hook of lifting
(d) Perform preventive maintenance
device (fig. 2-4), and attach a tag line to prevent cranechecks and services (para 36).
shovel from twisting or turning.
2-3
Figure 2-3. Front end attachments loaded and blocked for shipment (sheet 1 of 2).
out and secure each with a cotter pin. Complete crane
(e) Assure that crane-shovel has been
installation as follows:
inspected and serviced (para 2-1) then start engine
(para 2-10), and drive crane-shovel off flatcar to a
(a) Refer to view A of figure 2-7 and
suitable area near by where selected front end
reeve boom hoist cable, connect cable to dead end
attachment may be installed.
socket and secure with cable clamps.
c. Setting Up Instructions for Crone Operation.
(b) Refer to view C of figure 2-7 and
reeve
main
hoist
cable through hook block, connect to
(1) Description. The equipment required for
dead
end
socket,
and
secure with cable clamps.
crane operation consists of a 50 foot boom, boom
backstop, boom hoist guy cables, boom hoist cable,
(c) Raise boom (para 2-21c) to
snatch block, hook block, boom angle indicator and
operating position and install boom backstop (fig. 2-8).
boom harness sproader (cross-over).
(d) When jib boom is required, install
(2) Crane front end attachment installation.
as directed in paragraph 4-21, and reeve as shown in
With crane boom cribbed as illustrated in figure 2-6,
view B of figure 2-7.
move basic unit into position and connect boom by
2-4. Equipment Conversion
installation of two boom foot pins. Install pins with head
a. General.
The crane-shovel basic unit is
normally equipped as a crane, but, front end attach2-4
Figure 2-3. Front end attachments loaded and
blocked for shipment (sheet 2 of 2).
ments are available for conversion into backhoe,
clamshell, dragline, piledriver, and shovel front
operating units. The conversion instructions below will
assume that basic unit has been in operation as a crane,
and will list the different components required for
converting to new front end attachment.
Note
Crane boom of 50 foot length,
without center section, or jib boom.
b. Clamshell Front End Attachment.
The
attachment requires clamshell lagging, tagline winder,
closing and holding cables, and clamshell bucket
(1) Installation.
(a) Raise hook block to near boom
point sheave, then lower crane boom to horizontal
position.
(b) Remove clamps from hoist cable at
dead end socket (view C, fig. 27); remove hook block,
then remove hoist cable from drum. Remove cable
from right hand drum if necessary.
Note
Organizational
maintenance
personnel will remove, or install, all
drum lagging.
(c) Remove crane lagging (para 3-124)
and install clamshell lagging, then wind holding cable on
right hand drum, and closing cable on left hand drum.
Refer to table 1-2 for size and length of cables.
2-5
Figure 2-4. Unloading crane-shovel basic unit by lifting.
2-6
NOTE
MATERIAL USED FOR RAMP CONSTRUCTION MUST BE OF HARDWOOD AND FREE OF
KNOTTY DEFECTS BETWEEN SUPPORTS.
RAMP BASE, RAMP RUNNERS, AND RAMP
SUPPORTS MUST BE OF 6 INCH BY 6 INCH TIMBER, AND OF A LENGTH TO ASSURE NO MORE
THAN A 30 DEGREE ANGLE OR SLOPE. PLACE THREE OF THESE RAMPS UNDER EACH
TRACK AND CROSS SUPPORT THEM (ALL CROSS SUPPORTS MAY BE OF 2 INCH BY A INCH
DIMENSION), FOR STABILITY.
Figure 2-6. Crams boom, positioned for real or installation
(d) Position clamshell bucket under
c. Dragline Front End Attachment. This front end
boom point, reeve holding cable (fig. 2-9) and connect
attachment requires installation of dragline lagging,
to dead end socket at clamshell bucket. Secure with
fairlead, dragline bucket, dragline cable, and hoist cable.
cable clamps.
(1) Installation
(e) Reeve closing cable in similar
(a) Raise crane hook block to near
manner.
boom point sheave then lower crane boom to horizontal
(f) Install tagline winder (para 4-14);
position (fig. 2-11).
unwind and connect tagline to clamshell chain, and
(b) Remove clamps from hoist cable at
secure with cable clamps.
dead end socket (view C, fig. 2-7); remove hook block,
(g) Raise crane boom to proper height
then unwind and remove hoist cable from right hand
(fig. 2-10).
drum. Remove cable from left hand drum.
Note
(2) Removal. Remove clamshell front end
attachment by reversing steps (a) through (g) above and
Organizational
maintenance
revert to crane operation.
personnel will remove and install
lagging.
2-7
Figure 2-7. Cow boom and jib boom removal or sheet 1 of 2).
(d) Install dragline hoist able (table 1-2)
(c) Remove crane lagging (para 3-124);
on right hand drum.
install dragline lagging, then install digging (drag) cable
(e) Instill fairlead (para 4-16).
(table 1-2) on left hand drum (fig. 2-12).
(f) Position dragline bucket under
boom
2-8
Figure 2-7. Cam boom and jib boom diagram (sheet 2 of 2).
socket, and rewind on cable drum slowly while guiding
point reeve dragline hoist cable (fig. 2-12), then connect
cable through sheave.
at dead end socket on dragline bucket bridle and secure
with cable clamps.
(c) Remove boom hoist cable from
(g) Reeve drag (digging) cable (fig. 2drum and replace with pile driver boom hoist cable
12), connect to dead end socket on dragline bucket, and
(table 1-2).
secure with cable clamps.
(d) Separate boom point section from
(h) Raise boom to normal operating
base section (para 4-18) and install center (extension)
position (fig. 2-11).
section as shown in figure 2-11.
(i) Raise dragline bucket from ground.
(e) Reeve boom hoist cable (view A,
fig. 2-7) and connect to dead end socket. Secure with
(2) Removal. Remove dragline front end
proper clamps.
attachment by reversing steps la) through (i) above and
revert to crane operation.
(f) With 60 foot boom installed,
remove crane hoist cable from left hand drum and
d. Pile Driver Front End Attachment. For this
install pile cable (table 1-2) and reeve as shown in figure
attachment, pile adapters; pile leads catwalk; drop
2-18. Make loop and secure with cable clamps.
hammer; boom center (extension) section; boom hoist
cable; hammer cable, and pile cable are required.
(g) Position piledriver adapters and
spacers on boom point pin (fig. 2-14).
(1) Installation.
(h) Install bolts and nuts securing
(a) Lift hook block to near boom point
adapters
to
pile
leads.
sheave then lower crane boom (para 2-12c) to
horizontal position on cribbing (fig. 2-6); remove clamps
(i) Remove cable from right hand drum
from hoist cable at dead end socket (view C, fig. 2-7);
and install drop hammer cable (table 1-2) and reeve as
remove hook block, and wind hoist cable on drum.
shown on figure 2-13, over boom point sheave, down
through pile leads, then connect at
(b) Loosen tension on boom hoist cable
(view A, fig. 2-7), remove cable end from dead end
2-9
Figure 2-8. Crane front end attachment, with jib boom installed.
dead end socket at drop hammer and secure with cable
(1) Installation.
clamps.
(a) Remove crane boom (para 4-13)
(j) Raise boom until pile leads are
and crane lagging (para 3124).
above drop hammer; position pile leads so that hammer
Note
guides inside pile leads will enter grooves in hammer
Removal of lagging above, and
sides, then lower pile leads.
installation of lagging below, will be
(k) Raise drop hammer up into pile
accomplished
by
organizational
leads.
maintenance personnel.
(l) Position pile follower under pile
(b) Install backhoe lagging (para 3
leads; lower hammer to rest on pile follower; place pile
124).
follower cables over hooks on hammer, then raise
(c) Move crane shovel into position (fig.
hammer and pile follower to top of pile leads.
2-15) and connect backhoe boom by installing foot pins.
(m) Install catwalk at boom foot, then at
Secure with cotterpins.
pile leads (fig. 2-14), and secure with bolts, lockwashers
(d) Install auxiliary gantry and secure
and nuts.
with gantry pins.
(2) Removal. Remove piledriver front end
(e) Install backhoe digging cable (table
attachment by reversing steps (a) through (m) above
1-2) on drum lagging (fig. 2-16) and reeve through
and revert to crane operation.
guide sheaves (view C) to dead end socket, and secure
e. Backhoe Front End Attachment. Items required
end with cable clamps.
for backhoe operations are: auxiliary gantry, boom,
(f) Install boom hoist cable (table 1-2)
backhoe stick, pitch brace, dipper, backhoe lagging, and
and reeve as shown in view A of figure 2-16. Connect
cables. Convert as follows:
2-10
Figure 2-9. Clamshell front end attachment reeving diagram.
cable in dead end socket and secure
with cable clamps.
(g) Install hoist cable (table 1-2) and
reeve as shown in view B of figure 216. Connect cable in
dead end socket and secure with cable clamps.
(h) Raise gantry, insure that pitch brace
is properly installed (para 4-29b), then remove backhoe
front end attachment from cribbing.
(2) Removal.
(a) Extend backhoe dipper and build
cribbing under boom foot (fig. 2-15).
(b) Position blocking between boom and
backhoe stick.
(c) Build cribbing under boom point, then
lower boom to cribbing so that dipper rests on ground and
boom is horizontal.
(d) Remove clamps from cable at dead
end socket (view A, fig. 2-16), then slowly rewind cable
on drum as it is carefully guided through the sheaves.
(e) Remove clamps from digging cable
(view C) at dead end socket, then slowly rewind cable on
drum as it is carefully guided through the sheaves.
(f) Remove clamps from hoist cable
(view B) at dead end socket, then slowly rewind an drum
as it is carefully guided through the sheaves.
(g) Remove cotterpins from boom foot
pins (fig. 2-15); remove pins from brace and auxiliary
gantry, then back basic unit away from backhoe front end
attachment slowly until machine is clear.
(h) Remove cables from drums (views A,
B and C, fig. 2-16); remove backhoe lagging (para 3124); install crane lagging, then install crane cables (table
1-2).
(i) Install crane front end attachment
(para 2-3c).
f. Shovel Front End Attachment. Installation of
shovel front end attachment (fig. 2-18) re-
2-11
Figure 2-10. Clamshell front end attachment, installed view.
maintenance with assistance from the operator. See
quires organizational maintenance personnel to install
figure 2-19 for cable reeving, and paragraph 4-2 for
shovel sprocket, planetary pinion gear and crowd chain.
The shovel will be installed at organizational
installation instruction.
2-12
Figure 2-11. Dragline front end attachment, installed view.
Figure 2-12. Dragline front end attachment reeving diagram.
2-13
Figure 2-13. Piledriver font end attachment, reeving diagram.
2-14
Figure 2-14. Piledriver front end attachment, installed view.
Figure 2-15. Backhoe front end attachment, prepared for removal and installation.
2-15
Figure 2-16. Backhoe front end attachment, reeving diagram
2-16
ME 3810-201-12/2-17
Figure 2-17. Backhoe front end attachment, installed view.
2-17
Figure 2-18. Shovel front end attachment, installed view.
2-18
Figure 2-19. Shovel front end attachment, reeving diagram.
2-19
Section II. MOVEMENT TO A NEW WORKSITE
2-5. Dismantling for Movement
a. General. When it is necessary to move the
crane shovel to another worksite, it may be driven under
its own power, or it may be transported by rail. Method
of movement will depend on destination and distance
involved.
b. Movement for Short Distance. The crane shovel
is never dismantled for short distance movements.
Proceed as follows:
(2) Block all wheels of flatcar, and clear deck
of previous blocking, tie-downs, or other debris.
e. Loading by Drive-On.
(1) Perform preventive maintenance checks
end services (para 3-6).
(2) Start engine (para 2-10); drive crane
shovel slowly and carefully up ramp onto flatcar, and
position it as shown on figures 2-1 or 2-2.
f. Loading by Lifting.
(1) Position lifting device at flatcar, capable
of lifting a minimum of 102,000 pounds.
(2) Place lifting slings over lifting device hook
and attach to crane shovel lifting eyes (fig. 2-4).
(3) Attach tagline to keep crane shovel from
twisting or turning during lifting process.
(1) Perform preventive maintenance checks
and services (para 3-6).
(2) Insure that all tools and equipment to be
moved with crane-shovel are clean,
serviceable, and properly stowed.
(3) Start engine (para 2-10) and drive craneshovel to new worksite.
Warning
Keep all personnel not engaged in
loading procedure back and away
from working area to avoid injury,
should slings break during lift.
c. Dismantling for Long Distance Movement.
Refer to the appropriate paragraphs in chapter 4 and
remove the front end attachment now installed on
crane-shovel.
d. Preparation for Loading.
(1) Position flatcar on siding with permanent
ramp, preferably an earthen end ramp, or where an end
ramp may be constructed (fig. 2-5).
Caution
Do not allow crane shovel to turn or
twist during lift. The added stress on
lifting slings might cause them to
break
and
drop
crane-shovel,
causing excessive damage to the
equipment.
Figure 2-20. Anti-rotation bars, stowed.
2-20
(5) Position accessory boxes on flatcar and
secure as illustrated on figures 2-1 and 2-2. Refer to
Section 1 (General Rules) and the applicable figure(s) in
Section 4 of the Association of American Railroads
Rules governing the loading of commodities on open top
cars for detailed instructions.
(6) Load and secure front end attachments in
the manner shown on figure 2-3. Refer to Section 1
(General Rules) and the applicable figure(s) in Section 4
of the Association of American Railroads Rules
governing the loading of commodities on open top cars
for detailed instructions.
(4) Lift the crane shovel (on signal) and swing it
over flatcar then lower and position it as shown on
figures 2-1 or 2-2.
g. Preparation for Storage and Shipment.
(1) Prepare crane shovel for temporary
storage as directed in TM 740-93-1.
(2) Remove anti-rotation bars from their
stowed position (fig. 2-20), and install (fig. 2-21), to
prevent cab and platform movement.
(3) Remove floodlights (para 3-170) and pack
them in a box, protected by ample quantities of
cushioning material.
2-6. Reinstallation After Movement
(4) Install blocks, cribbing, hold-downs, and
wedges as shown on figures 2-1 and 2-2. Refer to
For installation after movement instructions, refer to
Section 1 (General Rules) and the applicable figure(s) in
paragraph 2-3.
Section 4 of the Association of American Railroads
Rules Governing the loading of commodities on open
top cars for detailed instructions.
Section III. CONTROLS AND INSTRUMENTS
instruments and provides operator/crew sufficient
information to insure proper operation of the craneshovel.
2-7. General
This
section
describes
the
various
controls
and
Figure 2-21. Anti-rotation bars, installed.
2-21
Figure 2-22. Instrument control stand.
2-8. Controls and Instruments
e. Swing Brake Hydraulic Control Handle.
This handle (fig. 2-23) locks swing brake. To apply
swing brake, push swing brake lever (fig. 2-24) forward,
then push down on hydraulic control handle and turn it
1/¼ turn clockwise to lock. To release swing brake, turn
hydraulic control handle 1/4 turn counterclockwise then
pull up.
a. General. The following instruments and controls
are identified on illustrations indicated.
b. Tachometer (Time Totalizing Meter).
(1) The tachometer-hour meter is located at
top of instrument panel (fig. 2-22) and indicates speed
(in revolutions per minute) at which engine is operating.
(2) The hour meter portion of tachometer is
calibrated to register engine hours at 1,411 rpm.
Operation at other speeds subject to interpolation.
f. Propel Brake Hydraulic Control Handle. This
handle (fig. 2-23) locks propel brake. To apply, push
hoist clutch and propel brake lever away from operator,
then push down on hydraulic control handle and turn
¼ /4 turn clockwise to lock. To release propel brakes,
turn the handle counterclockwise one quarter turn and
pull up.
c. Instrument Panel Lights. Two panel lights (fig.
2-22) illuminate instrument panel on control stand. Two
others illuminate lighting control box area.
d. Boom Hoist Pawl Control Handle. The boom
hoist pawl control handle (fig. 2-23) enables operator to
engage or disengage pawl from boom hoist drum
ratchet. Push down to engage. To release pawl from
engagement with the ratchet, raise boom slightly by
pulling boom hoist lever toward operator, to take
pressure off the pawl, then pull up on handle.
g. Horn Push Switch. When depressed, horn push
switch (fig. 2-22) completes electrical circuit and horn
sounds warning. When pressure is released, horn shuts
off.
h. Run-Shutdoum Switch (Applicable to Engine
Model 687C-18-ES Installation Only).
Moving this
switch (fig. 2-22) to RUN energizes
2-22
Figure 2-23. Crane operating control handles and levers.
starter circuit; fuel shutoff solenoid in fuel pump cover;
the low oil pressure /water high temperature warning
light switch circuits, and governor overspeed
microswitch circuit.
Before engine starts, low oil
pressure warning light will be red. If this red light does
not go out within 15 seconds after engine starts, move
switch to SHUTDOWN and investigate. If either light
becomes red during normal engine operation, stop
engine (para 2-11), move switch to SHUTDOWN and
investigate.
If governor overspeed microswitch
(normally closed) opens because engine speed reaches
1,935 rpm ± 15 rpm, open circuit will deenerigize
solenoid in fuel pump cover and shut off fuel supply,
stopping engine.
Always move this switch to
SHUTDOWN after engine has been stopped (para 211).
2-23
Figure 2-24. Crane, engine, and lighting controls.
i. Starter
Push
Switch.
After
moving
RUNSHUTDOWN switch to RUN, depressing this switch
(fig. 2-22) will cause starter solenoid to engage starter,
and start engine.
j. Low Oil Pressure Indicator (Warning) Light.
This light (fig. 2-2) when ON, (red) warns operator that
engine oil pressure is below safe operating level, and
that he should stop
2-24
engine (para 2-11) for an investigation of cause(s).
k. Hot Engine Indicator (Warning) Light. This light
(fig. 2-22) when ON, (red) warns operator that cooling
system is defective, and that The should stop engine
(para 2-11) for an investigation of cause(s).
l. Engine Oil Pressure Indicator. This indicator
(fig. 2-22), when engine is operating, indicates pressure
in lubrication system. The pressure indication at idle
speed should be 15 psi or above. Normal operating
pressure at governed speed is 35 psi.
m. Engine Water Temperature Indicator.
This
indicator (fig. 2-22), when engine is operating, indicates
temperature of coolant. Normal operating temperature
should range between 160°F and 180°F. If operating
temperature is not reached in a reasonably short time,
stop engine (para -1 1) and determine cause(s).
n. Ammeter. The ammeter (9g. 2-22), while
engine is operating, gives reading of battery condition.
When pointer is at zero (dial center) battery is fully
charged and generator (alternator) is supplying required
current for operation. Rate of battery discharge (current
use) is indicated by distance pointer is left of zero. Rate
of charge (after starting) will be indicated by distance
pointer is to right of zero.
Figure 2-25. Heat-start switch.
a two position toggle switch that controls all four
instrument lights for ON-OFF function.
t. Cab Light Switch. Located on lighting control
box (fig. 2-24), this two position toggle switch turns
interior cab lights ON and OFF.
o. Indicator Fuel Level. Located on operators
instrument panel (fig. 2-22), it indicates quantity of fuel
in tank.
u. Upper Floodlight Switch. Located on lighting
control box (fig. 2-24) this two position toggle switch
turns the duel floodlights ON and OFF. Floodlights are
mounted on top front of cab, and act as headlights when
crane is traveling.
p. Pressure Primer Discharge (Ether Injector).
Located on left side panel behind steering wheel (fig. 224), the ether injector forces ether vapor into air intake
manifold while trigger is held down, as an aid to starting
in cold weather (para 2-25). Release pressure on trigger
to stop ether vapor entry (after engine is running).
v. Lower Floodlight Switch. Located on lighting
control box (fig. 2-24) this two position toggle switch
turns single floodlights, mounted on either side of boom
foot, ON and OFF.
q. Heat-Start Switch (On Models With DS3STA
Engine). This switch (fig. 2-25) is also an aid to cold
weather starting (para 2-25) for the model D333TA
engine, and will replace starter push switch (fig. 2-22)
on operator's instrument panel as D333TA engines are
installed.
Refer to paragraph 225 for operating
instructions.
w. Heater Control Valve. These two valves (fig.
226) located on left side of engine, controls flow of
heated coolant from engine to personnel heater.
x. Dipper Trip Lever. This push-pull type lever (fig.
2-23) mounted on right side of operator's compartment,
controls opening of dipper door when operating with
shovel front end attachment. Pull this lever toward
operator to open dipper door. Release lever the instant
dipper door opens.
r. Swing Lock Lever Wedge. This wedge (fig. 224) must be installed when swing lock is disengaged
(para ab below), to prevent swing lock from engaging
while crane-shovel is in operation.
y. Engine Throttle Control Lever. Located on left
compartment panel at rear of operator's seat
s. Instrument Panel Light Switch. This switch (fig.
2-24), mounted on lighting control box, is
2-25
below throttle control lever (fig. 2-24) this control shuts
off fuel flow to injector pump. Pull to stop engine (para
2-11), then after engine stops, push in.
aa. Steering Gear Engaging Lever. Located behind
steering wheel (fig. 2-24), this lever should always be
up as illustrated, except when steering wheel is to be
used. Moving lever downward engages steering wheel
with steering gear.
ab Swing Lock Lever. This lever type control for
locking machine so it will not swing during
transportation, or prolonged storage. Lever is illustrated
in the unlocked position. To lock, remove wedge; grasp
trigger lever and squeeze together while moving lever
forward. (It may require swinging machinery deck a little
left or right before the lock will engage ring gear). Let
wedge hang on its chain.
Note
Anti-rotation bars (para 2-5g) must
also be installed for transportation
and storage.
ac. Swing Brake Lever. Located between steering
wheel and pressure primer discharger (fig. 2-24), push
this lever forward to apply hydraulic pressure to swing
brake. To lock the swing brake, push lever forward and
set brake, then push swing brake hydraulic control
handle in and turn one quarter turns clockwise. Release
by turning counterclockwise 1/4 turn and pulling up.
ad. Swing and Propel Shifter Lever. This lever,
located at left of steering wheel (fig. 2-24) and along
side instrument control stand, shifts motive power to
propel or swing. Move shifter lever fully forward to
travel machine, fully to the rear for swing motion.
ae. Hoist Brake Lock. Turning this lever to the left
(fig. 2-23) (after applying hoist brake) will lock hoist
brake in applied position. Move right to release.
af. Digging Brake Lock. Moving this lever to right
(fig. 2-23) after applying digging brake, will lock digging
brake in the applied position.
ag. Digging Brake Pedal. This pedal (fig. 2-23)
located on floor in front of lever stand, near instrument
control stand, applies brake to left hand or digging drum.
Figure 2-26. Heater control valves.
ah Hoist Brake Pedal. Located ,on floor in front of
lever stand to right of digging brake pedal (fig. 2-23),
this pedal applies brake to right hand or hoist drum.
(fig. 2-24) is used to set engine speed. Move forward to
increase speed, back to idle.
ai. Swing and Propel Clutch Lever. This lever (fig.
2-23) when used in conjunction with swing and propel
shifter lever (ad above) will swing or
z. Manual Engine Shut Off Control. Located
2-26
propel the machine. With swing shifter lever pulled
back in swing position, pull swing clutch lever toward
operator to swing right, push toward front to swing' left.
With propel shifter lever moved forward in propel
position, push propel clutch lever forward to travel
forward, or pull toward operator for reverse.
propel hydraulic control handle (e above) and turn
clockwise.
al. Boom Hoist Clutch Lever. This lever (fig. 2-23)
located at extreme right of lever stand, when pulled
toward operator, will wrap cable on boom hoist drum
and raise boom (or auxiliary gantry, when used with
backhoe). Push this lever away from operator to
release boom hoist brake and allow boom to lower by
gravity. Re
Caution
When traveling over 100 feet, or
longer distances, the crawler idler
sprockets must be at front of craneshovel, and must point in direction
of forward travel.
aj. Crowd (Digging) and Retract Clutch Lever. This
lever (fig. 2-23) is a push-pull type. lever which rotates
left hand (digging) crowd drum. Pull toward operator to
wrap cable on the drum. Push away from operator to
run cable off drum (when planetary pinions are
installed).
With shovel front end attachment and
sprocket installed, pull lever toward operator to crowd
shovel into bank, push lever away from operator to
retract dipper from bank after it is loaded.
ak. Hoist Clutch and Propel Brake Lever. This lever
(fig. 2-23) when pulled toward operator engages clutch
on hoist drum and wraps cable on drum. When this
lever is pushed away from operator, it applies the propel
brake. To lock propel brake in applied position, push
down on
Figure 2-28. Primer pump.
Figure 2-27. Boom angle (radius) indicator,
installed view.
2-27
push-down type lever, that engages or disengages
engine from machinery. Pull up to engage. Push down
to disengage.
Note
There is an auxiliary clutch lever
mounted on power take-off housing
that operator may use in the event
the engine clutch lever does not
function properly.
ap. Primer Pump. This pump (fig. 2-28) on engine
model 687C-18-ES (view A), D333TA (view B) is used
as starting aid in temperatures below -40'F, or after a
prolonged idle period. Releasing plunger and pumping
in and out a few strokes, fills fuel filter and lines, so that
fuel transfer pumps will be able to instantly send fuel to
injectors.
turn lever to neutral position to set boom hoist brake and
hold boom in new position.
am. Boom Hoist Hydraulic Control Handle. This
handle (fig. 2-23) must be squeezed toward boom hoist
clutch lever to close the pressure retaining valve
connected to boom hoist hydraulic line and lock hoist.
Clutch lever can then be pumped (moved to and from
operator more than once), to engage boom hoist clutch
more firmly on the drum.
an. Boom Angle (Radius) Indicator. This indicator
(fig. 2-27), pendulum type, is mounted on right hand
foot of crane boom, and is used in conjunction with
capacity plate mounted on right cab panel directly
behind cab door, to determine crane safety capacity at
any given boom length, or angle.
ao. Engine Clutch Lever. This lever (fig. 2-23),
located at lower left rear of operator's seat between
swing lock lever and cab left side panel, is a pull-up,
Section IV. OPERATION UNDER USUAL CONDITIONS
Caution
When engine fails to start on third
try, let starter rest for several
minutes, then repeat step (a).
(c) After engine starts, insure that there is
sufficient oil pressure to turn off low oil pressure warning
light (fig. 2-22). If light does not go out within 15
seconds, stop engine (para 2-11) and determine
cause(s).
Report deficiencies to organizational
maintenance personnel.
2-9. General
a. The instructions in this section are published for
the information and guidance of personnel responsible
for operation of the craneshovel.
b. The operator must know how to perform every
operation of which the crane-shovel is capable. This
section gives instructions on starting and stopping the
crane-shovel, operation of the crane-shovel, and on
coordinating the basic motions to perform the specific
tasks for which the equipment is designed. Since nearly
every job presents a different problem, the operator may
have to vary given procedures to fit the individual job.
(2) Model D333TA.
(a) When starting at an ambient
temperature below + 60°F, turn heat-start switch (para
2-8) to HEAT for time listed in table 2-1 after ambient
temperature, then move switch to START for 10
seconds, or until engine starts. As soon as engine
starts, move switch to HEAT position until engine is
running smoothly.
(b) If engine does not start after 10
seconds of cranking, repeat step (a) above.
(c) When engine fails to start on
second try, let starter rest for at least three minutes,
then repeat step (a) above.
2-10. Starting the Engine
a. Preparation for Starting.
(1) Perform required preventive maintenance
checks and services (para 36).
(2) Insure that all brakes are set (para 2-8)
and that engine clutch lever (fig. 2-24 and para 2-28) is
disengaged.
(3) Position engine throttle control lever at
half throttle, and move run-shutdown switch (fig. 2-22)
from shutdown to ON.
(4) If engine has not been run for several
days, prime fuel system with primer pump (fig. 2-28).
b. Starting.
(1) Model 687C-18-ES.
(a) Depress start push switch (fig. 222) for 15 seconds or until engine starts, then release
switch.
(b) If engine does not start within 15
seconds, let starter rest while fuel system is reprimed,
then repeat step (a) above.
Table 2-1. Use of Cold Weather Starting Aids
Ambient
Glow plug Use ether injection
temperature
beat time as Indicated below
Above +60 F
None
No
Between +60 F and +32 F
One minute
No
Between +32 F and +20 F
Two minutes
Yes
*Between +20 F and 0 F
Two minutes
Yes
*Below F
Yes
Non-winterized units will require preheating of crankcase oil
and coolant at these temperatures.
2-28
Caution
If work requires repeated short
swings, make one complete (360°)
swing to right every hour, to prevent
excessive wear on rollers of
turntable roller circle.
(1) Raise load from its resting place by
pulling hoist clutch and propel brake lever (fig 2-23)
toward operator, and at same time release hoist brake
pedal. When load is at proper height, return hoist lever
to neutral and apply hoist brake pedal to hold load in
position.
(2) Remove swing lock lever wedge (fig. 224), pull swing lock lever back to disengaged position,
then install wedge behind lever to prevent accidental
movement of swing lock lever.
(3) Move swing and propel shifter lever (fig.
2-23) back toward operator until it engages upper notch
on quadrant to engage swing gear.
(4) Release swing brake by turning swing
brake hydraulic control handle (fig. 2-23) one quarter
turn counterclockwise, then pulling handle up.
(5) To swing right, pull swing and propel
clutch lever (fig. 2-23) toward operator. To swing left,
push lever away from operator.
Note
When using a long boom, or when
load is suspended from a long cable,
operate engine at lowest practical
throttle setting to prevent load from
swinging wide of boom point when
stopping.
(6) To stop swinging, in either direction,
return swing and propel clutch lever to neutral. To stop
load from passing desired point, apply swing and propel
clutch lever in the opposite direction.
Note
If accurate stopping of load is
necessary, or if revolving frame has a
tendency to drift, apply swing brake
lever (fig. 2-23) and lock with swing
brake hydraulic control handle. This
will hold revolving frame in a fixed
position while the load is lowered.
(7) Lower load by releasing hoist brake pedal.
The rate of load descent can be regulated by varying
pressure applied to hoist brake pedal. When load is at
rest, release pressure on hoist brake pedal.
(8) Repeat steps (1) through (7) as
necessary.
c. Boom Raising or Lowering. With boom in a
horizontal position, assure that boom hoist cable is
properly reeved, then proceed to raise as follows:
(1) To raise boom pull back on boom hoist
clutch lever (fig. 2-23) to engage boom hoist clutch.
(Squeeze the boom hoist hydraulic control handle
against boom hoist clutch lever, and pump
(d) After engine starts, turn HEATSTART switch to
HEAT until engine runs smoothly; insure that there is
enough oil pressure to turn off low oil pressure warning
light (fig. 2-22). If light does not go out within 15
seconds, stop engine (para 2-11) and determine
cause(s).
Report deficiencies to organizational
maintenance personnel.
Caution
Do not turn HEAT-START switch to
HEAT while the engine is warm and
running.
c. Cold Weather Starting.
Starting the diesel
engine at ambient temperatures of + 40°F or lower
requires use of an ether starting aid. For operating
instructions on use of cold weather starting aids, refer to
paragraph 2-25.
2-11. Stopping the Engine
a. Preparation for Stopping.
(1) Lower load until it rests on ground.
(2) Apply swing and propel brakes and lock
with hydraulic control levers (para 2-8).
(3) Disengage engine clutch lever (fig. 2-24)
(4) Move engine throttle control lever to
closed position (fig. 2-24) and allow engine to idle for 5
to 10 minutes.
b. Stopping the Engine.
(1) Pull the manual engine shutoff control
(fig. 2-24) out and stop engine. When engine is
stopped, push shutoff control in
(2) Move RUN-SHUTDOWN switch (fig. 222) to SHUTDOWN.
(3) Turn all light switches OFF (fig. 2-24).
(4) Perform preventive maintenance checks
and services (para 3-6).
Warning
Be sure that dipper; bucket;
clamshell; hammer, or crane load is
lowered to ground when halting
operations, or leaving the crane
shovel.
After brake drums cool,
brakes may slip and allow load to
fall. Injury or death, and damage to
equipment, could occur should this
warning be ignored.
2-12. Operation of Equipment
a. General. This paragraph will describe all modes
of operation, assuming that operator has inspected and
serviced the machinery; the craneshovel is at an
operational site; the engine has been started (para 210); clutch has been engaged; unit has reached proper
operating temperature, and the crane-shovel is ready to
begin the assigned task(s).
b. Swinging.
2-29
lever for a second short stroke to engage the clutch
more firmly on boom hoist drum)
(2) Pull boom hoist pawl control handle out to
remove pawl from engagement with gear on boom hoist
drum.
(3) Pull boom hoist clutch lever toward
operator and raise boom. As boom approaches proper
position, slow down by moving clutch lever toward
neutral, and as boom angle indicator (para 2-8) shows
proper angle, move clutch to neutral, which sets brake,
stopping the boom.
(4) To lock and maintain booms stationary
position, push boom hoist pawl control handle down and
engage pawl in teeth of gear on boom hoist drum.
(5) In preparation for lowering boom, pull
boom hoist clutch lever back toward operator just
enough to take drum pressure off pawl; pull boom hoist
pawl control handle out to disengage pawl, then move
hoist clutch lever back to neutral.
(6) Lower boom by moving boom hoist clutch
lever away from operator. Boom will fall by gravity.
Operator will control rate of boom descent by moving
clutch lever back toward neutral. Leave clutch lever in
neutral when boom is in desired position.
Caution
When lowering boom to a horizontal
position, never lower it below plane
of crane-shovel. When the ground
level in front of crane-shovel is lower
than crawler tread, build up cribbing
under boom point to keep it
horizontal. Booms have collapsed
under lifting stress applied at this
critical angle.
d. Traveling. For traveling the crane-shovel more
than 100 feet, revolving frame must be positioned with
boom foot over crawler so that idler sprockets lead in
forward travel. Swing revolving frame (b above) into
proper position when necessary, then travel as follows:
(1) Remove wedge from in front of swing lock
lever (fig.
2-24), grasp trigger-lever and squeeze
together while moving swing lock lever forward. (It may
require swinging the revolving frame a little left or right
before lock will engage ring gear).
(2) Move the swing and propel shifter lever
(fig.
2-23) forward to engage forward notch on
quadrant.
(3) To travel forward, push the swing and
propel clutch lever (fig. 2-23) away from operator. To
travel in reverse, pull lever back towards operator. For
information on how to steer, refer to e below.
(4) When travel is completed, move swing
and propel shifter lever (fig. 2-23) back to engage rear
notch on quadrant.
(5) If further operation is to be performed,
grasp trigger-lever and squeeze together while moving
swing lock lever backward, then install swing lock lever
wedge in front of lever.
e. Steering.
(1) Engage steering wheel with steering gear
by turning steering gear engaging lever (fig. 2-24) to the
down position.
(2) There are four different positions (or
combinations) of the propel clutches and brakes
possible by turning steering wheel as follows:
(a) Position number one. Turn steering
wheel counterclockwise as far as it will go. This will
mechanically set both propel brakes and disengage both
of the jaw clutches. This position is used when digging,
or when machine is parked for a prolonged period.
(b) Position number two. Starting with
wheel in position number one, turn wheel about one and
one half turns clockwise. This will set the left hand
brake and engage the right hand jaw clutch. The craneshovel will turn, to the left when the swing/propel lever is
pushed away from the operator.
(c) Position number three. Starting with
wheel in position number one, turn wheel two turns
clockwise. This will release both propel brakes, and
engage both jaw clutches. The craneshovel will travel
straight ahead when the swing/ propel lever is pushed
away from operator.
(d) Position number four. Turn steering
wheel clockwise as far as it will go. This will set the right
hand brake and engage the left hand jaw clutch. The
crane-shovel will turn to the right when the swing/propel
lever is pushed away from operator.
Note
All travel directions are given with
the front of the crawler (idler
sprocket toward front) under the
front end of the upper revolving
machinery.
(3) When
travel
is
completed,
and
craneshovel is in position for next task, disengage,
steering wheel by lifting engaging lever (fig. 2-24) up.
f. Operation of Front End Components. Operation
of the various front end components are properly de
scribed in the section devoted to auxiliary materiel used
in conjunction with the crane-shovel as listed below.
Crane operation (para 2-28)
Clamshell operation (para 2-29)
Dragline operation (para 230)
Shovel operation (para 2-31)
Backhoe operation (para 2-32)
Piledriver operation (para 2-33)
Jib boom operation (para 2-34)
2-30
Section V. OPERATION UNDER UNUSUAL CONDITIONS
2-13. General
This section contains instructions for operating the
crane-shovel under special conditions that are unusual,
and not all of which are encountered in any one
operating area..
(2) Remove batteries from crane-shovel and
keep in heated storage area when not in use.
e. Controls. Operation of control levers will be
sluggish during extreme cold. Do not force levers into
first operation until after slow warming of engine has
thinned lubricant. Apply levers slowly and allow friction
to assist in warming of clutches, brakes, and fluids.
2-14. Operation in Extreme Cold
a. General. As temperatures drop below freezing,
metal and rubber parts become progressively more
brittle, and a relatively minor shock or jar can cause
serious damage. Generally, craneshovels assigned
work in extremely cold areas are winterized to take care
of these problems, but when conditions are encountered
always remember to warm machine up slowly and
carefully, and start all operations in low speed. Avoid
jerky handling and sharp impacts.
Warning
Do not touch metal parts with bare
hands during extreme cold, or
serious and painful injury may occur.
b. Lubrication.
(1) When temperature are below 0°F keep
crane-shovel in a heated enclosure while not in use. If
this is impossible, drain engine oil immediately after
halting operations for the day and store oil in a warm
place. If there is no warm place available for storage of
oil, preheat oil to approximately 180°F before returning
it to crankcase.
Caution
Be
sure
a
tag
is
placed
conspicuously
in
operator's
compartment warning personnel that
crankcase is empty.
(2) Refer to current lubrication order LO
53810-20612 and use proper lubricants a described in
key for the temperature expected.
c. Cooling System.
(1) The cooling system must be inspected
and serviced with anti-freeze as directed in TB ORD 65;
(Use of Anti-freeze Solution and Cleaning Compounds
in Engine Cooling Systems)
(2) Manufacture a cover out of card board
and cover enough of radiator core to assure coolant
temperature will rise to 160°F (minimum operating
temperature).
d. Electrical System.
(1) Keep electrolyte at least 8/8 inch above
plates and batteries fully charged (table 1-1).
Caution
Do not add water to batteries in
subzero temperatures, unless engine
is run for at least one hour after
addition.
The water will freeze
unless
charging
generator
(or
alternator) has an opportunity to mix
or convert to electrolyte.
f. Fuel System.
(1) Keep fuel tank as full as possible (refuel
frequently) during cold weather to minimize
condensation. If presence of water in fuel supply is
suspected, use suitable strainer while refueling.
(2) Drain condensate from fuel tank fre
quently (para 3-14b).
(3) Service primary fuel filter more frequently
(on models with engine 687C-18ES) (para 3-13).
(4) Service secondary fuel filter more
frequently (para 3-13).
g. Crawlers.
(1) When
subzero
temperatures
are
expected, remove accumulations of mud from crawlers
when halting operations for the day.
(2) When parking crane-shovel overnight in
subzero temperatures never park in a muddy area
without cleaning off mud, and placing crane crawlers
upon planks.
Caution
When crawlers are frozen (in areas
that were muddy when crane shovel
was parked), be sure and thaw mud
and ice from sprockets, chain and
track shoes, to avoid damage when
traveling away from parking area, or
to new worksite.
2-15. Operation in Extreme Heat
a. Cooling System.
(1) Assure that system is clean, free flowing,
and remove all obstructions to air passage through
radiator core.
(2) Check coolant level frequently, and add
water as required.
(3) Check fan belt adjustment frequently.
(4) Keep cab sliding panels open, to insure
more air circulation around engine.
(5) Keep water pump and drive well
lubricated (LO 5-3810-206-12).
b. Engine.
(1) Check oil level frequently. Add oil when
necessary (LO -5-3810-206-12).
2-31
(2) Keep fuel tank full to minimize
condensation.
(3) Drain condensate from tank daily (para 314b).
(4) Drain fuel filters frequently (para 3-13).
(2) If engine becomes overheated from lack
of water, allow it to cool before adding water, then run
engine at fast idle while adding water.
c. Electrical System.
(1) Do not allow batteries to overheat in
service. Open battery box cover in extreme heat, and
allow air to circulate around batteries.
(2) Check electrolyte more frequently in hot
weather, and add water unless stands at least 3/8 inch
above plates.
b. Bare Metal. Check crane-shovel carefully for
signs of corrosion. Wipe all moisture from bare metal
parts, and coat with lubricating oil, grease, or an
approved rust preventive. If painting is required, report
the condition to organizational maintenance.
c. Electrical System. Keep electrical components,
connectors, and wiring clean and dry. Coat battery
terminals with a light coat of grease to prevent
corrosion.
d. Lubrication. Lubricate and service craneshovel
more frequently (LO 5-3810-206-12).
Refer to
paragraph 3S4 for detailed lubrication instructions.
d. Lubrication. Lubricate more frequently in hot
weather, changing lubricants when required by LO 53810-206-12.
2-16. Operation in Dusty or Sandy Areas
a. Inspection and Lubrication. Fine sand or dust
has a tendency to penetrate into bushings and bearings.
Inspect, clean and lubricate at more frequent intervals
(paras 3-3 and 3-4, and LO 5-3810-206-12).
2-18. Operation in Salt Water Areas
a. Electrical System. Keep electrical connections
clean and dry. Coat battery terminals with grease to
prevent corrosion.
b. Bare Metal. Check all bare metal surfaces.
Wipe dry, and lubricate with oil or grease. If painting of
surface is necessary, report condition to organizational
maintenance.
c. Lubrication. Refer to paragraph 3-4; current
lubrication order (LO 5-4810-206-12), and lubricate
more frequently.
d. Cooling System. Do not use salt water in the
crane-shovel cooling system.
b. Fuel System. Keep fuel tank cap on tight, and
wipe free of sand and dust before removing to refuel.
Service fuel filters more frequently (para 3-13) to
remove sand and grit. Service air cleaners (para3l1)
more frequently.
c. Turntable Roller Path. Do not allow lubricant to
accumulate on roller path. Clean frequently under dusty
or sandy conditions, to prevent excessive wear.
d. Brakes and Clutches. Inspect all clutch and
brake bands frequently.
Use compressed air and
remove all sand or dust, or wipe clean. Failure to keep
bands clean will result in worn bands, scored drums, and
unsatisfactory operation.
e. Open Gears. Wash contaminated lubricant
from all open gears and relubricate frequently, to
eliminate excessive wear from sand and grit
accumulations.
f. Cables. Keep all unused cables in boxes.
Clean and lubricate operating cables more frequently, to
prevent excessive wear and insure satisfactory
operation.
g. Crawlers.
Inspect crawler and carbody
frequently for excessive lubricant that results in
accumulation of sand or- dust. Pay particular attention
to drive chains, sprockets, or gears, that wear easily.
Clean and relubricate frequently (LO 5-3810-201-12).
2-19. Operation in Snow
a. General.
Operation in snow combines
conditions found in extreme cold, and humid conditions.
Accumulations of snow turns to ice, and is damaging to
gears, or chains, and will contaminate fuel system.
b. Fuel System.
(1) Wipe all snow away from fuel filler cap
before servicing crane-shovel fuel tank.
(2) Drain condensate from fuel tank
frequently (para 3-14b).
(3) Keep fuel tank full to minimize
condensation.
c. Crawlers. Remove all accumulations of snow
from crane-shovel crawler to prevent snow from turning
to ice and causing damage.
217. Operation Under Rainy or Humid Conditions
a. Fuel System.
(1) Wipe away all moisture from filler cap and
neck before removing to service fuel tank.
2-32
11) more frequently, will assure full flow of air for
combustion.
b. With
Model
DSSSTA
Engine.
This
turbocharged engine operates best when operating at
altitude specified on warning plate installed on valve
cover. The highest altitude at which the engine may be
safely operated, without resetting, is listed on this plate.
The engine must be reset for higher altitudes. It may be
operated at a lower altitude without danger of engine
damage, but at less than maximum performance.
d. Parking. When possible, lay boards on snow
and drive crawlers up on them, then use compressed air
to blow away all snow accumulations from gears;
chains; sprockets; cable drums; sheaves of bucket, hook
block or boom.
2-20. Operation in Mud or Deep Water
a. General.
(1) When operating in mud, or water, check
footing of crane-shovel frequently to avoid tipping.
(2) When fording a body of water be careful
of hidden boulders or deep holes. Use dipper or
weighted hook block to feel the way across, stopping
crane travel to swing from side-to-side to detect
boulders. Lower dipper or hook to measure depth of
water and avoid dangerous holes.
b. Lubrication.
Lubricate
crane-shovel
immediately after washing or fording.
Keep all
operating mechanism thoroughly lubricated (LO 5-3810206-12).
2-22. Operation Below Sea Level
a. With Model 687C-18-ES Engine. This engine
will operate satisfactorily at altitudes below sea level
without special adjustment.
b. With Model D33STA Engine. This turbocharged
engine will operate at altitudes below sea level without
danger of damage to engine but with reduced efficiency.
Long periods of operation at low altitudes should not be
attempted without reporting details to proper authority,
so that required adjustments may be accomplished.
2-21. Operation at High Altitude
a. With Model 687C-1 8-ES Engine. The blowers
on this engine operate satisfactorily at higher altitudes
without special attention. Service of air cleaner (para 3Section VI. OPERATION OF AUXILIARY MATERIEL USED IN
CONJUNCTION WITH CRANE-SHOVEL
2-23. General
This section furnishes information on operation of
auxiliary materiel used on, or with the craneshovel.
Cold weather starting aids, fire extinguisher, heaters,
trouble light, and front end attachments are covered in
succeeding paragraphs.
(2) Replace cylinder that has been used, or
that does not weigh in accordance with marking on
cylinder.
2-25. Cold Weather Starting Aids
a. General. Units with engines model 687CES-18,
and some units with engine model D333TA installed, are
equipped with pressure primer discharger (fig. 2-24) for
use in cold weather starting. Model D333TA engines
also have glow plugs installed, and in this instance both
glow plugs and propane injection is used for cold
weather starting (table 2-1).
2-24. Fire Extinguisher (Dry Chemical Type)
a. Description.
The dry chemical type fire
extinguisher is suitable for use on all types of fire, and is
effective in areas where ambient temperature is -25°F
and above.
When winterized, (pressurized with
nitrogen) the fire extinguisher may be used in
temperatures below - 25°F. This extinguisher is a 2 1/2
pound, stored pressure, lever-operated fire extinguisher.
b. Cold Weather Starting Operation.
(1) Operating the pressure primer discharger.
Prepare for starting as directed in paragraph 2-10, then
proceed as follows:
(a) Move engine throttle control lever
(fig. 2-24) to half throttle position.
(c) Press on operating-lever which
allows gas pressure in cylinder to force propane into
intake manifold.
b. Operation.
(1) Remove fire extinguisher from its
mounting bracket on inside of cab, at right of operator's
seat.
(2) Lift handle; press lever, and direct
sweeping motion.
c. Maintenance.
(1) Inspect for broken seal.
2-33
smoothly, and insure that there is enough oil pressure to
turn off low oil pressure warning light. If warning light
does not go out within 15 seconds, step engine (para 211) and determine causes(s). Report deficiencies to
organizational maintenance.
Caution
Do not turn HEAT-START switch to
HEAT when engine is warm and
running.
(3) Operating glow plugs and pressure primer
discharger simultaneously.
(a) Refer to table 2-1, compare ambient
temperature with time required, then move HEATSTART switch to HEAT.
(b) After glow plugs have heated the allocated time,
press operating handle of pressure discharger; release
propane into intake manifold, and at same time move
HEAT-START switch to START.
(c) After engine starts, move HEATSTART switch
to HEAT until engine is running smoothly, then move
switch to OFF.
Note
Starting
crane-shovel
units
at
ambient temperature of +20'F or
lower may require preheating of
crankcase oil and coolant
Figure 2-29. Pressure primer discharger.
(d) Depress starter push switch (fig.
2-22)
simultaneously with operating lever of pressure primer
discharger and hold for 15 seconds, or until engine
starts.
(e) If engine does not start in 15 seconds, let starter
motor rest for at least 30 seconds then repeat steps (a)
through (d) above.
(f) When engine starts, decrease throttle control
lever to a low idle until engine oil pressure reaches
normal operating pressure, then run engine at half
throttle for at least five minutes before applying a load.
Caution
Use only enough propane to start the
engine, or to keep it running if it
begins to stall.
2-26. Personnel Heater
a. General.
These crane-shovel units are
equipped with a hot water type heater, mounted just
behind operator on floor of cab.
b. Fan and Heater Controls. A fan control toggle
switch is mounted on lighting control box in the cab (fig.
2-24). Two control valves (fig. 2-26) controls flow of
heated coolant from engine to heater.
c. Operation.
(1) Before attempting to use heater, be sure
that the two valves at engine are open (fig. 2-26).
(2) Operating the glow plugs (on engines
model DSSSTA).
(a) Refer to table 2-1 for time required, then move
HEAT-START switch (fig. 2-15) to HEAT.
(b) After plugs have heated the required time,
move HEAT-START switch to START and hold for 10
seconds, or until engine starts. As soon as engine
starts, move switch to HEAT position until engine is
running smoothly, then move switch to' OFF.
(c) If engine does not start after 10 seconds of
cranking, repeat steps (a) through (b) above.
(d) If engine fails to start on second try, let starter motor
rest for three minutes, then repeat step (a) above.
(e) After engine has started, move HEAT-START
switch to HEAT position until engine is running
(2) Start heater fan by moving toggle switch
(fig. 2-24) up to ON.
(3) In warm weather, heater fan may be used
to circulate air in the cab, by leaving water flow control
valves (fig. 2-26) closed.
2-27. Trouble Light
a. Description. The trouble light is a drop cord
type, 24 Vdc, and is stowed in the cab.
b. Operation. Remove light from stowed position
and plug into trouble light socket on lighting panel (fig.
2-24).
2-34
2-28. Operation of Crane Front End Attachment
a. Perform preventive maintenance checks and
services (para 3-6); start engine (para 2-10); engage
engine clutch (fig. 2-24), then raise boom (if necessary)
(para 2-12c.).
b. Lower hook block by releasing pressure on the
digging (main hoist) brake pedal; moving crowd and
retract clutch lever away from operator (fig. 2-23), and
allow hook block to drop slowly to center of load to be
lifted. Swing revolving frame (para 2-12b), or travel
craneshovel (para 2-12d) when necessary to center
hook over load.
c. When hook block is in desired position, return
crowd and retract clutch lever to neutral, apply main
hoist (digging) brake pedal and hold.
d. After load is safely attached, allow ground crew
to clear load, then pull back on crowd and retract clutch
lever (fig. 2-23), at the same time release main hoist
(digging) brake pedal.
e. When load is sufficiently high to swing safely,
return crowd and retract clutch lever to neutral position,
and at same time apply main hoist (digging) brake pedal
to hold load in position.
f. Swing revolving frame to desired position (para
2-12b).
Note
Engage swing and propel clutch
lever (fig. 2-23) slowly so that swing
motion will start and stop smoothly.
g. Lower load by moving crowd and retract clutch
lever away from operator releasing main hoist (digging)
brake pedal, and control rate of load descent by varying
the pressure applied to main hoist (digging) brake pedal.
When load is in proper position, move crowd and retract
clutch lever to neutral and apply main hoist (digging)
brake pedal.
Note
If it is necessary to unload at a
greater or lesser radius, the boom
may be raised or lowered as required
(para 2-12c) or, crane-shovel may be
traveled (para 2-12d). If boom is
lowered, load must be hoisted
simultaneously to prevent load from
lowering too fast and causing
damage. If traveled for less than 100
feet, it is not necessary to put idler
sprockets under boom foot.
h. When load is solidly at rest, release main hoist
(digging) brake pedal and give ground crew slack to
unfasten hitch.
i. When load is unhitched, pull back crowd and
retract clutch lever to raise hook block clear, and hold in
position with main hoist (digging) brake pedal.
Note
Travel, or adjust boom if necessary,
in reverse order to change made as a
result of note above.
j. Swing revolving frame to spot for next load
(para 2-12b).
k. Repeat steps a through j cycle as necessary.
l. Disengage engine clutch (fig.
2-24); stop
engine (para 2-11), then perform preventive
maintenance checks and services (para 3-6).
2-29. Operation 6f Clamshell Front End Attachment
a. Perform preventive maintenance checks and
services (para 36); start engine (para 2-10), then engage
engine clutch (fig. 2-24).
b. Raise the open clamshell bucket from ground by
releasing digging brake pedal and hoist brake pedal (fig.
2-24), and at the same time pulling back on the crowd
and retract clutch lever and the hoist and propel clutch
lever.
Note
The above clutch levers are side-byside, and may be controlled with one
hand, if desired. If the clamshell
bucket starts to close in mid air,
release pressure on crowd and
retract clutch lever just enough to
reopen bucket.
c. When bucket is high enough to clear
obstructions, return crowd and retract and hoist and
propel clutch levers (fig. 2-24) to neutral and at the
same time apply digging and hoist brake pedals to hold
open bucket in position.
d. Swing revolving frame in desired direction (para
2-12b).
e. Release digging brake pedal and hoist brake
pedal and lower open clamshell bucket to stockpile.
The rate of bucket descent is controlled by pressure on
hoist brake pedal. Allow closing (digging) line to run
free when lowering bucket.
Note
If necessary to force bucket teeth
into hard material, a long fast drop of
bucket from tip of boom to stockpile
will do the job.
f. As soon as bucket enters material, apply digging
and hoist brake pedals to prevent cables overrunning.
g. Release digging brake pedal, and at the same
time pull crowd and retract clutch lever toward operator
to close the bucket. To adjust digging depth, slack off
on hoist brake pedal as bucket closes and digs into
material.
h. When bucket is closed, pull the hoist clutch
lever toward operator, and at same time release hoist
brake pedal. As bucket rises it may be necessary to
slack off on hoist clutch lever to avoid opening bucket in
mid air.
i. Raise bucket high enough to clear obstructions;
release crowd and retract clutch lever and the hoist
clutch lever, and at the same time apply
2-35
boom height. Swing boom toward work area (para 212b) then apply swing brake to hold boom is desired
position.
pressure to digging brake and hoist brake pedals to hold
bucket in position.
j. Swing the revolving frame to desired dumping
position (para 2-12b), then release digging brake pedal
to open bucket.
k. Swing the open bucket back to loading point and
repeat steps b through 1 working cycle as often as
necessary.
l. When though with work for the day, lower
bucket to ground and disengage engine clutch (fig. 224).
m. Stop engine (para 2-11) and perform preventive
maintenance checks and services (para 3 6).
i. Release pressure on digging brake pedal and
hoist brake pedal simultaneously. Apply pressure to
both brake pedals to prevent cables from overrunning as
bucket reaches ground.
k. Repeat steps c through S, i and j above as
necessary.
l. When work for day is through, lower bucket to
ground, and disengage engine clutch (fig. 2-24).
m. Stop engine (para 2-11) and perform preventive
maintenance checks and services (para 3-6).
2-30. Operation of Dragline Front End Attachment
a. Perform preventive maintenance checks and
services (para 3-6); start engine (para 2-10), and
engage engine clutch (fig. 2-24).
b. Raise or lower boom (if necessary) (para 2-12c)
to between 40 and 45° angle, the normal angle for
dragline operation.
c. Release digging brake pedal, allow bucket to
trip, then lower bucket to work area by releasing
pressure on hoist brake pedal. When bucket touches
ground apply hoist brake pedal to prevent cable
overrunning.
2-31. Operation of Shovel Front End Attachment
a. Perform preventive maintenance checks and
services (para 3-6); start engine (para 2-10), and
engage engine clutch (fig. 2-24).
b. Travel (para 2-12d) to bank as shown in figure
1-7. When positioning crane-shovel near bank, keep
about 11/4 to 11/2 times dipper length between crawlers
and edge of bank.
c. Lower dipper by releasing hoist brake pedal (fig.
2-23). Control speed of lowering dipper by varying
pressure on hoist brake pedal.
d. To crowd dipper into bank, extend dipper stick
by pulling crowd and retract clutch lever toward
operator, then returning lever to neutral.
e. To load dipper from bank, move hoist clutch
lever toward operator, then just a moment later, pull
crowd and retract clutch lever toward operator.
Note
The dipper should slice a thin layer
from bank rather than digging in.
d. To fill dragline bucket, pull crowd and retract
clutch lever toward operator, slipping hoist brake as
required to allow bucket to level out when filled.
e. When bucket is loaded return crowd and retract
clutch lever to neutral and apply slight pressure to
digging brake pedal, then pull hoist and propel clutch
lever toward operator. The slight pressure on digging
brake keeps bucket level and prevents it from dumping
its load.
f. When bucket is high enough to clear
obstructions, swing to dumping area (para 2-12b), at the
same time slipping digging brake to allow bucket to
swing out under boom point.
g. When bucket has reached the desired position
for dumping, release all pressure on digging brake
pedal.
h. Swing bucket (para 2-12b) out over digging
position and repeat above working cycle as often as
necessary.
Note
Working or digging area can be
enlarged beyond boom point by
"casting" bucket.
f. When dipper is loaded, move crowd and retract
clutch lever away from operator and retract dipper from
bank.
g. When dipper is high enough to clear obstacles,
return hoist clutch to neutral and apply hoist brake
pedal, then swing dipper (para 2-12b) over unloading
area. Apply swing brake (fig. 2-23) when dipper is in
unloading position, then move dipper trip lever to open
dipper door and dump load.
h. Swing dipper back to loading area (para 2-12b)
then position crane-shovel for digging, and repeat above
work cycle as necessary.
i. To cast bucket beyond boom point, pull crowd
and retract clutch lever toward operator and bring
bucket toward boom foot, as bucket is hoisted to half
2-36
i. When work is finished for the day, lower dipper
to ground, and disengage engine clutch (fig. 2-24).
j. Stop engine (para 2-11) and perform preventive
maintenance checks and services (para 3-6).
f. Stop travel of backhoe dipper before dipper
sheave (fig. 2-17) strikes boom, by returning crowd and
retract clutch lever to neutral and applying pressure to
digging brake pedal.
g. Raise dipper out of cut and to dumping height
by holding pressure on digging brake pedal (keeping
dipper close to boom), and moving hoist clutch and
propel brake lever toward operator. When dipper is at
proper height return clutch lever to neutral and apply
pressure to hoist brake pedal.
h. Swing revolving frame (para 2-12b) to dumping
area.
i. Dump load by moving hoist clutch and propel
brake lever toward operator, at the same time moving
crowd and retract clutch lever away from operator,
keeping pressure on digging brake pedal to prevent
overrunning of digging cable. When load is dumped
and stick is extended return hoist clutch and propel
brake lever and crowd and retract clutch lever to neutral,
then apply pressure to both brake pedals to hold
backhoe in position.
j. Swing revolving frame (para 2-12b) back to
work area.
k. Repeat the above work cycle as necessary.
l. When work is through for the day lower dipper
to the ground, and disengage engine clutch (fig. 2-24).
m. Stop engine (para 2-11) and perform preventive
maintenance checks and services (para 3-6)
2-32. Operation of Backhoe Front End Attachment.
a. Perform preventive maintenance checks and
services (para 3-6); start engine (para 2-10), and
engage engine clutch (fig. 2-24).
Note
Observe that the position of auxiliary
gantry (fig. 2-17) is almost vertical,
and the backstop is almost closed.
Adjust position, if necessary, as
described for raising or lowering of
boom (para 2-12c).
b. Take up slack in hoist cable and digging cable
by moving hoist clutch and propel brake lever and crowd
and retract clutch lever (fig. 2-23) toward operator.
Move clutch levers back to neutral when cable tension is
equal.
c. To raise backhoe dipper boom and extend
dipper, pull the hoist clutch and propel brake lever (fig.
2-23) toward operator, at the same time move crowd
and retract clutch lever away from operator allowing
digging cable to run out. Control slack in digging cable
by varying pressure on digging brake pedal.
d. Continue raising of backhoe boom and dipper
extension until dipper is over the work area; then return
both clutch levers to neutral; hold digging cable tight
with pressure on digging brake pedal; allow backhoe
boom and dipper to lower, controlling rate of descent by
pressure on hoist brake pedal.
e. Fill dipper by pulling crowd and retract clutch
lever toward operator, at same time keeping tension on
hoist cable by applying pressure on hoist brake pedal.
Note
Depth of backhoe dipper cut is
controlled by tension on hoist brake
pedal. If hoist cable goes slack,
dipper will dig in instead of slicing
material from the cut. The pitch
brace between dipper and stick is
adjustable to three positions. For
normal operation brace pin is usually
set in center hole. For very deep
excavation, set brace pin in lower
hole. Where maximum height of lift
is required for dumping, set brace
pin in upper hole.
2-33. Operation of Piledriver Front End Attachment
a. Perform preventive maintenance checks and
services (para 34;); start engine (para 2-10), and engage
engine clutch (fig. 2-24).
b. Attach pile follower cable (fig. 2-14) to hooks on
hammer, then lift hammer and pile follower by moving
hoist clutch lever toward operator. When hammer
reaches top of hammer guides, return hoist clutch lever
to neutral, apply hoist brake pedal, and set hoist brake
lock (fig. 2-23) to hold hammer in raised position.
c. Run pile handling cable off drum by moving
crowd and retract clutch lever away from operator, and
at same time applying pressure to digging brake pedal
to prevent pile cable from overrunning. Attach pile
handling cable to upper end of a pile and raise it into
position within pile leads by moving crowd and retract
clutch lever toward operator, return clutch to neutral and
apply digging brake when pile is within pile leads.
d. Position pile in desired location by moving crane
as required (swing, para 2-12b, travel, para 2-12d), then
lower point of pile to ground by slowly moving crowd and
retract lever away
2-37
from operator, at same time applying digging brake
pedal to prevent cable overrunning drum.
j. Stop engine (para 2-11) and perform preventive
maintenance checks and services (para 3-6).
e. Wrap a heavy chain around pile and leads to
hold pile within leads, then remove pile handling cable
from pile.
Note
the chain should be sufficiently
loose not to bird pile when driving
begins.
f. Lower hammer and pile follower by releasing
hoist brake lock and pressure on hoist brake pedal
Allowing hammer and pile follower to drop slowly to top
of pile. Position pile in follower then remove pile
follower cables from hooks on hammer.
g. To drive the pile, raise hammer by pulling hoist
clutch lever toward operator. As hammer reaches top of
pile leads, return hoist clutch to neutral, and apply hoist
brake pedal immediately after hammer hits pile follower
to prevent hammer cable overrunning the drum. Repeat
this step until pile is driven.
h. Position another pile and repeat the above
operating cycle as often as necessary.
i. When work is through for the day, lower
hammer to rest on pile follower, and disengage engine
clutch (fig. 2-24).
2-34. Operation of Jib Boom Front End Attachment
a. When jib boom is installed to crane boom (fig.
24) and reeved (fig. 2-7), the job hoist line (or whip line)
is operated as described below.
b. Position boom with jib over center of load (by
swinging revolving frame, para 2-12b above, or
traveling, para. 2-12d above).
c. Lower weighted hook by releasing hoist brake
lock (fig. 2-23) and allowing hook to drop by gravity,
controlling rate of descent by varying pressure on hoist
brake pedal.
d. After load is attached to hook, lift load by
moving hoist clutch and propel brake lever (fig. 2-23)
toward operator.
e. When load is at proper height to clear all
obstacles, move hoist clutch and propel brake lever to
neutral and apply hoist brake pedal and lock with hoist
brake lock.
f. Complete handling of load in similar manner to
crane operation (para 2-28 above).
2-38
CHAPTER 3
OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I. OPERATOR'S AND ORGANIZATIONAL MAINTENANCE
REPAIR PARTS, TOOLS, AND EQUIPMENT
References and illustrations indicating the use of these
tools are listed in the table. No special equipment is
required by operator, crew, or organizational
maintenance personnel for performing maintenance on
the crane-shovel basic unit.
3-1. Tools and Equipment a. Basic issue tools and
repair parts issued with or authorized for the craneshovel basic unit are listed in the Basic Issue Items List,
Appendix B of this manual.
b. The special tools required to perform operator
and organizational maintenance on the craneshovel are
listed in table 3-1, and Appendix C.
3-2.
Organizational Maintenance Repair Parts
Organizational maintenance repair parts are listed and
illustrated in TM 5-3810-206-20P.
Tale 3-1. Special Tools
Item
PULLER, SHEAR WASHER
FSN or
part number
5120-690-7948
Ref
Fig
Par.
3-124
Use
Changing of lagging on hoist drums
Section II. LUBRICATION
3-3. General Lubrication Information
c. Operation After Lubrication. Start engine (para
2-1) and operate the crane-shovel immediately after
a. This section contains instructions which are
lubrication. Inspect lubrication oil filters for leaks, then
supplemental to, and not specifically covered in the
stop engine (para 2-11) and check all oil levels. Add oil,
lubrication order.
if necessary, to bring level up to full mark on dipstick
b. Refer to lubrication order LO 5-3810-206-12 for
level gage. Check for any additional leaks and correct
normal information on lubrication points and intervals.
them if found.
3-4. Detailed Lubrication, Information
a. General.
Keep all lubricants in closed
containers and store in a clean dry place, away from
external heat. Allow no dust, dirt, or other foreign
material to mix with the lubricant. Keep all lubrication
equipment clean and ready for use at all times.
b. Cleaning. Keep all external parts not requiring
lubrication clean of lubricants. Before lubricating the
crane-shovel, clean all lubricating points (fig. 3-1) to
prevent contaminates from entering housing under
applied pressure. After lubrication, wipe excess grease
from all lubrication points to prevent accumulation of
foreign matter.
d. OES Oil.
(1) The crankcase oil level must be, checked
frequently, as oil consumption may increase.
(2) The oil may require changing more
frequently, because contamination by dilution and
sludge formation will increase during cold weather
operation.
e. Engine Air Cleaners. The air cleaners may be
oil bath, or dry type depending on type of engine
installed in crane-shovel. Service as follows:
3-1
Figure 3-1. Lubricating point identification (sheet 1 of 14).
3-2
Figure 3-1. Lubricating point identification (sheet 2 of 14).
3-3
Figure 3-1. Lubricating point identification (sheet 4 of 14).
3-5
Figure 3-1. Lubricating point identification (sheet 5 of 14).
3-6
Figure 3-1. Lubricating point identification (sheet 6 of 14).
3-7
Figure 3-1. Lubricating point identification (sheet 7 of 14).
3-8
Figure 3-1. Lubricating point identification (sheet 8 of 14).
3-9
Figure 3-1. Lubricating point identification (sheet 9 of 14).
3-10
Figure 3-1. Lubricating point identification (sheet 10 of 14).
3-11
Figure 3-1. Lubricating point identification (sheet 11 of 14).
3-12
Figure 3-1. Lubricating point identification (sheet 12 of 14).
3-13
Figure 3-1. Lubricating point identification (sheet 13 of 14).
3-14
Figure 3-1. Lubricating point identification (sheet 14 of 14).
3-15
engine oil filters are located on left hand side of engine
at rear of cab. Service as follows:
(a) Refer to LO 5-3810-206-12 for
correct interval, then loosen bolt (fig. 3-3); remove
cover, spring, and gasket. Discard gasket.
(b) Remove pipe plug and drain filter.
(c) Remove and discard filter element.
(d) Clean cover, spring, and filter shell
by wiping away all sludge with a cloth wet in an
approved cleaning solvent, then dry thoroughly.
(e) Install pipe plug.
(f) Insert new filter element in shell;
position gasket in cover, then install cover and spring on
shell. Secure by tightening bolt.
Note.
Service remaining filter in a similar
manner.
(2) For engine model D333TA. These two
filters are mounted on a common base that is installed
on left hand side of engine. Service as follows:
(a) Refer to LO 5-3810-206-12 for
interval, then remove drain plug (fig. 3-4) and drain the
filters.
Figure 3-2. Air cleaner service (engine 687C-18-ES).
(1) Service for crane-shovel model 855BG
(engine 687C-18-ES).
(a) Refer to figure 3-2, loosen special
screw in clamp, then remove top cap from body.
(b) Loosen two wing nuts; remove
bottom pan from body, then empty old oil from pan.
(c) Remove three wing nuts that secure
screen to body, then remove screen.
(d) Clean all parts in an approved
cleaning solvent and dry thoroughly.
(e) Install screen on body and secure
with three wing nuts.
(f) Refer to LO 5-3810-206-12 for type
and quantity required, then fill bottom pan with oil.
(g) Install bottom pan over screen, then
tighten the two wing nuts.
(h) Install top cap on body and secure
by tightening special screw in holddown clamp.
(2) Service for crane-shovel model 855BG (engine
D333TA). Refer to paragraph 3-11b for service of dry
type air cleaner.
f. Engine Oil Filter Service.
(1) For engine model 687C-18-ES. The two
Figure 3-3. Engine oil filter service for model 687C-18-ES.
3-16
Figure 3-4. Engine oil filter service for engine model D333TA.
(b) Loosen the two cover screws;
remove cover from both cases, then remove and
discard used filter element from both cases.
(c) Remove
three
capscrews,
lockwashers, and clamps, then remove both cases from
filter base.
(d) Remove both gaskets from filter
base.
(e) Clean all removed parts in an
approved cleaning solvent, dry thoroughly, then use a
cloth dampened with solvent and wipe all sludge from
filter base.
Note
Discard all unserviceable gaskets.
(f) Install drain plug in filter base;
install serviceable gasket in both case grooves in filter
base, then position cases on base and secure with
clamp, lockwasher, and capscrew (3).
(g) Install new filter element in both
cases, then position cover on case and secure with
cover screw.
(h) After engine oil filters are serviced
fill crankcase; (LO 5-3810-206-12) start engine (para 210), and run for about five minutes at a fast idle.
Inspect oil filters for leaks, then stop
Figure 3-5. Engine oil strainer service (model 687C18-ES only).
3-17
Figure 3-6. Chain case fill cap and breather service.
engine (para 2-11) and check oil level. Add oil when
(6) Position filter element in housing; position
necessary.
spring on filter element; position new gasket on cover,
g.
Engine Oil Strainer Service (Model 687C18-ES
then place cover on housing and secure with two
Only).
lockwashers and nuts.
(1) Remove drain plug (fig. 3-5) and drain oil
h. Chain Case Fill Cap and Breather Service.
strainer.
(1) Refer to LO 5-3810-206-12 for interval,
(2) Remove two nuts, lockwashers, and
then remove fill cap (fig. 3-6), wash in an approved
cover.
cleaning solvent, and dry thoroughly with low pressure
(3) Remove cover gasket and the element
compressed air.
spring, then lift filter element from housing. Discard
(2) Inspect breather portion of fill cap for
cover gasket.
damage to filter screen wire, and assure removal of all
(4) Clean all parts in an approved cleaning
foreign matter.
solvent and dry thoroughly.
(3) Replace a defective fill cap breather.
(5) Visually inspect element spring for break
(4) Refer to current lubrication LO 5 3810or other defect, such as loss of tension. Replace a
206-12 for instructions on changing of oil in chain case.
defective spring.
3-18
(2) Refer to figure 3-7, remove screw and
breather cover, then remove filter body from short
nipple by turning body counterclockwise. Cover short
nipple with a clean cloth to prevent entry ,of
contaminating material into power takeoff.
(3) Clean all parts in an approved cleaning
solvent then dry thoroughly with low pressure
compressed air.
(4) Inspect filter wire mesh for damage, or
other defect to body. Replace a defective filter body.
(5) Install in reverse order.
(6) Refer to lubrication order LO 5-3810-20612 for interval and lubricant, then change as required.
j. Starter Motor Inboard Beating Service. Refer-to
LO 5-3810-206-12 for correct interval and lubricant, then
service as described below.
(1) Remove starter motor (para 3-81).
(2) Clean the starter motor and bendix drive
with an approved cleaning solvent. Use care not to
allow solvent inside motor, then dry thoroughly.
(3) Inspect all parts visually for signs of wear
or damage. Replace a defective starter motor.
(4) Lubricate as directed in LO 5-3810-20612.
(5) Install starter motor (para 3-81).
Figure 3-7. Power take-off breather service and
cover removal.
i. Power Take-Off Breather Service and Cover
Removal.
(1) Refer to current lubrication order LO
53810-20612 for correct interval, then remove and
service power take-off breather as directed below.
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
recorded together with the corrective action taken on DA
Form 2404 (Equipment Inspection and Maintenance
Worksheet) at the earliest possible opportunity.
3-5. General
To insure that the crane-shovel is ready at all times, it
must be inspected systematically so that defects may be
discovered and corrected before they result in serious
damage or failure.
The necessary preventive
maintenance checks and services to be performed are
listed and described in paragraph 3-6.
The item
numbers indicate the sequence of minimum inspection
requirements. Defects discovered during operation of
the unit will be noted for future correction, to be made as
soon as operation has ceased.
Stop operation
immediately if a deficiency is noted during operation
which would damage the equipment if operation were
continued. All deficiencies and shortcomings will be
3-6. Preventive Maintenance Checks and Services
Table 3-2 contains a listing of the minimum inspection
requirements for preventive maintenance checks and
services. This table indicates by an X in the appropriate
column (before, during, after, weekly, monthly, or
quarterly) when the inspection should be performed. A
quarterly interval for the crane-shovel unit is equal to
three months, or 500 hours of operation, whichever
occurs first.
3-19
Table 3-2. Preventative Maintenance Checks and Services
Interval
Item
Number
B-Before operation
D-During operation
Operator
A-After operation
W-Weekly
M-Monthly
Q-Quarterly
Org.
Daily
M
B
1
D
X
A
Q
X
X
2
3
Items to be inspected
X
Engine Fuel
Tank
Batteries
X
Track and Hook
Rollers
X
4
X
Crown Chain
Tightener, and
reverse
System
X
5
X
X
Lighting
X
6
X
X
Engine Oil
X
7
X
Engine Fuel
Filters
X
8
Procedure
Reference
W
X
Radiator
X
Check fuel level. Add fuel when necessary.
Check for leaks in tank or fittings. Replace a
defective fuel tank.
Check level of electrolyte. Proper level is 3/8 inch
above plates. Add water when necessary. (In
freezing weather run engine at least an hour
after adding water). Assure that ground and
battery cables are tight, and that no corrosion
is forming on cables or posts. Assure that
specific gravity of electrolyte is 1.250 or more.
Charge weak battery. Replace defective battery.
Visually inspect for loose hardware, excessive
wear, or improper adjustment Adjust track;
proper adjustment is 1 ½ inch minimum sag.
Adjust hook rollers.
Replace defective hook rollers. Replace track
Check operation and adjustment. Adjust if necessary. Report defective chain to organizational
maintenance. Report defective gears to direct
support maintenance.
Replace defective crowd chain.
Check all lighting. Clean all lenses, replace all
defective lamps.
Replace defective panel, floodlights, or dome
lights.
Check engine oil level. Add oil when necessary
(See Lubrication Order LO 5-3810-206-12).
Check external oil lines and fittings Tight
loose fittings. Replace defective fitting or hose.
Drain sediment. Clean or replace filter element.
Inspect fuel lines for leaks or defective fittings.
Replace defective fitting or hose
Check coolant level. Add coolant when necessary.
(Proper level in 2 inches below filler cap).
Drain, flush, neutralize, and refill when necessary.
Check for proper anti-freeze solution, clean raditor grill and core of all entrapped material.
Correct all coolant leaks in hose or fittings.
3-20
(para 2-1c)
(para 3-67)
(para 3-16)
(para 3-75)
(para 3-37)
(para 3-35) (para 3-118 and
(para 3-134) 3-119)
(para 3-31)
(para 4-3)
(para 3-15)
(para 3-173
through 3-175)
(para 3-61)
(para 3-13)
(para 3-13)
(para 3-70 or
para 3-71)
(para 3-19)
(para 3-100)
9
X
Engine Clutch
X
10
X
V Belts
X
11
X
Fire Extinguisher
X
12
X
X
Instruments
X
13
X
Hydraulic
System
X
14
X
Control Pedals
and Levers
X
15
16
X
X
X
Hoist Cables
Main Hoist and
Boom Hoist
X
17
X
Jackshaft
X
Report a defective radiator to direct support
maintenance.
Check for adjustment. Adjust if necessary.
Check lever and linkage for defects. Replace
defective parts.
Check adjustment of fan, generator, or alternator drive belts, Correct adjustment will allow belt to depress "A to % inch midway between pulleys.
Replace defective belts.
Check that extinguisher is in proper location
and that seal is unbroken.
Inspect for full charge, loose mounting, or
broken seal.
Check that no glass is broken and after starting engine check that all are operating correctly. Normal readings are as follows:
TACHOMETER:
with engine 687C-18-ES 1,700 rpm
with engine D333TA 2,000 rpm
OIL PRESSURE-15 to 35 psi
WATER TEMPERATURE-160o to 180 oF---AMMETER-at 0, or in charge area
Replace defective instruments
Check fluid level in reservoir. Service hydraulic
reservoir. Visually inspect lines and cylinders
for leaks. Report defects to organizational maintenance.
Replace defective lines, fittings, or cylinders.
Check for proper operation and adjustment. Report defects to organizational maintenance.
Adjust, repair, or replace control levers, pedals,
or linkage.
Inspect for excessive wear or fraying of strands.
Replace defective cables.
Visually inspect for frayed cables, excessive
wear, or kinks. Replace defective cables. Inspect brake and clutch bands on hoist drums.
Adjust as necessary. Report defective clutch
or brakes to organizational maintenance.
Replace defective clutch or brake linings
Check swing clutches for excessive wear and
adjustment. Adjust as necessary.
Replace defective clutch shoes as required.
3-21
(para 3-9)
(para 3-103)
(para 3-20 through 3-22)
(para's 3-99, 3-79 and 380)
(para 2-24)
(para 2-24)
(para 2-8)
(para 3-142).
(para 3-145)
(para 3-149)
(para 3-144 or
(para 3-142,
3-144, 3-150 and
3-149)
(para 3-18)
(para 3-113 through 3-119)
(para 2-8)
(para's 3-115 through 3-119)
(para 3-39)
(para 3-39)
(para 3-26
through 3-28)
(para's 3-124, 3-125 and
3-131)
(para 3-25)
(para 3-212)
Table 3-2. Preventative Maintenance Checks and Services
Interval
Item
Number
B-Before operation
D-During operation
Operator
A-After operation
W-Weekly
M-Monthly
Q-Quarterly
Org.
Daily
M
B
18
D
A
Q
Items to be inspected
Procedure
Reference
W
X
Engine Valve
Mechanism
Every 1,000 hours check valve adjustment. Correct setting for model 687C-18-ES is 0.012
inch (Hot) 0.014 inch (Cold).
Model D333TA is:
Intake 0.015” HOT
0.017” COLD
Exhaust 0.025” HOT
0.028” COLD
3-22
(para 3-56)
(fig. 3-34)
(fig. 3-35)
Section IV. OPERATOR'S MAINTENANCE
3-7. General
This section contains information necessary for
operator/crew maintenance of the crane-shovel, as
authorized by the maintenance allocation chart.
3-8. Engine Inspection and Service
a. Inspection. Visually inspect engine compartment
for cleanliness. Investigate all accumulations of oil, dirt,
or dust, to assure that no lubricant or coolant leakage
exists.
Assure that all external lines, fittings, or
accessories are securely mounted and that no hardware
or accessory is missing.
Report all defects to
organizational maintenance.
b. Service.
(1) Refer to current lubrication order LO 53810-206-12 for interval and type of lubricant to service
engine crankcase.
(2) Refer to paragraph 3-4 for service
instructions on oil filters, air cleaner, or oil strainer.
Figure 3-8. Engine clutch adjustment.
(7) When adjustment is correct, lock
adjusting ring by turning pin 1/4 turn clockwise.
(8) Position lock spring in the adjusting ring
and secure with lockwasher and screw.
(9) Position cover plate (fig. 3-7) on housing
and secure with two lockwashers and capscrews.
3-9. Engine Clutch Adjustment
a. General. The engine clutch, when engaged,
transfers power from engine to power take-off output
shaft which actuates the operating mechanisms. A drive
chain connects engine drive sprocket. Clutch control is
through adjustable linkage from lever at operator's
station to power takeoff. The clutch is in need of
adjustment when it will not pull the load; it gets hot, or
clutch control lever jumps out of the engaged position.
3-10. Engine Oil Filter Service
Refer to paragraph 384f and service engine oil filters.
3-11. Engine Air Cleaner Service
b. Adjusting the Engine Clutch.
(1) Refer to figure 3-7, remove two
capscrews, lockwashers, and cover plate from housing.
(2) Disengage the clutch (para 2-8) and turn
pressure plate until lock (fig. 3-8) is up.
(3) Remove screw, lockwasher, and lock
spring from the adjusting ring.
(4) Unlock the adjusting ring by turning
lockpin 14 turn counterclockwise.
(5) Turn the adjusting ring clockwise to
tighten clutch, counterclockwise to loosen.
(6) Test clutch by engaging clutch control
lever. When the clutch is properly adjusted, a distinct
pressure is required to engage clutch control lever.
a. Oil Bath Type. Refer to paragraph 3-4c and
service oil bath type engine air cleaners.
b. Dry Type. The rear mounted dry type engine air
cleaner, used on engines model D333TA, contains a
replaceable filter element which can be removed for
cleaning by compressed air, or by washing. Service as
follows:
(1) Loosen two wing nuts (fig. 3-9) and
remove cover from air cleaner.
(2) Remove filter element and packing from
body.
(3) Loosen screw and remove inlet screen
from body.
(4) Clean all removed parts in an approved
cleaning solvent and dry thoroughly, then use a damp
cloth to wipe accumulation of dust from body.
3-23
RESCREEN & SQUARE HALFTOMES
(3) Clean all parts in an approved cleaning
solvent and dry thoroughly with compressed air or lint
free cloth. Be sure that screen of filter element is free of
all sludge or foreign matter.
(4) Visually inspect all parts for cracks, holes,
or excessive wear. Repair by replacing defective parts.
(5) Install filter element on stud and secure
with nut.
(6) Place washer on bowl, position bowl
Figure 3-9. Air cleaner service for engine model
D333TA.
Caution:
When compressed air is used to
clean, or dry filter element, do not
blow dust from body while it is
installed
on
turbocharger.
Accumulations of dust might be
blown into turbocharger and cause
damage.
(5) Insert packing into body, then place filter
element in position with open end toward turbocharger.
(6) Install cover and secure by tightening two
wing nuts.
(7) Position screen over intake and secure by
tightening screw.
3-12. Engine Oil Strainer Service (Model 687C-18-ES
Only)
Refer to paragraph 3-4g and service engine oil strainer.
3-13. Fuel Filter Service
a. General.. The fuel filters strain all fuel prior to its
entering the injectors, removing water and foreign
matter that would clog the injectors. Engine model
687C-18-ES has both primary and secondary filters.
Engine model D333TA has only one filter.
b. Primary Fuel Filter Service (Model 687C-18-ES
Only)
(1) Remove nut and gasket (fig. 3-10) which
secures bowl to filter head and remove bowl and
washer.
(2) Remove nut that secures filter element to
stud in filter head, then remove filter element.
Figure 3-10. Primary fuel filter service (model 687C18-ES).
.
3-24
c.
ES)
Secondary Fuel Pump Service (Model 687C-18(1) Remove drain plug (fig. 3-11) and drain
filter.
(2) Remove plug from center bolt; remove
center bolt and center bolt washer, then remove filter
body from cover.
(3) Remove disposable filter element and
washer and discard.
(4) Clean all parts with an approved cleaning
solvent and dry thoroughly. Be sure that all sludge and
foreign matter has been removed from filter body.
(5) Install new filter element in body; install
washer on cover, then install filter body in cover and
secure with center bolt washer and center bolt.
Caution:
Be sure that washer between cover
and body is serviceable and properly
installed, or an air leak will occur that
will starve fuel injection pump.
(6) Install plug in center bolt then install drain
plug.
Figure 3-11. Secondary fuel filter service (model
687C-18-ES).
(7) Prime fuel system (para 871).
d. Fuel Filter Service (Model DSS3TA).
(1) Close valve in fuel line from tank; remove
drain plug (fig. 3-12); open ventvalve, and drain fuel
filter.
over filter element, and secure with gasket and nut.
(7) After fuel line is connected to inlet port
prime filter with primer pump (para 3-71).
Figure 3-12. Fuel filter service an engine model
D333TA.
3-25
d. Remove covering from tank opening, position
gasket and filter screen on tank adapter and secure with
six capscrews.
e. Install filler cap.
(2) Clean thoroughly around filter cover and
gasket to prevent dirt from dropping into filter when
cover is removed.
(3) Remove four nuts, lockwashers, and
flatwashers, then remove filter cover from housing.
(4) Remove filter element and gasket, and
discard.
(5) Remove rod and spring from housing,
then clean housing thoroughly by using a lint free cloth
dampened in an approved cleaning solvent. Wipe dry
with a clean cloth. Be sure all gummy sludge has been
removed.
(6) Install rod, place spring over rod and seat
it around boss in bottom of housing, then install a new
filter element.
(7) Install new gasket on housing, position
cover on studs, and secure with four flatwashers,
lockwashers, and nuts.
(8) Install drain plug, prime fuel system (para
3-71), then close vent valve in cover.
3-15. Floodlight Adjustment and Lamp Replacement
a. Floodlight Adjustment.
(1) To change horizontal position loosen
locknut (fig. 3-14), move beam to desired position, then
tighten locknut.
(2) To change vertical position, loosen
adjusting nut, move adjusting bracket until beam is in
desired position, then tighten adjusting nut.
b. Lamp Replacement.
(1) Remove three screw and lockwasher (fig.
3-14) from rear of body and remove lamp retainer.
(2) Remove three screw and lockwasher from
plate on rear of retainer, remove plate, then, remove
lamp and packing from lamp retainer.
Discard
unserviceable lamp.
(3) Install packing in retainer, install new
lamp; position plate on retainer, then secure with three
lockwasher and screws.
(4) Position lamp retainer on floodlight body,
so that lamp prongs engage socket in body, then secure
retainer to body with three lockwasher and screws.
3-14. Fuel Tank Filler Cap and Filter Service
a. Remove filler cap (fig. 3-13).
b. Remove six screws and lockwashers then remove
filter and gasket from fuel tank. Cover fuel tank opening
to prevent dirt entry. Open draincock in bottom of fuel
tank, drain sediment, then tighten draincock.
c. Clean filter screen in an approved cleaning
solvent and dry thoroughly with compressed air. Be
sure all foreign material is removed from filter screen.
Figure 3-13. Filler cap and filter service.
3-26
(1) Remove three wing nuts (fig.
3-15),
remove cover then place wing nuts back on screws for
safe keeping.
(2) Remove 12 filler caps; check level of
electrolyte, add electrolyte or distilled water, if
necessary, to bring level to 3/8 inch above plates.
(3) Clean vent holes in caps, then install all
caps on batteries.
(4) Check that battery cable and ground cable
connections are tight on terminals and free of corrosion.
Note.
A thin coating of grease on terminals
will prevent corrosion.
(5) Clean tops of batteries to remove all
spilled electrolyte or dirt.
(6) Visually inspect cables for serviceability.
Replace a defective cable.
(7) Remove wingnuts from cover holddown
screws, install cover on battery box, then secure with
three wingnuts.
3-17. Cold Weather Starting Aids
Figure 3-14. Floodlight adjustment and lamp
replacement.
Operator service to cold weather starting aid is limited to
replenishment of cylinder at pressure primer discharger.
Refer to paragraph 2-25 for operation.
3-16. Battery Service
3-18. Hydraulic Reservoir (Tank) Service
a. General. Batteries should be fully charged at all
times, and acid level must be maintained at 3/8 inch
above plates. Service batteries as directed in b. below.
b. Battery Service.
a. General. Operator service to hydraulic reservoir
(tank) is to drain, refill, and to maintain constant level.
b. Oil Level Check. Remove two dipsticks (1, fig. 31) and check level. Add oil, if necessary, by
Figure 3-15. Battery service.
3-27
removing two fill plugs (2). Replace plugs after oil has
been replenished.
c. Draining.
(1) Close drain plugs (3, fig. 3-1).
(2) Remove the two oil lines from adapter.
(3) Place container under drain plugs;
remove fill plugs; cover opening in tank to prevent dirt
entering, then open drain plugs.
(4) When oil is drained, close drain plugs,
then install oil lines on adapters.
(5) Remove covering placed over fill holes,
fill tank with required quantity of proper oil (LO 5-3810206-12).
(6) Open drain plugs and allow oil to enter
lines to hydraulic cylinders; add more oil in tank, if
necessary; then install fill plugs.
3-19. Radiator Service
a. Maintaining Water Level. Remove radiator cap,
add water until it stands two inches below filler neck,
then install radiator cap.
b. Draining, Cleaning, Flushing, Neutralizing, and
Filling. Refer to TB ORD 651 (Use of Antifreeze
Solutions and Cleaning Compounds in Engine Cooling
Systems) for instructions on cleaning, flushing, and
neutralizing radiator. Drain and refill as described
below.
(1) Remove radiator cap, then open
draincocks on radiator and engine block.
(2) When engine and radiator is fully drained,
close all draincocks.
(3) Fill system with clean water until it stands
two inches below the filler neck. Install radiator cap.
3-20. Fan Drive Belt Adjustment
a. On Engine Model 687C-18-ES.
(1) Loosen four capscrews (view A, fig. 3-16)
and locknut.
(2) Increase belt tension by turning setscrew
clockwise.
Loosen belt by turning setscrew
counterclockwise.
Note.
Proper adjustment will allow belt to
depress from 3/4 to one inch at a
point midway between pulleys, while
using a moderate pressure.
Figure 3-16. Fan drive belt adjustment (sheet 1 of 2).
(2) Loosen locknut on adjusting screw and
turn adjusting screw clockwise until the two belts can be
depressed approximately 1/2 inch midway between
pulleys with a force of approximately 25 pounds.
(3) When adjustment is correct, tighten the
two bracket retaining bolts and locknut.
Recheck
adjustment.
Note.
Fan drive belts must be replaced in
matched sets. When belts can be
depressed 3/4 inch midway between
pulleys, adjustment is required.
(3) When proper adjustment is attained,
tighten the four capscrews and locknut.
b. On Engine Model DSSSTA.
(1) Loosen the two bracket retaining bolts
which hold idler hub bracket to timing hear cover (view
B, fig. 3-16).
3-28
b. Loosen two nuts at generator pivot, pull
away from engine until belt will depress 1/2
point midway between pulleys.
c. When adjustment is correct, tighten
capscrew to hold generator in place.
adjustment.
generator
inch at a
nut and
Recheck
3-22. Alternator Drive Belt Adjustment (Engine
Model D333TA Only)
a. The alternator may be driven with one or two
belts. When two belts are used, they must be replaced
in matched sets.
b. Adjust alternator drive belts in a manner similar to
method used for generator drive belt (para 3-21).
3-23. Chain Case Fill Cap and Breather Service
Service chain case fill cap and breather as described in
paragraph 3-4h.
Figure 3-16. Fan drive belt adjustment (sheet 2 of 2)
3-21. Generator Drive Belt Adjustment (Engine
Model 687C-18-ES Only)
3-24. Power Take-Off Breather Service
a. Loosen nut and capscrew (fig. 3-17) on adjusting
strap.
Service power take-off breather as described in
paragraph 3-4i.
1
2
3
4
5
Figure 3-17. Generator drive belt adjustment.
3-29
Locknut
6 Setscrew
Spring
7 Cylinder
Shifter Collar
8 Clevis
Washer
9 Link
Locknut
10 Spring
Figure 3-18. Swing clutch shifter mechanism.
3-25. Swing (Jackshaft) Clutch Adjustment
a. Adjustment to compensate for Lining Wear.
(1) Be sure that swing clutch lever is in
neutral position, and that locknuts (fig. 3-18) hold spring
(2) compressed to approximately three inches. Check
on both ends of shifter rod for each swing clutch.
Note.
In released position, the shifter collar
(3) must rest against the washer (4)
on outer end of spider hub. Shifter
collar must travel a minimum
distance of 1 1/8 inches from
released
position
to
engaged
position for proper clutch action. To
change shifter travel, loosen one and
tighten the other locknut (5) on
opposite sides of the trunnion.
(2) Assure that point A is 1/4 inch below a
straight line between points B and C (with clutch
engaged). Be sure that setscrew (6) prevents
Figure 3-19. Swing clutch shoe lining wear adjustment and positioning of hoist drum clutch and brake bands.
3-30
Figure 3-1. Lubricating point identification (sheet 3 of 14).
3-4
hydraulic cylinder (7) from pushing link (9) and clevis (8)
into a straight line.
(3) Compensation for lining wear is
accomplished by loosening locknut (fig. 3-19) and
turning the adjusting bolt until the clutch lining has
proper clearance from clutch drum (0.012 to 0.015 inch).
NOTE
Measure clearance with a thickness
gauge blade that is long enough to
reach inside edge of shoe and drum,
to avoid possibility of a tilted shoe
that will drag.
b.
Adjustment After Lining Replacement or
Disassembly.
(1) Remove capscrew and lockplate, then
rotate adjusting sleeve (same as fig. 3-10) until there is
between 0.012 and 0.015 inch clearance between shoe
lining and clutch drum at dead end. Be sure shoes are
not tilted in drum (see note in a above).
(2) Continued adjustment in manner
described in paragraph 3-28c.
(4) When adjustment is correct, tighten
locknut, then recheck clearance. Readjust if necessary.
a.
General. Hoist drum brake and clutch bands
are spring mounted to allow bands to move slightly
during engagement or disengagement.
3-26. Positioning Clutch and Brake Bands on Hoist
Drum
Figure 3-20. Hoist clutch shoes adjustment and removal points.
3-31
Spring tension keeps them ill the desired position. With
applicable brake or clutch control lever in neutral,
position band on drum as described below.
b.
Installation Positioning. Install band on two
studs (fig. 3-19) on mounting bracket, and secure with
two lockwashers and nuts.
NOTE
See paragraph 3-123 for difference in
planetary
clutch
band
linkage
arrangement between shovel and
crane operation.
3-27. Hoist Brake, Digging Brake, or Planetary
Clutch Band Adjustment
a.
Position planetary clutch band (para 3-26).
b.
Adjust planetary clutch band (fig. 3-21) by
loosening locknut and tightening adjusting bolt as far as
it will go, then back-off on adjusting bolt until operation
of clutch lever engages clutch with band smoothly under
nominal pressure.
After clutch band is properly
adjusted, tighten locknut.
NOTE
A few drops of light oil on trunnions
will smooth out operations at band
and lever.
NOTE
See different linkage arrangement for
planetary clutch band in paragraph
3-123, for shovel or crane operation.
c.
Positioning Prior to Adjustment. Position
band so that it does not drag on drum by backing off the
upper and lower locknuts on both studs (fig. 3-19), then
tightening or loosening the lower or upper adjusting nuts
until there is clearance all around the drum. After band
is positioned correctly, tighten the four locknuts on the
two studs.
d.
Position hoist drum brake band, digging
drum brake band, and planetary clutch band in similar
manner, then proceed to adjust brake or clutch band
(para 3-27).
c.
Adjust digging brake and hoist brake bands
in a similar manner.
CAUTION
Do not adjust bands so tight that
operation of lever is hard. Tight
bands cause excessive wear on
linings and shorten their serviceable
life.
Figure 3-21. Hoist brake, digging brake, and planetary clutch band adjustment.
3-32
(2) To adjust clearance at point A, remove
capscrew and lockplate then rotate adjusting sleeve
(eccentric) until a minimum clearance of 1/32 inch is
obtained at point A.
(3) Establish approximately 1/16 inch
clearance at points B and C by backing off locknut (2)
and turning the two adjusting screws until clearance is
correct.
NOTE
Clearance at point D will always be
greater than that at points A, B and
C, and does not effect clutch
operation.
3-28. Hoist Clutch and Digging Clutch Adjustment
a.
General.
(1) Each main clutch has an auxiliary, or
booster clutch, which is the unit most frequently
requiring adjustment. However, determine which one
actually requires adjustment by engaging the hand lever
controlling the clutch to be checked, then setting the foot
brake pedal controlling the same drum.
NOTE
Setting the foot brake simulates a
load on the drum. If this is not done,
the clutch will not “wrap in” to the
drum as it does during normal
operation.
(4) The tension of three springs (fig. 3-20)
should be adjusted just tight enough to prevent clutch
shoes from engaging the clutch drum when machinery is
rotated at full speed. These springs should not be
tighter than necessary to prevent clutch shoes from
dragging.
(5) It may be necessary to bend the two
brackets slightly to get a good fit of the clutch shoe
within the clutch drum.
NOTE
It is good practice, before linings are
worn out, to exchange the dead shoe
for the live shoe. Most lining wear is
concentrated on the live shoe.
CAUTION
Be sure there is enough tension on
springs. Operation with clutches too
loose may cause breakage of release
spring.
(2) Engage the engine clutch long enough
for the clutch to “wrap in”, then measure gap (fig. 3-22)
between lug and stop on clutch spider. If there is less
than ½ inch clearance between these points, the main
clutch linings are worn and must be tightened. If there is
more than ½ inch clearance between the above points
the auxiliary clutch must be adjusted.
b.
Main Hoist or Digging Clutch Lining Wear
Adjustment. To compensate for lining wear on main
clutch, loosen locknut on adjusting bolt (fig. 3-20) and
turn adjusting bolt until clutch linings are in proper
adjustment. Tighten locknut to hold the adjustment.
c.
Main Clutch Shoe Adjustment.
(1) When clearance between clutch shoe
lining and the clutch drumpoints A, B and C (fig. 3-20)
exceeds 3/32 inch, or when new clutch
d.
Auxiliary (Booster) Clutch Adjustment.
(1) To compensate for normal clutch lining
wear, loosen locknut (fig. 3-23) and turn adjusting bolt.
Do not adjust nut for normal band wear adjustment.
Figure 3-22. Main hoist or auxiliary clutch lining
wear determination.
shoes are installed, the clutch shoes are installed, the
clutch must be adjusted for proper lining clearance.
Figure 3-23. Auxiliary (booster) clutch adjustment
points.
3-33
(c) Tighten adjusting nut until the
release spring is compressed to a length of
approximately 3½ inches.
(2) If the unit has been disassembled for
any reason, adjust as follows:
(a) Tighten nut until spring is
bottomed. Backoff nut one complete turn, then install
cotter pin through nut.
(b) Turn the two adjusting screws in
equally until distance Il is just slightly less than distance
A.
1
2
3
4
5
6
7
8
9
3-29. Steering Linkage, Swing Brake, and Propel
Brake Adjustment
a.
Steering Linkage Adjustment.
(1) Raise steering engage lever (fig. 2-24)
to engage steering gear.
Jaw clutch
Brake drum
Adjusting nut
Locknut
Rod
Nut
Nut
Locknut
Adjusting nut
10
11
12
13
14
15
16
17
18
Adjusting nut
Adjusting nut
Eye bolt
Spring
Lever
Pin
Link
Nut
Bolt
Figure 3-24. Steering linkage and propel brake adjustment.
3-34
(2) Turn steering wheel counterclockwise as
far as it will go. (This disengages both jaw clutches, and
sets both propel brakes in locked position).
(3) Measure distance between face of jaw
clutch (1, fig. 3-24) and face of brake drum (2), which
must be approximately ¾ inch. When distance is less,
turn adjusting nut (3) and locknut (4) downward until
distance between faces measures ¾ inch.
When
distance is greater, turn adjusting nut (3) and locknut (4)
upward until the distance is ¾ inch between faces.
(4) Spring tension on rod (5) against lever is
obtained by turning nuts (6) and (7) in an upward
direction.
(5) Turn steering wheel clockwise until both
jaw clutches (1) are fully engaged with recesses in brake
drum (2). When clutches are fully engaged, both propel
brakes will be in released position.
(6) Backoff locknut (8) and adjusting nuts
(9) and (10). Turn adjusting nut (11) on eyebolt (12)
until maximum tension is placed on spring (13) (the
hydraulic cylinder must be completely compressed).
(7) Pull lever (14) toward hydraulic cylinder,
hold it there while tightening adjusting nuts (10) and (9)
up against linkage. The pin (15) in lever (14) must be
snug against top of slot in link (16).
b.
Propel Brake Adjustment.
(1) Turn steering wheel counterclockwise as
far as it will go. Both propel brakes will be set in locked
position.
Figure 3-25. Swing brake adjustment.
(2) Tighten adjusting nut (17) on bolt (18)
until propel brake bands are tight.
Secure the
adjustment with locknut.
Figure 3-26. Boom hoist brake adjustment points.
3-35
adjusting bolt then tighten locknut. Check gap between
thimble and side plate after adjusting (c above).
NOTE
Levers should be parallel when brake
is released.
NOTE
A few drops of light engine oil on all
pins
and
trunnions,
before
adjustment, will allow smoother
operation.
c.
Swing Brake Adjustment. To compensate for
lining wear, back off locknut (fig. 3-25); tighten adjusting
nut just enough to get the proper feel on swing brake
lever (fig. 2-24), then tighten locknut (fig. 3-25).
3-30. Boom Hoist Brake Adjustment
a.
Before making any adjustment on boom hoist
brake, assure that pawl is engaged in hoist drum ratchet
gear to prevent boom from lowering.
b.
To adjust boom hoist brake, sufficient tension
must be placed on spring (fig. 3-26) to hold boom in
desired position. Position boom hoist lever in neutral.
(With boom hoist lever in neutral brake is applied and
clutch is disengaged). Turn nut clockwise until brake
band is tight, then tighten locknut.
c.
Always check clearance between thimble and
side plate. It should be at least 1/16 inch. Adjust this
clearance, when necessary, by backing off locknut then
turning adjusting screw. When clearance is correct,
tighten locknut.
d.
With brake applied, measure distances A
and B. Distance A should be from 3/8 inch to ½ inch
less than distance B. Make adjustment by turning
e.
Engage boom hoist clutch by pulling boom
hoist lever toward operator just enough to take pressure
off pawl, then disengage pawl. Return boom hoist lever
to neutral, slowly, to assure that brake will hold boom.
Readjust if necessary. After adjustment is complete,
engage boom hoist pawl, move boom hoist lever away
from operator to release brake, then check levers for
position described in note in d above.
3-31. Crowd Chain Adjustment
a.
Loosen top adjusting nut (fig. 3-27) and
bottom adjusting nut on the two studs.
Figure 3-27. Crowd chain and anti-sway spring adjusting points.
3-36
b.
Lift up on tightener sprocket to tighten, or
lower to loosen boom crowd chain, then tighten
adjusting nuts.
c.
Proper adjustment allows from three to four
inches of sag in chain between shipper shaft sprocket
and chain tightener sprocket.
d.
Adjust revolving frame crowd chain in a
similar manner.
3-33. Dipper Trip Adjustment
a.
If the brake drum (fig. 3-28) does not tend to
rotate when dipper trip lever (fig. 2-23) is operated, the
brake shoes (fig. 3-28) are probably worn enough to
require adjustment.
b.
Turn the bell crank (underneath revolving
frame) until the brake shoe just barely drags against
brake drum; turn bell crank back until brake shoe is just
clear of the drum, then loosen locknuts on rod and
adjust length of rod until top and bottom levers are both
from 15 to 20 degrees below a horizontal position.
c.
Loosen lever locknut and adjust setscrew so
that travel of rod is stopped before lever is bottomed in
upper clevis and bends rod.
d.
When brake shoe adjustment is correct,
tighten two locknuts on rod, and locknut on setscrew, to
hold the adjustment.
3-32. Anti-sway (Boom Foot) Spring Adjustment
a.
Tension on anti-sway springs allows boom
some freedom of movement, yet prevents excessive
swaying. At installation, tighten adjusting nut (fig. 3-27)
to compress spring until it is 14-5/8 inches in length.
CAUTION
Never tighten spring enough to
remove clearance between coils. If
spring coils are bottomed, all strain
will be transferred to boom foot lugs
and damage to the revolving frame
will result.
3-34. Trip Cable Adjustment
a.
Assure that trip cable is fastened to equalizer
bracket (fig. 3-29) with a cable clamp; loosen clamp at
bell crank; take up all slack, then refasten cable clamp
at bell crank.
b.
Assure that boom trip cable is reeved
correctly; from take-up drum mounted on shipper shaft;
through equalizer sheave on equalizer bracket, then
over idler sheave to dipper trip lever mounted on dipper
sticks near dipper.
c.
If there is any slack in boom trip cable;
loosen cable clamp at dipper trip lever; take up slack
until dipper trip lever is just downward from
perpendicular to the dipper sticks, then secure cable
clamp.
d.
Adjust length of trip chain as required.
b.
Operator will check shovel anti-sway springs
frequently. When length of spring is correct, but
excessive sway occurs because of weakened springs;
replace old springs with new, and adjust as directed in a
above.
3-35. Hook Roller Adjustment
a.
Lower boom to near the horizontal position.
This will put weight on rear hook rollers while both front
hook rollers are being adjusted.
b.
Remove screws, lockwashers and keeper
plate (fig. 3-30), then rotate eccentric shafts until both
rollers are snug against bottom of roller path. A
maximum of 1/16 inch clearance is allowed between
hook rollers and roller path. When adjustment is
correct, install keeper plate and secure with lockwashers
and screws.
c.
Build up cribbing equal to revolving frame
height under boom, and lower boom to reset on cribbing.
This will equalize weight of revolving rollers in same
manner as front hook rollers above.
Figure 3-28. Dipper trip adjustment points.
3-37
Figure 3-29. Trip cable adjustment.
was available, be sure and get
assistance from another crane or
hoisting device to lift boom tip above
the horizontal before using boom
hoist to position boom. Booms have
been known to collapse under stress
applied by boom hoist clutch when
boom tip was lower than boom foot
NOTE
When replacing keeper plates, the lip
of front hook roller keeper plate must
be between flange of eccentric shaft
and hook roller mounting bracket.
The lip of rear hook roller keeper
plate must be on outside of the
eccentric shaft.
3-36. Propel Chain Adjustment
CAUTION
a.
General. To properly adjust the propel chain,
the crane-shovel should be propelled backward for at
least the length of the crawler frame.
If boom tip had been lowered to rest
on the ground because no cribbing
3-38
Figure 3-30. Hook roller adjustment points.
Figure 3-31. Propel chain adjustment.
3-39
b.
Adjustment.
(1) Position a straight edge on track parallel
with frame, between upper roller (fig. 3-32) and high
point of track on top of drive sprocket. Measure
distance between straight edge and low point of track
sag. This distance should be approximately 1½ inches.
If sag is more than 1 ½ inch, loosen locknut on adjusting
bolt (on both sides of sprocket), then tighten adjusting
nuts until sag is correct.
at least the length of the crawler frame. This will place
the slack in the chain on top. Adjust as follows.
b.
Adjustment.
(1) Backoff locknuts on two eyebolts (fig. 331) (one on each side of sprocket) then, alternately turn
adjusting nuts, first on outside then on inside, in or out
until slack in propel chain can be raised approximately
1½ inches. Repeat on opposite side of frame for
remaining propel chain. When adjustment is correct,
tighten locknuts to secure adjustment.
CAUTION
Equalize turning of adjusting nuts,
so that idler shaft is parallel to front
axle. The teeth on idler sprocket
must be centered between side bars
on crawler track. Be sure locknuts
on adjusting bolts are drawn up tight
to adjusting blocks to secure the
adjustment.
NOTE
When a new propel chain is installed,
it must be adjusted tight (no slack),
to allows for stretch.
(2) Remove two capscrews, lockwashers,
and lockplate from the adjusting block on outboard
bearing of both propel sprockets, then turn adjusting nut
on adjusting-bolt, in or out, until crawler drive shaft is
parallel to the rear axle. When adjustment is correct,
install lockplates and secure with lockwashers and
capscrews.
(2) Measure compressed length of springs.
Each spring should measure 31 inches. To adjust
length, backoff, or tighten spring adjusting nut (fig. 332), until length is correct.
3-37.Track Adjustment
CAUTION
Correct tension on springs is
necessary to take up shock when
small stones lodge between idler
sprocket and crawler shoes.
a.
General. The crane-shovel unit should be
propelled in a forward direction for a distance equal to
length of crawlers, in order that sigh in track will be on
top. Adjust as follows.
Figure 3-32. Track adjustment.
3-40
3-38. Instrument Panel
Replacement
and
Cab
Light
(4) Position end of cable in dead end socket
of drum and secure by driving cable wedge into the
drum dead end socket.
(5) Wind cable length on hoist drum until
completely off of reel, or out of coil, then begin reeving
cable through sheaves as shown on applicable reeving
diagram.
(6) Install remaining cables in a similar
manner.
c.
Cable Lubrication.
(1) General. When cables are removed
from drums at time of front end attachment conversion,
the cable that is serviceable should be wiped free of dirt
and thoroughly lubricated with HDO engine oil (see
current lubrication order LO 5-3810-206-12) as it is
placed on reel, or in a coil, for storage.
(2) Method of lubrication at removal.
(a) Paint brush application.
For penetration
between strands, and safety from injury by a single
broken strand of wire, use two paint brushes from
opposite sides of wire. Saturate brushes freely and
frequently in HDO engine oil and cover cable thoroughly
on all sides as it comes off drum toward reel or coil.
Use drying brushes to wipe away excess oil as -it goes
on reel, or in coil.
(b) Rag application. Saturate two large rags in
HDO, hold one in each hand, and oil cable plentifully as
it comes off drum. Wipe away excess oil before cable
winds on reel, or in coil.
Lamp
a.
General. Illumination for performance of
preventive maintenance checks and services on
operating machinery within cab enclosure is furnished
by lamps in holders on cab ceiling behind operators seat
and on left rear side. These lamps are to be augmented
by use of trouble light (para 2-27).
Panel lights
illuminate instruments on control stand and switches on
lighting control panel.
b.
Lamp Replacement.
(1) Panel Lights. Remove cover by turning
counterclockwise; remove defective lamp by pressing in
and turning counterclockwise to free prongs. Insert new
lamp and install cover by reversing this procedure.
(2) Cab Lights. Remove lamp by pressing
in and turning counterclockwise to free prongs. Insert
new lamp, push in, and turn clockwise to engage prongs
of lamp in socket of holder.
3-39. Cable Replacement
a.
Cable Removal. To replace a defective
cable, from shovel hoist drum or when changing front
end attachment, proceed as follows:
(1) Remove cable clamps securing cable in
dead end socket on right hand boom point sheave (fig.
2-19).
(2) Slowly wind cable on drum through right
hand boom point sheave, dipper sheave, and left hand
boom point sheave.
(3) Unwind cable from hoist drum, carefully
coiling slack in a suitable box, or on a reel, then
disconnect cable from dead end on lagging of drum.
(4) Remove remaining cables in a similar
manner.
b.
Cable Installation.
(1) Refer to table 1-2 and select proper type
and length of cable for required operation.
(2) Place reel, or coil, of cable at left side of
crane-shovel near boom foot.
(3) Pull loose end of cable from reel, or coil,
and lead the end of cable to the proper drum.
WARNING
Use heavy leather gloves while
holding oily rags on cable, and avoid
injury by a broken strand of wire.
(3) Lubrication at installation.
The
procedure outlined above should be reversed at
installation, if cable being installed appears in need of
lubrication. Lubricate groove and hub of sheaves as
cable are reeved also (LO 5-3810-206-12).
NOTE
Field tests have proved that cables,
like any machined part, last longer
when they are kept well lubricated.
Section V. TROUBLESHOOTING
crane-shovel and its components. Malfunctions which
may occur are stated, and followed by a list of probable
causes of the trouble.
The corrective action
recommended is described opposite the probable cause.
3-40. General
This section provides information useful in diagnosing
and correcting unsatisfactory operation or failure of the
3-41
Any trouble beyond scope of organizational
maintenance personnel shall be reported to direct
support maintenance.
3-41. Troubleshooting
Refer to table 3-3 for listing of possible malfunctions.
Table 3-3. Troubleshooting.
Malfunction
1.
Engine will not start
Probable cause
a. No fuel, or fuel shutoff valve
closed
b. Low temperature.
c. Loss of fuel, or air leak
d. Defective batteries
e. Improper valve clearance.
2.
Engine hard to start
a. Air in fuel, or no fuel
Engine starts but will not run,
or stalls frequently
a. Low on fuel
b. Wrong type of fuel
c. Loss of fuel
d. Fuel filters clogged.
e. Air cleaner clogged or defective.
4.
Engine starts but misfires, or
vibrates excessively
a. Wrong fuel in tank
Engine lacks power
a. Air cleaner clogged or damaged.
b. Fuel filter, clogged or defective
c. Defective fuel lines
6.
Engine overheats
a. Loose fan belt
b. Obstructions in fins of radiator
c. Collapsed hose or loose connections
d. Low on coolant
e. Oil low in crankcase.
f.
b. Use cold weather starting aid (para 2-25).
c. Tighten loose fuel connections. Prime
fuel system (fig. 2-28).
d. Replace or recharge batteries (para 3-75).
e. Adjust valves (para 3-56).
a. Service fuel tank.
b. Drain fuel tank and service with proper fuel.
c. Tighten loose fuel line connections then
prime system (para 3-71).
d. Service fuel filters (para 3-13).
e. Service air cleaners (para 3-11) or replace
defective air cleaner (para 3-65).
a. Drain tank and service with proper
grade fuel.
b. Service fuel filters (para 3-13).
c. Service air cleaner (para 3-11).
d. Replace fuel injector (para 3-64).
b. Fuel filters clogged.
c. Air cleaner clogged.
d. Fuel injector defective.
5.
a. Open fuel shutoff valve, or fill tank.
a. Tighten loose connections, prime fuel
system (fig. 2-28) and service fuel tank.
b. Use cold weather starting aid (para 2-25).
c. Service air cleaner (para 3-11).
b. Low ambient temperature.
c. Clogged air cleaner
3.
Corrective action
Defective thermostat
a. Service dirty air cleaner (para 3-11) or
replace defective air cleaner (para 3-65).
b. Service fuel filters (para 3-13). Replace
defective filter (paras 3-68 and 3-69).
c. Tighten loose lines or fittings. Replace
a defective line (para 3-67).
a. Adjust (para 3-20).
b. Clean fins.
c. Check condition of coolant hose. Tighten
loose connections, or replace defective
hose (para 3-98).
d. Service radiator (para 3-19).
e. Check oil level. Add when necessary
(LO 5-3810-206-12).
f. Replace (para 3-98).
7.
Engine exhaust excessively
smoky
a. Air cleaner clogged.
b. Defective fuel injector
a. Service air cleaner (para 3-11).
b. Replace (para 364).
8.
Engine clutch slips
a. Clutch out of adjustment
b. Linkage out of adjustment
a. Adjust (para 3-9).
b. Adjust (para 3-101).
9.
Engine clutch will not engage
a. Linkage out of adjustment
b. Clutch out of adjustment
c. Worn clutch
a. Adjust (para 3-101).
b. Adjust (para 3-9).
c. Report defect to general support maintenance.
10.
Engine temperature fails to
raise
Water temperature indicator
inoperative.
Defective thermostat (stuck open)
Replace (para 3-98).
a. Loose electrical connection
a. Tighten all connections. Make good
ground.
b. Replace (para 3-85).
c. Replace (para 3-147).
11.
b. Transmitter defective.
c. Indicator defective.
3-42
Malfunction
12.
Oil pressure indicator inoperative
Probable cause
a. Loose electrical connections
b. Defective transmitter
c. Defective indicator
13.
Ammeter Inoperative
a. Battery cables loose or corroded
b. Dead batteries
c. Ammeter defective
14.
Starter motor inoperative
a. Loose electrical connections
b. Starter push switch defective
c. Batteries defective
d. Defective starter motor
15.
Lights are dim or do not light
a. Defective lamps or lights
b. Short in wiring
c. Batteries dead
d. Defective generator, alternator, or
regulator
16.
Revolving frame teeters, or will
not owing
Corrective action
a. Tighten all connections. See that ground
is good.
b. Replace (para 3-84).
c. Replace (para 3-143).
a. Remove corrosion and tighten cables
(para 3-75).
b. Charge or replace (para 3-75).
c. Replace (para 3-142).
a. Remove corrosion and tighten battery
cables (para 3-75) and at solenoid.
Replace defective cables.
b. Replace (para 3-150).
c. Replace (para 3-75).
d. Replace (para 3-81).
a. Replace (paras 3-15 and 3-38). Replace
defective light (paras 3-173 thru
3-175).
b. Replace defective leads (para 3-89).
c. Charge, or replace (para 3-75).
d. Test. Replace defective component (paras
3-77 thru 3-80).
a. Hook rollers out of adjustment or
worn excessively
b. Swing brake lock engaged, or out
of adjustment
c. Swing jaw clutch out of adjustment
a. Adjust (para 3-35) or replace (paras
3-118 and 3-119).
b. Release, or adjust (para 3-29).
c. Adjust shoe (para 3-25) or shifter
(para 3-29).
17.
Boom will not lower
a. Boom hoist pawl still engaged
b. Brake does not release
a. Release pawl (paras 2-8c and 2-12b).
b. Adjust boom hoist lever and linkage
(para 3-113), or clutch (para 3-0).
18.
Crane-shovel does not steer
properly
a. Steering gear not engaged
b. Steering linkage, clutch, or brake
out of adjustment
a. Engage (para 2-8aa).
b. Adjust (para 3-29 and/or 3-131).
19.
Cables twisted
c. Twisted during installation
b. Too much slack
a. Unwind cable from drum and rewind.
b. Refer to applicable front end attachment
reeving diagram and reeve correctly.
20.
Cables wear rapidly
a. Sheave(s) dragging or defective
a. Lubricate (LO 5-3810-206-12), or replace defective sheave bearing or shaft
(refer to applicable front end attachment paragraphs).
b. Incorrectly reeved and dragging
against another cable
b. Refer to applicable front end attachment
reeving diagram and reeve correctly.
a. Improper operation
a. Operator must center boom point
overload (para 2-28).
b. Improper operation
b. Do not allow cable overrun when dropping
clamshell or dragline (pares 2-29 or 2-30).
c. Improper reeving
a. Refer to applicable front end attachment
reeving diagram and reeve correctly.
21.
Cables jump boom point sheave
22.
Backhoe front end attachment
does not operate properly
a. Cable out of sheave
b. Improperly reeved
c. Dipper digs incorrectly
a. Install cable (para 3-39).
b. Refer to figure 2-16 and reeve correctly.
c. Adjust pitch brace (para 429b).
23.
Clamshell bucket fails to open
a. Closing cable jammed in sheaves
b. Closing cable too short
a. Lower clamshell and free cable.
b. Lower boom to a horizontal position and
replace short cable with one of proper
length (table 1-2 and fig. 2-9).
24.
Clamshell bucket will not take
proper bite
a. Operator holding too much tension
on hoist brake
b. Improper reeving (wrong cable)
c. Gradually release brake (para 2-29).
a. Hook block incorrectly reeved
a.
25.
Crane will not lift rated capacity
b. Crane not level
3-43
b. Lower boom to a horizontal position and
check cables (table 1-2 and fig. 29).
Reeve hook block with maximum parts of
the cable (fig. 2-7).
b. Crane must be level, and as near to load
as possible (boom near vertical) for
Malfunction
Probable cause
Corrective action
maximum lift and swing. (See capacity chart
in cab for boom angle or radius required for
lift).
26.
Dragline bucket will not dump
properly
a. Dump sheave binding
b. Fairlead sheaves binding
c. Bucket does not dump soon enough
d. Bucket dumps too soon
a. Clean and lubricate cable (para 3-39 and
sheave (LO 5-3810-206-12).
b. Clean sheave throat. Lubricate sheaves
(LO 5-3810-206-12).
c. Lengthen dump cable.
d. Shorten dump cable.
27.
Shovel front end attachment does
not operate properly
a. Clutches slipping
b. Dipper trip inoperative
c. Crowd chain loose
a Adjust (para 3-28).
b. Adjust (paras 3-33 and 3-34), or replace
clutch shoes (para 49).
c. Adjust (para 3-31).
28.
Propel chain excessively noisy
a. Chain loose or defective
b. Worn sprocket too tight
a. Adjust (para 3-36) or replace (para 3-137).
b. Replace (para 3-136).
29.
Pins and bushings in crawler
track wear excessively
a. Crawler track too tight
b. Crawler track too loose
a. Adjust (para 3-37).
b. Adjust (para 3-37).
30.
Idler roller wear excessive
a. Crawler track out of adjustment
b. Idler roller, or drive shaft, not
parallel to horizontal propel shaft
a. Adjust (para 3-37).
b. Adjust (para 3-37).
31.
Trackshoes wear excessively
a. Too much sag in track
b. Defective track
a. Adjust (para 3-37).
b. Replace (para 3-134).
Section VI. FIELD EXPEDIENT REPAIRS
3-45. Engine Starved for Fuel
3-42. General
Organizational maintenance troubles may occur while
the crane-shovel is operating in the field where supplies
and repair parts are not available and corrective action
cannot be performed. When this condition exists, the
following expedient repairs may be used in
emergencies, upon the decision of the unit commander.
Equipment so repaired must be removed from operation
as soon as possible and properly repaired before being
placed in service again.
Trouble
Defective fuel filter---------------------------- Remove fuel filter (paras 3-68
or 3-69), connect by-pass
line, and operate without
until one is received.
3-46. Low Engine Oil Pressure
3-43. Starter Motor Fails to Turn Engine
Trouble
Trouble
Expedient remedy
Clogged filter element ----------------------- Remove oil filter element (para
3-4f) and operate without
until one is received
Expedient remedy
Dead batteries --------------------------------- Use jumper cables from other
batteries or another piece
of equipment to supply
current for starting engine.
3-47. Engine Oil Strainer Faulty
3-44. Engine Overheats
Trouble
Expedient remedy
Clogged filter element ----------------------- Remove filter element (para 313) and operate without
until one is received.
Trouble
Expedient remedy
Clogged or defective filter element-------- Remove filter element (para 34g) reassemble oil strainer
and use without until one is
received.
Expedient remedy
Defective thermostat ------------------------- Remove thermostats (para 398) and operate without
until one is received.
3-44
Section VII. RADIO INTERFERENCE SUPPRESSION
(1) Remove capscrew (fig. 3-33) and IET
washer that secures ground strap to engine.
(2) Remove capscrew and IET washer that
secures ground strap to generator, and remove ground
strap.
(3) Place new ground strap in position and
secure to engine with IET washer and capscrew.
(4) Connect ground strap to generator and
secure with IET washer and capscrew.
c.
Voltage Regulator.
(1) Remove four nuts and screws (fig. 3-33)
that secure regulator and two mounts, and remove
regulator.
(2) Place new regulator in position with two
mounts and secure with four screws and nuts.
3-48. General Methods Used to Attain Proper
Suppression
Essentially, suppression is attained by providing a low
resistance path to ground for the stray currents. The
methods used include shielding the ignition and highfrequency wires, grounding the frame with bonding
straps, and using capacitors and resistors.
3-49. Interference Suppression Components
a.
Primary Suppression Components.
The
primary suppression components are those whose
primary function is to suppress radio interference.
These components are described and located in figure
3-33.
b.
Secondary Suppression Components. The
secondary suppression have radio interference
suppression functions which are incidental or secondary
to their primary function.
3-51. Testing of Radio Interference Suppression
Components
Test any capacitors for leaks and shorts on a capacitor
tester; replace defective capacitors. If test equipment is
not available and interference is indicated, isolate the
cause of interference by the trial and error method of
replacing each capacitor in turn until the cause of
interference is located and eliminated.
3-50. Replacement of Suppression Components
a.
General.
Replacement of suppression
components requires positive metal-to-metal contact
with washers and ground straps. Replace as follows:
b.
Generator Ground Strap.
3-45
Figure 3-33. Radio interference suppression components.
3-46
Section VIII. ORGANIZATIONAL MAINTENANCE PROCEDURES
3-52. General
3-53. Inspection and Test
The instructions in this section, and all subsequent
paragraphs and sections, are published for the
information and guidance of organizational maintenance
personnel in maintaining the crane-shovel.
All inspection and test requirements outlined in
maintenance allocation chart for organizational level are
covered in the paragraphs describing other maintenance
procedures within the system.
Section IX. ENGINE CYLINDER HEAD AND VALVE MECHANISM
leaks, then add engine oil to crankcase, if necessary
(LO 5-3810-206-12).
b.
Removal and Installation, Model DSSSTA
Engine.
(1) Remove the six bolts, flatwashers, and
seals that secure valve cover to cylinder head; remove
valve cover, and inspect gasket.
(2) Replace a defective gasket seal, then
carefully install valve cover. Be sure gasket fits recess
in valve cover, then install six seals in top of valve
cover; position flatwashers on bolts, install bolts through
seals, and tighten to between 12 and 18 foot pounds
torque.
(3) Start engine (para 2-10) and run until
engine reaches operating temperature, checking for oil
leaks at gasket and seals. Stop engine (Para 2-11),
correct any leaks, then add engine oil to crankcase if
necessary (LO 5-3810-206 12).
3-54. General
a.
Model 687C-18-ES Engine. On this two
cycle diesel engine the cylinder head forms the top of
the combustion chamber and contains passages for the
intake of air and the expulsion of gases. The exhaust
valve mechanism is attached to the head. The rocker
arm, which directly operates the exhaust valve, operates
on a short shaft mounted in two supports on the cylinder
head. Valve lash adjustment is accomplished with the
adjustable ball-ended screw in the rocker arm.
b.
Model DSSSTA Engine. On this four cycle
diesel engine the valves and valve mechanism admit
inlet air and release exhaust gases at precisely timed
intervals during engine operation. The inlet valve is
open during intake stroke of piston to permit air to enter
cylinder. After the power stroke, the exhaust valve is
opened to permit piston to force burned gases from the
cylinder as it moves upward in the exhaust stroke.
c.
Differences. There are other changes in
configuration between the two engines, in addition to
quantity of valves and stroke cycles, which will be
covered in the applicable maintenance paragraphs.
3-56. Valve (Rocker Arm) Adjustment
a.
General. The valve adjustment may be
accomplished with engine hot or cold. But when
adjusted cold, final adjustment must be made while hot.
These instructions will cover valve adjustment on a hot
engine (water temperature between 160°F and 180°F).
b.
Model
687C-18-ES
Engine
Valve
Adjustment.
(1) Remove valve cover (para 3-55).
(2) Start engine (para 2-10) and run until
operating temperature is reached (between 160° and
180°F).
(3) When
engine
is
at
operating
temperature, stop engine (para 2-11), with cylinder No. 1
at top dead center (valve seated closed). Use wrench
(fig. 3-44) to loosen locknut holding valve adjusting
screw.
(4) Use screw driver and turn adjusting
screw until a clearance of 0.012 inch (hot) to 0.014 inch
(cold) is obtained with thickness gauge.
3-55. Valve Cover and Gasket
a.
Engine.
Removal and Installation, Model 687C-18-ES
(1) Turn three locking hand-wheels securing
cover counterclockwise until they are loose, then
remove valve cover from cylinder head.
(2) Remove valve cover gasket from
cylinder head (or cover) and discard.
(3) Install new valve cover gasket on
cylinder head; position valve cover on gasket, then
secure by turning the three locking hand-wheels
clockwise until they are tight.
(4) Start engine (para 2-10), run until
engine reaches operating temperature, checking for oil
leaks at gasket. Stop engine (para 2-11); correct any
3-47
Figure 3-34. Valve (rocker arm) adjustment, model 687C-18-ES engine.
(6) Recheck
NOTE
When engine temperature is at 130°F
or below it is considered to be a cold
engine.
clearance.
Readjust
if
necessary.
(7) Repeat steps (3) through (6) above for
remaining cylinders. Cylinders fire in 1-6-2-4-3-5 order.
(8) Install valve cover (para 3-55).
c.
Model DSSSTA Engine Valve Adjustment.
(1) Remove valve cover (para 56).
(5) When clearance is correct, hold
adjusting screw with screwdriver and tighten the locknut.
Figure 3-35. Valve (rocker am) adjustment, Model D333TA engine.
3-48
(2) Start engine (para 2-10) and run until
operating temperature is reached (between 160° and
180°F).
(3) When
engine
is
at
operating
temperature, stop engine (para 2-11) with cylinder No. 1
at top dead center on compression stroke (both valves
seated closed). Refer to figure 335, and use a wrench
to loosen locknuts holding valve adjusting screws.
(4) Use screwdriver and adjust exhaust
valve with a clearance of 0.025 inch (hot) 0.028 inch
(cold) is obtained with thickness gauge (fig. 3-34).
F, or below, it is considered to be a
cold engine.
(5) When clearance is correct, hold
adjusting screw with screwdriver and tighten the locknut.
(6) Recheck clearance.
Readjust if
necessary.
(7) Repeat steps (3) through (6) for intake
valves, except use 0.015 inch (hot) 0.017 inch (cold).
(8) Repeat above procedure for remaining
cylinders. Cylinders fire in 1-5-3-6-2-4 order.
(9) Install valve cover (para 3-55).
NOTE
When engine temperature is at 130°
Section X. ENGINE LUBRICATING SYSTEM
charger components. The oil filter bypass valve opens
when filters become restricted and allows oil to bypass
filters and flow directly to outlet passage. Unless filters
become restricted, or oil viscosity is extremely high,
only filtered oil is furnished to the engine bearings. The
bypass valves assure a supply of lubricating oil any time
filter, cooler, or both may become clogged.
3-57. General
a.
Description.
A pressurized lubricating
system, filtered and strained, with full flow by-pass
features is pumped from crankcase oil pan through
strainer and filter to passages designed to distribute oil
where it is most required. Differences are described
under paragraph devoted to each engine.
b.
Engine Model 687C-18-ES. A gear type oil
pump is mounted in bottom of oil pan at rear of engine.
This pump forces oil to front of engine through a supply
line and cored passage to oil strainer; through strainer to
manifold on each side of engine, where it is distributed
to all moving parts by means of holes drilled at strategic
points.
Exhaust valve rocker arms are lubricated
through an external line which supplies oil to end rocker
arm shaft. The remaining rocker arms are lubricated by
means of short jumper connections. The blowers are
also lubricated through external lines. Drain plugs for
draining system are located on bottom of oil pan, and
side of oil strainer housing.
c.
Engine Model D333TA. A two section oil
pump contains a scavenge pump and a pressure pump.
Oil that does not return to pan is collected by a
scavenge tube and then returned to oil pan. Oil is
pumped from oil pan to oil cooler, then to oil filters,
except on starting, when it is bypassed through an
external line to the filters, cutting out the cooler for cold
oil. When engine is first started, unfiltered oil is passed
by the turbocharger lubrication valve to turbocharger
components by an external line. As the oil temperature
increases, the oil cooler by pass valve closes, forcing oil
through cooler to filter bases. As oil pressure is built up
through filters, the turbocharger lubrication valve closes
off flow of unfiltered oil and provides filtered oil to turbo
3-58. Engine Oil Filters
a.
For Engine Model 687C-18-ES.
(1) Removal and installation.
Figure 3-36. Engine oil filters (for engine 687C-18ES), removal and installation.
3-49
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Nut (4)
Capscrew (4)
Lockwasher (4)
Nut (4)
Bolt (4)
Lockwasher (4)
Flatwasher (4)
Bracket (2)
Drain plug
Nut (4)
Bolt (4)
Lockwasher (4)
Flatwasher (4)
Nut (2)
Bolt (2)
Straps (2)
Capscrew
18
19
20
21
22
23
24
25
26
27
28
29
30
81
32
33
Plug
Cover
Spring
Packing
Filter element
Tee
Tee
Elbow
Elbow
Filter
Bolt
Lockwasher
Flatwasher
Filler, pipe
Packing
Bracket
Figure 3-37. Engine oil filters (model 687C-18-ES) disassembly, and reassembly,
and oil filler pipe removal and installation.
(a) Refer to figure 3-36, disconnect oil
line from elbow at strainer, then remove oil line from
filter.
(b) Remove drain plug, drain filter,
then remove remaining oil lines and fittings. Plug line
ends or ports to prevent contamination of oil supply.
(c) Remove items 1 through 7, figure
3-37, then remove filter and mounting bracket (8) from
engine as an assembly.
(d) Remove remaining filter in a
similar manner.
(2) Disassembly and reassembly. Refer to
figure 3-37 and disassemble the oil filter in numerical (9
thru 27) order. Reassemble in reverse order.
3-50
(3) Cleaning, inspection, and repair.
(a) Clean all parts in an approved
cleaning solvent, except filter element and gaskets
which are discarded, then dry thoroughly.
(b) Visibly inspect all parts for signs or
damage or defect.
(c) Repair by replacing damaged or
defective part, all gaskets, and filter element.
b.
For Engine Model DSSSTA.
(1) Removal and installation. Remove drain
plug (view A, fig. 3-38) and drain oil filters, disconnect
oil lines, remove six capscrews and lockwashers then
remove oil filter base from engine.
Install in reverse order.
(2) Disassembly and reassembly. Refer to
view B of figure 3-38 and disassemble the oil filters in
numerical sequence. Reassemble in reverse order.
(3) Cleaning, inspection and repair.
(a) Clean all parts except filter
element, which is discarded, in an approved cleaning
solution and dry thoroughly.
(b) Visibly inspect all parts for
deformation, stripped threads, or excessive wear.
Inspect the three bypass valves and the seating
surfaces within filter base for wear or damage. Inspect
springs for loss of tension or deformation. Inspect
packing, seals and gaskets for signs of damage or
deterioration.
(c) Repair by replacing damaged or
defective parts.
3-59. Engine Oil Strainer (for Engine Model 687C18-ES)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Screw
Clip
Plate
Spring
Gasket
Cover
Seal
Washer
Filter element
Capscrew
Lockwasher
Clamp
Capscrew (2)
Lockwasher (2)
Clamps (2)
Case (2)
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
a.
Removal and Installation. Refer to figure 339, perform step 1 and remove oil strainer from engine.
Install in reverse order.
b.
Disassembly and Reassembly.
Refer to
figure 3-39, perform step 2 and disassemble oil strainer.
Reassemble in reverse order.
c.
Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly, using low pressure
compressed air to blow filter element dry. Be sure all
gummy sludge has been removed from filter element.
(2) Visually inspect all parts for bends,
breaks, or distortion, and mounting hardware for
stripped threads or other defects.
(3) Repair by replacing all gaskets, then
replace any other part that is excessively worn,
damaged or defective.
Gasket (2)
Spring pin (2)
Stud (2)
Adapter
Retainer
Spring
Valve
Plug (2)
Spring (2)
Valve (2)
Plug
Plug
Packing
Packing
Filter Base
3-60. Engine Oil Level Gauge (Dipstick)
a.
On Engine Model 687C-18-ES.
(1) Removal.
(a) Refer to figure 3-1 (6), reference
number 53, and remove dipstick from tube.
Figure 3-38. Oil filters, removal, disassembly,
reassembly and installation for engine Model
D333TA (sheet 1 of 2).
3-51
NOTE
THE RETAINER (21) IS A PRESS FIT, BUT IS EASILY REMOVED BY USING A 3/8-16 (NC) BOLT
OF SUITABLE LENGTH AND A SPACER.
NOTE
AT REASSEMBLY, COAT PREFORMED PACKING OR SEALS WITH LIQUID SOAP TO EASE
INSTALLATION.
Figure 3-38. Oil filters, removal, disassembly, reassembly, and installation
for engine Model D333TA (sheet 2 of 2).
(b) Remove tube from bushing by
turning in a counterclockwise direction.
(c) Remove bushing from block.
(2) Installation.
Install by reversing
procedure used in (1) above.
b.
On Engine Model DSSSTA.
(1) Removal.
(a) Refer to figure 3-40 and remove
dipstick from tube.
(b) Remove two capscrews and
lockwasher, then remove the tube from oil pan.
3-52
STEP 1
DISCONNECT OIL LINE (NOT SHOWN) FROM ADAPTER, REMOVE ITEM 1 AND 2 AND DRAIN
STRAINER. REMOVE ITEMS 3, 4, AND 5, THEN REMOVE STRAINER AND GASKETS 6 AND 7
FROM ENGINE.
Figure 3-39. Engine oil strainer (for engine Model 387C-18-ES), removal,
disassembly, reassembly and installation.
(2) Installation.
procedure in (1) above.
Install
by
reversing
3-61. External Oil and Ventilation Lines
a.
On Engine Model 687C-18-ES.
(1) Removal.
(a) Loosen coupling nut (fig. 3-41) and
remove air box drain tube from clamp.
(b) Remove crankcase ventilation line
by removing items 4 through 12 in sequence.
(c) Remove remaining external oil
lines in a similar manner.
(2) Installation.
Install external oil and
ventilation lines by reversing procedure in steps (a) (b)
and (c) above.
b.
On Engine Model D333TA. Remove and
install external oil and ventilation lines from engine
model D333TA in a manner similar to that described in a
above.
3-62. Crankcase Breather and Oil Filler Pipe
(1) Removal. Refer to figure 3-37 and
remove oil filler pipe by removing items 23 through 27 in
numerical sequence.
Figure 3-40. Engine oil level gauge (Dipstick).
3-53
Figure 3-41. External oil and ventilation lines, removal and installation.
(3) Installation. Reverse procedure in (1)
above for installation.
c.
Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect for deformation or
defect, including deterioration of hose or gaskets.
(3) Repair by replacing damaged or
defective parts.
(2) Installation. Install oil filler pipe by
reversing procedure in (1) above.
b.
Crankcase Breather and Oil Filter (on Model
D333TA).
(1) Removal Refer to figure 3-42 and
remove crankcase breather and oil filler from left hand
side of engine.
(2) Disassembly and reassembly. Refer to
figure 3-42 and disassemble crankcase breather and oil
filler. Reassemble in reverse order.
3-54
STEP 1
REMOVE CLIP FROM TUBE, BOLT (3) AND LOCKWASHER (3), THEN REMOVE BASF AND
GASKET FROM LEFT SIDE OF ENGINE.
STEP 2
DISASSEMBLE BY REMOVING ITEMS 5 THROUGH 18 IN NUMERICAL SEQUENCE FROM BASE
19.
NOTE
REASSEMBLE AND INSTALL BY REVERSING ABOVE PROCEDURE.
ME 3810-201-12/3-50
Figure 3-42. Crankcase breather and oil filler (engine model D333TA), removal, disassembly, reassembly and
installation.
Section XI. FUEL SYSTEM
fuel injection pump, It also includes a return flow line
from injectors to pump, and return lines through shutoff
valve to fuel tank. The injection pump forces a metered
amount of fuel through lines to injectors, and into engine
cylinders at high pressure. An overspeed governor
driven by tachometer drive, activates shutdown lever on
fuel injection pump
3-63. General
a.
Fuel System for Engine Model 687C-18-ES.
The fuel supply system for this engine consists of a fuel
tank, shutoff valve, primary filter, priming pump,
secondary filter, and a transfer pump that is built into the
3-55
through a micro-switch controlled circuit, when rpm
exceeds 1935 ± 15 rpm.
b.
Fuel System Flushing Procedure for Engine
Model 687C-18-ES.
(1) Disconnect fuel line at pump inlet and
place end of line in a suitable container.
(2) Pump the hand primer (para 2-8 ap)
several times to flush the lines and filters.
(3) Reconnect fuel line to pip inlet. Be sure
the fuel line connector screws, are set at proper torque
of 420 inch-pounds.
NOTE
A characteristic of the Roosa-Master
fuel injection pump is that if engine
misfiring occurs and it is traced to a
certain cylinder in which no
combustion is taking place, the
cause may be a nozzle valve sticking
open
in
the
cylinder
which
immediately precedes that cylinder in
the firing order. During injection to
the cylinder which has the nozzle
valve sticking in the open position,
the fuel rushes into that cylinder with
no restriction, causing a scavenging
effect in the pump distributor rotor
and a void which cannot be reached
to a sufficient degree to provide
opening pressure of fuel to the
following nozzle valve. Hence, no
combustion can take place.
NOTE
New fuel line connector washers
should be installed every time the
fuel line connector screws are
loosened.
(4) Disconnect injector fuel lines at the
injectors.
(5) Crank the engine with starter for thirty
seconds.
(6)
c.
Fuel System for Engine Model D333TA. The
fuel is drawn from supply tank by a gear type transfer
pump that forces fuel through a drilled
Reconnect injector fuel lines
Figure 3-43. Fuel injector and fuel line removal and installation (engine model 687C-18-ES).
3-56
(b)
passage in filter housing to the outside of filter element.
A spring loaded bypass valve on front of filter housing
maintains a maximum pressure of approximately 15 psi
on the fuel in filter housing; as indicated on fuel
pressure gauge mounted on housing. This fuel transfer
pump supplies more fuel than is required by engine, or
to maintain 15 psi pressure. Excess fuel is bypassed
around valve and returned to fuel tank. Filtered fuel
flows up center of filter housing into a passage through
cover then down rear of housing to fuel manifold, which
distributes fuel to the injection pumps. A cam activated
injection pump for each cylinder, forces fuel through an
injection line to proper fuel injector where a definite
quantity of fuel is forced into pre-combustion chamber at
the proper time.
d.
Fuel System Flushing Procedure for Engine
Model D333TA.
(1) Operate vent valve at front of filter
cover.
(2) Operate primer pump (para 2-8 ap)
several times, until a solid stream of fuel flows out of the
drain tube, indicating that all air has been flushed from
the system.
(3) Close the vent valve.
by
reversing
procedure
(2) On engine Model DSSSTA.
(a) Refer to figure 344 and remove
glow plug to prevent damage.
(b) Remove remaining items in
numerical sequence.
(c) Install by reversing procedure
above.
3-65. Air Cleaners
a.
Used by Engine Model 687C-18-ES.
(1) Removal and installation.
Refer to
figure 3-45, remove items 1 through 5 in numerical
sequence, and remove air cleaner from engine.
Install in reverse order.
(2) Disassembly and Reassembly. Refer to
figure 3-45, remove items 6 through 21 in numerical
sequence and disassemble air cleaner.
Reassemble in reverse order.
(3) Mounting
Bracket
Removal
and
Installation. Refer to figure 3-45, remove items 23
through 33 in numerical sequence and remove mounting
bracket from engine. Install in reverse order.
(4) Cleaning, inspection and repair.
(a) Clean all parts with an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect for dents, breaks,
cracks, stripped threads on mounting hardware, or
deterioration of packing.
(c) Repair by replacing defective
packing, hardware, or damaged air cleaner.
(5) Service.
Service air cleaner as
described in paragraph 3-4.
NOTE
The fuel system may also be flushed
by using transfer pump to force fuel
out of drain tube. Open vent valve
and operate starter for approximately
thirty seconds, or until a solid stream
of fuel flows out of drain tube,
whichever requires the shorter time,
then close vent valve.
3-64
Install
above.
Fuel Injector and Fuel Line
a.
General. Fuel injector or fuel line that is
loose, damaged, or defective will effect diesel engine
operation. When it is suspected that a fuel injector is
defective, the defective injector can be isolated by the
following process of elimination:
(1) Loosen fuel line coupling nut at fuel
injector while engine is idling, and observe engine
performance.
(2) If idling speed slows down, the injector
is working.
(3) If there is no noticeable difference in
engine speed, that injector is defective. Repeat on
remaining five injectors. Replace a defective injector or
damaged fuel line.
b.
Removal and Installation.
(1) On engine model 687C-18-ES.
(a) Refer to figure 3-43 and remove
items in numerical sequence.
Figure 3-44. Fuel injector, fuel line and glow plug,
removal and installation.
3-57
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Hose damp (2)
Hose
Nut (4)
Lockwasher (4)
Capscrew (4)
Nut
Lockwasher
Capscrew
Clamp
Cover
Wing nut (2)
Lockwashers (2)
Thumbscrew (2)
Oil cup
Wingnut (3)
Tray
Packing (2)
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Nut (2)
Lockwasher (2)
Capscrew (2)
Bands
Body
Nut (2)
Lockwasher (2)
Capscrew
Bracket
Nut
Lockwasher
Nut
Lockwasher
Stud
Spacer
Bracket
Figure 3-45. Air cleaner and mounting bracket, removal, disassembly and installation (on Crane model 855BG
with engine 687C-18-ES).
3-58
Figure 3-46. Air cleaner, dry type, removal, disassembly, reassembly, and installation (for engine model D333TA).
3-59
b.
Cleaning, inspection, and repair.
(1) Clean all parts with an approved
cleaning solvent and dry thoroughly.
(2) Visually inspect all parts for bends,
cracks, other damage or defects.
(3) Repair by straightening bends, welding
cracks, or replacing damaged gaskets, defective
manifold or mounting hardware.
c.
Installation. Install by reversing procedure
described in a above.
b.
Used by Engine Model D333TA.
(1) Removal and installation.
Refer to
figure 3-46, remove items 1 through 3 in numerical
sequence, then remove air cleaner from support bracket
and turbocharger coupling. Install in reverse order.
(2) Disassembly and reassembly. Refer to
figure 346, disassemble air cleaner by removing items 4
through 10 in numerical sequence. Reassemble in
reverse order.
(3) Support
bracket
removal
and
installation. Refer to figure 3-46, remove items 11 and
12, then remove support bracket from engine. Install in
reverse order.
(4) Cleaning, inspection, and repair.
(a) Clean all parts with an approved
cleaning solvent and dry thoroughly. Dry filter element
with, low pressure compressed air.
(b) Visually inspect all parts for
damage, defect, or deterioration.
(c) Repair by replacing damaged or
defective parts.
(5) Service. Service dry type air cleaner as
directed in paragraph 3-11.
3-67. Fuel Tanks, Lines, and Fittings
a.
Removal and Installation. Refer to figure 348 and remove fuel tank, lines, and fittings. Install in
reverse order.
b.
Cleaning and inspection.
(1) Clean all parts with an approved
cleaning solvent and dry thoroughly.
(2) Visually inspect all parts for cracks,
breaks, or other damage. Inspect hardware for stripped
threads or other defect. Inspect fuel strainers for
breaks, tears of screen, or other damage. Inspect fuel
tank for leaks.
Replace defective components or
mounting hardware.
(3) Repair cracks and breaks by welding.
Repair a leaking tank as follows:
(a) Remove fuel tank (a above).
(b) Fill tank with water to avoid
concentration of fumes.
(c) Weld leaking area.
(d) Drain water from tank, blow dry as
possible with compressed air, then pour about ½ gallon
of fuel oil into-tank and slosh it around
3-66. Air Manifold (Blower to Blower) Engine Model
687C-18-ES
a.
Removal.
(1) Remove two hose clamps (fig. 3-47)
from hose.
(2) Remove eight capscrew, lockwasher,
and flatwasher, then remove blower-to-blower air
manifold and gaskets from blower adapters.
Figure 3-47. Air manifold and blower adapters, installed view.
3-60
STEP 1
REMOVE CAP, OPEN DRAINCOCK AND DRAIN FUEL FROM TANK, THEN LOOSEN NUT AND
REMOVE TUBE FROM ADAPTERS (2) AND PLUG OR COVER END OF TUBES AND ADAPTERS.
DISCONNECT ELECTRICAL LEAD (NOT SHOWN) FROM FUEL LEVEL TRANSMITTER.
STEP 2
REMOVE NUT (4), LOCKWASHER (4), PAD (4), AND SCREW (4) THEN REMOVE FUEL TANK
FROM REVOLVING FRAME.
ME 3810-206-12/3-48
Figure 3-48. Fuel tank, lines, and fittings, removal and installation.
to pick up remaining moisture. Let tank set in normal
position for about 10 minutes, then remove drain plug
and drain tank. Install drain plug.
(e) Install fuel tank by reversing
procedure used to remove in (a) above.
49, remove items 1 through 3, then remove filter from
engine. Install in reverse order.
b.
Disassembly and Reassembly.
Refer to
figure 3-49 and disassemble filter by removing items 4
through 13 in numerical sequence from item 14.
Reassemble in reverse order.
c.
Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
3-68. Primary Fuel Filter (Engine Model 687C-18-ES
Only)
a.
Removal and Installation. Refer to figure 3-
3-61
Figure 3-50. Fuel filter (secondary), removal,
disassembly, reassembly and installation (engine
model 687C-18-ES).
figure 3-50 and disassemble fuel filter by removing
items 5 through 19 in numerical sequence from item 20.
Reassemble in reverse order.
(3) Cleaning, inspection, and repair.
(a) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(b) Visually inspect all parts for dents,
cracks, stripped threads, or other damage.
(c) Repair
by
replacing
defective
components or mounting hardware.
(4) Service. Service fuel filter as directed in
paragraph 3-18.
b.
Fuel Filter on Engine Model DSSSTA.
(1) Removal and installation.
Refer to
figure 3-1, perform steps 1 and 2, and remove fuel filter.
Install in reverse order.
(2) Disassembly and reassembly. Refer to
figure 3-51, perform step 3, and disassemble fuel filter.
Reassemble in reverse order.
(3) Cleaning, inspection, and repair.
(a) Clean all parts except pressure gauge
Figure 3-49. Primary fuel filter (on engine model
687C-18-ES only) removal, disassembly, reassembly
and installation.
(2) Visually inspect all parts for damage or
defect.
(3) Repair by replacing defective parts.
Replace all gaskets at reassembly.
3-69. Fuel Filter (Secondary, on Engine Model
687C1 ES)
a.
Secondary Fuel Filter on Engine Model
687C-18-ES.
(1) Removal and installation.
(a) Refer to figure 3-50, remove items 1
and 2, and drain filter.
(b) Remove items 3 and 4 and remove filter
and bracket from engine.
(2) Disassembly and reassembly. Refer to
3-62
Figure 3-51. Fuel filter (for engine model D333TA), removal, disassembly, reassembly, and installation.
3-63
(2) Visually inspect mounting hardware for
stripped threads or other defects. Move flexible control
through housing to check freedom and ease of
movement.
Inspect housing for dents or other
deformation.
(3) Repair by replacing defective items.
When housing of control cable is deformed and binds
control, replace the flexible control.
c.
Adjustment.
The flexible control is
adjustable at either the engine, or throttle lever end.
When throttle lever is not correctly positioned on
quadrant, at idle or high speed, adjust as follows:
(1) Remove cotterpin and pin from rod end
clevis (fig. 3-63), back off locknut, then turn clevis on
rod end clockwise to shorten, or counterclockwise to
lengthen control cable.
(2) Reinstall cable rod end on shaft and try
throttle lever position.
(3) Repeat steps (1) and (2) until
adjustment is correct, then tighten locknut.
and switch, and filter element which is discarded, in an
approved cleaning solvent and dry thoroughly. Wipe
gauge and switch clean with a rag dampened in cleaning
solution, then wipe dry.
(b) Visually inspect all parts for
excessive wear, cracks, dents, or stripped threads. Test
continuity of low fuel pressure switch. Test fuel pressure
gauge with controlled air pressure.
(c) Repair by replacing damaged,
defective, or worn parts. Install new filter element at
reassembly.
(4) Service. Service fuel filter as directed in
paragraph 3-13.
3-70. Governor Throttle Control Linkage
a.
Removal and Installation. Refer to figure 352 and remove governor throttle control linkage in
numerical sequence. Install in reverse order.
b.
Cling, Inspection, and Repair.
(1) Clean all parts except flexible control
cable in an approved cleaning solvent and dry
thoroughly. Wipe housing and rod ends of control cable
clean with rag dampened in cleaning solvent, then wipe
dry.
3-71. Primer Pump, Lines, and Fittings
a.
For Engine Model 687C-18-ES.
Figure 3-52. Governor throttle control linkage, removal and installation.
3-64
Figure 3-53. Primer pump (for engine model 687C18-ES) removal and installation.
(1) Removal and installation.
Refer to
figure 3-53 and remove primer pump in numerical
sequence. Install in reverse order.
(2) Cleaning, inspection, and repair.
(a) Clean all parts in an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect for bent or clogged
fuel lines, burs, or stripped threads.
(c) Repair
by
removing
burs,
replacing
Figure 3-54. Primer pump (for engine model
D333TA) removal, disassembly, reassembly and
installation (sheet 2 of 2).
Figure 3-54. Primer pump (for engine model
D333TA) removal, disassembly, reassembly and
installation (sheet 1 of 2).
damaged or defective hardware or replacing a defective
primer pump.
3-65
solvent and dry thoroughly.
(2) Visually inspect all hardware for burred
or stripped threads, test that flexible control pulls
through housing easily (does not bind), and that knob is
serviceable.
(3) Repair by replacing defective hardware
of flexible control.
b.
For Engine Model D333TA.
(1) Removal and Installation. Refer to view
A of figure 3-54 and remove items in numerical
sequence. Install in reverse order.
(2) Disassembly and Reassembly. Refer to
view B of figure 3-54 and disassemble the primer pump
in numerical sequence. Reassemble in reverse order.
(3) Cleaning, Inspection and Repair.
(a) Clean all parts in an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect for burred threads,
weak springs, damaged seals, and bent or clogged fuel
lines (tubes).
(c) Repair by replacing defective
items.
3-73. Blower Adapters (For Engine Model 687C-18ES)
a.
Removal and Installation. Refer to figure 356 and remove blower adapters. Install in re verse
order.
b.
Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for dents,
cracks, excessive wear, or other defect Inspect gaskets
and hose for deterioration or other defect.
Inspect mounting hardware for burs, stripped
threads, or other defect.
(3) Repair
by
replacing
defective
component or mounting hardware.
3-72. Engine Shutoff Control
a.
Removal and Installation. Refer to figure 355, remove items in numerical sequence, and remove
engine shutoff control. Install in reverse order.
b.
Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
Figure 3-22. Engine shutoff control, removal and installation.
3-66
Figure 3-56. Blower Adapters, removal and installation (Engine Model 687C-18-ES).
3-67
Section XII. ELECTRICAL SYSTEM
diagram (view B of fig. 1-9).
c.
Organizational Maintenance Procedures.
This section will outline and illustrate organizational
maintenance procedures authorized by the Maintenance
Allocation Chart (app. C).
3-74. General
a.
For Crane Units with Engine Model 687C-18ES. This 24 volt electrical system consists of two 12
volt batteries connected in series, a belt driven batterycharging generator, starter, starter solenoid relay, panel
lights, generator voltage regulator, trouble light, oil
pressure transmitter, water temperature transmitter, low
oil pressure switch, water high temperature switch, and
ammeter. An over speed governor driven through
tachometer drive, actuates the shutdown lever on
injection pump through a micro-switch controlled circuit
when engine overspeeds the predetermined limit. The
cranes are also equipped with a horn and floodlight.
See wiring schematic diagram (view A of fig. 1-9).
b.
For Crane Units with Engine Model D333TA.
This unit is equipped with battery-charging alternator
and alternator voltage regulator instead of generator and
generator voltage regulator. It is not equipped with the
micro-switch overspeed governor shutdown circuit, but
has a low fuel pressure switch mounted on clean side of
fuel filter that is normally open to prevent electrical
current from flowing back to the alternator when engine
is stopped, and cause damage to rectifiers in alternator
or transistors in regulator.
See wiring schematic
3-75. Batteries
a.
Removal and Installation.
(1) Refer to figure 3-57, perform steps 1
and 2, and remove batteries.
(2) Install in reverse order.
b.
Cleaning, Inspection, and Repair.
(1) Clean batteries with an approved
cleaning solution and dry thoroughly. Remove all
corrosion from battery cables and terminal posts.
(2) Visually inspect battery cases and vent
caps for cracks, or terminals for looseness. Use a
hydrometer and test electrolyte for specific gravity.
Charge, or replace a battery reading less than 1.250 on
hydrometer.
(3) Repair by replacing defective cables or
battery.
STEP 1
REMOVE THREE WING NUTS, REMOVE COVER (NOT SHOWN). THEN REMOVE GROUND
CABLE.
STEP 2
REMOVE JUMPER CABLE, POSITIVE CABLE, THREE CLAMPS, THEN REMOVE TWO
BATTERIES.
STEP 3
REMOVE FOUR CAPSCREW, LOCKWASHER AND NUT FROM END BRACKET, THEN REMOVE
BATTERY BOX FROM CAB FLOOR.
ME 3810-201-12/3-68
Figure 3-57. Battery and Battery Box, removal and installation.
3-68
3-76. Battery Box
NOTE
Batteries must be fully charged for
this test.
a.
Removal.
(1) Remove batteries (para 3-75).
(2) Refer to figure 3-57, perform step 3, and
remove battery box.
b.
Installation. Refer to figure 3-57, perform
step 3 in reverse order, and install battery box.
(c) Read ammeter. Correct reading
should be from 1.00 to 1.05 ampere.
(d) When readings do not meet
requirements of (b) and (c) above, generator is
defective and must be replaced.
(2) Motoring test.
Connect test set as
illustrated in view B of figure 3-59.
(a) Adjust
variable
resistor
to
maximum resistance.
(b) Close battery switch then gradually
reduce resistance until armature begins to rotate. It
should rotate freely.
(c) When armature falls to rotate
freely, generator is defective and must be replaced.
(d) Remove test set, install inspection
band, and replace shielded cable.
b.
Removal and Installation.
(1) Tag and remove all electrical leads.
(2) Remove capscrew from adjusting
bracket, move generator toward engine block and
remove belt from pulley.
(3) Remove two capscrews, washers and
nuts from generator mounting bracket, then lift
generator from bracket.
(4) Install in reverse order.
c.
Cleaning, Inspection and Repair.
(1) Clean exterior of generator housing with
a rag dampened in an approved cleaning solvent then
dry thoroughly. Blow dust from armature brush area
with low pressure compressed air.
(2) Inspect mounting hardware for worn or
stripped threads, inspect belt for excessive wear, frayed,
or deteriorating condition. Visually inspect housing, end
bells, or pulley for breaks or cracks. Inspect brushes for
wear beyond 50 percent of original length.
(3) Repair by replacing defective mounting
hardware, belt, or worn brushes. Replace a defective
generator.
d.
Brush Replacement. Worn brushes will be
replaced in a manner similar to that described for starter
motor brushes (para. 3-81).
e.
Belt Removal, Installation and Adjustment.
(1) Removal and Installation. Remove belt
as described in b (2) above. Install in reverse order.
(2) Adjustment. Adjust generator belt as
shown on figure 3-17.
3-77. Generator and Belt (For Engine Model 687C18-ES)
a.
On Equipment Test of Generator.
(1) Field current test. Refer to figure
remove shielded cable, and inspection band
generator.
(a) Use automotive generator
voltage regulator test set as illustrated in view
figure 3-59 and test field current output.
(b) Adjust variable resistance
voltmeter reads 24 volts.
3-58,
from
and
A of
until
Figure 3-58. Generator and voltage regulator test
points.
3-69
Figure 3-59. Generator test connections.
3-78. Alternator and Belt (For Engines Model
D333TA)
operating. This would damage the
voltage regulator.
CAUTION
Never operate alternator without
battery being connected in circuit.
a.
General.
The self-rectifying charging
alternator is designed to give long and satisfactory
service with a minimum amount of maintenance, but the
following precautions must be observed.
CAUTION
When charging batteries from an
external source of power, be sure
battery is disconnected from circuit
before beginning charging operation,
to prevent damage to alternator
rectifying diodes
CAUTION
Do not attempt to polarize the
alternator.
If
an
accidental
connection were made between the
battery terminal and either of the
terminals “F1” or “F2” on the
alternator the transistors in voltage
regulator will be damaged.
CAUTION
Do not make, or break, any alternator
connections while alternator is
CAUTION
Before using booster cables to start
the engine, be sure of the lead
polarity and connect the batteries
correctly. Incorrect connection, even
for
an
instant,
will
destroy
alternator's rectifying diodes.
3-70
thoroughly. Blow all dust from brush area with low
pressure compressed air.
(2) Visually inspect all mounting hardware for
wear or stripped threads. Inspect alternator for cracks or
breaks in pulley, housing, or end bells. Inspect belt for
wear, frayed condition, or deterioration.
(3) Repair by replacing defective hardware,
belt, or alternator.
e. Belt Removal, Installation, and Adjustment.
(1) Removal and installation.
Remove
alternator belt in manner similar to that described for
generator (para 3-77). Install in reverse order.
(2) Adjustment.
Adjust generator belt as
shown on figure 3-17.
Caution
Do not operate the alternator simultaneously
with a DC generator on a common battery
circuit.
b. On Equipment Test.
(1) Disconnect battery cables and tie back to
prevent accidental flash current.
(2) Tag accurately for position, then remove all
electrical leads from alternator.
(3) Use automotive generator and voltage
regulator test set and hook up as illustrated in figure 3-60.
(4) Operate the alternator at approximately
2,500 RPM.
Caution:
Do not allow voltage to exceed the
recommended voltage setting of the
regulator.
3-79. Generator Regulator (For Engine Model 687C18-ES)
a. On Equipment Test.
(1) Remove electrical leads from voltage
regulator (fig. 3-58).
(2) Test voltage regulator in conjunction with
generator (para. 3-77) by using connections illustrated in
view B, figure 3-61. Polarize generator by momentarily
touching jumper wire as shown in view A.
(3) Start generator and gradually increase
speed until cutout relay points close. Closing voltage
should be 26 volts.
(4) With generator operating at 4,000 RPM,
reading on voltmeter should be 28.2 volts, and ammeter
should read 40 amperes.
(5) If requirements of (3) and (4) above are not
met, regulator is defective, and must be replaced.
(5) Adjust the load rheostat to obtain 28 volts.
When the correct voltage is obtained, the ammeter should
read 61 amperes.
(6) If the correct output is not obtained, replace
the alternator.
(7) If the correct output is obtained and the
batteries are not charging correctly, check remainder of
the charging circuit (view B of fig.1-9).
(8) Remove test set harness, reconnect all
electrical leads, then remove tags.
(9) Install battery cables.
c. Removal and Installation.
(1) Remove battery cables 'and tie back to
prevent flash currents.
(2) Tag correctly for position, then remove all
electrical leads from alternator.
(3) Remove alternator in manner similar to that
described for generator (para 3-77).
Note.
Do not remove voltage regulator
except when replacement is required
b. Removal and Installation. Refer to figure 3-62
and remove items. 1 through 4 in numerical sequence to
remove voltage regulator. Items 5 through 8 removes
shock mount. Install in reverse order.
3-80. Alternator Voltage Regulator (For Engine Model
D333TA)
a. General. The alternator voltage regulator senses
charge condition of batteries as well as electrical system
power demand, and controls alternator output accordingly.
As battery charge increases, charging rate decreases,
until batteries
Figure 3-60. Alternator test connections .
d. Cleaning, Inspection and Repair.
(1) Clean exterior of alternator with a rag
dampened in an approved cleaning solvent then dry
3-71
Figure 3-61. Generator voltage regulator test connection.
are fully charged and ammeter will indicate a rate only
perceptibly above zero. Since this regulator is factory
adjusted for average operating conditions, it may require
adjustment for the particular ambient temperature in
which the engine is operating.
b. Test and Adjustment.
(1) Use voltmeter set on 0 to 60 vdc scale,
refer to view B of figure 1-9 and connect positive (red)
lead of voltmeter to alternator terminal "FI", connect
negative lead (black) to ground, then start engine.
3-72
Figure 3-62. Generator voltage regulator and shook mount, removal and installation
(2) Operate alternator at approximately 2,500 RPM
and read voltmeter. It should read between 27.5 and 28.5
volts.
(3) If reading is not within limits pre ,scribed in (2)
above, remove plug (fig. 3-63) from voltage regulator and
use screwdriver to adjust screw within regulator
counterclockwise to reduce voltage, clockwise to increase
voltage, until reading on voltmeter is correct.
(4) When regulator will not adjust to prescribed
reading, regulator is defective and must be replaced.
(5) Stop engine and remove voltmeter.
Note
Do not remove regulator except we
replacement is required.
c. Removal and Installation
(1) Disconnect battery cables and tie back to prevent
flash currents.
(2) Disconnect electrical connector (fig. 3-63) from
voltage regulator.
Figure 3-63. Alternator voltage regulator, adjustment
, removal and installation.
3-73
(3) Remove three nuts, washers, and capscrews,
then remove voltage regulator from mounting bracket.
(4) Install in reverse order.
1
2
3
4
5
6
7
8
9
10
Nut
Electrical lead
Nut
Electrical lead
Nut
Electrical lead
Nut
Electrical lead
Electrical lead
Electrical lead
3-81. Starter Motor
a Removal and Installation. Refer to figure 3-64,
remove items (2) and (13) through (18)
11
12
13
14
15
16
17
18
19
20
Bolt, washer and nut (2)
Relay solenoid
Nut
Nut
Electrical lead
Nut (3)
Lockwasher (8)
Starter motor
Screw and nut (2)
Inspection band
Figure 3-64. Starter motor relay solenoid and inspection band removal and installation.
3-74
in numerical sequence, and starter motor is removed.
Install in reverse order.
(4) Remove brush from guide by pulling
outward on brush lead.
(5) Install new brush by first lifting outward on
brush spring.
(6) Insert brush into guide, push it down into
contact with commutator, and let spring down on top of
brush.
(7) Seat brush so it has perfect surface contact
with commutator.
Note
Brushes can be seated perfectly by
drawing a piece of 00 grade sandpaper
between commutator and brush and
against brushholder. Sand only as
much as is necessary to obtain a
perfect brush fit. Blow the sand and
carbon dust out of starter motor with
low pressure compressed air.
(8) Pull brush outward 1/4 inch and then allow spring
to push it back down into guide. Repeat this step as often
as necessary to assure brush is free in guide and will not
bind.
(9) Connect brush cable terminal to brushholder with
screw and lockwasher.
(10) Install remaining brushes by repeating steps (3)
through (9) for each brush.
(11) Position inspection band on starter and secure
with two screws and nuts (fig. 3-64).
(12) Refer to figure 3-64 and install starter by
reversing numerical sequence (18) through (13), then (2).
b. Cleaning and Inspection.
(1) Clean all parts with a rag dampened in an
approved cleaning solution and dry thoroughly. Blow dust
from brush area with low pressure compressed air.
(2) Visually inspect mounting hardware for
wear or stripped threads. Replace defective hardware or
starter motor. Repair by replacing defective brush set (c
below).
c. Starter Motor Brush Replacement.
(1) Remove starter motor (a above).
(2) Refer to fig. 3-64 and remove items (19)
and (20).
Note
Remove and replace one brush at a
time, until set of eight is replaced.
(3) Refer to figure 3-65,
lockwasher from brushholder.
remove
screw
and
3-82. Relay Solenoid (Starter)
a. Removal and Installation.
(1) From engine model 687C-18-ES. Refer to figure
3-64, remove items (1) through (12) in numerical
sequence, to remove relay solenoid. Install in reverse
order.
(2) From engine model D333TA. Remove or install
in a manner similar to that' described in (1) above.
b. Cleaning, Inspection and Repair.
(1) Clean relay solenoid with a rag dampened in an
approved cleaning solvent and dry thoroughly.
(2) Visually inspect mounting hardware for excessive
wear or stripped threads, electrical leads for loose
terminals, bare wire, or frayed insulation, and test relay
for proper operation by placing source-of 24 vdc power
across terminals and listen for solenoid movement.
(3) Repair by replacing defective hardware, electrical
lead, or defective relay solenoid.
3-83. Receptacle (Slave) Electrical Connector
a. Removal and Installation.
Figure 3-65. Starter motor brush replacement.
3-75
(3) Repair by replacing defective hardware,
electrical leads, or receptacles.
384. Lubricating Oil Pressure Transmitter
a. Removal and Installation.
(1) Refer to figure 3-67 and remove lubricating
oil pressure transmitter from engine model 687C-18ES.
Install in reverse order.
(2) Remove lubricating oil pressure transmitter
from engine model D333TA in a manner similar to that
given in (1) above.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts with an approved cleaning
solvent-and dry thoroughly.
(2) Visually inspect electrical connector for
defective connections or frayed lead, inspect transmitter
for defective threads, cracked housing, or other defect.
(3) Repair by repairing electrical lead (para 389) or replacing defective lead or transmitter.
Figure 3-66. Receptacle (slave) electrical connector,
removal and installation
(1) Remove capscrew, lockwasher, and ground
cable (fig. 3-66).
(2) Remove nut (7, fig. 3-64) and electrical
lead (8) then remove clip and grommet (fig.3-66).
(3) Remove capscrews (4), lockwashers, nuts,
and receptacle (slave) electrical connector.
(4) Install by reversing steps (3) through (1)
above.
b. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect hardware for excessive
wear or stripped threads, electrical leads for loose
terminals, bare wire, or frayed insulation, and receptacle
for proper mating with plug electrical connector.
Figure 3-67. Lubricating oil pressure transmitter,
removal and installation
3-76
3-85. Water Temperature Transmitter
a. Removal and Installation.
(1) Refer to figure 3-68 disconnect electrical
connector, and remove water temperature transmitter
from engine model 687C-18ES. Install in reverse order.
(2) Remove transmitter from engine model
D333TA in a similar manner to that given in (1) above.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect electrical connector for
defective connections or frayed lead, inspect transmitter
for defective threads, cracked housing, or other defect.
(3) Repair by repairing electrical lead (para 389), replacing lead, or transmitter.
3-86. Water High Temperature Switch
a. Removal and Installation.
(1) Refer to figure 3-68, tag and disconnect
three electrical leads, then remove water high
temperature switch from engine model 687C-18-ES.
Install in reverse order.
(2) Remove water high temperature switch
Figure 3-68. Water temperature transmitter, and water high temperature switch, removal and installation.
3-77
from engine model D333TA in a manner similar to that
given in (1) above.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect electrical leads for loose
connections or frayed insulation, inspect switch for
cracked or dented housing.
(3) Repair by replacing defective lead or
Switch.
3-87. Low Oil Pressure Switch
a. Removal and Installation.
(1) Refer to figure 3-69, tag and disconnect
three electrical leads, then remove low oil pressure switch
from engine model 687C18ES. Install in reverse order.
(2) Remove low oil pressure switch from
engines model DB83TA in a manner similar to that given
in (1) above.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect electrical leads for loose
connections or frayed insulation, inspect switch for
cracked or dented housing.
(3) Repair by replacing defective lead or switch
3-38.
Overspeed Governor (On Engine Model 687C18-ES)
a. Removal and Installation.
(1) Disconnect and remove tachometer drive
cable (fig. 3-70), then tag and disconnect two electrical
leads,
(2) Remove four capescrew, lockwasher, and
flatwashers securing overspeed governor to engine front
cover, then remove governor.
(3) Install in reverie order.
b. Cling and Inspection
(1) Clean all metal parts with an approved
cleaning. solvent and dry thoroughly. Wipe microswitch
with a rag dampened in solvent.
(2) Visually inspect mounting hardware and
other threaded surfaces for burs or stripped threads.
Replace defective parts.
c. Test for Speed Adjustment.
(1) Start engine (par 2-10).
(2) Run at full throttle. If tachometer indicates
more than 1,985 ± 15 RPM without shutting down engine,
overspeed governor requires adjustment.
(3) If engine shuts down before tachometer
indicates 1,920 RPM, overspeed governor requires
adjustment
d. Adjustment.
(1) If engine shuts down before tachometer
indicates 1,920 RPM, increase between head of the
adjustment
screw (fig. 3-70) and microswitch arm by
turning adjusting screw counterclockwise then moving
adjusting nut toward throttle lever. Repeat adjustment, by
trial and error, until engine shuts down at 1,985 ± 15
RPM.
(2) If adjustment does not shutdown when
tachometer indicates more than 1,950 RPM, decrease
distance between head of dusting screw and microswitch
arm by backing off adjusting nut, turn adjusting screw
clockwise, then move adjusting nut toward throttle lever.
Repeat adjustment by trial and error until engine shuts
down at 1,985 ± 15 RPKL
(3) Throttle spring tendon is adjusted in a
similar manner by adjustment screw on back side of
overspeed governor. Tighten adjusting screw against
bracket to increase tension screw from bracket to decree
tension.
3-89. Wiring
a. general Crane electrical system consists of wiring
of varied types including harness single including harness,
single
Figure 3-69. Low oil pressure switch removal and
installation.
3-78
Figure 3-70. Overspeed governor, removal, installation, and speed adjustment
(engine model 687C-18-ES).
loose end closer to fixed end for ease in reaching
terminals by problems of multimeter or test lamp.
c. Inspection. Visually inspect insulation or looms
for cracks or fraying. Closely examine lead or harness at
all points where passage is over rough or sharp edges, or
through holes without grommet protection. Examine lead
terminals for security to lead or terminal post of junction
box and accessory. Carefully trace leads by referring to
applicable portion of wiring diagram (fig.1-9, view A and
B). Repair or replace defective leads or harness.
d. Replacement.
(1) Individual leads will be replaced by disconnecting at both terminal points, and installing a new
lead of .exactly the same size wire. Be sure that end
terminals are secure on lead and terminal post, and that
markers are removed from old
wires, and conduit protected circuits between junction
boxes.
Caution
Keep all wiring free of grease, oil, and
accumulations of dust and dirt.
Grease and oil will cause rapid
deterioration
of
insulation,
and
excessive dust accumulations will
speed grounding at cracked insulation
of electrical leads
b. Testing. Individual electrical leads may be tested
for continuity by use of a multimeter or low voltage test
lamp. Leads within a harness may be tested similarly by
tagging and disconnecting one end of a harness, moving
3-79
and disconnect and remove harness. Install new harness,
making sure that all leads are correctly positioned and
securely fastened to terminals.
Caution
Never remove, or install, leads to alternator while
battery cables are installed.
Disconnect and tie
battery cables back to pre vent flash current
Rectifying diodes in alternator, or transistors in
voltage regulator are easily damaged by flash current.
lead and installed on new lead in a similar manner.
(2) Individual leads within a harness may be
replaced by cutting a length of wire lead as long. as the
defective lead, taping it to outside of harness at frequent
intervals, installing end terminals and connecting to
proper terminals. Be sure that protruding ends of old lead
are cut off as close to harness as practical, and that
markers are removed from old lead and installed on both
ends of the substitute lead.
(3) When there are two or more defective
leads within a harness, the harness should be replaced.
Tag terminals, identifying lead color or marker number,
Section XIII. EXHAUST SYSTEM
Refer to figure 3-72, unscrew coupling and muffler to
remove. Install in reverse order.
3-90. General
a. Engine Model 687C-18-ES. This exhaust system
provides a positive method of expelling exhaust gases
from cylinders to atmosphere through twin mufflers and
pipes.
Each muffler handles the exhaust of three
cylinders.
b. Engine Model D333TA. This exhaust system
uses gases to power the turbocharger. The exhaust
manifold directs gases to turbocharger, and thence to
atmosphere through an unruffled exhaust pipe.
3-93 Exhaust Manifold (Engine Model 687C-18-ES)
a. Removal and Installation
(1) Remove exhaust pipe and cap (para 3-19).
(2) Remove muffler (para 3-92).
(3) Refer to figure 3-71, remove four nuts,
capscrews, flange and gaskets.
(4) Remove four nuts and clamp, four nuts and
washers, then remove two exhaust manifolds and
gaskets.
(5) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solution and dry thoroughly.
(2) Visually inspect manifold for cracks, breaks,
or other defect. Inspect gaskets for damage or defect.
Inspect mounting hardware for bur, stripped threads or
other defect.
(3) Repair by welding cracks or breaks, and
replacing defective mounting hardware. Replace an
excessively damaged manifold.
3-91. Exhaust Pipe and Cap
a. Engine Model 687C-18-ES. Refer to figure 3-71
and remove cap, and unscrew exhaust pipe from
coupling. Install in reverse order.
b. Engine Model D333TA. Refer to figure 3-72
perform steps 1 and 2 and remove cap, hood, and
exhaust pipe. Perform step 3 and remove elbow and
plugs. Install in reverse order.
3-92. Muffler (Engine Model 687C-18-ES only)
3-80
Figure 3-71. Exhaust pipe, muffler, and cap, removal and installation (engine model 687C-18-ES).
3-81
Figure 3-72. Exhaust pipe, hood, cap and elbow, removal and installation (engine model D333TA).
Section XIV. COOLING SYSTEM
3-94. General
The sealed-type liquid cooling system consists of:
radiator, fan, fan drive belt, thermostat, water temperature
transmitter (para 3-85), water high temperature switch
(para 3-86), water temperature indicator (para 3-147)
water high temperature warning indicator light (para 3148), by pass line, and hoses and fittings connecting
radiator to engine and water pump. Coolant is drawn
from bottom of radiator by the water pump, circulated
through engine, and returned to radiator through upper
connections, ,or through the bypass line for recirculation
through system. When engine is operating, air is drawn
through radiator core by the fan to cool and maintain
correct operating temperature of the engine. The six
blade fan is driven by a single belt.
3-95. Radiator, Shroud, and Fan Guard
a. Remove and Installation (Engine Model 687C-18ES).
Figure 3-73. Radiator removal points.
3-82
(fig. 3-73) by loosening hose clamps at radiator and
suction side of water pump.
(c) Remove radiator inlet (top) hose (fig. 3-74)
in a similar manner.
(d) Remove two capscrews, lockwashers, and
flatwashers, then remove pipe flange from thermostat
housing (fig. 3-68).
(e) Remove 12 screws (fig. 3-74) that secures
fan guard to shroud, then remove fan guard.
(f) Remove eight screws (fig. 3-73) during
shroud to radiator, then remove shroud.
(g) Install in reverse order.
(2) Radiator.
Note
Provide lifting device that will reach
through cab side door and couple
close to radiator.
(a) Remove fan guard and shroud ( (1) above).
(b) Refer to figure 3-73, remove two cap
screws and lockwashers, lift radiator off of pad and out of
side door.
(c) Remove pad and support from mounting
bracket.
(d) Install in reverse order.
b. Removal and Installation (Engine Model
D33STA).
(1) Fan guard and shroud.
(a) Refer to figure 3-75 and remove fan guard.
(b) Shroud is welded to this radiator and is not
ordinarily removable at organizational maintenance.
(2) Radiator.
Note
Provide lifting device that will reach
through cab side door and couple
close to radiator.
(a) Drain cooling system (para 3-19).
(b) Remove fan guard ( (1) above).
(c) Refer to figure 3-76 and remove radiator.
(d) Install in reverse order.
3-96. Fan
a. Fan and Support Bracket (Engine Model 687C-1
8-ES).
Figure 3-74. Fan guard and shroud (engine model 687C-18-ES), removal and installation
3-83
(a) Refer to figure 3-78 and remove fan.
(b) Install in reverse order.
(2) Cleaning, Inspection and Repair.
(a) Clean all parts in an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect fan blades for bends,
cracks, or other damage. Inspect mounting hardware for
burs or stripped threads.
(c) Repair by straightening bends,
welding cracks, or replacing defective hardware.
c. Fan Idler Pulley (Engine Model D333TA).
(1) Removal and installation. Refer to view A
of figure 3-79 and remove fan idler pulley. Install in
reverse order.
(2) Disassembly and reassembly. Refer to
view D of figure 3-79 and reassemble fan hub.
Reassemble in reverse order.
(3) Cleaning, inspection, and repair.
(a) Clean all parts in an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect all parts for damage
or defect. Inspect seal for deterioration, bearings for wear
or scoring, and mounting hardware for burs or stripped
threads.
(c) Repair by replacing damaged,
defective, or worn parts.
3-97. Fan Belt
a. Removal and Installation
(1) From engine model 687-18-ES. Refer to
figure 3-16, loosen adjustment screw, then remove belt
from pulleys. Install in reverse order.
(2) From engine model D333TA. Refer to view
A of figure 3-79, loosen adjustment screw, then remove
belts from pulleys. Install in reverse order.
Note
When twin belts are used, replace
belts in matched pairs when one is
defective
Figure 3-75. Fan guard (engine model D33TA)
removal and installation.
(1) Removal and installation
(a) Remove fan belt (para 3-97).
(b) Refer to figure 3-77 and remove fan and
support bracket
(c) Install in reverse order.
(2) Cleaning, inspection and repair.
(a) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(b) Visually inspect all parts for cracks, breaks,
damaged threads, or other defect.
(c) Repair by replacing defective parts or
mounting hardware.
b. Fan (Engine Model DE33TA).
(1) Removal and Installation
b. Cleaning and Installation.
(1) Clean belts with a rag dampened in an
approved cleaning solution and dry thoroughly.
(2) Visually inspect belt for fraying, tearing, or
other deterioration. Replace defective belt(s). See note
in a(2) above 398. Thermostat Housing, Thermostat, and
Coolant Lines
a. On Engine Model 687C-18-ES.
3-84
Figure 3-76. Radiator, removal and installation
gaskets and seals for tears,' deterioration, or other
damage or defects
(c) Repair
by
replacing
defective
or
excessively worn parts. Replace a defective seal or
gasket.
(4) Thermostat removal an installation.
(a) Remove thermostat housing (1) above).
(b) Disassemble thermostat housing ( (2)
above).
(c) Remove thermostat for test below.
(d) Install in reverse order.
(5) Testing the thermostat
(1) Thermostat housing removal and installation ,
(a) Drain coolant system below manifold level
(para 3-19).
(b) Refer to figure 3-68, remove pipe flange,
disconnect bypass line, then remove thermostat housing
and gasket from manifold.
(c) Install in reverse order.
(2) Thermostat housing disassembly and reassembly.
Refer to figure 3-40 and disassemble the thermostat
housing. Reassemble in reverse order.
(3) Cleaning, inspection, and repair.
(a) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(b) Visually inspect all metal parts for
excessive wear, burs, or scoring of surface. Inspect
3-85
Figure 3-77. Fan and support bracket (engine model 687C-18-ES), removal and installation
(c) Disconnect bypass line from water pump
connection in similar manner.
(d) Remove remaining coolant lines in a similar
manner.
(e) Install in reverse order.
b. On Engine Model D333TA.
The thermostat
housing, thermostat, and coolant lines are removed from
and installed on engine model D33STA in a manner
similar to that described above.
3-99. Water Manifold (Model 687C-18-ES)
a Removal and Installation.
(1) Remove the exhaust manifold from
crankcase (para 3-93).
(2) Remove high water temperature switch
(para 3-86).
(3) Remove the water temperature transmitter
(para 3-85).
(4) Remove thermostat housing (para 3-98).
(5) Remove 12 capscrews, washers, and
lockwashers, that secure water manifold to crankcase.
(6) Remove water manifold and six gaskets
from engine.
(7) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Scrape or brush all carbon, corrosion, or
rust off parts, clean with an approved cleaning solvent
and dry thoroughly.
(2) Visually inspect water manifold for cracks,
breaks, or warping.
Figure 3-78. Fan (engine model DJ33TA), removal or
installation
(a) Insert
thermostat
and
a
suitable
thermometer in a container 'of water.
(b) Heat water until thermostat is open, noting
temperature when thermostat 'begins to open, and when it
is fully open. Thermostat should begin to open at 165°F,
and be fully open at 180°F.
(c) When
thermostat
does
not
meet
requirements of (b) above, it is defective and must be
replaced.
(6) Coolant Lines removal and installation.
(a) Drain coolant system (para 3-19).
(b) Loosen two hose clamp (fig. 3-68) and
remove hose from bypass line.
3-86
Figure 3-79.Fan Idler pulley fan hub and fan belt removal disassembly reassembly installation and adjustment.
(3) Visually inspect 11 threaded surtax for burs or
defective W4W AS.
(4) Replace a defective manifold, all gaskets, and
defective mounting hardware.
3-87
Figure 3-80. Thermostat housing, disassembly and reassembly.
Section XV. ENGINE CLUTCH
3-100. General
The clutch, when engaged, transfers power from engine
to power takeoff output shaft, which actuates the
operating mechanism. A drive chain connects the engine
drive sprocket, working off the output shaft, to the main
drive sprocket.
The clutch is controlled, through
adjustable linkage, from the operators cab. An auxiliary
control lever is located on the power takeoff housing. The
engine clutch requires adjustment if it will not pull the
load, heats, or the operating lever jumps out of
engagement
3-101. Clutch Lever and Linkage
a. Removal and Installation. Refer to figure 3-81
and remove clutch lever and linkage. Install in reverse
order.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for excessive
wear, burs, stripped threads, ,or other damage or defect.
(3) Repair by replacing a damaged or defective
part, or defective mounting hardware
c. Adjustment.
(1) Refer to paragraph 3-9 for instructions on
engine clutch adjustment
(2) Adjust lever and linkage by removing pins
from clevises, and turning each clevis clock
Figure 3-81. Clutch lever and linkage,
removal and installation.
3-88
wise to shorten, counterclockwise to lengthen, until
operators control lever is properly positioned on quadrant
when clutch is in the engaged or disengaged position.
3-102. Auxiliary Clutch Lever
a. Removal and installation. Refer to figure 3-82,
remove capscrew and lockwasher from lever, then
remove lever from crossbar. Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean lever and mounting hardware in an
approved cleaning solvent and dry thoroughly.
(2) Visually inspect lever for bend, crack, or
excessive wear. Inspect hardware for burs, or stripped
threads.
(3) Repair by replacing worn or defective parts.
Figure 3-82. Auxiliary clutch lever and ventilation
breather, removal points.
\
3-103. General
Section XVI. POWER TRANSFER
3-105. Transfer Chain Case Cover
The main drive chain case is located at right rear side of
crane shovel unit inside the cab. The case completely
surrounds the input and main shaft sprockets, and the
transfer chain. The transfer chain is a multiple strand
roller chain which connects input and main shaft
sprockets.
a. Removal and Installation.
(1) Refer to figure 3-43 and remove transfer
chain case cover.
(2) Remove gasket from cover, or case.
(3) Install in reverse order.
3-104. Ventilation Breather (Filter)
b. Cleaning, Inspection, and Repair.
a. Removal and Installation
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect case for dents or cracks.
Inspect mounting hardware for burs or stripped threads.
Inspect gasket for deterioration.
(3) Repair by straightening dents or welding
cracks. Replace a defective cover damaged gasket, or
mounting hardware.
(1) Refer to figure 3-82, remove screw, and
cover, from ventilation breather (filter).
(2) Remove ventilation breather (filter) from
nipple by turning counterclockwise. Remove a damaged
nipple.
(3) Install in reverse order.
b. Cleaning, Inspection and Repair.
3-106. Transfer Chain
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
Use low pressure
compressed air to dry breather (filter).
(2) Visually inspect screw for burs or stripped
threads. Inspect breather for excess clogging of filter
portion.
(3) Repair by replacing a defective breather or
screw.
a. Removal and Installation.
(1) Remove transfer chain case cover (para 3105).
(2) Remove two cotterpins (fig. 3-84) and
master link from chain, then remove transfer chain from
input and main shaft sprockets.
3-89
NOTE
REMOVE DRAIN PLUG AND DRAIN OIL BEFORE REMOVING CHAIN CASE COVER. AT
INSTALLATION, REFER TO CURRENT LUBRICATION ORDER AND REFILL THROUGH FILL PIPE
UNTIL OIL RUNS OUT OF LEVEL PLUG HOLE.
Figure 3-83. Transfer chain case cover, removal and installation.
(3) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean chain in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect chain for damaged links,
pins, or cotterpins.
(3) Repair by replacing damaged links, pins, or
removed cotterpins.
3-107. Input Shaft Chain Sprocket a. Removal and
Installation.
(1) Remove transfer chain case cover (para 3105).
(2) Remove transfer chain (para 3-106).
(3) Remove lockwire from two screws in input
shaft (fig. 3-84).
(4) Remove two screws and plate, then remove
input shaft sprocket from input shaft.
(5) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect mounting hardware for burs
or stripped threads. Inspect sprocket for cracked or
broken teeth.
(3) Repair by replacing a damaged sprocket, or
defective hardware.
3-90
Figure 3-84. Transfer chain, removal and installation
3-108. Main Shaft Sprocket
(3) Remove cotterpin, nut, and flatwashers
from mainshaft, then remove mainshaft sprocket.
a. Removal and Installation.
(4) Install in reverse order.
(1) Remove transfer chain case cover (para 3105).
b. Cleaning, Inspection and Repair. Clean, inspect,
and repair in manner similar to that described in
(2) Remove transfer 'chain (para 3-106).
paragraph 3-107, above.
Section XVII. HYDRAULIC SYSTEM
When pressure is released from pedal or lever, springs
cause pistons in hydraulic cylinders to return to normal
position.
3-109. General
a. Description. Each hydraulic control lever or foot
pedal is connected to a master cylinder (compensator).
Each master cylinder is connected by a hydraulic line to
an hydraulic cylinder. The hydraulic cylinder is connected
to brake, clutch, or other mechanism by mechanical
linkage. When the lever or foot pedal is moved, there is a
corresponding movement of the piston in master cylinder,
which transmits fluid to hydraulic cylinders, thus actuating
brake or clutch.
b. Bleeding the Hydraulic System. When air is present in the hydraulic system, controls become
"spongy" and do not hold brake or clutch firmly as they
should. To remove air from system proceed as follows:
(1) Fill hydraulic tank with clean hydraulic fluid (para 3-18
and LO 5-3810-206-12). Check level in tank frequently
during bleeding operation, to prevent air from entering
supply line.
3-91
(2) Be sure shutoff cock (drain cock) in supply line at
bottom of tank is open to assure gravity flow of fluid to
cylinders, then bleed compensator (cylinders) in lever
stand by opening bleeder cap in each compensator,
starting with the lower compenstor, and working upward
through the top row.
(3) After bleeding lever stand compenstor begin
bleeding clutch and brake cylinders, starting with the
lowest one than working upward toward cylinders
mounted at highest point Attach one end of bleeder hose
to bleeder hose then let opposite hose end rest in jar
partially filled with hydraulic fluid. Always keep this end
of hose under fluid to prevent air from entering bleeder
hose and reentering the hydraulic system Open bleeder
screw, apply pressure to appropriate lever or pedal and
watch hose end in jar. When bubbles no longer form in
fluid, close bleeder screw and remove bleeder hose from
screw. Repeat above procedure for each cylinder in
system
(4) Move each control lever or pedal slowly and note
clutch or brake action. If any of the controls still feel
spongy, repeat bleeding operation.
(5) Fill both hydraulic tanks (para 3-18 -and LO 53810-206-12) with clean fluid. Check level frequently
while bleeding cylinders, then bleed air from the propel
brake cylinders in car body. Reach through holes in turret
just above the tread. The bleed screw for these cylinders
is toward inside of car body. Reach around the cylinder,
install bleeder hose, then open screw. Tighten bleeder
screw as soon as bubbles no longer appear in bleeder jar.
Repeat procedure on remaining propel clutch hydraulic
cylinder.
Figure 3-85. Hydraulic tank removal and installation.
(3) Repair by welding cracks, straightening
dents, or replacing defective hardware or hydraulic tank.
3-111. Hydraulic Hose, Lines Tubes and Fittings.
a. Removal and Installation. Refer to figure 3-86
and remove appropriate hydraulic hose line tube or fitting.
Install in reverse order.
b. Cleaning, Inspect and Raw.
3-110. Hydraulic Tank (Reservoir)
a. Removal and Installation.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all for leaking connection,
dents, or cracks. Inspect hardware and fittings for signs
of excessive wear or damaged condition.
(3) Repair by -replacing defective components.
(1) Close shutoff cocks in two supply lines
beneath tank, tag and disconnect supply lines, then plug
lines to prevent contamination of hydraulic system.
(2) Open tank by removing breather or filler
plugs, position suitable container to receive fluid, then
open shutoff cocks and drain hydraulic fluid from tank.
(3) Refer to figure 3-85 and remove hydraulic
tank.
3-112. Compensators (Cylinders)
a. Removal and Installation. Refer to sheet 1 of
figure 3-87, and remove applicable compensator. Install
in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for dents, cracks,
or excessive wear.
b. Clean , Inspection and Repair
(1) Clean all parts with an approved cleaning
solvent and dry thorough.
3-92
NOTE:
1
2
3
4
o
6
7
8
9
10
11
WHEN A LINE IS REMOVED, MARK ITS FITTINGS AND POSITION ON THE REVOLVING
FRAME. PLUG OR COVER ENDS OR PORTS TO PREVENT CONTAMINATION OF
HYDRAULIC SYSTEM.
Hydraulic tank
Fill plug
Fluid level plug
Lockwasher (2)
Capscrew (2)
Conduit
Tubing
Tubing nut
Bracket
Tubing
Home
12
13
14
15
16
17
18
19
20
21
22
Tubing
Conduit
Tubing
Tubing
Tubing
Tubing
Tubing
Tubing
Conduit
Tubing
Hose (10)
23
24
25
26
27
28
29
30
31
32
33
Screw (2)
Adapter (22)
Lockwasher (2)
Nut (2)
Bracket
Spring clip (22)
Flatwasher (2)
Nut
Clamp
Capscrew
Conduit
84 Tubing
35 Tubing
36 Nut connector (80)
87 Adapter (2)
88 Shutoff cock
39 Conduit
40 Conduit
41 Tubing
42 Clamp
43 Tubing
44 Conduit
Figure 3-86. Hydraulic hose, lines, tubes, and fittings, removal and installation.
lever stand and its components, therefore, these
instructions will cover individual component removal.
b. Lever and Linkage Removal and Installation
(1) Remove upper and lower cover plates
from lever stand.
(2) Remove boom hoist hydraulic control
handle (fig. 2-23) from boom hoist lever, and applicable
(raise and lower) compensator
(2) Visually inspect compensator for external
damage or excessive wear, burs, or stripped threads on
mounting hardware, or deterioration of boot on push rod.
(3) Repair by replacing damaged hardware,
defective boot or compensator.
3-113. Levers and Linkage (Lever Stand)
a. General. Normal servicing of this equipment
win not require complete removal or disassembly of the
3-93
NOTE:
TAG, DISCONNECT, AND PLUG ALL HYDRAULIC LINES REMOVED, THEN PLUG OR
COVER PORTS OF COMPENSATORS TO PREVENT CONTAMINATION OF HYDRAULIC
SYSTEM.
Figure 3-87. Lever stand, showing compensator, lever, pedal and linkage removal and adjustment points (sheet
1 of 2).
(cylinder) from lever stand (para 3-112).
(3) Refer to sheet 2 of figure 3-87 and
remove boom hoist lever and linkage from lever stand.
(4) Install in reverse order.
c. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for breaks,
cracks, deformation, or excessive wear.
Inspect
mounting hardware for burs, or stripped threads.
(3) Repair by replacing defective parts or
mounting hardware.
d. Adjustment.
(1) Make adjustment to mechanical linkage
by lengthening or shortening adjusting setscrews in lever
bar (sheet 2 of fig. 3-87) or clevis at rod end.
(2) Adjust the adjusting screws at both
compensator push rods until lever remains in neutral
when push rods are snug against piston.
(3) Minor adjustment of foot pedals are made
by connecting links to pedals in either the front or rear
holes in lower portion of pedal. Pus rod adjustment at
pedal compensator are made in a manner similar to that
described in (2) above.
3-114. Swing and Propel Shiner Lever and Linkage
a. Removal and Installation
(1) Refer to figure 3-88 and remove swing
and propel shifter lever and linkage.
(2) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for excessive
wear, bends, breaks, or other defect. Inspect mounting
hardware for burs or stripped threads.
(3) Repair by replacing damaged parts or
defective hardware.
c. Adjustment. Adjust the linkage for positive
3-94
Figure 3-87. Lever stand showing compensator, lever, pedal, and linkage removal and adjustment points (sheet 2 of 2).
3-95
Figure 3-88. Swing and propel shifter lever and linkage, removal and installation.
engagement at of the swing or propel jaw clutches by
adjusting the overall length of pipe and two rod ends as
follows:
(1) Remove cotterpin and pin that connects
rod end clevis to lever.
(2) Loosen locknut at rod end, then turn pipe
clockwise to shorten, counterclockwise to lengthen.
(3) When length is satisfactory, tighten
locknut up to rod end and connect rod end to lever by
installing pin and securing
3-115. Swing Broke Hydraulic Control and Linkage
Adjustment
a. Swing Brake Hydraulic Control, Removal and
Installation.
3-96
Figure 3-89. Swing and propel shifter lever and linkages removal and installation.
3-97
(1) Remove side panel from instrument
control stand.
(2) Position a suitable container under control
stand to receive hydraulic fluid, then refer to figure 3-89
and remove items in numerical sequence to remove
wing brake hydraulic control.
(3) Install in reverse order.
(3) Repair by replacing defective components
for mounting hardware.
c. Swing Brake Linkage Adjustment.
(1) Refer to figure 3-90, adjust locknuts on
either side of point A so that lever touches edge of slot
in the side stand.
(2) Lay a straight edge from point A to point
B. Point C should be 5/8 inch nearer brake drum. This
will keep linkage from "toggling in". When toggling in
does occur, the brake will not release when pressure on
hydraulic cylinder is released.
(3) Adjust two locknuts so that alignment of
points A,B, and C are maintained as described in (1)
and (2) above.
(4) Adjust two locknuts on eyebolt at brake
release spring until there is just enough tension on
spring to release brake when hydraulic pressure is
released.
Note
Remove
.remaining
hydraulic
controls in a similar manner.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for excessive
wear, burs, stripped threads, or other damage. Inspect
push-pull controls for freedom of movement.
3-116. Hydraulic Clutch and Brake Cylinders and
Linkage
a. Removal and Installation.
(1) Position container to receive fluid, then
disconnect hydraulic line at clutch cylinders (fig. 3-91),
or brake cylinder (fig. 3-92), and plug or cover end of
line and port of cylinder to prevent contamination of
hydraulic system.
(2) Refer to figure 3-91 and remove clutch
cylinder or figure 892 to remove brake cylinder.
(3) Remove remaining cylinders in a similar
manner.
(4) Install in reverse order.
b. Clean, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect linkage and mounting
hardware for distortion, wear, burs, or stripped threads.
Inspect hydraulic cylinder for signs of leakage or
deterioration of end cups.
(3) Repair by replacing defective linkage
parts, mounting hardware, and a leaking or defective
hydraulic cylinder.
NOTE: HARD OPERATION WILL RESULT IF
THERE IS TOO MUCH TENSION ON BRAKE
RELEASE SPRING.
ME 3810-201-12/3-103
Figure 3-90. Swing brake linkage adjustment.
3-98
Figure 3-91. Hydraulic clutch cylinder, removal and installation.
3-99
Figure 3-92. Boom hoist hydraulic brake cylinder, removal and installation.
Section XVIII. ROTATING BASE (REVOLVING FRAME)
3-117. General
The rotating base (revolving frame) of the crane-shovel
unit is the mounting base for all operating components
including front end attachments, engine, hoisting
mechanism, and cab. The revolving frame derives
swing power through a vertical swing shaft and revolves
on rollers traveling in the roller circle. Front and rear
hook rollers are provided to reduce strain on center
gudgeon, while 8,250 pounds of counterweight slugs in
box plus the counterweight extension, provides stability
during swinging operation. Keep the hook rollers in
proper adjustment at all times (para 3-35).
counterweight extension installed.
The unit could tip over backward,
causing damage to the unit, and
possible injury to the operator.
3-118. Front Hook Rollers
a. Removal and Installation.
(1) Lower boom to approximate horizontal
position.
(2) Remove two capscrews, lockwashers, and
keeper plate from bracket (fig. 3-93).
(3) Drive hook roller shaft backward slightly
to make lockring accessible, remove lockring, then pull
hook roller shaft forward out of mounting bracket and
remove hook roller.
Warning: Never travel crane-shovel
basic unit (less front end attachment)
over
rough
terrain
with
3-100
Figure 3-93. Front hook rollers, removal and installation.
and keeper plate, use wedges on cribbing, or the jack to
take arm weight off eccentric pin, then remove eccentric
pin.
(3) Remove four capscrews, lockwashers,
and two keeper plates, push roller pins inward slightly to
make retainer accessible, remove retainer, then pull
roller pips outward and remove rollers and pins.
Remove lubrication fittings and bushings from the two
roller pin.
(4) Remove remaining rear hook roller in a
similar manner.
(5) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean all part in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect pins for grooves, cracks,
chips or other damage. Inspect mounting hardware for
burs or stripped to.
(3) Repair by replacing damaged, defective,
or worn parts.
c. Adjustment. Adjust rear hook rollers an directed
in paragraph 3-35.
(4) Remove remaining hook roller in a similar
manner.
(5) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect mounting hardware for
burs or stripped threads, inspect eccentric shaft (pins) or
rollers for signs of excessive wear, grooves, chips, or
cracks.
(3) Repair by replacing damaged, defective
or worn parts.
c. Adjustment. Adjust hook rollers as directed in
paragraph 3-35.
3-119. Rear Hook Rollers
a. Removal and Installation.
(1) Lower boom until point is slightly below
the horizontal with weight of boom resting on cribbing
similar to that shown in figure 2-6.
(2) Support the swivel arm (fig. 3-94) with
cribbing or a jack, remove two capscrews, lockwashers,
3-101
Figure 3-94. Rear hook rollers, removal and installation.
3-120. Roller Circle Rollers
a. Removal and Installation.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect mounting hardware for
burs, stripped threads or excessive As car. Inspect
roller for chipping, cracks, breaks, or flat spots (wear).
(3) Repair by replacing defective hardware or
roller.
Note. To remove a damaged roller,
always move revolving frame left or
right until damaged roller is on high
side of frame, opposite the opening
in frame. This will take most of the
frame weight off damaged roller and
make it easier to withdraw the fluid
pressure bolt from roller segment
shaft.
3-121. Jackshaft Clutch Shoes
a. Removal and Installation.
(1) Relieve tension on three shoe return
springs (fig. 3-95), by loosening nuts on studs, then
remove springs from stud and clutch shoe.
(2) Loosen locknut and adjusting bolt until the
adjusting assembly can be removed from between the
clutch shoes.
(3) Loosen three locknuts on three setscrews
and back setscrews out of brackets enough to free
shoes.
(4) Remove capscrew, lockwasher, and
sleeve from eccentric, then lift both clutch shoes out of
drum.
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts except clutch shoe
in an approved cleaning solvent and dry thoroughly.
Blow dust off clutch shoe lining and
(1) Remove nut and lockwasher from fluid
pressure bolt (fig. 3-94), then withdraw bolt from
segment roller shaft, and remove roller from roller circle
frame.
(2) Remove lubrication fitting and bushing
from fluid pressure bolt.
(3) Remove shaft from segment roller.
(4) Install in reverse order.
(5) Remove or install remaining rollers in a
similar manner.
b. Cleaning, Inspection, and Repair.
3-102
Figure 3-95. Jackshaft clutch shoes, removal and installation.
shoe with low pressure compressed air, or wipe with dry
clean cloth.
(2) Visually inspect clutch shoe lining for
wear, mounting hardware for burs or stripped threads,
and test the strength of springs.
(3) Repair by replacing weak or damaged
springs or defective mounting hardware. Replace,
clutch shoe when lining is worn to within 50 percent of
original thickness.
c. Adjustment. Refer to paragraph 3-25 and adjust
swing (jackshaft) clutch shoes.
3-122. Main Hoist Shaft Clutch Shoes
a. Removal and Installation.
(1) Remove auxiliary clutch hydraulic brake
cylinder (para 3-116).
(2) Refer to figure 3-96 and remove main
hoist shaft clutch shoes.
(3) Remove remaining clutch shoes in a
similar manner.
(4) Install in reverse order.
b. Cleaning, Inspection, and Repair. Clean,
inspect and repair clutch shoes in manner described in
3-121b above.
Note. Clutch shoes may be itched,
placing the "dead" shoe in "live"
position, since dead shoe receives
very little wear.
3-103
Figure 3-96. Main hoist clutch shoes, removal and installation.
c. Adjustment.
Refer to paragraph 3-28 for
adjustment procedures.
(2) Refer to figure 3-97 and remove band
from support bracket.
(3) Remove the remaining bands in a similar
manner.
(4) Install in reverse order.
c. Cleaning, Inspection, and Repair.
(1) Clean all metal parts in an approved
cleaning solvent and dry thoroughly. Clean clutch or
brake band by wiping with a clean rag, or use of
compressed air.
(2) Visually inspect clutch or brake band for
cracks, breaks, worn, or damaged condition Inspect
springs for deformation, strength, or other defect.
Inspect mounting hardware for burs, wear, stripped
thread, or elongated holes.
3-123. Planetary Clutch Band and Broke Bands
(Main Shaft)
a. General. For shovel operation, the planetary
clutch band must be positioned with dead end above the
hydraulic cylinder. This is accomplished by use of a
longer link and bracket (fig. 3-97), which is removed and
installed in a manner similar to that described in b,
below.
b. Removal and Installation.
(1) Remove hydraulic clutch cylinder (par;.3116).
3-104
Figure 3-97. Planetary clutch band and brake band, removal and installation.
(3) Repair by replacing defective mounting
hardware, defective springs, and clutch or brake bands
when lining is worn to within 1/16 inch of rivet heads.
3-124. Drum Legging and Sleeve
Washer)
a. Removal and Installation.
Nut
(1) Remove cable from drum (para 3-39).
(2) Remove the four capscrews (fig. 3-98)
and washers from lagging.
(3) Refer to figure 3-99 and remove sleeve
nut (shear washer) by use of special tool (table 3-1).
(4) Secure lifting device to lagging halves,
(Shear
3-105
Figure 3-98. Drum Lagging, removal and installation.
sprocket, which must be removed when converting to
any other front end attachment.
b. Removal and Installation.
(1) Remove revolving frame crowd and
retract chain (para 4-3).
(2) Refer to view A of figure 3-101 and
remove shovel sprocket.
(3) Refer to view B of figure 3-101 and
remove planetary pinion gear.
remove the two nuts, washers and bolts that hold halves
together, then lift lagging off drum.
(5) Remove remaining lagging in a similar
manner.
(6) Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect mounting hardware for
worn, burred, or stripped thread condition. Inspection
lagging for wear, cracks, or other damage.
(3) Repair by replacing defective mounting
hardware, and replacement of damaged or defective
lagging.
Note. Lubrication arrangement (view
A, fig. 3-101) for sprocket installation
must be modified to that shown in
figure 3-100 when other front end
attachments are installed.
Note. When lagging is removed for
conversion to another front end
attachment, the removed lagging
must be prepared for storage.
c. Lubrication.
fitting arrangement.
(4) Install in reverse order.
c. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect mounting hardware for
burrs, stripped threads or other damage.
Inspect
sprocket or pinion for cracks, breaks, excessive wear, or
other damage.
(3) Repair by replacing damaged or defective
Refer to figure 3-100, lubrication
3-125. Shovel Sprocket and Planetary Pinion Gear
a. General. The shovel front end attachment
requires installation of planetary pinion gear and shovel
3-106
3-126. Gear and Dirt Guards or Shields
a. Swing Brake Dirt Guard Removal and
Installation. Refer to figure 3-102 and remove swing
brake dirt guard. Install in reverse order.
b. Dragline Dirt Guards, Removal and Installation.
Refer to figure 3-103 and remove dragline dirt guard.
Install in reverse order.
c. Hoist Gear Guard, Removal and Installation.
Refer to figure 3-104 and remove hoist gear guard.
Install in reverse order.
d. Vertical Propel Shaft Guard, Removal and
Installation. Refer to figure 3-105 and remove vertical
propel shaft guard. Install in reverse order.
e. Planetary Gear Guard, Removal and Installation.
Refer to figure 3-105 and remove planetary gear guard.
Install in reverse order.
f. Horizontal Gear Train Cover, Removal and
Installation. Refer to figure 3-105 and remove horizontal
gear train cover. Install in reverse order.
g. Intermediate Hoist and Jackshaft Cover,
Removal and Installation. Refer to figure 3-106 and
remove intermediate hoist and jackshaft cover. Install
in reverse order.
h. Cleaning, Inspection, and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect guards and covers for
cracks, breaks, or dents. Inspect mounting hardware for
burs, stripped threads or other damage.
(3) Repair by welding cracks or breaks,
straightening dents, or replacing defective hardware,
guards, or covers.
Figure 3-99. Sleeve nut, removal and installation.
3-127. Vertical Intermediate Shaft Adjustment
a. Remove cotterpin (fig. 3-107) and lockpin from
bearing retainer.
b. Turn bearing retainer clockwise until all
backlash is removed between the bevel pinions and the
bevel gear.
c. Back off bearing retainer three holes, then
secure retainer with lockpin and cotterpin.
3-128. Swing Brake Band
a. Removal and Installation. Refer to figure 3-108
and remove swing brake band. Install in reverse order.
b. Cleaning, Inspection, and Repair.
(1) Clean all metal parts in an approved
cleaning solvent and dry thoroughly. Wipe brake lining
with a clean cloth, or blow clean with compressed air.
Figure 3-100. Lubricating fitting arrangement for
lagging.
mounting, hardware, sprocket, or planetary pinion gear.
3-107
Figure 3-101. Shovel sprocket and planetary pinion gear, removal and installation.
(2) Visually inspect all parts for damage,
defect, or excessive wear.
(3) Repair by replacing damaged, or
defective parts. Replace brake band when lining is worn
to within 1/16 inch of rivet heads.
c. Adjustment. Adjust swing brake linkage as
shown on figure 3-90. Adjust swing brake (para 3-29).
(2) Remove two cotterpins and pins from
hydraulic cylinder linkage then remove cylinder (para 3116).
(3) Remove two cotterpins and pins securing
brake band to link (fig. 3-109) then remove brake band.
(4) Remove remaining cylinder and band in a
similar manner.
(5) Install in reverse order.
b. Boom Hoist Holding Pawl, Removal and Installation.
(1) Refer to figure 3-110 and remove boom
hoist holding pawl.
(2) Install in reverse order.
c. Cleaning, Inspection, and Repair.
(1) Clean all metal parts in an approved
3-129. Boom Hoist Planetary Broke, Hoist Brake,
and Boom Hoist Holding Pawl
a. Planetary or Hoist Brake Band Removal and
Installation.
(1) Loosen two tubing nuts (fig. 3-109) and
remove hydraulic line.
3-108
b. Steering Linkage and Propel Brake Adjustment.
Refer to paragraph 3-29 and adjust steering linkage and
propel brakes.
3-132. Steering Wheel Adjustment
Refer to figure 3-112 and adjust the steering wheel.
Figure 3-102. Swing brake dirt guard, removal and
installation.
cleaning solvent and dry thoroughly. Clean brake end
lining with a cloth, or blow dry with compressed air.
(2) Visually inspect all parts for damage or
defects, and brake lining for excessive wear.
(3) Repair by replacing brake band when
lining is worn to within 1/16 inch of rivet heads, and
replacing all damaged or defective mounting hardware
or parts as required.
3-130. Propel Broke Band and Linkage
a. Removal and Installation. Refer to figure 3-111
and remove propel brake band and linkage. Install in
reverse order.
b. Cleaning, Inspection, and Repair. Clean, adjust,
and repair in manner similar to that described in
paragraph 3-123.
c. Adjustment.
Refer to paragraph 3-29 for
adjustment instructions.
Figure 3-10. Dragline dirt guard removal and
installation.
3-131. Propel and Steering Mechanism Adjustment
a. Steering Wheel Adjustment. Refer to paragraph
3-132 and adjust the steering wheel.
3-109
Figure 3-104. Hoist gear guard, removal and installation.
3-110
Figure 3-105. Vertical propel shaft guard, planetary gear guard, and horizontal gear train cover, removal and
installation.
Figure 3-106. Intermediate hoist and jackshaft
cover, removal and installation.
Figure 3-107. Vertical Intermediate shaft
adjustment.
3-111
Figure 3-108. Swing brake band, removal and installation
Figure 3-109. Boom Planetary or hoist brake band, removal and installation.
3-112
Figure 3-110. Boom hoist holding pawl, removal and installation.
3-113
Figure 3-111. Propel brake band and linkage, removal and installation.
3-114
Figure 3-112. Steering wheel adjustment.
3-115
Section XIX. TRACKS
3-133. General
This section describes maintenance procedures for the
portion of the crawler assembly authorized at
organization by the maintenance allocation chart. The
track consists of track shoes pinned together around
drive sprockets, upper support and bottom idler rollers,
to form a continuous tread for traveling of the craneshovel basic unit. Two drive chains run from sprockets
on propel shaft to sprockets on track drive shaft to
operate individual tracks.
(3) Travel crane-shovel unit slowly away from
removed master pin until the track is flat on the ground.
(4) Position suitable jack under crawler frame
on the side where track is being removed and raise
crawler frame until track is free of lower track roller and
sprocket.
(5) Pull the track assembly from under the
crane-shovel unit.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect side bars, shoulder bolts,
bushings, nuts, links, link pins, master link pins, and
shoes for cracks, breaks, excessive wear, or other
damage.
(3) Repair side bars by welding cracks or
breaks and replace other components that are damaged
or defective.
3-134. Track (Tread), Links, and Pins
a. Removal.
(1) Travel crane-shovel unit to firm ground
that is as level as possible, and stop with one of the
master pins (fig. 3-113) at one end of crawler frame.
(2) Drive out master pin, then remove spacer
and master bushing from link.
Figure 3-113. Track, removal and installation.
3-116
c. Installation.
(1) Pull the assembled track under lower track
rollers and drive sprocket.
Leave enough track
protruding beyond drive sprocket in such a way that end
of track can be lifted up around sprocket.
Note.
Be sure roller flanges are directly above track.
(2) Remove adjusting nut at end of rod bolt
and back off the one on other side of adjusting block
until rod bolt will come out of bracket at end of springs.
(3) Remove rod bolt from bracket, pull rod
bolt out of adjusting block, then remove and separate
the two springs.
Note.
At installation, position adjusting nut
and spring control nut on rod bolt at
their approximate positions when
rod bolt was removed above.
(2) Lower jack and crawler frame until lower
track rollers rest properly on track.
(3) Pull ends of track up and around sprocket,
and over upper track roller until ends meet, install
bushing in link, install spacers, then install master pin.
(4) Remove jack from crawler frame.
d. Adjustment. Refer to paragraph 3-37 and adjust
track.
3-135. Upper Track Support Rollers
a. Removal and Installation.
(1)
Provide slack for removal of upper
support rollers by loosening the adjusting nuts
(fig. 13) on rod bolt.
(2) Remove two nuts, lockwashers, and bolts
from roller pin.
(3) Raise track assembly with a long pry bar,
insert blocking between track and crawler frame to
provide clearance for removal of roller.
(4) Drive out pin and remove roller.
(5) Remove remaining rollers in a similar
manner.
(6) Install in reverse order.
(7) Adjust track (para 3-37).
b. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect rollers and pins for wear
or breakage. Inspect mounting hardware for burs,
stripped threads, or other damage.
Inspect roller
mounting brackets for cracks, or breaks.
(3) Repair by replacing defective mounting
hardware, worn roller pins, or welding cracks or breaks
in mounting brackets.
Replace damaged rollers.
Damaged or defective rollers will be forward(-d to direct
support maintenance for repair.
3-136. Track Idler Adjusting Springs
a. Removal and Installation.
(1) Remove cotterpin and nut (fig. 3-113)
from end of rod bolt. Remove cotterpin from nut at end
of spring, and move nut toward adjusting block until
tension on springs is relieved.
(4) Install in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect mounting hardware for
burs, or stripped threads. Inspect springs for loss of
tension (no space between coils) or breaks.
(3) Repair by replacing damaged mounting
hardware, or a weak or broken spring.
3-137. Drive Chain
a. Removal and Installation.
(1) Remove lockpin (fig. 3-114) from pin in
drive chain, and drive pin from chain link.
(2) If necessary to give slack, remove two
capscrews and lockwashers from lockplate on
adjustment block, remove lockplate, then turn adjusting
bolt until chain has enough slack to allow pins easy
removal.
(3) Loosen adjusting nuts on two eyebolts one
on inside the other on outside of frame.
(4) Remove drive chain.
(5) Remove remaining drive chain in similar
manner.
(6) Install in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect each link of chain for bent
link, worn link rollers, bent pin, or excessive]y worn
chain.
(3) Repair by replacing worn or bent links,
pins, or rollers. Replace the complete chain when wear
appears to be equal, but excessive throughout its entire
length.
c. Adjustment.
After installation, refer to
paragraph 3-36 for adjustment instructions.
3-117
Figure 5-114. Drive (propel) chain, removal and installation
3-138. Mud Guard
b. Cleaning, Inspection and Repair.
a. Removal and Installation.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(1) Remove track (para 3-134).
(2) Visually inspect mud guard for bends,
(2) Remove 20 nuts (fig. 3-113) then remove
cracks, or other damage.
mud guard.
(3) Repair by straightening bends, welding
(3) Remove remaining mud guard in similar
cracks, and replacement of defective mounting
manner.
hardware. Replace a mud guard damaged beyond
(4) Install in reverse order.
repair.
Section XX. INSTRUMENTS AND CONTROLS
3-139. General
This section describes organizational maintenance for
the instruments and controls, which consists of
ammeter, tachometer-hourmeter, oil pressure indicator,
water temperature indicator, starter push switch, horn
push switch, run-shut- down switch, governor control,
manual shutdown control, and (warning) indicator lights.
3-140. Tachometer-Time Totalizing Meter
a. Removal and Installation.
(1) Refer to figure 3-115. and loosen cable
housing nut.
(2) Remove two nuts and lockwashers
securing tachometer to control panel, then lift
tachometer indicator from control panel.
3-118'
Figure 3-115. Tachometer-time totalizing meter, oil pressure indicator, fuel lever
indicator, and ammeter, removal and installation.
3-119
(3)
b. Cleaning and Inspection.
(1) Clean oil pressure indicator with a soft
cloth dampened in an approved cleaning solvent, and
dry thoroughly.
(2) Visually inspect indicator for broken glass
or other damage. Inspect transmitter leads for good
terminal connections at indicator. If transmitter checks
out (para 3-84) but indicator does not operate, return to
direct support for calibration.
(3) Replace a defective oil pressure indicator,
or damaged mounting hardware.
Install in reverse order.
b. Cleaning, and Inspection.
(1) Clean tachometer with a soft cloth
dampened in an approved cleaning solvent, then dry
thoroughly.
(2) Visually inspect tachometer for broken
glass and free movement of drive shaft. Replace a
defective tachometer.
3-141. Overspeed Governor Microswitch
Engine Model 687C-1 DES)
(For
3-144. Indicator (Warning) Light, Low Oil Pressure
a. Removal and Installation.
(1) Refer to figure 3-70, tag and disconnect
two electrical leads, remove two screws securing switch
to overspeed governor, then remove microswitch.
(2) Install in reverse order.
a. Removal and Installation.
(1) Refer to figure 3-116 and remove the low
oil pressure indicator (warning) light.
(2) Install in reverse order.
b. Cleaning, Inspection and Test.
(1) Clean microswitch with a soft cloth
dampened in an approved cleaning solvent and dry
thoroughly.
(2) Visually inspect for corroded terminals
and damaged or weak arm contact.
(3) Use a multimeter and test between
normally open and normally closed contacts for
continuity. If continuity is shown, switch is defective.
Replace a damaged or defective microswitch.
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts with an approved
cleaning solvent and dry thoroughly.
(2) Visually inspect light for damage or
defect. Check that lamp is not burned out. Inspect red
lens for cracks or breaks.
(3) Repair by replacing a burned out lamp.
Replace a light that is defective, or when lens is broken.
3-142. Ammeter
a. Removal and Installation.
(1) Refer to figure 8115 and remove fuel
level indicator.
(2) Install in reverse order.
3-145. Fuel Level Indicator
a. Removal and Installation.
(1) Refer to figure 3-115 and remove the
ammeter.
(2) Install in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean
indicator
with
clean
cloth
dampened in an approved cleaning solvent and dry
thoroughly.
(2) Visually inspect indicator for dents, broken
glass, or other damage. Inspect mounting hardware for
burs, stripped threads, or other defect. Inspect electrical
leads for fraying insulation, broken wire, or loose
terminals. Check indicator. for operation in conjunction
with transmitter (para 3-146).
(3) Repair by replacing defective indicator,
mounting hardware, or electrical lead.
3-146. Transmitter Fuel Level
b. Cleaning, Inspection and Test.
(1) Clean ammeter with a soft cloth
dampened in an approved cleaning solvent and dry
thoroughly.
(2) Visually inspect ammeter for corroded
terminals, cracked glass, and other damage or defect.
(3) Use a multimeter and check across
terminals for continuity.
Replace a damaged or
defective ammeter.
3-143. Oil Pressure Indicator
a. Removal and Installation. Refer to figure 3-48
and remove fuel level transmitter. Install in reverse
order.
a. Removal and Installation.
(1) Refer to figure 3-115 and remove the oil
pressure indicator.
(2) Install in reverse order.
3-120
Figure 3-116. Indicator light and switch, removal and installation.
3-121
(2) Visually inspect switch for damage or
defect. Use multimeter and test for continuity between
terminals when switch is ON. When switch is OFF, no
continuity should be indicated.
(3) Repair by replacing a defective switch.
b. Cleaning, Inspection and Repair.
(1) Clean transmitter in an approved cleaning
solvent and dry thoroughly.
(2) Use a multimeter set on l,)w ohm scale
across terminals then move float through arc to full
position. During float travel multimeter should indicate
increasing ohms. When increasing ohms are indicated,
install electrical lead then check position of pointer on
indicator with position of float relative to distance
traveled.
(3) Repair
by
replacing
a
defective
transmitter or mounting hardware.
3-147. Water Temperature Indicator
3-150. Starter Push Switch
a. Removal and Installation.
(1) Refer to figure 3-116 and remove starter
push switch.
(2) Install in reverse order.
b. Cleaning, Inspection and Repair.
Refer to
paragraph 3-149 and clean, inspect, or repair starter
push switch in a similar manner.
a. Removal and Installation.
(1) Refer to figure 3-115 and remove the
water temperature indicator.
(2) Install in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean indicator with a soft cloth
dampened in an approved cleaning solvent and dry
thoroughly.
(2) Visually inspect indicator for dents, broken
glass, or other defect. Inspect mounting hardware for
burs, stripped threads, or other damage.
(3) Repair by replacing mounting hardware or
water temperature indicator.
3-151. Horn Push Switch
a. Removal and Installation.
(1) Refer to figure 3-116 and remove horn
push switch.
(2) Install in reverse order.
b. Cleaning, Inspection and Repair. Refer to.
paragraph 3-149 and clean, inspect, or repair horn
switch in a similar manner.
3-152. Electrical Connector (Quick Disconnect)
Receptacle
a. Removal.
(1) Remove
electrical
connector
from
receptacle at bottom of instrument panel (fig.
2-23).
(2) Remove side panel from control pedestal.
(3) Remove four nuts, lockwashers, and
screws, then remove electrical connector receptacle
from bottom of control panel.
b. Installation. Install by reversing procedure
in a, above.
3-148. Indicator (Warning) Li ghts, Water High
Temperature
a. Removal and Installation. Refer to figure 3-116
and remove indicator (warning) light water high
temperature. Install in reverse order.
b. Cleaning, Inspection and Repair.
Clean,
inspect, and repair indicator light in manner described in
paragraph 3-144.
3-149. Run-Shutdown Switch
3-153. Terminal Board and Wiring
a. Removal and Installation.
(1) Refer to figure 3-116 and remove run
shutdown toggle switch.
(2) Install in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean switch in an approved cleaning
solvent and dry thoroughly with compressed air.
a. Removal and Installation.
(1) Refer to figure 3-115 and remove terminal
board.
(2) Install in reverse order.
b. Wiring Test and Repair. Refer to paragraph 389 for test and repair of wiring.
Section XXI. COUNTERWEIGHTS
3-154. General
counterweight extension is removed.
This will avoid danger of tipping the
unit over, damaging the equipment,
or injury to personnel.
Warning:
Do not travel over rough terrain with
crane-shovel basic unit (without
front
end
attachment),
unless
The counterweight consists of slug punchings
3-122
which are stored in, compartments of revolving frame,
and the extension, which mounts on rear of revolving
frame. Purpose of counterweight extension is to offset
extended weights of front end attachment and load. Slug
punchings are not ordinarily removed from revolving
frame.
(3) Secure lifting hooks in lifting eyebolts,
take up slack then remove bolts and washers.
(4) Lift extension up and off revolving frame,
and move to a suitable storage area.
b. Installation.
(1) With a suitable lifting device, lift
counterweight extension, move to rear of crane-shovel
basic unit and position it for installation.
(2) Install bolts and washer to secure
extension to frame, then remove lifting hooks.
(3) Remove two lifting eyebolts, then install
plugs in bolt holes.
3-155. Counterweight Extension
a. Removal.
(1) Position lifting device capable of lifting
10,000 lbs at rear of crane-shovel unit.
(2) Remove two plugs (fig. 3-117) from
counterweight extension, and install two lifting eyebolts
in counterweight.
Figure 3-117. Counterweight extension, removal and installation.
Section XXII. CAB, PANELS, DOORS, WINDOWS, AND SEATS
3-156. General
(3) Install in reverse order.
The cab of the crane-shovel basic unit is manufactured
of sheet metal sections, panels, doors, and window
frames, which are bolted to one another and to the
revolving frame. Any part of the cab can be removed for
repair, or in sections to provide access to machinery
components that require repair or adjustment.
b. Cleaning, Inspection and Repair.
(1) Clean handrail in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect handrail for bends,
cracks, or burs on threads
(3) Repair by straightening bends, welding
cracks, and chase burs off threads.
Replace a defective handrail.
3-157. Door Handrail (Grip)
a. Removal and Installation
(1) Remove two nuts (fig. 3-118) and two
washers, then remove handrail from cab.
3-158. Door and Window Glass
a. Removal.
(1) Insert hook end of channel tool in
(2) Remove the two remaining nuts from
handrail.
3-123
NOTE:
REMOVE APPLICABLE MOUNTING HARDWARE, THEN REMOVE PANEL.
Figure 3-118. Handrail, panel, window frame, and cab, removal and installation.
groove of channel (fig. 3-118) and slide tool completely
around channel to break the seal.
(1) Clean edges of window frame, inside and
out, with an approved cleaning solvent and dry
thoroughly.
(2) Visually inspect channel for cracks,
breaks, deterioration or other damage. Inspect window
frame or panels for dents or cracks.
(3) Repair
by
welding
cracks
and
straightening dents in window frame. Replace defective
channel or broken glass.
(2) Insert.
straight end of channel tool
between channel and glass, move tool slowly around
window or door glass to break seal of channel to glass.
Press glass outward gently while breaking seal and the
glass will slide out of the frame when seal is completely
broken.
3-159. Swinging Door
b. Installation.
(1) Start channel along the side of opening.
(2) Fit narrow edge of channel over edge of
window frame and continue around frame until the two
ends of channel are joined.
(3) When glass is in position, insert hooked
end of tool into channel, move around window forcing
locking strip into position and completing the installation.
a. Removal and Installation.
(1) Unhook latch.
(2) Refer to figure 3-119, remove nine nuts,
washers and screws, then remove swinging door.
(3) Install in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect door for defective hinges,
dents, cracks, or other defect.
(3) Repair by straightening bends, welding
cracks, or replacing defective hinge or door.
Note.
Do not begin locking operation at
channel joint. Start around the
corners smoothly to avoid buckling
or crimping the channel. Use care,
and assure weather protection.
c. Cleaning, Inspection and Repair.
3-124
Figure 3-119. Panels and swinging door, removal and installation.
3-160. Sliding Doors
b. Cleaning, Inspection and Repair.
Clean,
inspect, and repair panels in manner similar to that
described for doors in paragraph 3-159.
a. Removal and Installation.
(1) Refer to figure 3-120 and unhook latch.
(2) Remove two roller bearings and washers
from pins then lift right rear sliding door from guides.
(3) Remove left rear sliding door in similar
manner.
(4) Install in reverse order.
3-162. Left Hand Front Panel
Refer to paragraph 3161 and remove or install left hand
front panel in a similar manner.
3-163. Left Front Panel Door
b. Cleaning, Inspection and Repair.
(1) Clean door with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect bearings for excessive
wear, door for bends, cracks, or other damage.
(3) Repair by straightening bends, welding
cracks, or replacing defective bearings or door.
a. Removal and Installation.
(1) Refer to figure 3-121 and remove left
front panel door.
(2) Install in reverse order.
b. Cleaning, Inspection and Repair.
Clean,
inspect, and repair left front panel door in manner
similar to that described in paragraph 3-159.
3-161. Center Side Panel
a. Removal and Installation.
(1) Refer to figure 3-119 and remove center
panel from left hand side.
(2) Install in reverse order.
3-164. Rear Cab Panel
Refer to figure 3-121 and remove or install the rear cab
panel.
3-125
3-165. Right Rear Side Panel
Remove or install right rear side panel in manner similar
to that described for louver panel (para 3-166).
(2) Visually inspect for dents, cracks, or bent
louvers. Inspect mounting hardware for burs, stripped
threads, or other damage.
(3) Repair by straightening bends and dents,
or welding cracks. Replace defective mounting
hardware, or panel.
3-166. Louver Panel
a. Removal and Installation.
(1) Refer to figure 3-119 and remove louver
panel from left hand side of cab.
(2) Install in reverse order.
b. Cleaning, Inspection and Repair.
(1) Clean panel in an approved
solvent and dry thoroughly.
3-167. Right Hand Side Center Cab Panel
Remove or install right hand side center cab panel in
similar manner as described for louver panel (para 3166).
3-168. Operator's Seat
Refer to figure 3-122 and remove operator's seat. Install
in reverse order.
cleaning
3-126
Figure 3-121. Panel, cover, and doors, removal and installation
3-127
Figure 3-122. Operator's seat, removal and installation.
3-128
Section XXIII. LIGHTS, LIGHT ENCLOSURE, AND COMPONENTS
3-171. Cab Light
3-169. General
The lightning system consists of upper and lower
floodlights, cab lights, and panel lights, with condition
from junction boxes to light enclosure, or cab light
lampholders. The panel lights are identical with those
on instrument control panel and are mounted at top of
lighting enclosure.
a. Removal and Installation
(1) Remove lamp.
(2) Refer to figure 3-124 and remove cab
light lampholder.
(3) Install in reverse order.
3-170. Floodlights
a. Removal and Installations.
(1) Tag and remove electrical leads.
(2) nut (fig. 3-14) from stem inside adjusting
bracket
b. Disassembly and Reassembly. Refer to figure
3-123 and disassemble the floodlight. Reassemble in
reverse order.
c. Cleaning, Inspection and Repair.
b. Inspection and Repair.
(1) Visually inspect wiring at lampholder for
good connection. Inspect for frayed or defective leads.
Test lamp for serviceability. Inspect hardware for
damage or defect.
(2) Repair by replacing defective wiring,
lamp, or lampholder.
(1) Clean all metal parts in an approved
cleaning solvent and dry thoroughly.
(2) Visually inspect electrical terminals for
corrosion or looseness. Inspect and test lamp for
serviceable condition. Inspect mounting hardware for
stripped threads or other defect Inspect packing for
deterioration.
(3) Repair by replacing defective lamp or
packing.
a. Removal and Installation
(1) Remove two screws and open cover (fig.
3-124).
(2) Tag and disconnect conduit and electrical
leads from light enclosure.
(3) Remove four nuts, lockwashers, and
screws, then remove light enclosure.
(4) Install in reverse order.
3-172. Light Enclosure
b. Component Removal Installation..
(1) Open cover.
(2) Tag and disconnect applicable lead(s),
then remove defective component
(3) Install in reverse order.
Figure 3-123.Floodlight, disassembly and reassembly
3-129
NOTE:
TAG AND REMOVE ELECTRICAL LEADS AND MOUNTING HARDWARE AS REQUIRED.
Figure 3-124. Light enclosures and components, removal and installations
3-173. Gun Case and Tool Box
(3) Remove tubing clips, then remove tube
from air box.
(4) Install in reverse order.
Refer to figure S125 and remove run case or tool box.
Install in reverse order.
b. Cleaning and Inspect
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Inspect tubing for kinks or clogging,
mounting hardware for stripped threads or other
damage, and cylinder for contents.
(3) Replace a defective tube, damaged or
defective mounting hardware, or an empty cylinder.
3-174. Heater
a. Removal and Installation. Refer to figure 3-126
and remove the heater. Install in reverse order.
b. Refer to paragraph 2-26 for operating
instructions.
3-175. Pressure Primmer Discharge
3-176. Glow Plus (Engine Model D333TA
Only)
a. Removal.
a. Removal and Installation
(1) Refer to figure 2-29, loosen tubing nut,
and remove tube from bushing
(2) Remove four screws, nut and lockwashers
that secures primer discharger to cab wall, then remove
primer discharger.
3-130
Figure 3-125. Gun case and tool box, removal and installation.
Figure 3-126. Heater, removal and installation.
3-131
(1) Tag and disconnect electrical lead at glow
plug from precombustion chamber. Remove
(2) Remove glow plug (fig. 3-127) by turning
counterclockwise with wrench on wrenching surface until
threads are disengaged then lift glow plug from
precombustion chamber. Remove remaining plugs in a
similar manner.
b. Cleaning, Inspection, Test and Repair.
(1) Clean electrical lead and glow plug with a
rag dampened in an approved cleaning solvent and dry
thoroughly.
(2) Visually inspect electrical lead for cracked
or deteriorating insulation,. or loose terminals. Inspect
glow plug for visible signs of short circuit (discoloration),
or' other damage.
(3) Use an ohmmeter, place probe at each
end of lead and test for continuity. Replace a defective
electrical lead.
(4) Use an ohmmeter, place negative probe
at threads and positive probe at glow plug terminal, then
test for continuity. Replace a defective glow plug.
Note.
In absence of an ohmmeter the glow
plug may be tested by grounding
threads at cylinder head, attaching
known 24 vdc hot lead at glow plug
terminal. If heat cannot be felt at tip,
or plug fails to glow, it is defective
and must be replaced.
c. Installation.
(1) Install glow plug (fig.
3-127) in
precombustion chamber by turning clockwise until
threads are seated finger tight.
(2) Use torque wrench on wrenching surface
and tighten to between 10 and 12 ft-lbs.
(3) Connect electrical lead and remove tag.
(4) Install remaining glow plugs in a similar
manner.
Figure 3-127. Glow plug, removal and installation
3-132
CHAPTER 4
MATERIAL USED IN CONNECTION WITH CRANE-SHOVEL
Section I. SHOVEL FRONT END ATTACHMENT
4-1.
General
(1) Remove front and attachment currently
a. Description. The crane
?
4-2.
Note.
When crows and retract mechanism
is not installed on boom foot, this
must be accomplished at direct
support maintenance before shovel
front end attachment can be
installed at organization.
b. Preparation Prior to Installation or Shovel
Attachment.
Shovel Front End Attachment
a. General. The shovel front end attachment is
normally positioned on cribbing (fig. 4-1) for storage
between periods of use , but may be received
disassembled as shown on figures 2-2 and 2-3. In the
latter case, assembly of the shovel attachment will
require the assistance of another crane, or suitable
lifting device, and components
Figure 4-1. Shovel front end attachment, cribbed for removal or installation.
4-1
Figure 4-2. Revolving frame component relationship.
should be assembled in the reverse order of removal
from shovel boom (para 4-10).
install boom foot pins through eye bolt; lugs on revolving
frame; lugs on boom foot, then secure with cotterpins.
b. Installation.
(1) Assure that crane-shovel basic unit has
been prepared for shovel front end attachment
installation as outlined in paragraph 4-1b, above.
(2) Install shovel hoist cable (table 1-2) on
hoist drum (fig. 4-2) (para 3-39) and shovel boom hoist
cable on boom hoist drum. Wind cables an drums.
(3) Position crane-shovel basic unit at end of
shovel boom as illustrated in figure 4-1; position
antisway spring eye bolt at lug on revolving frame, then
Note
Be sure boom foot pins are installed
from outside to inside.
(4) Install trip cable (from equalizer bracket)
through guide sheaves on boom foot, then connect to
lever underneath revolving frame.
(5) Refer to figure 2-19 and reeve both hoist
cables, securing them at dead end sockets with cable
clamps.
4-2
accordance with current lubrication order (LO 5381020612), paying particular attention to dipper handle,
crowd chains, and crowd and reversing mechanism.
Protect all unpainted surface from rust or corrosion.
(11) When removal is for purpose of installing
crane front end attachment, remove shovel hoist cable
(para 3-39); shovel boom hoist cable; shovel sprocket
and planetary pinion gear from digging drum (para 3125); reposition planetary brake band (para 3-123), then
install crane lagging (para 3-124).
(6) Tighten adjusting nuts fig. 4-1) on
antisway springs to obtain spring tension, then hold
adjustment by tightening locknuts.
(7) Install revolving frame crowd chain on
crowd reversing mechanism then on digging drum
sprocket, and secure by installing master link (para 4-3),
then adjust (para 3-31). Install boom crowd chain on
reversing mechanism and sprocket on shipper shaft,
then adjust in a similar manner.
(8) Adjust dipper trip (para 3-33) and trip
cable (para 3-34).
(9) Perform preventive maintenance checks
and services (para 3-6), then raise boom (para 2-12b).
c. Removal.
(1) Remove crane-shovel unit to storage
area, an area that is level, preferably hard surfaced,
under cover, suitable for storage of shovel front end
attachment.
(2) Position two blocks, approximately 24 feet
from boom foot (fig. 4-1), then lower boom (para 2-12 b)
until dipper rests on blocks. Position blocking between
dipper handle and boom point, then lower boom until
point rests on blocking.
(3) Build a substantial crib under boom, near
foot, until there is just room enough to insert wedges, or
jacks, to take weight of boom off boom foot pins.
(4) Remove master pin of revolving frame
crowd chain and remove chain from shovel sprocket on
digging drum. Reinstall master pin and position crowd
chain back over boom crowd chain temporarily, until
cleaning and preserving is performed ((10) below).
(5) Loosen locknut and adjusting nut from
antisway springs until all tension is removed from
springs.
(6) Remove cable clamps from dead end
sockets of dipper hoist cable and, boom hoist cable (fig.
2-19) and carefully reel them in on hoist drums, guiding
ends through sheaves as this is accomplished.
(7) Disconnect trip cable from lever
underneath revolving frame, remove from guide sheave
at boom foot and secure it to boom and equalizer
bracket.
(8) Remove cotter pins from boom foot pins
(2), drive wedges between cribbing and boom foot until
weight is off foot pins (or raise jacks), then remove
boom foot pins.
(9) Move crane-shovel unit away from shovel
front end attachment.
(10) When attachment is to be stored on
blocks for a prolonged period, clean with an approved
solvent, dry thoroughly, and lubricate attachment in
4-3. Crowd and Retract Chain, Idler, and Tightener
a. Crowd and Retract Chain Removal and
Installation.
(1) Remove cotterpin, roller, and master pin
from link of boom crowd and retract chain (fig.
4-3), then lift chain off crowd and reverse mechanism at
foot of boom, chain tightener sprocket and shipper shaft
sprocket.
(2) Remove revolving frame crowd and
retract chain- from digging drum sprocket, idler roller,
and crowd and reverse mechanism in manner similar to
(1) above.
(3) Install in reverse order of removal.
b. Chain Tightener Adjustment.
Refer to
paragraph 3-1 and adjust chain tightener.
c. Idler Roller Adjustment.
Adjust in manner
similar to that used for chain tightener (para 3-31).
4-4. Shovel Dipper
a. Removal
(1) Lower dipper to rest on blocks, then
remove hoist cable from bail sheave only (fig.
2-19).
(2) Refer to figure 4-4, disconnect trip chain
from trip lever, remove cotterpins from two pins
securing braces to dipper handle, then remove pins.
(3) Remove cotterpin and washer from two
handle pins, remove handle pins, then remove dipper
from handle.
b. Disassembly and Reassembly of Dipper.
(1) Remove cotterpin and bail pin (fig.4-4),
then remove bail.
(2) Remove bolt from chain at latch lever,
then remove chain.
(3) Remove cotterpin and pin from two
braces, then remove braces.
4-3
Figure 4-3. Crowd and retract chain, removal, installation, and adjustment.
Figure 4-4. Shovel dipper, removal, disassembly, reassembly, and -installation.
4-4
man on each side of boom to help guide dipper handle
into saddle blocks.
(4) Pull hoist cable in slowly and move lifting
device forward.
(5) Guide dipper handle into saddle blocks,
making sure that racks engage with pinions on shipper
shaft.
(6) Install boom crowd chain over sprocket on
shipper shaft and crowd and reversing mechanism at
foot of boom and secure with master pin, roller, and
cotter pin (para 4-3).
(7) Install dipper trip cable on dipper handle
(para 4-8).
(8) Install shovel dipper (para 4-4).
(4) Remove two bolt and nut from latch lever,
remove latch lever, then remove clevis and latch bar
from dipper door.
(5) Remove cotterpin from two door hinge
pins, remove pins, then remove dipper door.
(6) When necessary to remove latch keeper
for repair or replacement, remove two short and four
long rivets then remove keeper.
(7) Disassemble bail (para 4-6).
(8) Reassemble in reverse order of
disassembly.
c. Cleaning, Inspection, and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for signs of
excessive wear, cracks, breaks, bends, stripped threads
on hardware, or elongation of holes.
(3) Repair by welding cracks or breaks,
straightening bends and replacing all defective hardware
or excessively worn parts.
d. Installation.
(1) Position dipper at end of dipper handle,
install two handle pins and secure each with washer and
cotterpin.
(2) Place two braces at lugs on dipper
handle, install pins and secure with cotterpins.
(3) Connect door trip chain to trip lever, then
reeve hoist cable (fig. 2-19).
4-5. Dipper Handle
4-6. Dipper Bail and Sheave
a. Removal.
(1) Remove shovel dipper (para 4-4).
(2) Remove bail (para 4-4b(1)).
b. Disassembly and Reassembly.
(1) Remove cotterpin and slotted nut from
sheave pin.
(2) Remove sheave pin, then remove sheave
from bail.
(3) Reassemble by reversing steps (1) and
(2) above.
c. Cleaning and Inspection.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect sheave for scored sleeve
bearing, cracks, worn groove, or other defect. Inspect
bail for cracks, breaks, elongated mounting holes, or
defective mounting hardware. Replace all defective
parts.
d. Installation.
(1) Install bail on dipper (para 4-4b).
(2) Install shovel dipper (para 4-4d).
a. Removal.
(1) Open boom crowd chain by removing
cotterpin, roller, and master pin, then lifting chain off
sprocket on shipper shaft.
(2) Remove shovel bucket (para 4-4).
(3) Remove dipper trip cable from dipper
handle (para 4-8).
(4) Lash saddle blocks to boom so that they
are prevented from changing angles when dipper handle
is removed from shipper shaft.
(5) Fasten one end of a heavy rope about
three feet from dipper end of handle, the other end of
rope to boom point of lifting device. Move dipper
handle until pointed end is almost at shipper shaft, and
almost free of saddle blocks.
(6) Lower dipper end, if necessary, then work
points of handle over pinions, carefully, and lower dipper
handle to ground.
b. Installation.
(1) Position shovel boom to receive dipper
handle, making sure saddle blocks are lashed secure to
boom.
(2) Position lifting device, and clamp hoist
cable -round dipper handle at balance point (about three
feet from dipper end).
(3) Lash a heavy rope to point end of handle,
thread it through, or over shipper shaft, then station one
47.
Dipper Teeth
Caution:
Never dig with shovel front end
attachment while a tooth is missing
from dipper, even for a short time.
The tooth socket will wear to such an
extent that a replacement tooth will
never fit properly. Reinstall old worn
tooth and use until new one is
available, when continued operation
is imperative.
a. Tooth Removal.
(1) Lower dipper to rest on blocking or
4-5
Figure 4-5. Dipper teeth, removal and installation. .
cribbing at door end, allowing crewman room to drive
tooth locking wedge from tooth (fig. 4-5).
(2) Use drift punch ,or other suitable tool at
small point (bottom of wedge), then drive upward until
wedge is free of tooth.
(3) Loosen tooth in socket with side-to-side
taps of hammer, then remove defective tooth.
(4) Remove remaining teeth in a similar
manner.
b. Tooth Installation.
(1) Clean tooth and wedge socket, insert
tooth in position, then drive tooth until it is seated in
socket.
(2) Position tooth locking wedge and drive it
into place until tooth is secure.
(3) Install
remaining
teeth
in
a
similar
manner.
4-8. Dipper Trip Mechanism and Trip Lines
a. General. The dipper trip mechanism (fig.4-6) is
used for opening the door of shovel dipper only, but
once installed on main hoist drum shaft, need not be
removed when shovels is converted to any other front
end arrangement. The boom trip line, consisting of
chain from bucket door latch to dipper handle trip lever;
trip line from trip lever over idler sheave on shipper
shaft, through equalizer sheave on equalizer bracket
back to take up drum on shipper shaft (fig. 4-7). The
revolving frame trip line runs from equal-
4-6
secure
(1) Install dipper trip lever (fig. 2-23) and
with
pin
to mounting bracket. Install hydraulic compensator and
line to main header (paras 3-111, 3-112 and 3-113).
(2) Refer to figure 4-6 and install dipper trip
mechanism.
(3) Install bellcrank mounting bracket under
revolving frame, and guide sheave mounting bracket on
revolving frame at boom foot (fig. 4-7) .
(4) When shovel front end attachment is
installed, install revolving frame trip line.
(5) Adjust dipper trip mechanism (paras 3-33
and 3-34).
Note.
The above procedure assumes that
shovel tripping mechanism is
installed on boom of shovel front
end attachment.
c. Removal. The entire dipper trip mechanism may
be removed for replacement or repair as follows:
(1) Dipper trip clutch mechanism removal.
(a) Remove pin from clevis at lever
(fig. 4-6) and remove clevis from lever.
(b) Lossen coupling nut and remove
hydraulic hose from wheel brake cylinder.
(c) Grasp brake drum firmly and turn
counterclockwise to remove mechanism from end of
main hoist 6rum shaft.
(2) Disassembly and reassembly. Refer to
figure 4-8 and disassemble dipper trip clutch mechanism
in numerical sequence. Assemble in reverse order.
Figure 4-6. Dipper trip mechanism, removal
or installation.
izer bracket on boom, through guide sheaves on bracket
mounted on revolving frame at boom foot to bell crank
lever mounted. underneath revolving frame. When
properly adjusted (para 3-33 and 3-34), dipper is tripped
when dipper trip lever (fig. 2-93) is actuated.
b. Installation.
4-7
Figure 4-8. Dipper trip clutch mechanism, disassembly and reassembly.
4-8
(3) Remove capscrew (fig. 4-9), lock-washer,
and flatwasher, then remove backplate from brake
drum.
(4) Remove two retainers, springs, and brake
spring rods.
(5) Disconnect and remove brake return
spring.
(6) Remove two locks, brakeshoes, washers,
and flatwashers from back plate.
(3) Cleaning, inspection and repair.
(a) Clean all parts in an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect brakeshoes for
excessively worn, or defective lining. Replace
brakeshoes when lining defective.
(c) Visually inspect brakedrum for
scored or damaged friction surface. Replace a damaged
or defective brakedrum.
(d) Visually inspect mounting hardware,
seals, springs or retainers for defects. Replace defective
parts.
(e) Visually inspect hydraulic cylinder
for leakage, or lack of freedom in movement of piston.
Replace a defective cylinder.
4-9. Dipper Trip Clutch Brakeshoe
b. Cleaning, inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually
inspect
brakeshoes
for
excessively worn or cracked lining. Replace both shoes
when lining is defective.
(3) Check brake drum for scored or damaged
friction surface. Replace a defective brake drum (para
4-8 above).
a. Removal.
(1) Remove pin (fig. 4-6) from clevis at lever
and disconnect clevis.
(2) Disconnect hydraulic hose at coupling unit
c. Installation.
(1) Position brakeshoes (fig. 4-9) on back
plate, install washer and flatwasher, then secure with
locks.
Figure 4-9. Clutch brakeshoes, removal and installation.
4-9
(2) Visually inspect boom for cracks, breaks,
or excessive wear at boom foot, point, or saddle blocks.
Inspect bumper blocks for excessive wear.
(3) Repair boom by replacing worn bumper
blocks, or welding small cracks. Report large cracks,
bends, or excessive wear beyond scope of organization
repair to direct support maintenance.
Note.
When shovel boom has been
returned to direct support for repair
or replacement, be sure the returned
or
replacement
boom
comes
equipped with boom point sheaves,
bridle bar, shipper shaft, and crowd
and reverse mechanism.
c. Installation.
(1) Install shovel boom (para 42).
(2) Install dipper handle (para 4-5).
(3) Install shovel dipper (para 4-4).
(4) Perform preventive maintenance checks
and services (para 3-6).
(2) Install brake return spring.
(3) Install two brake spring rods, springs, and
secure with retainers.
(4) Install back plate in brake drum. Make
sure lever (fig. 4-6) is in proper position, then secure
back plate to mechanism with flatwasher (fig. 4-9)
lockwasher, and capscrew.
(5) Connect hydraulic hose at coupling nut,
position clevis on lever, then secure pin.
4-10. Shovel Boom
a. Removal.
(1) Remove shovel dipper (para 4-1).
(2) Remove dipper handle (para 4-5).
(3) Lower shovel boom (para 2-12b) to
cribbing similar to that shown in figure 4-1 and
disconnect boom from crane-shovel unit (para 4-2).
b. Cleaning, Inspection and Repair.
(1) Clean shovel boom with an approved
cleaning solvent and dry thoroughly.
Section II. CLAMSHELL, CRANE, AND DRAGLINE FRONT END ATTACHMENTS
digging, or drag cables at dead end socket, then wind
cables on drums slowly, while guiding cable end through
sheaves.
(4) Use wedges between cribbing at boom
foot and boom; drive them in from each side to take
weight off boom foot pins; remove cotterpins, then
remove boom foot pins (fig. 4-10).
(5) Move crane-shovel basic unit away from
boom.
4-11. General
The clamshell, crane, and dragline front end
attachments use a similar boom arrangement, which
consists of the base section, an upper section, and
which may be lengthened by insertion of boom
section(s) (para 4-13). For crane operation, there is the
jib boom attachment that may be installed as required
(para 4-21). For clamshell operation, a tagline winder
(para 4-14) is used to stabilize the bucket. For dragline
operation, a fairlead and sheaves (para 4-16) is installed
at revolving frame. All of these attachments use the
boom backstop (para 4-22), radius (boom angle)
indicator (para 4-23) and boom harness spreader (para
4-15). All use drum cable lagging (para 3-124) and
cables (table 1-2), although size and lengths differ
according to operation being performed, or length of
boom in use. This section will cover organizational
maintenance as outlined in Maintenance Allocation
Chart.
b. Disassembly and Reassembly.
(1) Remove two cotter pins (fig. 4-10) and
pin, then remove boom backstop. Disassemble boom
backstop (para 4-20).
(2) Remove radius (boom angle) indicator
(para 4-23).
(3) Remove two pendant cables (fig. 4-10)
from boom point, remove cotterpins and pins, then
remove cables from boom spreader.
(4) Remove 16 nuts, lockwashers, and bolts
securing base section to upper section, or boom
(extension) section (fig. 4-11).
412. Drum Cable Lagging
The drum lagging for crane, clamshell, and dragline are
removed or installed, in manner similar to that described
in paragraph 3124.
Note.
When boom (extension) section is
installed in boom, proceed as in step
(5) below.
4-13. Boom
a. Removal.
(1) Disconnect boom backstop from gantry
(para 4-22).
(2) Lower boom (para 2-12b) to rest on
cribbing (fig. 2-6).
(3) Refer to reeving diagram of front end
attachment in use, disconnect boom hoist, hoist,
(5) Remove 16 nuts, lockwashers, and bolts
securing boom (extension) section to upper section,
then remove boom (extension) section from upper
section.
4-10
Figure 4-10. Boom disassembly and reassembly.
4-11
Figure 4-11. Boom (extension) section, removal and installation
(1) Disconnect tagline from clamshell bucket
and remove line from reel (fig. 4-12), or wind on reel
and secure loose end.
(2) Remove four nuts, lockwashers, bolts,
and two places securing left end of tagline winder to
boom.
(3) Remove four nuts, lockwashers, two bolts,
and two plates securing right end of winder to boom,
then lift tagline winder from boom.
b. Cleaning and Inspection
(1) Clean tagline winder with an approved
cleaning solvent and dry thoroughly.
(2) Inspect mounting hardware for burrs,
stripped threads, or cracked plates. Replace defective
hardware. Replace a defective tagline winder.
c. Installation.
(1) Position tagline winder in boom Install two
U-bolts, and two plates, then secure right end of winder
with four lockwashers and nuts.
(2) Install two plates, four bolts, and four
lockwashers, to secure left end of winder to boom with
four nuts.
(6) Separate the two 10 foot pendant cables
from the 25 foot cables by removing cotterpins and pins
from rope sockets.
(7) Remove boom point sheaves (para 4-20)
from upper section.
(8) Reassemble by reversing steps (7)
through (1) above.
Note.
When boom (extension) section is
not used, eliminate steps (5) and (6)
above.
c. Cleaning, inspection and Repair.
(1) Clean all parts in an approved solution
and dry thoroughly.
(2) Visually inspect all parts for signs of
excessive wear, damaged threads, scored bushings,
damaged bearing, or other defects.
(3) Repair by replacing worn or defective
parts.
4-14. Tagline Winder
a. Removal.
4-12
(3) Install tagline on winder, then attach line
to clamshell bucket.
4-15. Boom Harness Spreader
a. Removal and Installation.
(1) Lower boom (para 2-12b) to rest on
cribbing (fig. 2-6), then slack off on boom hoist cable
until spreader rests on boom.
(2) Disconnect boom hoist cable from dead
end socket on gantry, then wind cable on boom hoist
drum slowly while guiding cable end through sheaves
(fig. 43).
(3) Remove two cotterpins and pins, then
remove two cable sockets from boom harness spreader.
(5) Install in reverse order.
b. Disassembly ad Reassembly.
(1) Remove four capscrews, lockwashers,
and two keeper plates which secure two pins in
spreader.
(2) Remove two pins and lift four sheaves
from spreader.
(3) Reassemble
by
reversing
above
procedure.
c. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect mounting hardware for
stripped threads or burs; inspect sheaves for cracks or
excessive wear, then inspect spreader for bent, cracked,
or defective condition.
(3) Repair
by
replacing
components, or mounting hardware.
defective
4-16. Fairlead and Sheaves
Figure 4-12. Tagline under, removal and
installation.
a. Removal and Installation.
(1) Lower dragline bucket to ground and
remove all tension from cables.
(2) Disconnect drag cable at dead end socket
on bucket (fig. 2-12), then wind drag
(4) Lift the spreader off the boom.
Figure 4-1. Boom harness spreader, removal and installation.
4-13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Sheave (2)
16
Shaft (2)
Bearing (2)
17
Bolt (2)
Fitting (6)
18
Pin (2)
Bushing (6)
19
Capscrew (8)
Cotter pin (4)
20
Bearing (2)
Sheave (2)
21
Spacer (2)
Bearing (2)
22
Guide plate, lh
Pin (2)
23
Guide plate, rh
Base
24
Nut (10)
Lock pin (2)
25
Lockwasher (10)
Cotter pin (4)
26
Frame
Rod
27
Shaft (2)
Cotter pin (2)
28
Pin (2)
Shaft, lower
29
Cotter pin (4)
Thrust collar (2)
30
Pin (2)
Figure 4-14. Fair lead and sheaves, disassembly and reassembly.
cable on drum, slowly, while guiding cable end through
b. Disassembly or Reassembly.
sheaves.
(1) Remove four cotter pins (29, (fig. 4-14)
(3) Remove fairlead from revolving frame by
and two pins (18) from the two pivot pins (8); remove
removing four cotterpins (11, fig. 4-14) securing pins
two pivot pins, then separate frame (26) from base (9).
(10) in upper base rod (12); remove two cotterpins (13)
(2) Remove four cotter pins (5) and two pins
from lower base shaft (14) then remove upper base rod
(28) from two horizontal sheave shafts (27), then
and lower base shaft. Remove two thrust collars (15).
remove shafts and sheaves (6) from frame (26).
(4) Install in reverse order.
4-14
(3) Remove two nuts (24), lockwvashers (25),
bolts (17), and spacers (21) from frame (26).
(4) Remove two nuts (24), lockwashers (25),
and capscrews (19) which secure right and left hand
guide plates (23 and 22) to frame (26), then remove
guide plates.
(5) Remove four cotter pins (29) and two pins
(30) from vertical sheave shafts (16) Drive vertical
sheave shafts (16) out and remove two sheaves (1)
from frame (26).
Note.
Do not remove bushings or bearings
unless replacement is required.
(6) Remove bearings (7) from two horizontal
sheaves (6).
(7) Remove bearings (2) from two vertical
sheaves (1).
(8) Remove six lubrication fittings (3) and
bushings (4) from two shafts (16 and 27), and two pins
(8).
(9) Reassemble by reversing steps (8)
through (1) above.
c. Cleaning, Inspection, and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all bushings and bearings
for scoring, or excessive wear; sheave shafts for
excessive wear; sheaves for cracks, bends, or
excessive wear; mounting base and frame for bends,
cracks, or breaks, and mounting hardware for stripped
threads, elongated hole, or other defects.
(3) Repair by welding cracks, or breaks;
straightening bends, or replacement of parts, repair of
which is beyond scope or organizational maintenance.
Replace defective bearings, bushings, or mounting
hardware.
Figure 4-15. Clamshell bucket teeth replacement.
and slowly wind cables on drums, as ends are guided
through sheaves.
c. Clamshell Bucket Teeth Replacement.
(1) Removal. Position bucket on its side,
remove 30 nuts, (fig. 4-15), lockwashers, and bolts, and
six teeth from clam jaws.
(2) Cleaning, Inspection and Repair.
(a) Clean all parts with an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect mounting hardware
for stripped threads or other defects; inspect teeth for
bent, cracked, or excessively worn condition.
(c) Replace damaged or defective
parts.
(3) Installation of Teeth. Install teeth on jaws
(fig. 4-15) and secure with bolts, lockwashers, and nuts.
d. Bucket Installation.
(1) Position boom over bucket, reeve holding
and closing cables (fig. 2-9), and secure to dead end
sockets on bucket.
(2) Attach tagline to bucket.
4-17. Clamshell Bucket Teeth
a. Description. The clamshell bucket consists of
two half-scoops, hinged together at top so that they will
close over material to be picked up Bucket opens when
closing line is allowed to run free, closes when pressure
on hoist brake is slackened and crowd and retract clutch
is engaged.
b. Removal.
(1) Lower open bucket to ground until there is
slack in the holding and closing cables.
(2) Disconnect tagline from bucket and wind
tagline on winder drum.
(3) Disconnect both holding and closing
cables at dead and sockets on bucket (fig. 2-9)
4-15
Figure 4-16. Dragline bucket, teeth replacement.
4-18. Dragline Bucket and Teeth
a. Removal
(1) Lower dragline bucket to ground then
slacken hoist and drag cable.
(2) Remove drag, hoist, and dump cables
from dead end (fig. 416).
(3) Wind cables on drums, slowly, as cable
ends are guided through sheaves (fig. 2-12).
b. Bucket Teeth Replacement.
(1) Removal. Position bucket on its side and
remove four cotter pins, nuts, and lockwashers from
recess in teeth, then remove four wedge screws and
teeth from bucket.
(2) Cleanings, Inspection and Repair.
(a) Clean all parts in an approved
cleaning solvent and dry thoroughly.
(b) Visually inspect teeth for excessive
wear, and mounting hardware for stripped threads or
other defects.
(c) Replace all defective parts.
Figure 4-17. Hook block and weighted hook,
(3) Teeth Installation
removal or installation.
(a) Position teeth on lip of bucket.
(b) Insert wedge screw and secure
tooth (4)in position with lockwasher, nut, and cotter pin
(4).
4-16
Figure 4-18. Boot point and idler sheaves, removal and installation
c. Installation of Bucket. Reeve drag cable, hoist
cable, and dump cable and connect to dead ends (fig. 416).
(5) Remove capscrew, lockwasher, and rod
end that secures boom point sheave shaft, drive out
shaft, then remove spacers and sheaves.
(6) Remove four nut, lockwasher, and cap
screw, then remove guard.
419. Hook Block and Weighted Hook
Refer to reeving diagram (fig. 2-7) and figure 4-17 for
removal and installation of hook block or weighted hook.
Note
Do not remove bearings unless
replacement is required.
420. Boom Point and idler Sheaves
b. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for signs of
excessive wear, cracks, breaks, bends, or stripped
threads.
(3) Replace all defective, damaged, or worn
parts.
a. Removal
(1) Lower boom (para 2-12b).
(2) Remove hook (para 4-19) or bucket
(paras 417 or 418), that is currently is use, then wind
cables on drum(s).
(3) Remove nut (fig. 4-18), two lock-washers,
bolt, and spacer.
(4) Remove capscrew, lockwasher, and rod
end securing idler sheave shaft, remove shaft, two
spacers, and three idler sheaves.
4-17
Figure 4-19. Jib boom, cribbed for installation, or removal.
Figure 4-20. Crane boom with jib, installed view.
4-18
Figure 4-21. Jib boom, disassembly or reassembly.
4-19
(1) Remove cotterpins, pins, and two
turnbuckles from pendant wire ropes (fig. 4-21), then
remove cotterpins and pins from pendant wire ropes and
remove wire ropes from jib boom and strut.
(2) Remove capscrew, lockwasher, and
keeper rod securing strut sheave pin; remove sheave
pin, spacer and sheave from strut. Remove fitting and
bushing from strut sheave pin.
Note
Do not remove bearings from
sheaves unless replacement is
required.
(3) Remove four cotterpins from two strut
pins, remove pins, then remove strut from jib boom.
(4) Remove three nuts and lockwashers from
two capscrews and bolt, remove bolt and capscrews,
then remove sheave guard.
(5) Remove nut, lockwasher, capscrew, and
keeper rod securing jib boom point sheave shaft,
remove shaft, spacer, and sheave. Remove fitting and
bushing from sheave shaft.
Note.
Do not remove bearings unless
replacement is required.
(6) Reassemble by reversing procedure of
steps (5) through (1) above.
d. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect jib boom for cracks,
breaks, or bent sections. Inspect sheave pins and
shafts for excessive wear. Inspect mounting hardware
for stripped threads or elongated holes.
(3) Repair breaks and cracks by welding,
straighten all bends, and replace all worn, damaged, or
defective parts.
c. Installation.
Install boom point and idler
sheaves by reversing steps (6) through (1) in a above.
4-21. Jib Boom, Strut, and Sheaves
a. Installation. When use of jib boom is required, it
will be installed as follows:
(1) Build cribbing at end of cribbed jib boom
(fig. 4-19) in line with and of equal height for crane
boom.
(2) Lower hook block to ground, remove two
clamps (fig. 4-20) from hoist cable, remove hook block,
then wind hoist cable onto drum.
(3) Lower crane boom (para 2-12b) to rest on
cribbing (fig. 4-19).
(4) Move jib boom into position over crane
boom point and install jib to boom point pin (fig.
4-21) then install keeper rod and secure with lockwasher
and capscrew.
(5) Install strut on jib boom, install two strut
pins, and secure pins with four cotterpins.
(6) Position pendant wire ropes at strut, install
pins through sockets and secure with cotterpins.
(7) Connect wire ropes to jib boom point,
install pins and secure pins with cotterpins.
(8) Connect longer wire ropes to eyebolt of
turnbuckle, connect turnbuckle to crane boom foot,
install pins and secure with cotter pins.
(9) Refer to figure 2-7 and reeve crane hook
block and jib boom hoist cables.
(10) Raise boom (para 2-12b).
b. Removal of Jib Boom.
(1) Move crane-shovel unit into position for
placement of jib boom, then build cribbing (fig. 4-19).
(2) Lower jib boom weighted hook to ground,
remove clamps, then cable from weighted hook. Wind
cable onto hoist drum.
Note.
If crane boom is to be removed,
remove hook block in a manner
similar to (2) above, winding cable
onto digging drum.
(3) Lower boom (para 2-12b) until jib boom
rests on prepared cribbing, then disconnect two pendant
wire rope turnbuckles from crane boom foot.
(4) Remove capscrew, lockwasher, and
keeper rod securing jib boom point pin, then remove pin.
Note.
If crane boom is to be removed,
proceed as directed in paragraph 4-2.
(5) Move crane-shovel unit away from
cribbed jib boom.
c. Disassembly and Reassembly.
4-22. Boom Backstop
a. Removal and Installation.
(1) If necessary, raise boom (para 2-12b) to a
moderate angle and take pressure off mounting
hardware; remove four nuts, lockwashers, and
capscrews (fig. 4-22) then lift tow bearings from gantry.
(2) Lower boom to a horizontal position with
cribbing at boom point (fig. 2-46).
(3) Remove two cotterpins from pin securing
bearing (fig. 4-22) at boom; drive pin from bearing, then
remove boom backstop.
(4) Install in reverse order.
b. Disassembly and Reassembly.
(1) Slide bottom bearing, spring, seat, and
pipe as an assembly (fig. 4-22) off of two pipes
connected to upper bearing; unscrew two pipes
4-20
(2) Remove two pipes and spacers from
upper bearing.
(3) Reassembly by reversing procedure in
steps (2) and (1) above.
c. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect parts for excessive wear,
bends, cracks, or other defects.
(3) Repair by straightening bends, welding
cracks, or replacement of all parts damaged beyond
repair.
4-23. Radius Indicator (Boom Angle Indicacator)
Figure 4-22. Boom, backstop, removal,
disassembly, reassembly, and installation.
from bearings, then remove pipes, seats, and springs.
a. Removal and installation . Refer to figure 2-27,
remove three mounting capscrews and lockwashers,
then remove radius indicator from crane boom. Install in
reverse order.
b. Disassembly and Reassembly.
(1) Remove eight screws (fig. 4-23),
flatwashers, and two plates to expose bearings and
Figure 4-23. Radius (boom angle) indicator, disassembly and reassembly.
4-21
shafts. Remove four capscrews and washer, then
remove end plate.
(2) Remove retaining rings from ends of
drum shaft; move pendulum aside, move drum shaft
against bearing and press bearing out of frame until
drum shaft is free of remaining bearing; remove bearing
from drum shaft, then remove drum and shaft from
frame.
(3) Loosen setscrew securing drum to shaft
and remove drum from shaft. Remove bearing retaining
ring, then remove remaining drum shaft bearing from
frame. Drive pin from gear and shaft, then remove gear
from shaft.
(4) Loosen setscrew and remove gear from
pendulum shaft. Remove capscrew and shim from
pendulum, then remove pendulum from shaft.
(5) Remove retainer from outer shaft bearing;
drive bearing inward until free of frame; remove
bearings from pendulum shaft, then remove shaft.
Note.
Do not remove rivets from plate on
drum unless plate is to be replaced.
(6) Reassemble by reversing procedure in
steps (,5) through (1) above.
Note.
At reassembly, assure that pendulum
and bind. Test by moving frame
back and forth through drum
measurement are.
c. Cleaning, Inspection and Repair.
(1) Clean -all parts, except bearings, in an
approved cleaning solvent and dry thoroughly.
(2) Visually inspect bearings for signs of
scoring in races, excessive wear, or other defect.
Clean serviceable bearings by wiping exterior with a
cloth dampened' in engine lubricating oil, then lay them
aside protected from contamination until reassembly.
Replace all defective bearings.
(3) Visually inspect all parts for signs of
excessive wear or other defect. Replace all defective
parts.
Section III. BACKHOE FRONT END ATTACHMENT
4-24. General
(para 4-30); lower auxiliary gantry toward boom until
blocking can be positioned (fig. 2-15).
(4) Disconnect backhoe digging cable, boom
hoist cable and boom (gantry) hoist cable from dead end
sockets, then unreeve by winding cables on drums (fig.
2-16). Wind cables slowly, while ends are carefully
guided through sheaves.
(5) Use wedges or jacks to raise boom foot
enough to take weight off pins; remove pins which
attach backhoe boom adapters to revolving frame lugs.
The backhoe boom and gantry remain attached to boom
foot adapters. Secure backstop in closed position on
gantry.
(6) Move crane-shovel unit away from
backhoe front end attachment.
b. Disassembly and Reassembly.
(1) Remove backstop (para 4-30).
(2) Remove auxiliary gantry (para 4-27).
(3) Remove backhoe bucket (dipper) (para 428).
(4) Remove backhoe bucket (dipper) stick
(para 4-29).
(5) Disassemble or reassemble backhoe
boom (para 4-30).
(6) Disassemble and reassemble components
as described in the paragraphs listed above.
(7) Reassemble backhoe attachment by
reversing steps (4) through (1) above.
c. Installation.
When backhoe front end
attachment is to be installed, assure that backhoe lag-
The backhoe front end attachment (fig, 4-24) does not
use the planetary pinion gear of the shovel, therefore if
the crane-shovel unit is so equipped, they must be
removed (para 3-125). Backhoe attachment consists of
boom, bucket handle, brace, bucket, auxiliary gantry,
spreader bar, backstop, boom foot adapters and
backhoe lagging for digging drum. Cables for backhoe
operation are listed in table 1-2, and are reeved as
shown in figure 2-16.
Caution:
When reeving the digging cable, be
sure that a second layer does not
wrap on drum. Over wrapping
causes very rapid cable wear.
4-25. Lagging
Backhoe lagging for digging drum is installed, or
removed, in manner described in paragraph 3-124.
4-26. Backhoe Front End Attachment
a. Removal.
(1) Select a firm level area in which to work.
Caution:
If attachment will not be used for a
considerable
period
of
time,
arrangements should be made to
protect the machinery from damage
by the elements.
(2) Pull bucket under boom and lower boom
gradually until blocking may be placed between pitch
brace and boom (fig. 2-15).
(3) Build cribbing at boom point and foot (fig.
2-15); lower boom to cribbing, disconnect backstop
4-22
Figure 4-24. Backhoe front end attachment, installed view.
4-23
ging is installed on digging drum (para 3-124) then
proceed as follows:
(1) Move crane-shovel unit into position at
cribbed backhoe attachment as shown in figure 2-15.
(2) Use wedges or jacks to raise boom from
cribbing so that adapters line up with revolving frame
foot lugs, install pins that secure boom foot adapters to
revolving frame and secure pins with cotter pins (fig. 424).
(3) Lift auxiliary gantry from boom, lean it
toward crane-shovel, then attach backstop to revolving
frame gantry pin (para 4-30).
(4) Remove blocking that is between auxiliary
gantry and boom (fig. 2-15); install backhoe cables
shown in table 1-2 as described in paragraph 3-29, and
reeve (fig. 2-16).
(5) Adjust boom hoist cable on drum until
auxiliary gantry is vertical; use hoist cable to raise boom
and remove cribbing at point and foot of boom, then
release digging cable and allow bucket to drop so
blocking can be removed from between brace and boom
(fig. 2-15).
(6) Perform preventive maintenance checks
and services (para 3-6).
4-27. Backhoe Auxiliary Gantry
a. Removal.
(1) Lower boom (para 2-12b) to rest on
cribbing (fig.2-15b).
(2) Disconnect boom hoist, hoist, and digging
cables at dead end sockets (fig. 2-16) then wind on
drums (unreeve).
(3) Remove backstop (para 4-30).
(4) Remove four cotterpins (fig 4-25) from
two pins securing gantry to left and right hand boom foot
adapters, remove pins, then remove auxiliary gantry.
b. Disassembly and Reassembly.
(1) Refer to figure 4-26, remove items 1
through 9 is numerical sequence, then remove sheave
frames from gantry.
(2) Refer to figure 4-25 to remove adapters
and wire rope socket from gantry frame.
(3) Complete disassembly, numerically, as
shown on figure 4-26.
(4) Reassemble in reverse order.
c. Installation. Install the auxiliary gantry by
reversing procedure in steps (4) through (1) in a above.
Figure 4-25. Auxiliary gantry and boom foot adapters.
4-24
Figure 4-26. Auxiliary gantry sheaves.
4-25
NOTE:
DO NOT REMOVE BEARINGS OR BUSHINGS UNLESS REPLACEMENT IS REQUIRED.
Figure 4-27. Backhoe bucket, disassembly and reassembly.
d. Cleaning, Inspection, and Repair.
(2) Remove bail and link by removing cotter
pins, nuts, washers, and bolts (fig. 4-27).
(3) Remove cotter pin, nut, washers and bolt
securing brace to bucket. Remove cotter pins ,and pin
(fig. 4-28) securing bucket to bucket stick, then remove
bucket.
b. Disassembly and Reassembly.
(1) Disassemble bail by removing two bolts,
lockwashers, and keeper plastic (fig. 4-27), remove pin,
then remove sheave from bail.
(2) Remove 12 nuts and bolts, and remove
left and right hand cutting edges.
(3) Drive pins and plugs out of five teeth then
remove teeth from adapter.
(4) Drive key out of five adapters, then
remove adapters from bucket.
(1) Clean all parts in an approve cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for cracks,
breaks, bends or other defect.
(3) Repair by welding cracks or breaks,
straightening bends, or replacing defective mounting
hardware.
4-28. Backhoe Bucket, Bail, and Teeth
a. Removal.
(1) Raise boom (par, 2-12b) build cribbing
under boom near foot, lower boom to rest, then
disconnect and unreeve the digging cable (fig. 2-16).
4-26
NOTE
DO NOT REMOVE BUSHINGS OR BEARINGS UNLESS
REPLACEMENT IS REQUIRED.
Figure 4-28. Backhoe bucket stick, disassembly and reassembly.
4-27
a. Removal.
(1) Remove four locknuts, nuts, and two U
Figure 4-19.
(5) Reassemble by reversing procedure of
steps (4) through (1) above.
c. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for cracks,
breaks, bends or excessive wear.
(3) Repair by welding cracks or breaks,
straightening bends, or replacing excessively worn
parts.
d. Installation. Install bucket, bail, and teeth by
reversing procedure in steps (3) through (1) in a above.
4-29. Backhoe Bucket Stick
a. Removal.
(1) Lower boom to rest on cribbing, near foot,
then unreeve hoist and digging cables (fig.
3-16).
(2) Attach lifting device to bucket stick,
remove keeper rod (fig. 4-28) and boom point pin, then
remove bucket stick from boom.
b. Disassembly and Reassembly.
(1) Remove bucket (para 4-28).
(2) Remove cotterpin, nut, washers, and bolt from pitch
brace (fig. 4-28) then remove brace from stick.
Note.
At reassembly, depth of bucket slice
is adjusted by position of bolt in
brace. For deep excavation put bolt
through
lower
hole.
Where
maximum
dumping
height
is
required put bolt in upper hole. For
normal operation the bolt should be
in center hole.
(3) Remove nut, lockwasher and bolt then
remove sheave frame from bucket stick.
(4) Remove cotter pin, nut, lockwasher.
spacer, sheave, and bolt from frame.
(5) Remove cotter pin, nut, wedge socket,
and pin from frame.
(6) Reassemble by reversing procedures in
steps (5) through (1) above.
c. Cleaning, inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect parts for cracks, breaks,
bends, or excessive wear.
(3) Repair by welding cracks or breaks, .
Lightening bends, or replacing worn or defective parts.
d. Installation. Install bucket stick by reversing
procedure used in removal (a above).
Figure 4-29. Backhoe safety backstop, removal,
disassembly, reassembly, and installation.
Backhoe safety backstop, removal, disassembly,
reassembly, and installation bolts (fig.
4-9), and
disconnect backstop from revolving frame gantry pin.
(2) Remove two cotter pins from pin, remove
pin, then remove backstop from auxiliary gantry.
b. Disassembly and Reassembly.
(1) Separate the two pipes by pulling smaller
out of the larger (fig. 4-29).
(2) Remove washer and spring from the
larger pipe.
(3) Reassemble by reversing procedure in
steps (2) and (1) above.
c. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved c ing
solvent and dry thoroughly..
(2) Visually inspect pipes for bend or other
defect, and spring for compression strength.
(3) Repair by straightening bends, or
replacing defective parts.
d. Installation. Install backstop by reversing
procedure in a above.
4-30. Backhoe Safety Backstop
4-28
Figure 4-30. Backhoe boom disassembly and reassembly.
4-29
4-31. Backhoe Boom
a. Removal. When boom must be repaired, or
replaced, proceed as follows:
(1) Pull bucket under boom and lower boom
to rest on cribbing at boom foot only, then unreeve all
cables (fig. 2-16), winding them carefully on drums.
(2) Remove boom safety backstop (para 430).
(3) Remove auxiliary gantry (para 4-27).
(4) Remove bucket stick (para 4-29).
(5) Build cribbing under boom point, use
wedges or jacks to take weight off boom foot pins (fig.
4-30) remove pins, then move crane-shovel unit away
from boom.
b. Disassembly and Reassembly.
(1) Remove two cotter pins, pins, and guide
sheaves from boom foot.
(2) Remove cotter pin, pin, and guide sheave
from under sheave guard.
(3) Remove two cotterpins, pin, wedge, then
remove cotter pin, nut, socket, lockwasher and bolt from
boom.
(4) Remove two nuts, lockwashers, and bolts
from bumper blocks, then remove bumper blocks from
boom.
Note.
Do not remove bushings or bearings
unless replacement is required.
(5) Reassemble boom and components by
reversing procedure in steps (4) through (1) above.
c. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect all parts for cracks,
breaks, bends, scored or worn bearings, worn bumper
blocks, or other defects.
(3) Repair by welding cracks or breaks,
straightening bends, and replacing worn or defective
parts.
d. Installation. Install backhoe boom by reversing
procedures in a above.
Section IV. PILEDRIVER FRONT END ATTACHMENT
4-32. General
(5) Raise boom (para 2-12b) just enough to
The piledriver front end attachment (fig. 2-14) consists
allow cribbing to be removed. Remove cribbing, then
of a standard crane boom (para 4-13) with one 10 foot
install pile leads (para 4-35).
boom section inserted between base and point sections,
(6) Reeve hammer and pile handling cables
pile leads, hangers, catwalk, adapters, hammer, pile
(fig. 2-13), run off enough slack in pile handling cable to
cap, pile collar, and special cables for hoist and digging
keep looped end in reach, then guide hammer cable
drums (table 1-2).
down through pile threads. Raise boom (para 2-12b)
Caution:
and travel unit forward (para 2-12c) simultaneously until
Crane-shovel unit must be level
pile leads are suspended vertically (fig. 2-14) with
when using piledriver attachment. If
bottom of leads touching the ground.
it is impracticable to grade site level,
Caution:
timbers must be used to level the
Do not drag bottom of leads on
unit.
ground by raising boom without
4-33. Piledriver Front End Attachment
traveling crane-shovel unit, and
a. Installation. Assuming the shovel front end
avoid damage to leads.
attachment has been installed, proceed as follows:
(7) Install adapters on catwalk (para 4-47)
(1) Remove shovel front end attachment
then install catwalk.
(para 4-2).
(8) Install pile hammer, pile cap, and pile
(2) Remove shovel cables from drums (para
collar (para 4-36).
3-39), remove shovel sprocket and planetary pinion
(9) Lower hammer, cap, and collar to ground,
gear, (para 3-125), install crane lagging (para 3-124),
then perform preventive maintenance checks and
and reposition planetary clutch band to crane
services (para 3-6).
configuration (para 3-123).
b. Removal. When piledriver front end attachment
(3) Install piledriver cables (table 1-2) (para
is
to
be removed and stored so that craneshovel unit
3-39) and wind boom hoist, pile handling, and hammer
may
be
converted for other use, proceed as follows:
cables on drums.
(1) Move piledriver unit to a suitable area for
(4) Move crane-shovel unit into position to
storage,
then
remove collar, cap, and hammer (para 4install boom similar to that shown in figure 26, connect
36).
boom to revolving frame (para 4-13), then reeve boom
(2) Remove pile leads (para 4-35).
hoist cable (fig. 2-7).
(3) When shovel or backhoe front end at4-30
tachment is to be installed, remove crane boom (para 413).
Note.
When crane, clamshell, or dragline
front end attachment is to be
installed, disregard step (3) above
and proceed as in step (4) below.
(4) Remove pile driver cables (para 3-39),
and after referal to appropriate paragraph, install lagging
and cables (table 1-2) for the new front end attachment.
Caution:
When it is intended to store any
removed front end attachment for a
considerable period of time, all
components must be lubricated in
accordance with current lubricating
order (LO 5381020612), and protected
against deterioration by the elements
during period of storage.
4-34. Pile Lead Hangers
a. Removal. Remove six nuts, lockwashers, and
bolts from each hanger (fig.
4-31), then remove
hangers from pile lead.
b. Cleaning, Inspection and Repair.
(1) Clean all parts in an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect hangers for cracks,
bends, or breaks, and mounting hardware for stripped
threads, or other defects.
(3) Repair by straightening bends, welding
cracks or breaks, or replacement of defective part.
c. Installation. Position lead hangers on lead, then
secure each one with six bolts, lockwashers, and nuts.
4-35. Pile Leads
a. Installation.
(1) Remove one lead hanger (para 4-34)
move crane-
shovel unit with proper boom installed into position at
cribbed pile leads, position installed hanger over boom
point sheave pin, position loose hanger over boom point
sheave pin, then secure it to lead with six bolts,
lockwashers, and nuts.
(2) Position two spacers (fig. 4-32) on boom
point sheave pin ends, install two split collars, and
secure each with bolt, lockwasher and nut.
b. Removal.
(1) Remove collar, cap, and hammer (para
436).
(2) Remove catwalk and adapters (para 0 437).
(3) Position cribbing for foot of pile lead (fig.
4-31) then lower boom (para 2-12b) and travel craneshovel unit (para 2-12c) backward simultaneously, until
boom point is just above the horizontal, then build
cribbing to support top and center of pile leads (fig. 431).
Caution:
Be sure cribbing is high enough to
keep boom point above the
horizontal.
(4) Use wedges or jacks to take weight off of
pile hangers, remove two nuts, lockwashers, and bolts
securing split collars (fig. 4-32), remove two collars, and
two spacers.
(5) Remove one lead hanger (para 4-34)
work remaining hanger off boom point sheave pin, move
crane shovel unit away; from leads, then reinstall
removed hanger on lead.
(6) Raise boom and move crane-shovel unit
to area for boom removal, if required.
4-36. Hammer, Pile Cap, and Pile Collar
a. Installation.
(1) Raise pile leads above hammer, swing
Figure 4-31. Pile leads, cribbed for removal or installation.
4-31
Figure 4-32. Pile lead attaching hardware.
disconnect hammer cable from pin and remove hammer
boom until leads are over hammer, then install hammer
by raising pile leads and swinging them aside.
cable to pin (fig. 4-32).
(2) Lift hammer up into pile leads, making
sure guides of hammer engage pile guides.
4-37. Catwalk and Adapters
(3) Position pile leads over pile cap and
collar, lower hammer to rest on cap, then place two
a. Installation.
collar cable loops over hooks on hammer.
(1) Install two adapters (fig. 4-34) on end of
b. Removal
catwalk, and secure each with two capscrews,
lockwashers, and nuts.
(1) Lower hammer to ground, lift two collar
cable loops off hooks on hammer and leave collar and
(2) Position adapters and connect to
cap on ground.
revolving frame, then extend the telescoping catwalk
toward pile lead and install two capscrews. Secure with
(2) Raise hammer and pile leads clear of cap
lockwashers and nuts.
and collar, swing it to one side, lower hammer to
ground,
then
4-32
b.
Removal
(1) Remove two nuts, lockwashers, and
capscrews securing catwalk to pile lead (fig. 2-14).
Telescope catwalk to its shortest length, then disconnect
adapters from revolving frame.
(2) Remove four nuts, lockwashers and
capscrews (fig, 4-32), then remove two adapters from
catwalk.
Section V. ACCESSORIES
4-38. General
The accessory items installed on crane-shovel units
include horn and extension (trouble) light.
This section will describe organizational maintenance
responsibilities for these items.
4-39. Horn
a. Removal.
(1) Tag and disconnect two electrical leads
(fig. 4-33).
(2) Remove two nuts, lockwashers, clamp,
and screws that secures horn to underside of revolving
frame and remove horn.
b. Cleaning, Inspection and Repair.
Figure 4-33. Horn, removal and installation.
and remove tags. Insure that ample electrical connector
plugs are well seated in the female half.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly.
(2) Visually inspect horn and mounting
hardware for damage or defect. Inspect electrical leads
for defective insulation or connectors.
Test leads and horn for continuity.
(3) Replace defective horn, lead, or mounting
hardware.
4-40. Extension (Trouble) Light
The trouble light hangs in cab ready for installation of
quick connector plug into trouble light socket (fig. 2-24)
on lighting control panel.
Length of light cord allows use of light at any place
inside cab enclosure.
c. Installation.
(1) Position horn on revolving frame (fig. 433), install two screws, clamp, lockwashers, and secure
with two nuts.
(2) Install two electrical leads as tagged
Figure 4-33. Horn, removal and installation.
4-33
CHAPTER 5
SHIPMENT AND LIMITED STORAGE, AND DEMOLITION TO PREVENT ENEMY USE
5-1. General
Section I. SHIPMENT AND LIMITED STORAGE
5-3. Loading Crane-Shovel for Shipment
When mobile equipment is being transported from place
to place in the zone of interior, other than by it's own
locomotion, it is considered as being in administrative
storage during the period of shipment. Administrative
storage is defined as limited storage, a storage period of
up to 90 days, when equipment must be preserved from
deterioration caused by the elements.
a. Rail Shipment. Blocking, bracing, and tiedown
of the crane and attachments shall be in accordance
with Section No. 1 (General Rules) and applicable
figure(s) in Section 4 of the Association of American
Railroads, "Rules Governing the Loading of
Commodities on Open Top Car."
5-2. Preparation for Limited Storage
b. Anti-Rotation Rods and Crane Cab (Swing)
Lock. Secure the crane cab (swing) lock in the locked
position to prevent displacement. The anti-rotation rods
shall be installed (fig. 2-20 and 2-21) and positive
means provided to prevent nuts from working loose.
Refer to TM 740-90-1, Administrative Storage of
Equipment, for detailed instructions on preparation of
the crane-shovel basic unit for administrative storage
and maintenance during storage.
c. Movement to New Worksite.
Instructions
covering move to new worksite are provided in
paragraph 2-5.
Section II. DEMOLITION OF MATERIAL TO PREVENT ENEMY USE
5-4. General
When capture or abandonment of the crane-shovel is
imminent, the responsible unit commander must make
the decision either to destroy the equipment or render it
inoperative. Based upon this decision, orders are issued
which cover the desired extent of destruction. Whatever
method of destruction is employed, -it is essential to
destroy the same vital parts of all crane-shovel units and
all corresponding spare parts in the critical area. When
lack of time or personnel prevents complete destruction
of the crane-shovel, the following priority will be used in
destruction of essential parts:
Priority
1
2
3
4
5
Priority
Part
6
7
8
9
10
Clamshell and dragline buckets.
Gantry.
Hook rollers and roller circle.
Cables (all).
Propelling gear, sprockets, crawler
sprockets, and treads.
5-5. Demolition to Render Crane-Shovel Inoperative
a. Demolition by Mechanical Means. Use sledge
hammers, crowbars, picks, axes, cutting, or any other
tools which may be available to demolish items in the
priority established in paragraph 5-4 above.
Part
Engine clutch and drive sprocket,
jackshaft drive sprocket, drive pinion,
gears, drum clutches, swing clutches,
and boom hoist mechanism.
Engine block, head, fuel injectors, and
all control mechanisms.
Machinery side frame castings.
Boom foot connections.
Shovel
attachment,
backhoe
attachment, piledriver, crane and jib
booms.
b. Demolition by Misuse.
(1) Drain engine radiator and crankcase.
(2) Throw sand or other abrasive material into
engine clutch main drive chain case, jackshaft bevel
gear case, horizontal gear train, and propelling shaft oil
pan.
(3) Start engine and engage clutch.
(4) Operate the front end attachment forci
5-1
bly into a bank or tree, or another object, to damage
boom and break cables.
(5) Drop bolts, nuts, and tools into gear trains.
(6) Operate unit until failure occurs.
(17) One 1-pound charge against each corner
angle at midpoint of crane boom.
(18) One 6-pound charge at boom point
sheaves on crane.
(19) One 4-pound charge at dragline pins and
a 2-pound charge at hoist line pins of dragline bucket.
(20) One 4-pound charge on upper closing
sheaves and one 4pound charge at lower closing
sheaves and hinges of clamshell bucket.
(21) Three 4-pound charges along piledriver
leads.
(22) One 6-pound charge in propelling gear oil
pan.
(23) One 4-pound charge on each of the
crawler tracks at crawler drive sprocket.
(24) One 4pound charge on each chain drive
sprockets on end of horizontal propelling shaft.
b. Demolition by Weapons Fire.
Fire on
craneshovel unit with the heaviest weapon available.
5-6. Demolition by Explosives or Weapons Fire
a. Demolition by Explosives. Place as many of the
following charges as the situation permits, and detonate
them simultaneously with detonating cord and a suitable
detonator.
(1) One 4-pound charge on engine drive
sprocket and jackshaft sprocket.
(2) One 4pound charge against the main
clutch and machinery side frame castings at each end of
main drum shaft.
(3) One 4-pound charge against boom hoist
mechanism.
(4) One 2-pound charge against each of the
swing clutches on the jackshaft.
(5) One 4-pound charge in the jackshaft
bevel gear case.
(6) One 4-pound charge on top of the vertical
propelling shaft.
(7) One 2-pound charge between starter and
engine.
(8) One 4-pound charge at each of the boom
hinges.
(9) One 4-pound charge against each of the
hook rollers.
(10) One 4-pound charge against side of
engine.
Note.
The above charges are considered
minimum requirements for this
method.
(11) One 8-pound charge on shipper shaft of
shovel boom.
(12) One 8-pound charge on dipper handlebucket connection.
(13) One 1-pound charge on each of boom
hoist sheaves.
(14) One 8-pound charge at bucket-dipper
stick connection of backhoe attachment.
(15) One 4-pound charge at stick point, and
another at stick pivot of backhoe attachment.
(16) One 6-pound charge against auxiliary
gantry of backhoe attachment.
5-7. Other Demolition Methods
a. By Scattering and concealment. Remove all
easily accessible vital parts, such as fuel injectors,
hydraulic lines, control levers, brake and clutch
cylinders, starting motor, and hook rollers. Scatter these
parts through dense foliage; bury them in dirt or sand, or
throw them in lake, stream, well, or other body of water.
b. Burning. Pack rags, clothing or canvas under
and around unit, particularly around engine, clutches,
brakes, and fuel tanks saturate this packing with
gasoline, oil or diesel fuel and ignite it.
c. Submersion. Totally submerge the craneshovel
unit in a body of deep water to provide water damage
and concealment. (Salt water does most damage to
metal parts).
5-8. Training
All operator's should receive thorough training in
methods of destroying the crane-shovel unit. Refer to
FM 5-25. Simulated destruction, using methods listed
above, should be included in operator training programs.
It must be emphasized in training that demolition
operations are only necessitated by critical situations,
when time available for destruction is limited. For this
reason, it is necessary that operators be thoroughly
familiar with all methods of destruction and be able to
perform demolition without refering to this or any other
manual.
5-2
APPENDIX A
REFERENCES
A-1. Fire Protection
TB 5-4200-200-10
Hand Portable Fire Extinguishers for Army Users
A-2. Lubrication
C9100-IL
L0 5-3810-206-12-1-2-3-4-5
Fuels, Lubricants, Oils and Waxes Lubrication Order
A-3. Painting
TM 9-213
Painting Instructions for Field Use
A-4. Radio Suppression
TM 11-483
Radio Interference Suppression
A-5. Maintenance
TM 38-750
TB ORD 651
TM 5-3810-206-20P
TM 9-61 40-200-15
TB 385-101
Equipment
A-6. Shipment and Storage
TM 740-90-1
Army Equipment Record Procedure
Use of Antifreeze Solutions and Cleaning Compounds in Engine
Cooling Systems
Organizational Maintenance Repair Parts and Special Tools Lists
Operation and Organizational, Field and Depot Maintenance Storage
Batteries, Lead/Acid Type
Safety Use of Cranes, Crane-Shovel Dragline, and Similar
Near Electric Power Lines
Administrative Storage of Equipment
A-1
APPENDIX B
BASIC ISSUE ITEMS LIST
Section I. INTRODUCTION
B-1. Scope
Code
This appendix lists items which accompany the craneshovel basis unit or are required for installation,
operation, or operator's maintenance.
R
B-2. General
This Basic Issue Items List is divided into the following
sections:
a. Basic Issue Items-Section II. A list of items
which accompany the crane-shovel basic unit and are
required by the operator/crew for installation, operation,
or maintenance.
b. Maintenance and Operating Supplies-Section III.
A listing of maintenance and operating supplies required
for initial operation.
S
T
B-3. Explanation of Columns
The following provides an explanation of columns in the
tabular list of Basic Issue Items, Section II.
a. Source, Maintenance and Recoverability Codes
(SMR), Column (1):
Note.
Common hardware items known to
be readily available in Army supply
will be assigned Maintenance Codes
only. Source Codes, Recoverability
Codes, and Quantity Authorized will
not be assigned this category of
items.
(1) Source code, indicates the selection
status and source for the listed item. Source codes are:
Code
Explanation
P
Applied to repair parts which are stocked in
or supplied from GSA/DSA or Army supply
system, and authorized for use at indicated
maintenance categories.
(2) Maintenance code, indicates the lowest
category of maintenance authorized to install the listed
item. The maintenance level code is:
Code
Explanation
U
Explanation
Applied to repair parts and assemblies
which are economically repairable at DSU
and GSU activities and are normally
furnished by supply on an exchange basis.
Applied to repair parts and assemblies
which are economically repairable at DSU
and GSU activities and which normally are
furnished by supply on an exchange basis.
When items are determined by a GSU to be
uneconomically repairable, they will be
evacuated to a depot for evaluation and
analysis before final disposition.
Applied to high dollar value recoverable
repair parts which are subject to special
handling and are issued on an exchange
basis. Such repair parts are normally
repaired or overhauled at depot
maintenance activities.
Applied to repair parts specifically selected
for salvage by reclamation units because of
precious metal content, critical materials, or
high dollar value reusable casings or
castings.
b. Federal Stock Number, Column (2).
This
column indicates the Federal stock number assigned to
the item and will be used for requisitioning purposes.
c. Description, Column (3). This column indicates
the Federal item name and any additional description of
the item required. The abbreviation “w/e", when used as
a part of the nomenclature, indicates the Federal stock
number includes all armament, equipment, accessories,
and repair parts issued with the item. A part number or
other reference number is followed by the applicable
five-digit Federal supply code for manufacturers in
parenthesis. The physical security classification of the
item is indicated by the parenthetical entry repair parts
quantities included in kits, sets, and assemblies are
shown in front of the repair part name.
d. Unit of Measure (u/m), Column (4).
A-2
character alphabetic abbreviation indicating the amount
or quantity of the item upon which the allowances are
based, e.g., ft, ea, pr, etc.
e. Quantity Incorporated in Unit Column (5).
This column indicates the quantity of the item used in
the functional group or the assembly
(3) Recoverability code, indicates whether
unserviceable items should be returned for recovery or
salvage.
Items not coded are expendable.
Recoverability codes are:
B-1
group. A "V" appearing in this column in lieu of a
quantity indicates that a definite quanity cannot be
indicated (e.g. shims, spacers, etc).
the item and will be used for requisitioning purposes.
c. Description, Column (8). This column indicates
the item name and brief description.
f. Quantity Furnished with Equipment, Column (6).
This column indicates the quantity of an item furnished
with the equipment.
g. Illustration, Column (7). This column is divided
as follows:
(1) Figure Number, Column (7) (a). Indicates
the figure number of the illustration in which the item is
shown.
(2) Item Number, Column (7) (b). Indicates
the callout number used to reference the item in the
illustration.
d. Quantity Required for Initial Operation, Column
(4).
This column indicates the quantity of each
maintenance or operating supply item required for initial
operation of the equipment.
e. Quantity Required for 8 Hours Operation,
Column (5).
This column indicates the estimated
quantity required for an average 8 hours of operation.
f. Notes, Column (6).
This column indicates
informative notes keyed to data appearing in a
preceding column.
B-4. Explanation of Column in the Tabular List of
Maintenance and Operating Supplies-Section III
B-5. Federal Supply Code for Manufacturers
a. Component Application, Column (1) . This
column identifies the component application of each
maintenance or operating supply item.
Code
Manufacture
27315.................. Harnischfeger Corporation, 4400 W.
National Ave., Milwaukee, Wisconsin
53246
b. Federal Stock Number, Column (2).
This
column indicates the Federal stock number assigned to
Section II. BASIC ISSUE ITEMS
(1)
(2)
(3)
Federal
Stock
Number
Description
SMR
Code
Reference Number & Mfr. Code
(4)
Unit
of
meas
(5)
Qty
inc
in
unit
(6)
Qty
furn
with
equip
Usable On Code
GROUP 31-BASIC ISSUE ITEMS,
MANUFACTURER INSTALLED
3100-BASIC ISSUE ITEMS MANUFACTURER
OR DEPOT INSTALLED
PC
7510-889-3494
PC
PC
2590-045-9611
7520-559-9618
PC
4210-889--2221
PC
5120-690-7948
BINDER, LOOSELEAF: U. S. Army Equipment Log
Book
CASE ASSEMBLY, RIFLE
CASE: operation and maintenance publications, water
repellant, mildew resistant, MIL-B-11743B
DEPARTMENT OF THE ARMY LUBRICATION
ORDER LO 5-3810-206-12-1
LO 5-3810--206-12-2
LO 5-3810--206-12-3
LO 5-3810-206-12-4
LO 5-3810-206-12-5
DEPARTMENT OF THE ARMY OPERATOR AND
ORGANIZATIONAL MAINTENANCE MANUAL
TM 5-3810206-12
DEPARTMENT OF THE ARMY ORGANIZATIONAL
MAINTENANCE REPAIR PARTS AND SPECIAL
TOOLS LISTS TM 5-3810--206-20P
EXTINGUISHER, FIRE DIRY CHEMICAL: hand type,
2/2 lb. Stored pressure 1 wall bracket
PULLER, MECHANICAL: 92172 (27315)
B-2
EA
1
EA
EA
1
1
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
EA
1
EA
1
EA
1
(7)
Illustration
(A)
Fig
No.
(B)
Item
No.
Section III. MAINTENANCE AND OPERATING SUPPLIES
(1)
(2)
(3)
Component
application
Federal.
stock number
Description
AIR CLEANER (1)
9150-680-1105 (2)
9150-680-1104 (2)
9150-242-7604 (2)
COOLING SYSTEM
CRANKCASE (1)
9150-234-5199 (2)
EXPOSED GEAR
CHAINS
9150-234-5199 (2)
FUEL TANK
GREASE POINTS
9140-286-5294 (2)
9150-190-0907 (2)
HYDRAULIC
SYSTEM
STARTING AID
TRANSMISSION
9150252-6375
2910-646-9727
9150-577-5841
9150-577-5844 (2)
9150-257-5440 (2)
(4)
Quantity
required
f/initial
operation
LUBRICATING OIL, ENGINE: 55 gal
drum 18 gage, as follows:
HDO-10
HDO-30
OES
WATER
ANTIFREEZE: Ethylene glycol
ANTIFREEZE: Compound arctic
LUBRICATING OIL, ENGINE: (1) (same
as item 1 above)
LUBRICATING OIL, CHAIN-WIRE
ROPE EXPOSED GEAR: 5-lb can,
CW-11, B type 11
FUEL OIL, DIESEL: Bulk as follows:
Regular grade (DF-2)
GREASE, AUTOMOTIVE AND ARTIL35-lb pail, Type GAA
BRAKE FLUID, AUTOMOTIVE: Nonmineral oil, 1 gal cans
Type HBA
Tank, fuel, cold starting aid (61112) LP535
LUBRICATING OIL, GEAR: 6 gal drums
as follows:
GO-80
GO-90
GOS
B-3
(5)
Quantity
required
f/8 hrs
operation
4 1/2 (1)
(3)
62 ½ qt (1)
62 ½ qt (1)
62 ½ qt (1)
36 qt
(4)
(4)
32 qt (1)
(3)
(3)
(3)
5 lb
4 lb (3)
90 gal (5)
60 gal (6)
10 lb
8 lb (3)
13 pts (7)
1 ea
(3)
(9)
10 gal (8)
10 gal (8)
10 gal (8)
(3)
(3)
(3)
(3)
(6)
Notes
(1) Included in quantity required to fill
system as follows:
32 qts Crankcase
2 qts Oil filters
4 1/2 Air Cleaner
8 qts Air Cleaner
16 qts Tagline Winder
(2) See C9100-IL for additional data and
for requisitioning procedures.
(3) See current LO for grade application
and replenishment intervals.
(4) See TB ORD 651 for quantities, CW-11, B
ambient temperatures specific gravities
and replenishment data.
(5) Tank capacity.
(6) Average fuel consumption is 7 1/2 gal
per hour of continuous operation.
(7) Includes ½ qt in swing brake master S"'
cylinder and 1t it in dipper trip master
cylinder.
(8) Includes 20 qts in jackshaft gear case
and 12 qts in propel shaft gear case.
(9) Quantity required is determined by
number or times engine is shut down,
and low temperatures.
APPENDIX C
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
function the item is to be used with. The letter is
representative of columns A through K on the MAC.
E Aline: To adjust specified variable elements of an
item to bring to optimum performance.
F Calibrate: To determine the corrections to be made
in the readings of instruments or test equipment
used in precise measurement. Consists of the
comparisons of two instruments, one of which is a
certified standard of known accuracy, to detect and
adjust any discrepancy in the accuracy of the
instrument being compared with the certified
standard.
G. Install: To set up for use in an operational
environment such as an emplacement, site, or
vehicle.
H Replace: To replace unserviceable items with
serviceable assemblies, subassemblies, or parts.
I
Repair: To restore an item 1 to serviceable
condition.
This includes but is not limited to, inspection,
cleaning, preserving, adjusting, replacing, welding,
riveting, and strengthening.
J Overhaul: To restore an item to a completely
serviceable condition as prescribed by maintenance
serviceability standards using the Inspect and
Repair Only as Necessary (IROAN) technique.
K Rebuild: To restore all item to a standard as nearly
as possible to original or new condition in
appearance, performance, arid life expectancy.
This is accomplished through complete disassembly
of the item, inspection of all parts or components,
repair or replacement of worn or unserviceable
elements (items) using original manufacturing
tolerances and specifications, and subsequent
reassembly of the item.
d. Tools and Equipment, Column (4). This column
is provided for referencing by code the special tools and
test equipment, (Section III) required to perform the
maintenance functions (Section II).
e. Remarks, Column (5). This column is provided
for referencing by code the remarks (Section IV)
pertinent to the maintenance. functions.
C-1. General
a. This section provides a general explanation of
all maintenance and repair functions authorized at
various maintenance levels.
b. Section II designates overall responsibility for
the performance of maintenance functions on the
identified end item or component. The implementation
of the maintenance functions upon the end item or
component will be consistent with the assigned
maintenance functions.
c. Section III lists the special tools and test
equipment required for each maintenance function as
referenced from Section II.
d. Section IV contains supplemental instructions,
explanatory notes and/or illustrations required for a
particular maintenance function.
C-2. Explanation of Columns in Section 11
a. Group Number, Column (1). The functional
group is a numerical group set up on a functional basis.
The applicable functional grouping indexes (obtained
from TB 750-931, Functional Grouping (;odes) are listed
on the MAC in the appropriate numerical sequence.
These indexes are normally set up in accordance with
their function and proximity to each other.
b. Functional Group, Column (2). This column
contains a brief description of the components of each
functional group.
c. Maintenance Functions, Column (3).
This
column lists the various maintenance functions (A
through K) and indicates the lowest maintenance
category authorized to perform these functions. The
symbol designations for the various maintenance
categories are as follows:
C Operator or crew
O Organizational maintenance
F Direct support maintenance
H General support maintenance
D Depot maintenance
The maintenance functions are defined as follows:
A Inspect: To determine serviceability of an item by
comparing its physical, mechanical and electrical
characteristics with established standards.
B Test: To verify serviceability and to detect electrical
or mechanical failure by use of test equipment.
C
D
C-3. Explanation of Columns in Section III
a. Reference Code. This column consists of a
number and a letter separated by a dash. The number
references the T&TE requirements column on the MAC.
The letter represents the
Service: To clean, to preserve, to charge, to paint,
and to add fuel, lubricants, cooling agents, and air.
Adjust: To rectify to the extent necessary to bring
into proper operating ranges specific maintenance
C-1
specific maintenance function the item is to be used
with. The letter is representative of columns A through
K on the MAC.
b. Maintenance Category. This column shows the
lowest level of maintenance authorized to use the
special tool or test equipment.
c. Nomenclature. This column lists the name or
identification of the tool or test equipment.
d. Tool Number.
This column lists the
manufacturer's code and part number, or Federal:
Stock Number of tools and test equipment.
C-4-. Explanation of Columns in Section IV
a. Reference Code. This column consists of two
letters separated by a dash, both of which are
references to Section II. The first letter references
column 5 and the second letter references a main,
tenance function, column 3, A through K.
b. Remarks.
This column lists information
pertinent to the-maintenance function being performed,
as indicated on the MAC, Section II.
Section II. MAINTENANCE ALLOCATION CHART
(1)
G
R
O
U
P
(2)
Functional Group
A
N
U
M
B
E
R
01
0100
0101
0102
0103
0104
0106
0106
0108
0109
(3)
Maintenance functions
ENGINE
Engine Assembly (687C-18-ES)
Engine Assembly (D383TA) -----------Crankcase, Block Cylinder Head
Crankcase assembly
B
C
I
N
S
P
E
C
T
C
C
D
G
H
T
E
S
T
S
E
R
V
I
C
E
I
N
S
T
A
L
L
F
F
C -----------------------------H
C--------------------------------F
A
D
J
U
S
T
E
A
L
I
G
N
F
C
A
L
I
B
R
A
T
E
(4)
Tools and
equipment
O-----------------------------------------------H
Head and valve assembly
(D3S3TA)------------------------------------------------------------------------------------ H
Head and valve assembly
(687C-18-ES)------------------------------------------------------------------------------ H
Crankshaft
Cover assembly --------------------------------------------------------------------------- F
Crankshaft assembly--------------------------------------------------------------------- H
Damper assembly------------------------------------------------------------------------ F
Flywheel Assembly (D333TA)----------------------------------------------------------------- .H
Flywheel Assembly (687C18ES)--------------------------------------------------------------------------------------------- F
Pistons, Connecting Rods .------------------H------------------------------------------------ H
Valves, Camshaft, and Timing
System
Arm assembly, rocker-------------------------------------------O--------------------- F
Cover assembly, cam pocket ---------------------------------------------------------------FF
Cover assembly, valve gear- --------O------------------------------------------------O
Camshaft assembly--------------------H------------------------------------------------H
Valves, seats (687C-18-ES)
H ------------------ ------------------------- H
Valves, seats (D333TA)-------------------F------------------------------------------------- F
Engine Lubrication System
Cooler, oil (DS38TA)--------------------0----------------------------------------------- F
Filter assembly, oil---------------------------------------C-------------------------------O
Pan, oil (687C-18-ES)----------------------------------------------------------------------- -H
Pan, oil (D338TA)----------------------------------------------------------------------------- .F
Pump, oil---------------------------------------H-------------------------------------------------H
Strainer, oil pumpH
H
Strainer, lube oil--------------------------------C-------------------------------------- O
Manifolds, exhaust-----------------------O------------------------------------------------O
Accessory Driving Mechanisms
(687C-18-ES) ----------------------------- -----------------------------------------------------H
Accessory Driving Mechanisms
(D333TA)-----------------------------------------------------------------------------------------FF
C-2
(5)
Remarks
I
J
K
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
O
O
H
H
D -------------------------------------------- A
D
H---------------------
F
1,2,3,
&4
5
H
F
D---------------------------------------6-----------F
H-----------------------------------------------------------F
H ---------------------------
B
C
7, 8
F
H---------------------------------10
H----------------------------------------9---------------------D
F
O
H
H
H
H
Section II. MAINTENANCE ALLOCATION CHART
(1)
G
R
O
U
P
N
U
M
B
E
R
02
0200
0202
03
0301
0302
0304
0305
0306
0308
0309
0311
0312
04
0401
06
0501
0502
0503
0504
0505
06
0601
0602
0602
(2)
Functional Group
(3)
Maintenance functions
A
I
N
S
P
E
C
T
B
C
T
E
S
T
S
E
R
V
I
C
E
D
A
D
J
U
S
T
E
A
L
I
G
N
F
C
A
L
I
B
R
A
T
E
(4)
Tools and
equipment
G
H
I
N
S
T
A
L
L
R
E
P
L
A
C
E
CLUTCH
Clutch Assembly------------------------H --------- C
C---------------------------- H
Clutch Release Mechanism
Cable, flexible control -----------------------------------C---------------------------------------- O
Linkage; lever----------------------------------------------------- O---------------------------- O
Shaft; bearing; yoke---------------------H ------------------------------------------------------- H
FUEL SYSTEM
Fuel injector---------------------------------------F-------------------------------------------------O
Fuel Pump,
Pump fuel injection--------------------------H------------------H---------------------- F
Air Cleaner----------------------------------------------------C-----------------------------------------------Blower-Turbocharger
Blower assembly (687C
18-ES) ------------------ -------------------------------------------------------------------------------F
Manifold (687C-18-ES) ---------------O --------- --------------------------------------------- O
Manifold (D333TA) ----------------------- O------------------------------------------------------ F
Turbocharger (D333TA) ------------------------------------------------------------------------------ F
Tanks, Lines, Fittings
Cap, fuel tank -------------------------------C --------------------------------------------------------- C
Tank, fuel ------------------------------------C----------------C --------------------------------------- O
Engine speed Governor and
Controls
Governor (D833TA) -------------------------------------------------------------------------------F
Shaft assembly, governor
drive---------------------------------------------------------------------------------------------------- H
Fuel Filters---------------------------------------------------------C --------------------------------------- O
Engine Starting Aids------------------------------------------------------------------------------------- O
Accelerator, Throttle or Choke
Controls ----------------------------------------------------------------O---------------------------------O
EXHAUST SYSTEM
Muffler and Pipes------------------------O---------------------------------------------------------O
COOLING SYSTEM
Radiator
Cap, radiator --------------------------------------O----------------------------------------------- O
Guard ---------------------------------O--------------------------------------------------------O
Radiator (D333TA)----------------------- C
O
C--------------------------------------- O
Radiator (687C-18-ES) ---C
F
C----------------------------------------F
Shroud --------------------------------------------------O---------------------------------------------- O
Water Manifold, Headers,
Thermostat, and Housing
Gasket-----------------------------------------O----------------------------------------------- O
Water Pump---------------------------------------------------------------------------------------------- F
Fam Assembly
Belt, V drive-------------------------------C -------------------- -C ------------------------------- O
Fan Assembly----------------------------O--------------------------------------------------------- O
Support assembly (687C-18-ES)------------------------------------------------------------------- O
ELECTRICAL SYSTEM
Generator-Alternator
Alternator (D333TA) ----------------------------------O --------------------------------------- O
Belt, V drive----------------------------------C -------------------------C--------------------------------O
Generator (687C-18-ES)------------------------- O------------------------------------------------O
Generator Regulator --------------------------------O ------------------------------------------------ O
Alternator Regulator--------------------------------O--------------O----------------------------- O
C-3
I
J
K
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
(5)
Remarks
H
O
F
O
----------------
11, 12
H ----------------
13, 14,
15, 16,
17, 18,
19, 20
O
F
H--------------------
21, 22,
23, 24,
25
O
H
H
O
O
O
F
F
O
F---------------------------26
F
F
O
F--------------------------------------
E
Section II. MAINTENANCE ALLOCATION CHART
(1)
G
R
O
U
P
N
U
M
B
E
R
- 0603
0606
0607
0608
0609
0611
0612
0613
0615
08
0801
0804
13
1302
1303
1304
1305
15
1501
18
1801
1806
1808
22
2202
(2)
Functional Group
(3)
Maintenance functions
A
I
N
S
P
E
C
T
B
C
T
E
S
T
S
E
R
V
I
C
E
D
A
D
J
U
S
T
E
A
L
I
G
N
F
C
A
L
I
B
R
A
T
E
(4)
Tools and
equipment
G
H
I
N
S
T
A
L
L
R
E
P
L
A
C
E
I
J
K
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
O
F---------------------------------------F
Starting Motor
Cable assemblies------------------------------------------------------------------------------------- O
O
Starter-------------------------------------------------- O
C--------------------------------------------- O
Engine Safety Controls
Governor assembly, overspeed
(687C-18-ES)-------------------------------------------------------------------------------------- O
F
Switches------------------------------------------------------------------------------------------------- O
Wires------------------------------------------------------------------------------------------------------- O
O
Instrument or Engine Control
Panel
Control box: gages; switches;
lights; indicator; panels;
terminal boards--------------------------- O
O--------------------------------------------------------O
Lamps-------------------------------------------C--------------------------------------------------------------- C
Wiring----------------------------------------------------------------------------------------------------------------O
Miscellaneous items
Circuit breaker; light; junction
boxes, receptacles . -------------------- C---------------------------------------------------------------- O
Lamps---------------------------------------- C---------------------------------------------------------------- C
Wiring-------------------------------------------------------------------------------------------------------------- O
Lights
Floodlights and cab lightsC -------- ----------C ----------------------------------------O
Horn
O-----------------------------------------------------------O
Batteries
------- O
C---------------------------------------------- O
Chassis Wiring Harness-----------------------------------------------------------------------------------H
Radio Interference Suppression
Capacitors (687C-18-ES)---------------------------O-------------------------------------------------------- O
Lead, ground----------------------------------O----------------------------------------------------------------- O
TRANSFER ASSEMBLY
Power Transfer Assembly-------------------C -----------C -------------------------------------------------H
Lubrication Components
Breather, assembly ------------------------------------C - ------------------------------------------------O
TRACKS
Track Support Rollers and
Brackets
Roller assembly, lower------------------------------------C
C---------------------------------------.F
Roller assembly, upper------------------------------------C
C
Track idlers and Brackets
Shaft assembly, drive------------------------C--------------------------------------------------F
Rod, spring----------------------------------------------------------O--------------------------------------- O
Track Drive Sprockets
Chain, drive--------------------------------------------------------C-------------------------------------- O
Shaft assembly, drive-------------------------------------- C-------------------------------------------------F
Track Assembly------------------------------------------------------C----------------------------------------- O
FRAME
Frame Assembly
Mud guard------------------------------- O----------------------------------------------------------------- O
Counterweights----------------------------- O-----------------------------------------------------------------O
BODY, CAB, HOOD AND HULL
Body, Cab, Hood, Hull
Assemblies
Brace: angle; lug; shackle---------H-----------------------------------------------------------------H
Cab assembly------------------------------------------------------------------------------------------------ H
Seats--------------------------------------------------------------------------------------------------------------- O
Boxes, Carrying Cases-----------------O---------------------------------------------------------------- O
BODY CHASSIS OR HULL,
AND ACCESSORY ITEMS
Accessory items
Heater assembly, personnel---------------------------C--------------------------------------------------
C-4
(5)
Remarks
.
O
O
F
H
F
F
O
F
O----------------------------------------G
O
O
O
O
Section II. MAINTENANCE ALLOCATION CHART
(1)
G
R
O
U
P
N
U
M
B
E
R
2210
43
4301
4305
4307
4308
4309
47
4701
74
7410
7411
7412
7413
7414
7416
7419
7420
(2)
Functional Group
(3)
Maintenance functions
A
I
N
S
P
E
C
T
B
C
T
E
S
T
S
E
R
V
I
C
E
D
A
D
J
U
S
T
E
A
L
I
G
N
F
C
A
L
I
B
R
A
T
E
(4)
Tools and
equipment
G
H
I
N
S
T
A
L
L
R
E
P
L
A
C
E
I
J
K
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
Data Plates
Plate, data (C.O.E.)---------------------F-------------------------------------------------------------------F
Plate, instruction-------------------------O------------------------------------------------------------------O
HYDRAULIC SYSTEMS
Strainers Filters, Hose, Pipe
Fittings, Tubing-------------------------------------------------------------------------------------------- O
Mainfold and/or Control Valves--------------------------------------------------------------------------O
Hydraulic Cylinders------------------------------------------------------------------------------------------- O
Liquid Tank------------------------------------------------C----------------------------------------------- O
Manual Controls-----------------------------------------C
O----------------------------------------O
GAGES
Instruments------------------------------------------------- C---------------------------------------------- O
CRANES, SHOVELS, AND
EARTH MOVING EQUIPMENT COMPONENTS
Shovel Front Attachments
Bail assembly, dipper; sheave--------------------C---------------------------------------------- O
Bar assembly, bridle; boom
point assembly; shipper
shaft assembly; tightener
assembly, chain-----------------------------------C---------------------------------------------- F
Boom assembly, shovel----------------------------C-----------------------------------------------C
Chain, crowd---------------------------------------------------C----------------------------------------O
Lagging, sprockets, planetary
pinion gear--------------------------O-----------------------------------------------------------------O
Shell assembly, dipper;
handle, dipper--------------------C------------------------------------------------------------------O
Teeth, dipper-------------------------C------------------------------------------------------------------O
Crane Dragline or Clamshell
Attachment---------------------------------------------C------------------------------------------------C
Back Hoe Attachment---------------------------------C------------------------------------------------C
Pile Driver Attachment---------------------------------C------------------------------------------------C
Base Deck
Frame Assembly, Crane---------------------------C---------------------------------------------- H
Rollers, hook------------------------------------------C
C----------------------------------------O
Rollers; pin (ratchet)--------------------------------C-------------------------------------------------O
Shafts
Brake bands; and clutch
shoes-------------------------------------------------------------- C-------------------------------------- H
Case assembly, chain---------------------------------------C------------------------------------------------OF
Chains--------------------------------------------------------------O--------------------------------------O
Clutch assembly-------------------------------------------------C
Dipper trip assembly and
cables----------------------------------C--------------C
O---------------------------------------C
Guards; covers------------------------------------------------------------------------------------------------ O
Jackshaft assembly-------------------------------------C------------------------------------------------H
Shaft assembly, drum and
idler-----------------------------------------------------C-------------------------------------------------H
Sproket, power take-off
drive-------------------------------------- O-------------------------------------------------------------- O
Turntable
Brake band assembly---------------------------------- C
C---------------------------------------- F
Drum-------------------------------------- H--------------------------------------------------------------- H
Swing lock assembly------------------------------------------------------------------------------------- O
Machinery Gear Case or Frame
Breathers-----------------------------------------------C---------------------------------------------- C
Pan assembly, oil--------------------------------------C------------------------------------------------- H-
C-5
O
F
F
O
F
F
O
O
F
F
O
O
O
O
F
F
O
O
H
H
F
O
H
(5)
Remarks
Section II. MAINTENANCE ALLOCATION CHART
(1)
G
R
O
U
P
(2)
Functional Group
A
I
N
S
P
E
C
T
N
U
M
B
E
R
7421
7422
7423
7424
7425
7499
76
7603
(3)
Maintenance functions
B
C
T
E
S
T
S
E
R
V
I
C
E
D
A
D
J
U
S
T
E
A
L
I
G
N
F
C
A
L
I
B
R
A
T
E
(4)
Tools and
equipment
G
H
I
N
S
T
A
L
L
R
E
P
L
A
C
E
Independent or Precision Boom
Hoist
Brake bands, and clutch
shoes---------------------------------------------------------C--------------------------------O
Drum, cable; spider assemblies--------------------------------------------------C-------------------------------------- H
Planetary brake, holding pawl----------------------------C---------------------------- O
Machinery Mechanism Controls----------------------C
C---------------------------- O
Gantry
Gantry---------------------------------------------------------------------------------------------F
Spreader bar assembly;
sheaves----------------------------------------------C----------------------------------------O
Crawler Bed; Frame and Ring
Gear
Frame and axle assembly-------------------------C
C---------------------------- H
Propel and steering Mechanism
Brake band assembly-------------------------------C
O---------------------------- O
Shaft assemblies; gear assembly, steering----------------------------------------C
O---------------------------- F
Cables------------------------------------C------------------------------------------------------ C
FIRE EXTINGUISHERS
Extinguishers, fire----------------------C-------------------------------------------------------- C
I
J
K
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
F
H
O
F
F
H
H
H
Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS
Reference
code
1-I
2-I
3-I
4-I
5-I
6-H
7-H
8-H
9-H
10-H
11-I
12-I
13-I
14-I
15-I
16-I
17-I
18-I
19-I
20-I
21-I
22-I
23-I
24-I
25-I
26-I
Maintenance
level
H
H
H
H
H
H
H
H
H
H
F
F
H
H
H
H
H
H
H
H
H
H
H
H
H
F
Nomenclature
Puller
Plate (11083)
Puller, Mechanical
Puller, Mechanical
Wrench (11083)
Adapter
Expander (11083)
Compressor (11083)
Lifter, Valve Spring
Puller
Maintenance Fixture
Cleaning Tool Group
Tool Kit, Roosamaster; injector pump
Wrench: Box, halfmoon opening
Extractor
Wrench
Gage
Gage: Rack setting
Seal Tamping Tool
Seal tamping tool guide
Wrench
Fixture Adapter
Fixture
Ring Expander Sleeve
Spacer Block
Puller, Mechanical
C-6
Tool
number
5120-417-2952
5F7362
5120-766-4747
5120-707-1266
5F8353
5120-316-9170
5F9059
5F6502
5120-679-3416
5120-293-1430
4910-657-7429
5120-423-9520
5180-679-3417
5120-649-9184
5120-861-4015
5120-861-4014
4910-861-1344
5210-861-1345
Fabricate
Fabricate
Fabricate
Fabricate
Fabricate
Fabricate
Fabricate
5120-766-4748
(5)
Remarks
Section IV. REMARKS
Reference
code
A— B
B--I.
C--I
D--I
Reference
code
E— I
Remarks
Test of engine includes operation
and compression.
Repair of Crankshaft includes metalizing,
grinding, and alining
Repair of flywheel includes replacing ring gear.
Repair of valves and seats includes refacing.
F— I
G— I
C-7
Remarks
Repair of generator includes brush
replacement only.
Repair of starter includes brushes
and solenoid replacement only.
Organizational repairs track by
replacing trackshoes.
INDEX
Adapters, blower ..........................................................................................
Adapters, catwalk and ..................................................................................
Adjustment:
Alternator drive belt ...............................................................................
And lamp replacement, floodlight ..........................................................
Anti sway (boom foot) spring..................................................................
Boom hoist brake...................................................................................
Crowd chain ..........................................................................................
Dipper trip .............................................................................................
Engine clutch .........................................................................................
Fan drive belt ........................................................................................
Generator drive belt ...............................................................................
Hoist brake, digging brake or planetary clutch band ..............................
Hoist clutch and digging clutch ..............................................................
Hook roller .............................................................................................
Propel chain...........................................................................................
Steering linkage, swing brake, and propel brake ....................................
Steering wheel .......................................................................................
Swing brake hydraulic control and linkage..............................................
Vertical intermediate shaft ....................................................................
Swing (jackshaft) clutch .........................................................................
Track ....................................................................................................
Track idler..............................................................................................
Trip cable ..............................................................................................
Valve (rocker arm) .................................................................................
Aids, cold weather starting ...........................................................................
..............................................................................................................
Air cleaner....................................................................................................
Air cleaner services, engine .........................................................................
Air manifold (blower to blower} (Model 687C18-ES) .....................................
Alternator and belt (Engine Model D333TA) .................................................
Alternator drive belt adjustment (Engine Model D333TA Only) .....................
Alternator regulator (Engine Model D333TA) ...............................................
Altitude, operation at high ............................................................................
Ammeter .....................................................................................................
Anti-sway (boom foot) spring adjustment......................................................
Attachment:
Backhoe front end .................................................................................
Clamnshell front end .............................................................................
Crane front end .....................................................................................
Dragline front end ..................................................................................
Operation of backhoe front end..............................................................
Operation of clamshell front end ............................................................
Operation of crane front end .................................................................
Operation of dragline front end .............................................................
Operation of jib boom front end .............................................................
Operation of piledriver front end ............................................................
Operation of shovel front end.................................................................
Piledriver front end ................................................................................
Shovel front end ...................................................................................
Auxiliary clutch lever ....................................................................................
Auxiliary gantry, backhoe .............................................................................
Backhoe auxiliary gantry ..............................................................................
Backhoe boom ............................................................................................
Backhoe bucket, bail, and teeth ...................................................................
Backhoe bucket stick ...................................................................................
Backhoe front end attachment, operation of ..........................................
I-1
Paragraph
Page
3-73
4-37
3-66
4-32
3-22
3-15
3-32
3-30
3-31
3-33
3-9
3-20
3-21
3-27
3-28
3-35
3-36
3-29
3-132
3-115
3-127
3-25
3-37
3-136
3-34
3-56
2-25
3-17
3-65
3-11
3-66
3-78
3-22
3-80
2-21
3-142
3-32
3-29
3-26
3-37
3-36
3-36
3-37
3-23
3-28
3-29
3-32
3-33
3-37
3-38
3-34
3-109
3-96
3-107
3-30
3-40
3-117
3-37
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2-38
3-27
3-57
3-23
3-36
2-70
3-29
3-71
2-33
3-120
3-37
4-26
4-11
4-11
4-11
2-42
2-29
2-28
2-30
2-34
2-38
2-31
4-33
4-2
3-102
4-27
4-22
4-10
4-10
4-10
2-37
2-35
2-35
2-36
2-28
2-37
2-36
4-30
4-1
3-89
4-24
4-27
4-31
4-28
4-29
2-32
4-24
4-30
4-26
4-28
2-37
Paragraph
Page
Backhoe front end attachment......................................................................
Backhoe safety backstop..............................................................................
Backstop, backhoe safety.............................................................................
Backstop, boom ...........................................................................................
Bail and sheave, dipper................................................................................
Bands, swing brake ......................................................................................
Batteries.......................................................................................................
Battery box...................................................................................................
Battery service .............................................................................................
Belt adjustment, alternator drive...................................................................
Belt adjustment, fan drive ............................................................................
Belt adjustment, generator drive...................................................................
Belt, alternator and.......................................................................................
Belt, fan .......................................................................................................
Belt, generator and.......................................................................................
Blower adapters (Model 687C-18-ES Only) ..................................................
Boom ...........................................................................................................
Boom angle (radius) indicator.......................................................................
Boom, backhoe ............................................................................................
Boom backstop ............................................................................................
Boom harness spreader ...............................................................................
Boom hoist brake adjustment .......................................................................
Boom hoist brake, clutch band, and holding pawl .........................................
Boom point and idler sheaves ......................................................................
Boom, shovel ...............................................................................................
Box, battery..................................................................................................
Bracket, fan and support ..............................................................................
Brake adjustment, boom hoist ......................................................................
Brake bands on hoist drum positioning clutch and ........................................
Brake bands, planetary clutch band and .......................................................
Brake bands, propel .....................................................................................
Brake bands, swing ......................................................................................
Brake cylinders, hydraulic clutch and............................................................
Brake shoe, dipper trip clutch .......................................................................
Breather and oil filter, crankcase ..................................................................
Breather service, chain case fill cap and .....................................................
Breather service, fuel tank filler filter and .....................................................
Breather service, power take off...................................................................
Breather, ventilation .....................................................................................
Bucket and teeth, clamshell .........................................................................
Bucket and teeth, dragline............................................................................
Bucket, bail, and teeth, backhoe...................................................................
Bucket stick, backhoe...................................................................................
4-26
4-30
4-30
4-22
4-6
3-130
3-128
3-75
3-76
3-16
3-22
3-20
3-21
3-78
3-77
3-73
4-13
4-23
4-31
4-22
4-15
3-30
3-129
4-20
4-10
3-76
3-96
3-30
3-26
3-123
3-130
3-128
3-116
4-9
3-62
3-23
3-14
3-24
3-104
4-17
4-18
4-28
4-29
4-22
4-28
4-28
4-20
4-5
3-109
3-107
3-68
3-69
3-27
3-29
3-28
3-29
3-70
3-84
3-66
4-10
4-21
4-30
4-20
4-13
3-36
3-108
4-17
4-10
4-10
3-83
3-36
3-31
3-104
3-107
3-107
3-98
4-9
3-53
3-29
3-26
3-29
3-89
4-15
4-16
4-26
4-28
Cable adjustment, dipper trip........................................................................
Cable replacement .......................................................................................
Cab light ......................................................................................................
Cab rear panel .............................................................................................
Cab light lamp replacement, instrument panel and .......................................
Catwalk and adapters...................................................................................
Center cab panel, right side..........................................................................
Center side panel, left hand..........................................................................
Chain adjustment, propel .............................................................................
Chain case fill cap and breather service .......................................................
Chain, drive .................................................................................................
Chain sprocket, input shaft ...........................................................................
Chain, transfer .............................................................................................
Chain idler and tightener crowd and retract ..................................................
Checks and services, preventive maintenance.............................................
Circle rollers.................................................................................................
Clamshell bucket and teeth ..........................................................................
Clamshell front end attachment, operation of ...............................................
Cleaner, air ..................................................................................................
Clutch adjustment, engine............................................................................
Clutch adjustment, swing (jackshaft) ............................................................
Clutch and brake band positioning on hoist drum .........................................
3-34
3-39
3-171
3-164
3-38
4-37
3-167
3-161
3-36
3-23
3-137
3-127
3-106
4-3
3-6
3-120
4-17
2-29
3-65
3-9
3-25
3-26
3-37
3-41
3-129
3-125
3-41
4-32
3-126
3-125
3-38
3-29
3-117
3-107
3-89
4-3
3-19
3-102
4-15
2-35
3-57
3-23
3-30
3-31
I-2
Paragraph
Page
Clutch band and brake bands, planetary ......................................................
Clutch band, and holding pawl, boom hoist brake.........................................
Clutch brake shoe, dipper trip ......................................................................
Clutch lever and linkage ..............................................................................
Clutch lever, auxiliary ..................................................................................
Clutch shoes, jackshaft ...............................................................................
Clutch shoes, mainhust shaft........................................................................
Cold, operation in extreme ..........................................................................
Cold weather starting aids ...........................................................................
..............................................................................................................
Compensators (cylinders).............................................................................
Components, installation of separately packed.............................................
Components of light enclosure .....................................................................
Connector (quick disconnect) electrical .......................................................
Connector, receptacle (slaving) electrical ....................................................
Control, engine shutoff ................................................................................
Control panel wiring ....................................................................................
Controls and instruments .............................................................................
Conversion of equipment ............................................................................
Coolant lines, thermostat housing, thermostat and .......................................
Crane front end attachment, operation of ....................................................
Crane-shovel inoperative, demolition to render ............................................
Crankcase breather and oil filler ..................................................................
Crowd and retract chain, idler, and tightener ...............................................
Crowd chain adjustment ...............................................................................
Counterweight extension .............................................................................
Cover and gasket, valve ..............................................................................
Cover, transfer chain case ...........................................................................
(Cylinders), compensators............................................................................
Cylinders, hydraulic clutch and brake ..........................................................
3-123
3-129
4-9
3-101
3-102
3-121
3-122
2-14
2-23
3-17
3-112
2-2
3-172
3-152
3-83
3-72
3-153
2-8
2-4
3-98
2-28
5-5
3-62
4-3
3-31
3-155
3-55
3-105
3-112
3-116
3-104
3-108
4-9
3-88
3-89
3-102
3-103
2-31
2-33
3-27
3-92
2-1
3-129
3-122
3-75
3-66
3-122
2-22
2-4
3-84
2-35
5-1
3-53
4-3
3-36
3-123
3-47
3-89
3-92
3-98
Data, identification and tabulated .................................................................
Deep water, operation in mud or .................................................................
Demolition by explosives or weapons fire.....................................................
Demolition methods, other ...........................................................................
Demolition to render crane-shovel -inoperative ............................................
Description ..................................................................................................
Detailed lubrication information ....................................................................
Difference in models ....................................................................................
Digging brake, or planetary clutch band adjustment, hoist brake ..................
Digging clutch adjustment, hoist clutch and .................................................
Dipper bail and sheave.................................................................................
Dipper handle...............................................................................................
Dipper shovel...............................................................................................
Dipper teeth .................................................................................................
Dipper trip adjustment ..................................................................................
Dipper trip clutch brakeshoe ........................................................................
Dipper trip mechanism and trip lines ............................................................
(Dipstick), engine oil level gage ...................................................................
Dirtguards and shields, gear and ..................................................................
Discharger, pressure primer .........................................................................
Dismantling for movement ...........................................................................
Door and window glass ................................................................................
Door handrail (grip) ......................................................................................
Door, left front panel ....................................................................................
Door, sliding ................................................................................................
Door, swinging ............................................................................................
Dragline bucket and teeth ............................................................................
Dragline front end attachment, operation of .................................................
Drive chain...................................................................................................
Drum cable lagging ......................................................................................
Drum lagging ...............................................................................................
Drum lagging and sleeve nut (shear washer)................................................
Dry chemical type fire extinguisher ..............................................................
Dusty or sandy areas, operation in ..............................................................
1-4
2-20
5-6
5-7
5-5
1-3
5-4
1-5
3-27
3-28
4-6
4-5
4-4
4-7
3-33
4-9
4-8
3-60
3-126
3-175
2-5
3-158
3-157
3-163
3-160
3-159
4-18
2-30
3-137
4-12
4-25
3-124
2-24
2-16
1-2
2-33
5-2
5-2
5-1
1-1
5-1
1-11
3-32
3-33
4-5
4-5
4-3
4-5
4-3
4-5
4-6
3-51
3-107
3-130
2-20
3-123
3-123
3-125
3-125
3-124
4-16
2-36
3-117
4-10
4-22
8-105
2-33
2-32
Electrical connector (quick disconnect).........................................................
I-3
3-152
3-122
Paragraph
Page
Electrical connector, rectacle (slave)............................................................
Enclosure and components, light .................................................................
Engine air cleaner service ............................................................................
Engine clutch adjustment ............................................................................
Engine inspection and services ....................................................................
Engine oil filters ..........................................................................................
Engine oil filter service ................................................................................
Engine oil lever gage (dipstick) ....................................................................
Engine shutoff control ..................................................................................
Engine oil strainer ........................................................................................
Engine oil strainer service (Model 657C-18-ES Only) ...................................
Engine overheats ........................................................................................
Engine starved for fuel ................................................................................
Engine starting the .......................................................................................
Engine stopping the......................................................................................
Equipment, conversion of.............................................................................
Equipment, inspecting and servicing the ......................................................
Equipment, operation of ...............................................................................
Equipment, tools and ...................................................................................
Exhaust manifold .........................................................................................
Exhaust pipe ................................................................................................
Explosives or weapons fire, demolition by ....................................................
Extension, counterweight .............................................................................
Extension (trouble) light ...............................................................................
External oil ventilation lines..........................................................................
Extinguisher, fire (dry chemical type) ...........................................................
Extreme cold, operation in ...........................................................................
Extreme heat, operation in ...........................................................................
3-83
3-172
3-11
3-9
3-8
3-58
3-10
3-60
3-72
3-59
3-12
3-44
3-45
2-10
2-11
2-4
2-1
2-12
3-1
3-93
3-91
5-6
3-155
2-27
3-61
2-24
2-14
2-15
3-75
3-129
3-23
3-23
3-23
3-49
3-23
3-51
3-66
3-51
3-24
3-44
3-44
2-28
2-29
2-4
2-1
2-29
3-1
3-80
3-80
5-2
3-123
2-34
3-53
2-33
2-31
2-31
Fairlead sheaves..........................................................................................
Fan and support bracket...............................................................................
Fan belt........................................................................................................
Fan drive belt adjustment.............................................................................
Fan guard, radiator, shroud and ...................................................................
Field expedient repairs:
Engine oil strainer faulty.........................................................................
Engine overheats...................................................................................
Engine starved for fuel...........................................................................
Low oil pressure.....................................................................................
Starter motor fails to turn engine............................................................
Fill cap and breather service, chain case......................................................
Filler, crankcase breather and oil..................................................................
Filter and breather service, fuel tank filler.....................................................
Filter, fuel.....................................................................................................
Filter, fuel (secondary) .................................................................................
Filter, primary fuel........................................................................................
Filters, engine oil..........................................................................................
Filter service, fuel ........................................................................................
Filter services, engine oil..............................................................................
Fire extinguisher (dry chemical type)............................................................
Fittings, fuel tank lines and...........................................................................
Floodlight adjustment and lamp replacement ...............................................
Floodlights ...................................................................................................
Forms and records .......................................................................................
Front end attachment ...................................................................................
Front end attachment, operation of backhoe ................................................
Front end attachment, operation of clamshell...............................................
Front end attachment, operation of crane.....................................................
Front end attachment, operation of dragline .................................................
Front end attachment, operation of jib boom ................................................
Front end attachment, operation of piledriver ...............................................
Front end attachment, operation of shovel ...................................................
Front end attachment, backhoe ....................................................................
Front end attachment, piledriver...................................................................
Front hook roller adjustment.........................................................................
4-16
3-96
3-97
3-20
3-95
4-13
3-83
3-83
3-28
3-82
3-47
3-44
3-45
3-46
3-43
3-23
3-62
3-14
3-69
3-69
3-68
3-58
3-13
3-10
2-24
3-67
3-15
3-170
1-2
4-2
2-32
2-29
2-28
2-28
2-28
2-28
2-28
4-26
4-33
3-35
3-44
3-44
3-44
3-44
3-44
3-29
3-53
3-26
3-62
3-62
3-61
3-49
3-24
3-23
2-33
3-60
3-26
3-129
1-1
4-1
2-37
2-35
2-35
2-35
2-35
2-35
2-35
4-22
4-30
3-37
I-4
Paragraph
Page
Front hook rollers .........................................................................................
Front panel door, left - - ...............................................................................
Front side panel, left hand ...........................................................................
Fuel filter (Model D333TA engine) ...............................................................
Fuel filter, primary .......................................................................................
Fuel filter (secondary on Model 687C-18-ES) ..............................................
Fuel filter service ........................................................................................
Fuel injectors ..............................................................................................
Fuel level indicator ......................................................................................
Fuel level transmitter ..................................................................................
Fuel tank filler cap, filter, and breather service ............................................
Fuel tank, lines, and fittings .........................................................................
3-118
3-163
3-162
3-69
3-68
3-69
3-13
3-64
3-145
3-146
3-14
3 67
3-100
3-125
3-125
3-62
3-61
3-62
3-24
3-57
3-120
3-120
3-26
3-60
Gage (dipstick), engine oil level ..................................................................
Gantry, auxiliary backhoe ............................................................................
Gasket, valve cover and .............................................................................
Gear and dirt guards and shields .................................................................
General lubrication information ...................................................................
General methods used to attain proper suppression ....................................
Generator and belt (Engine Model 687C18-ES) ...........................................
Generator drive belt adjustment (Engine Model 687C18-ES Only) ..............
Generator regulator (Engine Model 687C18-ES) .........................................
Glass, win(low and door ..............................................................................
Glow plugs (Engine Model D)333TA Only) ..................................................
Governor, overspeed - ................................................................................
Governor overspeed microswitch ................................................................
Governor throttle control linkage .................................................................
Grip, door handrail ......................................................................................
Guard, mud .................................................................................................
Guard, radiator shroud and fan ....................................................................
Gun case and tool box ................................................................................
3-60
4-27
3-55
3-126
3-3
3-48
3-77
3-21
3-79
3-158
3-176
3-88
3-141
3-70
3-157
3-138
3-95
3-173
3-61
4-24
3-47
3-107
3-1
3-45
3-69
3-29
3-71
3-123
3-130
3-78
3-120
3-64
3-123
3-118
3-82
3-130
Hammer, pile cap, and pile collar ................................................................
Handle, dipper .............................................................................................
Handrail, (grip) door ....................................................................................
Hangers, pile lead .......................................................................................
Harness spreader, boom .............................................................................
Heater, personnel ........................................................................................
Heater, operation of ....................................................................................
Heat, operation in extreme - ........................................................................
High altitude, operation at - .........................................................................
High temperature switch, water - .................................................................
High temperature warning light, water .........................................................
Hoist brake, digging brake, or planetary clutch band adjustment .................
Hoist clutch and digging clutch adjustment ..................................................
Hoist drum clutch and brake bands .............................................................
Hook block and weighted hook ....................................................................
Hook roller adjustment ................................................................................
Hook rollers, front ........................................................................................
Hook rollers, rear .........................................................................................
Holding pawl, boom hoist brake, clutch and .................................................
Horn ............................................................................................................
Horn push switch .........................................................................................
Housing, thermostat ....................................................................................
Humid conditions, operation under rainy or .................................................
Hydraulic clutch and brake cylinders ...........................................................
Hydraulic hose, lines, tubes, and fittings ......................................................
Hydraulic reservoir (tank) service ................................................................
Hydraulic tank .............................................................................................
4-36
4-5
3-165
4-34
4-15
3-174
2-26
2-15
2-21
3-86
3-148
3-27
3-28
3-26
4-19
3-35
3-118
3-119
3-129
4-39
3-151
3-98
2-17
3-116
3-111
3-18
3-110
4-31
4-5
3-126
4-31
4-13
3-130
2-34
2-31
2-33
3-77
3-122
3-32
3-33
3-31
4-17
3-37
3-100
3-101
3-108
4-33
3-122
3-84
2-32
3-98
3-92
3-27
3-92
Identification and tabulated data ..................................................................
Idler adjustment, track .................................................................................
Idler and tightener, crowd and retract chain .................................................
Idler sheaves, boom point and ....................................................................
Indicator, boom angle ..................................................................................
Indicator, fuel level ......................................................................................
Indicator, oil pressure ..................................................................................
I-5
1-4
3-136
4-3
4-20
4-23
3-145
3-143
1-2
3-117
4-3
4-17
4-21
3-120
3-120
Paragraph
Page
Indicator, radius ..........................................................................................
Indicator (warning) light, high water temperature .........................................
Indicator (warning) light, low oil pressure .....................................................
Indicator, water temperature ........................................................................
Information, detailed lubrication ..................................................................
Information, general lubrication ...................................................................
Injectors, fuel ..............................................................................................
Input shaft chain sprocket ............................................................................
Inspecting and servicing the equipment .......................................................
Inspection and services, engine ..................................................................
Inspection and test ......................................................................................
Installation of separately packed components .............................................
Installation or setting up instructions ............................................................
Instructions, installation or setting up ...........................................................
Instrument panel and cab light lamp replacement ........................................
Instruments, controls and ............................................................................
Interference suppression components .........................................................
Intermediate shaft adjustment, vertical ........................................................
4-23
3-148
3-144
3-147
3-4
3-3
3-64
3-107
2-1
3-8
3-53
2-2
2-3
2-3
3-38
2-8
3-49
3-127
4-21
3-122
3-120
3-122
3-1
3-1
3-57
3-90
2-1
3-23
3-47
2-1
2-2
2-2
3-41
2-22
3-46
3-107
Jackshaft clutch shoes ................................................................................
Jib boom front end attachment operation of ................................................
Jib boom strut and sheaves .........................................................................
3-121
2-34
4-21
3-102
2-38
4-20
Lagging .......................................................................................................
Lagging cable drum .....................................................................................
Lamp replacement, floodlight adjustment and .............................................
Lead hangers, pile .......................................................................................
Leads, pile ..................................................................................................
Left front panel door ....................................................................................
Left hand center side panel .........................................................................
Left hand front side panel ............................................................................
Left side louver panel ..................................................................................
Lever and linkage, clutch ............................................................................
Lever, auxiliary clutch .................................................................................
Lever stand levers and linkage ....................................................................
Light, cab ....................................................................................................
Light enclosure and components .................................................................
Light, extension (trouble) .............................................................................
Light, water high temperature warning .........................................................
Light, low oil pressure warning .....................................................................
Light, trouble ...............................................................................................
Lights, flood ................................................................................................
Limited storage, preparation for ...................................................................
Lines and fittings, fuel tank ..........................................................................
Lines and fittings, primer pump ...................................................................
Lines, external oil ventilation .......................................................................
Lines, tubes, and fittings hydraulic hose .......................................................
Linkage, governor throttle control ................................................................
Lines, lever stand levers and .......................................................................
Linkage, lever stand levers and ...................................................................
Linkage, propel and steering mechanism ....................................................
Links and pins, track ....................................................................................
Loading crane-shovel for shipment ..............................................................
Louver panel, left side .................................................................................
Low engine air pressure ..............................................................................
Low oil pressure switch ................................................................................
Low oil pressure warning indicator light .......................................................
Lubrication information, detailed .................................................................
Lubrication information, general ..................................................................
4-25
4-12
3-15
4-34
4-35
3-163
3-161
3-162
3-166
3-101
3-102
3-113
3-171
3-172
3-27
3-148
3-144
2-27
3-170
5-2
3-67
3-71
3-61
3-111
3-70
3-113
3-113
3-131
3-134
5-3
3-166
3-46
3-87
3-144
3-4
3-3
4-22
4-10
3-26
4-1
4-31
3-125
3-125
3-125
3-126
3-88
3-89
3-93
3-129
3-129
2-34
3-122
3-120
2-34
3-129
5-1
3-60
3-64
3-93
3-92
3-64
3-93
3-109
3-109
3-116
5-1
8-126
3-44
3-78
3-120
3-1
3-1
Main hoist shaft clutch shoes .......................................................................
Main shaft sprocket .....................................................................................
Maintenance checks and services, preventive .............................................
Maintenance repair parts, organizational .....................................................
Mainfold (blower to blower) air ....................................................................
Manifold, exhaust ........................................................................................
Manifold, water ............................................................................................
Mechanism and trip lines, dipper trip
I-6
3-122
3-108
3-6
3-2
3-66
3-93
3-99
4-8
3-103
3-91
3-19
3-1
3-60
3-80
3-86
4-6
Paragraph
Page
Meter, tachometer time totalizing .................................................................
Micro switch, overspeed governor ...............................................................
Models, difference in....................................................................................
Motor, starter ...............................................................................................
Movement, dismantling for...........................................................................
Movement, reinstallation after .....................................................................
Mud guard ...................................................................................................
Mud or deep water, operation in ..................................................................
Muffler ........................................................................................................
3-140
3-141
1-6
3-81
2-5
2-6
3-138
2-20
3-92
3-118
3-120
1-11
3-74
2-20
2-21
3-107
2-33
3-80
Oil filler, crankcase breather and .................................................................
Oil filters, engine ..........................................................................................
Oil filter services, engine .............................................................................
Oil level gage (dipstick), engine ...................................................................
Oil pressure indicator ...................................................................................
Oil pressure switch, low................................................................................
Oil pressure transmitter ...............................................................................
Oil strainer, engine ......................................................................................
Oil strainer service, engine ..........................................................................
Oil ventilation lines, external .......................................................................
Operation at high altitude ............................................................................
Operation below seal level ..........................................................................
Operation in dusty or sandy areas ...............................................................
Operation in extreme cold ............................................................................
Operation in extreme heat ...........................................................................
Operation in mud or deep water ..................................................................
Operation in salt water areas........................................................................
Operation in snow .......................................................................................
Operation of backhoe front end attachment .................................................
Operation of clamshell front end attachment ...............................................
Operation of crane front end attachment .....................................................
Operation of dragline front end attachment ..................................................
Operation of equipment ...............................................................................
Operation of heaters ...................................................................................
Operation of jib boom front end attachment ................................................
Operation of piledriver front end attachment ................................................
Operation of shovel front end attachment ....................................................
Operation under rainy or humid conditions ..................................................
Operators seat .............................................................................................
Organizational maintenance repair parts .....................................................
Other demolition methods ...........................................................................
Overspeed governor micro switch ...............................................................
Overspeed governor (Model 687C18-ES) ....................................................
3-62
3-58
3-10
3-60
3-143
3-87
3-84
3-59
3-12
3-41
2-21
2-22
2-16
2-14
2-15
2-20
2-18
2-19
2-32
2-29
2-28
2-30
2-12
2-26
2-34
2-33
2-31
2-17
3-168
3-2
5-7
3-141
3-88
3-53
3-59
3-23
3-51
8-120
3-78
3-76
3-51
3-24
3-53
2-33
2-33
2-32
2-31
2-81
2-33
2-32
2-32
2-37
2-35
2-35
2-36
2-29
2-34
2-38
2-37
2-36
2-32
3-126
3-1
5-2
3-120
3-78
Panel and cab light lamp replacement .........................................................
Panel, cab rear ............................................................................................
Panel, center, right side ...............................................................................
Panel door, left front ....................................................................................
Panel, left hand center side .........................................................................
Panel, left hand front side ............................................................................
Panel, left side louver ..................................................................................
Panel, right rear side ....................................................................................
Parts, organizational maintenance repair .....................................................
Pile cap and pile collar, hammer ..................................................................
Pile collar, hammer, pile cap and .................................................................
Pile lead hangers ........................................................................................
Pile leads .....................................................................................................
Piledriver front end attachment ....................................................................
Piledriver front end and attachment, operation of .........................................
Pipe, exhaust ...............................................................................................
Pins, track links and .....................................................................................
Planetary clutch band adjustment, hoist brake, digging brake or ..................
Planetary clutch band and brake bands (main shaft) ...................................
Planetary pinion gear and shovel sprocket ..................................................
Plugs, glow ..................................................................................................
Positioning clutch and brake bands on hoist drum .......................................
Power take-off breather service....................................................................
I-7
3-38
3-164
3-167
3-168
3-161
3-162
3-166
3-166
3-165
4-46
4-36
4-34
4-45
4-33
2-33
3-91
3-134
3-27
3-123
3-125
3-176
3-26
8-24
3-41
3-125
3-126
3-125
3-125
3-125
3-126
3-126
3-126
3-126
3-1
4-31
4-31
4-40
2-37
3-80
3-116
3-32
3-104
3-106
3-130
3-31
3-29
Paragraph
Page
Preparation for limited storage ....................................................................
Pressure indicator, oil .................................................................................. .
Pressure primer discharger (ether injector) ..................................................
Pressure switch, low oil ...............................................................................
Pressure transmitter, oil - ............................................................................
Preventive maintenance checks and services .............................................
Primary fuel filter (Model 687C18-ES Only) .................................................
Primer pump, lines, anf fittings ....................................................................
Propel and steering mechanism linkage ......................................................
Propel brake adjustment, steering linkage, swing brake and ........................
Propel brake bands .....................................................................................
Propel chain adjustment...............................................................................
Pump, lines and fittings, primer ...................................................................
Push switch, horn ........................................................................................
Push switch, starter .....................................................................................
5-2
3-143
3-175
3-87
3-84
3-6
3-8
3-71
3-131
3-29
3-130
3-36
3-71
3-151
3-150
5-1
3-120
3-130
3-78
3-76
3-19
3-61
3-64
3-109
3-38
3-109
3-38
3-64
3-122
3-122
Radiator, shroud, ant fan guard ...................................................................
Radiator service ..........................................................................................
Radio interference suppression:
General methods use to attain ..............................................................
Components .........................................................................................
Replacement ........................................................................................
Testing ..................................................................................................
Radius indicator (Boom angle indicator) ......................................................
Rainy or humid conditions, operation under .................................................
Rear cab panel ............................................................................................
Rear hook roller adjustment ........................................................................
Rear hook rollers .........................................................................................
Records, forms and .....................................................................................
Receptacle (slave) electrical connector .......................................................
Regulator, alternator ...................................................................................
Regulator, generator ...................................................................................
Reinstallation after movement .....................................................................
Relay, starter solenoid .................................................................................
Render crane-shovel inoperative, demolition to ...........................................
Repair parts, organizational maintenance ....................................................
Repairs, field expedient:
Engine oil strainer faulty ........................................................................
Engine overheats ..................................................................................
Engine starved for fuel ..........................................................................
Low oil pressure ....................................................................................
Starter motor fails to turn engine ...........................................................
Replacement, cable ....................................................................................
Replacement of suppression components ...................................................
Right rear side panel ...................................................................................
Right side center cab panel .........................................................................
Roller circle .................................................................................................
Rollers, upper track support - ......................................................................
Run shutdown switch ...................................................................................
3-95
3-19
3-82
3-28
3-48
3-49
3-50
3-51
4-23
2-17
3-64
3-35
3-119
1-2
3-83
3-80
3-79
2-6
3-82
5-5
3-2
3-45
3-45
3-45
3-45
4-21
2-32
3-125
3-37
3-101
1-1
3-75
3-71
3-79
2-21
3-75
5-1
3-2
3-47
3-44
3-45
3-46
3-43
3-39
3-50
3-165
3-167
3-120
3-135
3-149
3-44
3-44
3-44
3-44
3-44
3-41
3-45
3-126
3-126
3-102
3-117
3-122
Safety backstop, backhoe ............................................................................
Salt water areas, operation in ......................................................................
Sandy areas, operation in dusty or ..............................................................
Scope .........................................................................................................
Seal level, operation below .........................................................................
Seat, operator .............................................................................................
Secondary fuel filter ....................................................................................
Separately packed components, installation of ............................................
Service, battery ...........................................................................................
Service, chain case fill cap and breather .....................................................
Service, engine air cleaner ..........................................................................
Service, engine oil filters .............................................................................
Service, fuel filter ........................................................................................
Service, fuel tank filler cap, filter and breather ............................................
Service, hydraulic reservoir (tank)................................................................
Service power take off breather ...................................................................
Service, radiator...........................................................................................
4-30
2-18
2-16
1-1
2-22
3-168
3-69
2-2
3-16
3-23
3-11
3-10
3-13
3-14
3-18
3-24
3-19
4-28
2-32
2-32
1-1
2-33
3-126
3-62
2-2
3-27
3-29
3-23
3-23
3-26
3-26
3-27
3-29
3-28
I-8
Paragraph
Service, engine inspection and ....................................................................
Services, preventive maintenance checks and ............................................
Servicing the equipment, inspecting and .....................................................
Setting up instructions, installation or ..........................................................
Sheaves, boom point and idler ....................................................................
Sheave, dipper bail and ..............................................................................
Sheaves, fairlead ........................................................................................
Sheaves, jib boom, strut and .......................................................................
Shifter lever, swing and propel ....................................................................
Shipment, loading crane shovel for .............................................................
Shovel boom ...............................................................................................
Shovel dipper ..............................................................................................
Shovel front end attachment .......................................................................
Shovel front end attachment, operation of ...................................................
Shovel sprocket, planetary pinion gear and .................................................
Shroud and fan guard, radiator ....................................................................
Shutdown switch, run ..................................................................................
Shutoff control, engine ................................................................................
Slaving receptacle .......................................................................................
Sleeve nut (shear washer), drum lagging and ..............................................
Sliding doors ...............................................................................................
Snow, operation in ......................................................................................
Solenoid relay, starter .................................................................................
Spreader, boom harness .............................................................................
Spring adjustment, anti-sway .......................................................................
Sprocket, input shaft chain ..........................................................................
Sprocket, main shaft - - ...............................................................................
Starter motor ...............................................................................................
Starter motor fails to turn engine .................................................................
Starter push switch ......................................................................................
Starter solenoid relay ..................................................................................
Starting aids, cold weather ..........................................................................
Starting the engine ......................................................................................
Steering linkage, swing brake and propel brake adjustment .........................
Steering mechanism linkage, propel and .....................................................
Steering wheel adjustment ..........................................................................
Stick, backhoe bucket .................................................................................
Stopping the engine ....................................................................................
Storage, preparation for limited ...................................................................
Strainer, engine oil .....................................................................................
Strut and sheaves, jib boom ........................................................................
Support bracket fan and ..............................................................................
Support rollers, upper track .........................................................................
Suppression, radio interference:
General methods used to attain ............................................................
Components .......................................................................................
Replacement .........................................................................................
Testing ..................................................................................................
Swing and propel shifter lever .....................................................................
Swing brake band ........................................................................................
Swing brake hydraulic control and linkage adjustment .................................
Swing (Jackshaft) clutch adjustment.............................................................
Swinging door .............................................................................................
Switch, water high temperature ....................................................................
Switch, horn push ........................................................................................
Switch, low oil pressure ...............................................................................
Switch, overspaced governor micro .............................................................
Switch, run shutdown ..................................................................................
Switch, starter push .....................................................................................
Page
3-8
3-6
2-1
2-3
4-20
4-6
4-16
4-21
3-114
5-3
4-10
4-4
4-2
2-31
3-125
3-95
3-156
3-72
3-83
3-124
3-160
2-19
3-82
4-15
3-32
3-107
3-108
3-81
3-43
3-150
3-82
2-25
2-10
3-29
3-131
3-132
4-29
2-11
5-2
3-59
4-21
3-96
3-135
3-23
3-19
2-1
2-3
4-17
4-5
4-13
4-20
8-94
8-1
4-19
4-8
4-1
2-36
3-106
3-32
3-123
3-65
3-75
4-18
3-125
2-32
3-75
4-18
3-37
3-90
3-91
3-74
3-64
3-122
3-75
2-33
2-23
3-34
3-109
3-109
4-28
2-29
5-1
3-51
4-30
3-33
3-127
3-48
3-49
3-50
3-51
3-114
3-128
3-115
3-25
3-159
3-86
3-151
3-87
3-141
3-149
3-150
3-8
3-45
3-45
3-45
3-86
3-107
3-98
3-90
3-98
3-77
3-122
3-73
3-130
3-123
3-122
Tables:
Table 1-1 Specific gravity temperature corrections for batteries ............................................
Table 1-2 Cable lengths, diameter, and use .......................................................................... .
Table 2-1 Use of cold weather starting aids.............................................................................
Table 3-1 Special tools ...........................................................................................................
Table 3-2 Preventive maintenance checks and services .........................................................
Table 3-3 Troubleshooting ......................................................................................................
I-9
1-6
1-6
2-23
3-1
3-26
2-2
Paragraph
Page
Tabulated data, identification and ................................................................
Tachometer time totalizing meter ................................................................
Tagline winder .............................................................................................
Tank, hydraulic ............................................................................................
Tank, lines, and fittings, fuel ........................................................................
Tank service, hydraulic ...............................................................................
Teeth, backhoe, bucket, bail, and ................................................................
Teeth, clamshell bucket and ........................................................................
Teeth, dipper ...............................................................................................
Teeth, dragline bucket and ..........................................................................
Temperature indicator, water .......................................................................
Temperature switch, water high ...................................................................
Temperature transmitter, water ...................................................................
Test and inspection .....................................................................................
Testing of radio interference suppression components ................................
Thermostat ..................................................................................................
Thermostat housing, thermostat, and coolant lines ......................................
Thottle control linkage, govenor ..................................................................
Tools and equipment ...................................................................................
Track adjustment ........................................................................................
Track idler adjustment .................................................................................
Track support rollers, upper .........................................................................
Training .......................................................................................................
Transfer chains ............................................................................................
Transfer chain case cover ............................................................................
Transfer fuel level ........................................................................................
Transmitter, oil pressure...............................................................................
Transmitter, water temperature ....................................................................
Tread (track), links, and pins ........................................................................
Trip adjustment, dipper ...............................................................................
Trip cable adjustment...................................................................................
Trip clutch brake shoe, dipper ......................................................................
Trip mechanism and trip lines, dipper ..........................................................
Trouble light ................................................................................................
Trouble shooting (table 3-3) ........................................................................
Tubes, and fittings, hydraulic hose, lines ......................................................
1-4
3-140
4-14
3-110
3-67
3-18
4-28
4-17
4-7
4-18
3-147
3-86
3-85
3-53
3-51
3-98
3-98
3-70
3-1
3-37
3-136
3-135
5-8
3-106
3-105
3-153
3-84
3-85
3-134
3-33
3-34
4-9
4-8
2-27
3-41
3-111
1-2
3-118
4-12
3-92
3-60
3-27
4-26
4-15
4-5
4-16
3-122
3-77
3-77
3-47
3-45
3-84
3-84
3-64
3-1
3-40
3-117
3-117
5-2
3-89
3-89
3-122
3-76
3-77
3-116
3-37
3-37
4-9
4-6
2-34
3-42
3-92
Upper track support rollers ..........................................................................
3-135
3-117
Valve (rocker arm) adjustment ....................................................................
Valve cover and gasket ...............................................................................
Ventilation breather .....................................................................................
Ventilation lines, external oil ........................................................................
Vertical intermediate shaft adjustment .........................................................
3-56
3-55
3-104
3-61
3-127
3-47
3-47
3-89
3-53
3-107
Water areas, operation in salt.......................................................................
Water manifold (Model 6S7G18-ES) ...........................................................
Water, operation in mud or deep .................................................................
Water temperature indicator ........................................................................
Water temperature switch, high ...................................................................
Water temperature transmitter ....................................................................
Weapon fire, demolition by explosives or ....................................................
Weighted hook, hook block and ..................................................................
Wheel adjustment, steering .........................................................................
Winder, tagline ............................................................................................
Window glass, door and ..............................................................................
Wiring .........................................................................................................
Wiring, control panel ...................................................................................
2-18
3-99
2-20
3-147
3-86
3-85
5-6
4-19
3-132
4-14
3-158
3-89
3-153
2-32
3-86
2-33
3-122
3-77
3-77
5-2
4-17
3-109
4-12
3-123
3-78
3-122
I-10
By Order of the Secretary of the Army:
W. C. WESTMORELAND,
General, United States Army,
Chief of Staff.
Official:
KENNETH G. WICKHAM,
Major General, United States Army,
The Adjutant General.
Distribution:
To be distributed in accordance with DA Form 12-25, Section II, (qty rqr block No. 350) organizational maintenance
requirements for Crane-Shovel, Crawlers, 40 Ton.
U.S. GOVERNMENT PRINTING OFFICE: 1995 O - 388-421 (43102)
The Metric System and Equivalents
Linear Measure
Liquid Measure
1 centiliter = 10 milliters = .34 fl. ounce
1 deciliter = 10 centiliters = 3.38 fl. ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons
1 centimeter = 10 millimeters = .39 inch
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1 dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet
Square Measure
Weights
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 decagram = 10 grams = .35 ounce
1 hectogram = 10 decagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors
To change
To
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
pound-feet
pound-inches
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
Newton-meters
Newton-meters
Multiply by
To change
2.540
.305
.914
1.609
6.451
.093
.836
2.590
.405
.028
.765
29,573
.473
.946
3.785
28.349
.454
.907
1.356
.11296
ounce-inches
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
To
Newton-meters
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
Temperature (Exact)
°F
Fahrenheit
temperature
5/9 (after
subtracting 32)
Celsius
temperature
°C
Multiply by
.007062
.394
3.280
1.094
.621
.155
10.764
1.196
.386
2.471
35.315
1.308
.034
2.113
1.057
.264
.035
2.205
1.102
PIN: 012229-004
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