Chapter 1. INTRODUCTION - TM-5-3810-201-120012
Figure 1-1. Crane-shovel basic unit, non-winterized, right rear view, and shipping dimensions.
Figure 1-2. Crane-shovel basic unit, non winterized, with crane boom installed.
Figure 1-3. Crane-shovel basic unit, winterized, rear view.
Tabulated Data. - TM-5-3810-201-120016
Tabulated Data - continued - TM-5-3810-201-120017
Table 1-1. Specific Gravity Temperature Corrections for Batteries.
Figure 1-4. Crane and jib working ranges.
9Table 1-2. Cable Lengths, Diameter, and Use
Table 1-2. Cable Lengths, Diameter, and Use - TM-5-3810-201-120021
Figure 1-6. Dragline working ranges
Figure 1-8. Backhoe working ranges
Figure 1-9. Piledriver clearance diagram
Difference in Models - TM-5-3810-201-120025
Figure 1-10. Wiring diagram (sheet 1 of 7).
Figure 1-10. Wiring diagram (sheet 2 of 7).
Figure 1-10. Wiring diagram (sheet 3 of 7).
Figure 1-10. Wiring diagram (sheet 4 of 7).
Figure 1-10. Wiring diagram (sheet 5 of 7).
Figure 1-10. Wiring diagram (sheet 6 of 7).
Figure 1-10. Wiring diagram (sheet 7 of 7).
Chapter 2. INSTALLATION AND OPERATING INSTRUCTIONS - TM-5-3810-201-120033
Figure 2-1. Crane-shovel basic unit, and accessories loaded and blocked for shipment, front view. - TM-5-3810-201-120034
Figure 2-2. Crane-shovel basic unit, and accessories loaded and block for shipment, rear view.
Figure 2-3. Front end attachments loaded and blocked for shipment (sheet 1 of 2). - TM-5-3810-201-120036
Equipment Conversion - TM-5-3810-201-120037
Figure 2-4. Unloading crane-shovel basic unit by lifting. - TM-5-3810-201-120038
Figure 2-6. Crane boom, positioned for removal or installation.
Figure 2-7. Crane boom and jib boom reeving diagram (sheet 1 of 2).
Backhoe Front End Attachment
Figure 2-8. Crane front end attachment, with jib boom installed. - TM-5-3810-201-120042
Figure 2-9. Clamshell front end attachment reeving diagram. - TM-5-3810-201-120043
Figure 2-10. Clamshell front end attachment, installed view. - TM-5-3810-201-120044
Figure 2-11. Dragline front end attachment, installed view. - TM-5-3810-201-120045
Figure 2-12. Dragline front end attachment reeving diagram.
Figure 2-13. Piledriver front end attachment, reeving diagram.
Figure 2-15. Backhoe front end attachment, prepared for removal and installation.
Figure 2-16. Backhoe front end attachment, reeving diagram.
Figure 2-17. Backhoe front end attachment, installed view. - TM-5-3810-201-120050
Figure 2-18. Shovel front end attachment, installed view. - TM-5-3810-201-120051
Figure 2-19. Shovel front end attachment reeving diagram.
Section II. MOVEMENT TO A NEW WORKSITE - TM-5-3810-201-120053
Figure 2-20. Anti-rotation bars, stowed.
Section III. CONTROLS AND INSTRUMENTS - TM-5-3810-201-120055
Figure 2-23. Crane operating control handles and levers. - TM-5-3810-201-120056
Figure 2-24. Crane, engine and lighting controls.
Figure 2-25. Heat-start switch.
Engine Throttle Control Lever
Figure 2-27. Boom angle (radius) indicator, installed view
Figure 2-29. Heater control box.
Section IV. OPERATION UNDER USUAL CONDITIONS - TM-5-3810-201-120062
Table 2-1. Use of Cold Weather Starting Aids.
Boom Raising or Lowering
Section V. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-3810-201-120065
Operation in Extreme Heat - TM-5-3810-201-120066
Operation in Snow
Cold Weather Starting Aids - TM-5-3810-201-120068
Heaters
Operation of Dragline Fro nt End Attachment
Operation of Shovel Front End Attachment
Operation of Backhoe Front End Attachment
Chapter 3. OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS - TM-5-3810-201-120073
Figure 3-1. Lubricating point identification (sheet 1 of 14). - TM-5-3810-201-120074
Figure 3-1. Lubricating point identification (sheet 2 of 14). - TM-5-3810-201-120075
Figure 3-1. Lubricating point identification (sheet 3 of 14). - TM-5-3810-201-120076
Figure 3-1. Lubricating point identification (sheet 4 of 14).
Figure 3-1. Lubricating point identification (sheet 5 of 14). - TM-5-3810-201-120078
Figure 3-1. Lubricating point identification (sheet 6 of 14). - TM-5-3810-201-120079
Figure 3-1. Lubricating point identification (sheet 7 of 14). - TM-5-3810-201-120080
Figure 3-1. Lubricating point identification (sheet 8 of 14). - TM-5-3810-201-120081
Figure 3-1. Lubricating point identification (sheet 9 of 14). - TM-5-3810-201-120082
Figure 3-1. Lubricating point identification (sheet 10 of 14). - TM-5-3810-201-120083
Figure 3-1. Lubricating point identification (sheet 11 of 14). - TM-5-3810-201-120084
Figure 3-1. Lubricating point identification (sheet 12 of 14). - TM-5-3810-201-120085
Figure 3-1. Lubricating point identification (sheet 13 of 14). - TM-5-3810-201-120086
Figure 3-1. Lubricating point identification (sheet 14 of 14). - TM-5-3810-201-120087
Figure 3-2. Air cleaner service (crane-shovel model 855BG2).'
Engine Oil Filter Service.
Figure 3-5. Engine oil filter service for engine model D333TA.
Figure 3-6. Engine oil strainer service (model 687C-18-ES only).
Figure 3-7. Chain case fill cap and breather service.
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-3810-201-120093
Table 3-2. Preventive Maintenance Checks and Services - TM-5-3810-201-120094
Table 3-2. Preventive Maintenance Checks and Services - continued - TM-5-3810-201-120095
Table 3-2. Preventive Maintenance Checks and Services - continued - TM-5-3810-201-120096
Figure 3-9. Engine clutch adjustment.
Figure 3-11. Primary fuel filter service. (model 687C-18-ES).
Figure 3-13. Fuel filter service on engine model D333TA.
Figure 3-15. Filler cap and filter service, model 855BG3.
Figure 3-16. Fuel tank breather service, model 855BG3.
Figure 3-19. Battery service (non-winterized models).
Battery Service (Winterized Models)
Radiator Service - TM-5-3810-201-120104
Generator Drive Belt Adjustment (Engine Model 687C-18-ES Only)
Heater Fuel Strainer Service (Winterized Models)
Swing ( jackshaft) Clutch Adjustment
Figure 3-28. Hoist clutch shoes adjustment and removal points.
Positioning Clutch and Brake Bands on Hoist Drum
Hoist Clutch and Digging Clutch Adjustment - TM-5-3810-201-120110
Figure 3-32. Steering linkage and propel brake adjustment.
Steering Linkage, Swing Broke and Propel Brake Adjustment
Figure 3-34. Boom hoist brake adjustment points.
Crowd Chain Adjustment
Figure 3-37. Trip cable adjustment.
Figure 3-38. Hook roller adjustment points
Figure 3-39. Propel chain adjustment.
Figure 3-40. Track adjustment.
Section V. TROUBLESHOOTING - TM-5-3810-201-120119
Table 3-3. Troubleshooting
Table 3-3. Troubleshooting - continued
Section VI. FIELD EXPEDIENT REPAIRS - TM-5-3810-201-120122
Testing of Radio Interference Suppression Components
Section VIII. ORGANIZATIONAL MAINTENANCE PROCEDURES - TM-5-3810-201-120124
Figure 3-42. Valve (rocker arm) adjustment, model 687C-18-ES engine.
Section X. ENGINE LUBRICATION SYSTEM
Engine Oil Level Gage (Dipstick)
Figure 3-45. Engine oil filters (Model 887C-18-ES) disassembly, and reassembly, and oil filter pipe removal and installation.
Figure 3-46. Oil filters, removal, disassembly, reassembly and installation for engine Model D333TA (sheet 1 of 2).
Figure 3-46. Oil filters, removal, disassembly, reassembly, and installation for engine Model D333TA (sheet 2 of 2).
Figure 3-47. Engine oil strainer (for engine Model 687C-18-ES), removal, disassembly, reassembly and installation.
Figure 3-49. External oil and ventilation lines, removal and installation.
Figure 3-50. Crankcase breather and oil filler (engine model D333TA), removal, disassembly, reassembly and installation.
Section XI. FULL SYSTEM
Figure 3-51. Fuel injector and fuel line removal and installation (engine model 687C-18-ES).
Fuel Tanks, Lines, and Fittings - TM-5-3810-201-120136
Figure 3-53. Air cleaner and mounting bracket, removal, disassembly and installation (on Crane model 855BG with engine 687C-18-ES).
Figure 3-54. Air cleaner, disassembly and reassembly (on crane models 855BGs with engine model 687C-18-ES).
Figure 3-55. Air cleaner, dry type, removal, disassembly, reassembly, and installation (for engine mode D333TA).
Figure 3-56. Air manifold and blower adapters, installed view.
Figure 3-57. Fuel tank, lines, and fittings (on crane models 855-BG2), removal and installation.
Figure 3-58. Filler pipe and fuel level gage (crane model 855Bg only), removal and installation.
Figure 3-59. Fuel line and breather (crane model/855BG3), installed view.
Figure 3-60. Primary fuel filter (on engine model 687C-18 ES only) removal, disassembly, reassembly and installation.
Figure 3-61. Fuel filter (secondary), removal, disassembly , reassembly and installation (engine model 687C-18-ES).
Governor Throttle Control Linkage
Figure 3-62. Fuel filter (for engine model D333TA), removal, disassembly, reassembly, and installation.
Figure 3-64. Primer pump (for engine model 687C-18-ES) removal and installation.
Figure 3-65. Primer pump (for engine model D333TA) removal, disassembly, reassembly and installation (sheet 1 of 2).
Figure 3-65. Primer pump (for engine Model D333TA) removal, disassembly, reassembly and installation (sheet 2 of 2).
Figure 3-66. Engine shutoff control, removal and installation.
Figure 3-67. Blower Adapters, removal and installation (Engine Model 687C-18-ES).
Section XII. ELECTRICAL SYSTEM - TM-5-3810-201-120153
Figure 3-68. Battery and Battery Box removal and installation (nonwinterized units).
On Equipment Test. - TM-5-3810-201-120155
Generator Regulator (For Engine Model 687C-18-ES).
Figure 3-70. Insulation panels and temperature controls, removal and installation (winterized units)
Figure 3-71. Generator and voltage regulator test points
Figure 3-72. Generator test connections.
Figure 3-73. Alternator test connections.
Figure 3-74. Generator voltage regulator test connections.
Figure 3-75. Generator voltage regulator and shock mounts, removal and installation.
Water Temperature Transmitter
Figure 3-77. Starter motor, relay solenoid, and inspection band, removal and installation.
Figure 3-78. Starter motor brush replacement
Replacement.
Figure 3-81 Water temperature transmitter, and water high temperature switch, removal and installation.
Figure 3-82. Low Oil pressure switch, removal and installation.
Figure 3-83. Overspeed governor, removal, installation, and speed adjustment (engine model 687C-18-ES).
Section XIII. EXHAUST SYSTEM - TM-5-3810-201-120170
Figure 3-85. Exhaust pipe, hood, cap, and elbow, removal and installation (engine model D333TA).
Radiator, Shroud, and Fan Shroud
Figure 3-87. Fan guard and shroud (engine model 687C-18-ES), removal and installation.
Figure 3-88. Fan guard (engine model DS33TA) removal and installation.
Figure 3-89. Radiator, removal and installation.
Figure 3-90. Fan and support bracket (engine model 687C-18-ES), removal and installation.
Figure 3-92. Fan idler pulley, fan hub, and fan belt removal, disassembly, reassembly, installation, and adjustment.
Section XV. ENGINE CLUTCH
Section XVI. POWER TRANSFER - TM-5-3810-201-120179
Figure 3-96. Transfer chain case cover, removal and installation.
Figure 3-97. Transfer chain, removal and installation.
Section XVII. HYDRAULIC SYSTEM - TM-5-3810-201-120182
Hydraulic, Hose, Lines, Tubes and Fittings
Compensators (Cylinders)
Figure 3-100. Lever stand showing compensator, lever, pedal, and linkage removal and adjustment points (sheet 2 of 2).
Swing and Propel Shifter Lever and Linkage
Figure 3-102. Swing brake hydraulic control, removal and installation.
Hydraulic Clutch and Brake Cylinders and Linkage
Figure 3-104. Hydraulic clutch cylinder, removal and installation.
Section XVIII. ROTATING BASE (REVOLVING FRAME) - TM-5-3810-201-120190
Figure 3-106. Front hook rollers, removal and installation.
Figure 3-107. Rear hook rollers, removal and installation.
Figure 3-108. Jackshaft clutch shoes, removal and installation.
Figure 3-109. Main hoist clutch shoes, removal and installation.
Figure 3-110. Planetary clutch band and brake band, removal and installation.
Figure 3-111. Drum lagging, removal and installation.
Gear and Dirt Guards or Shields
Figure 3-114. Shovel sprocket and planetary pinion gear, removal and installation.
Figure 3-115. Swing brake dirt guard, removal and installation
Figure 3-117. Hoist gear guard, removal and installation.
Figure 3-119. Intermediate hoist and jackshaft cover, removal and installation.
Figure 3-121. Swing brake band, removal and installation.
Figure 3-122. Boom planetary of hoist brake band, removal and installation.
Figure 3-123. Boom hoist holding pawl, removal and installation.
Figure 3-124. Propel brake band and linkage, removal and installation.
Figure 3-125. Steering wheel adjustment.
Section XIX. TRACKS - TM-5-3810-201-120207
Upper Track Support Rollers - TM-5-3810-201-120208
Section XX. INSTRUMENTS AND CONTROLS - TM-5-3810-201-120209
Figure 3-128. Tachometer-time totalizing meter, oil pressure indicator, fuel lever indicator, and ammeter, removal and installation
Ammeter
Figure 3-129. Indicator light and switch, removal and installation.
Water Temperature Indicator - TM-5-3810-201-120213
Figure 3-130. Counterweight extension, removal and installation.
Figure 3-131. Handrail, panel, window frame, and cab, removal and installation.
Figure 3-132. Panels and swinging door, removal and installation.
Figure 3-133. Sliding and winterized doors, removal and installation.
Figure 3-134. Front doors on winterized model.
Figure 3-135. Panel, covers, and doors, removal and installation.
Figure 3-136. Upper and lower doors (winterized models) removal and installations.
Figure 3-137. Operator's seat, removal and installation (Model 855BG-2).
Figure 3-138. Operator's seat, removal and installation (Model 855BG-3).
Figure 3-139. Floodlight, disassembly and assembly.
Figure 3-140. Light enclosure and components, removal and installation.
Figure 3-141. Gun case and tool box, removal and installation.
Figure 4-1. Shovel front end attachment, cribbed for removal or installation.
Figure 4-2. Revolving frame component relationship. - TM-5-3810-201-120227
Figure 4-3. Crowd and retract chain, removal, installation, and adjustment. - TM-5-3810-201-120228
Figure 4-4. Shovel dipper, removal, disassembly, reassembly, and installation.
Shovel Dipper a. Removal.
Figure 4-5. Dipper teeth, removal and installation.
Dipper Trip Mechanism and Trip Lines
Figure 4-8. Dipper trip clutch mechanism, disassembly and reassembly. - TM-5-3810-201-120233
Figure 4-9. Clutch brakeshoes, removal and installation.
Section II. CLAMSHELL, CRANE, AND DRAGLINE FRONT AND ATTACHMENTS
Figure 4-10. Boom disassembly and reassembly. - TM-5-3810-201-120236
Figure 4-11. Boom (extension) section, removal and installation.
Figure 4-12. Tagline winder, removal and installation.
Figure 4-14. Fair lead and sheaves, disassembly and reassembly. - TM-5-3810-201-120239
Clamshell Bucket and Teeth
Figure 4-16. Dragline bucket, teeth replacement. - TM-5-3810-201-120241
Figure 4-18. Boom point and idler sheaves, removal and installation.
Figure 4-20. Crane boom with jib, installed view.
Figure 4-21. Jib boom, disassembly or reassembly. - TM-5-3810-201-120244
Boom Backstop
Figure 4-23. Radius (boom angle) indicator, removal, disassembly, reassembly, and installation
Section III. BACKHOE FRONT END ATTACHMENT - TM-5-3810-201-120247
Figure 4-24. Backhoe front end attachment, installed view. - TM-5-3810-201-120248
Figure 4-25. Auxiliary gantry and boom foot adapters. - TM-5-3810-201-120249
Figure 4-26. Auxiliary gantry sheaves. - TM-5-3810-201-120250
Figure 4-27. Backhoe bucket, disassembly and reassembly. - TM-5-3810-201-120251
Figure 4-28. Backhoe bucket stick, disassembly and reassembly. - TM-5-3810-201-120252
Backhoe Safety Backstop
Figure 4-30. Backhoe boom disassembly and reassembly. - TM-5-3810-201-120254
Section IV. PILEDRIVER FRONT END ATTACHMENT - TM-5-3810-201-120255
Figure 4-31. Pile leads, cribs for removal or installation.
Figure 4-32. Pile lead attaching hardware
Section V. ACCESSORIES - TM-5-3810-201-120258
Section VI. WINTERIZATION EQUIPMENT
Figure 4-35. Personnel heater removal and installation.
Figure 4-36. Personnel or engine heater, disassembly and reassembly.
Figure 4-37. Personnel and engine heater control, disassembly and reassembly.
Figure 4-38. Engine heater and battery heater, removal and installation (sheet I of 2).
Figure 4-39. Battery heater, disassembly and reassembly.
Figure 4-40. Battery heater control, disassembly and reassembly.
Figure 4-41. Heater fuel tank, strainers, and fuel pump group, removal and installation.
Figure 4-42. Heater control panel, removal, disassembly, reassembly and installation (sheet 1 of 2).
Figure 4-42. Heater control panel, removal, disassembly, reassembly, and installation (Sheet 2 of 2).
Winterfront
Figure 4-44. Defroster, hose, and manifold group, removal and installation.
Figure 4-45. Pressure Primer discharge, removal and installation
Figure 4-47. Glow plug, removal and installation.
Figure 4-48. Winterfront, removal, disassembly, reassembly, and installation
Chapter 5. SHIPMENT AND LIMITED STORAGE, AND DEMOLITION TO PREVENT ENEMY USE - TM-5-3810-201-120274
Demolition by Explosives or Weapons Fire - TM-5-3810-201-120275
Appendix A. REFERENCES - TM-5-3810-201-120276
Appendix B. BASIC ISSUE ITEMS LIST - TM-5-3810-201-120277
Section II. BASIC ISSUE ITEMS - TM-5-3810-201-120278
Section III. MAINTENANCE AND OPERATING SUPPLIES - TM-5-3810-201-120279
Appendix C. MAINTENANCE ALLOCATION CHART - TM-5-3810-201-120280
Section II. MAINTENANCE ALLOCATION CHART - TM-5-3810-201-120281
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120282
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120283
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120284
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120285
Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS - TM-5-3810-201-120286
TM-5-3810-201-12 Crane-Shovel Basic Unit Crawler Mounted 40 Ton 2 Cu Yd Diesel Driven Manual
Figure 1-1. Crane-shovel basic unit, non-winterized, right rear view, and shipping dimensions.
Figure 1-2. Crane-shovel basic unit, non winterized, with crane boom installed.
Figure 1-3. Crane-shovel basic unit, winterized, rear view.
Tabulated Data. - TM-5-3810-201-120016
Tabulated Data - continued - TM-5-3810-201-120017
Table 1-1. Specific Gravity Temperature Corrections for Batteries.
Figure 1-4. Crane and jib working ranges.
9Table 1-2. Cable Lengths, Diameter, and Use
Table 1-2. Cable Lengths, Diameter, and Use - TM-5-3810-201-120021
Figure 1-6. Dragline working ranges
Figure 1-8. Backhoe working ranges
Figure 1-9. Piledriver clearance diagram
Difference in Models - TM-5-3810-201-120025
Figure 1-10. Wiring diagram (sheet 1 of 7).
Figure 1-10. Wiring diagram (sheet 2 of 7).
Figure 1-10. Wiring diagram (sheet 3 of 7).
Figure 1-10. Wiring diagram (sheet 4 of 7).
Figure 1-10. Wiring diagram (sheet 5 of 7).
Figure 1-10. Wiring diagram (sheet 6 of 7).
Figure 1-10. Wiring diagram (sheet 7 of 7).
Chapter 2. INSTALLATION AND OPERATING INSTRUCTIONS - TM-5-3810-201-120033
Figure 2-1. Crane-shovel basic unit, and accessories loaded and blocked for shipment, front view. - TM-5-3810-201-120034
Figure 2-2. Crane-shovel basic unit, and accessories loaded and block for shipment, rear view.
Figure 2-3. Front end attachments loaded and blocked for shipment (sheet 1 of 2). - TM-5-3810-201-120036
Equipment Conversion - TM-5-3810-201-120037
Figure 2-4. Unloading crane-shovel basic unit by lifting. - TM-5-3810-201-120038
Figure 2-6. Crane boom, positioned for removal or installation.
Figure 2-7. Crane boom and jib boom reeving diagram (sheet 1 of 2).
Backhoe Front End Attachment
Figure 2-8. Crane front end attachment, with jib boom installed. - TM-5-3810-201-120042
Figure 2-9. Clamshell front end attachment reeving diagram. - TM-5-3810-201-120043
Figure 2-10. Clamshell front end attachment, installed view. - TM-5-3810-201-120044
Figure 2-11. Dragline front end attachment, installed view. - TM-5-3810-201-120045
Figure 2-12. Dragline front end attachment reeving diagram.
Figure 2-13. Piledriver front end attachment, reeving diagram.
Figure 2-15. Backhoe front end attachment, prepared for removal and installation.
Figure 2-16. Backhoe front end attachment, reeving diagram.
Figure 2-17. Backhoe front end attachment, installed view. - TM-5-3810-201-120050
Figure 2-18. Shovel front end attachment, installed view. - TM-5-3810-201-120051
Figure 2-19. Shovel front end attachment reeving diagram.
Section II. MOVEMENT TO A NEW WORKSITE - TM-5-3810-201-120053
Figure 2-20. Anti-rotation bars, stowed.
Section III. CONTROLS AND INSTRUMENTS - TM-5-3810-201-120055
Figure 2-23. Crane operating control handles and levers. - TM-5-3810-201-120056
Figure 2-24. Crane, engine and lighting controls.
Figure 2-25. Heat-start switch.
Engine Throttle Control Lever
Figure 2-27. Boom angle (radius) indicator, installed view
Figure 2-29. Heater control box.
Section IV. OPERATION UNDER USUAL CONDITIONS - TM-5-3810-201-120062
Table 2-1. Use of Cold Weather Starting Aids.
Boom Raising or Lowering
Section V. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-3810-201-120065
Operation in Extreme Heat - TM-5-3810-201-120066
Operation in Snow
Cold Weather Starting Aids - TM-5-3810-201-120068
Heaters
Operation of Dragline Fro nt End Attachment
Operation of Shovel Front End Attachment
Operation of Backhoe Front End Attachment
Chapter 3. OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS - TM-5-3810-201-120073
Figure 3-1. Lubricating point identification (sheet 1 of 14). - TM-5-3810-201-120074
Figure 3-1. Lubricating point identification (sheet 2 of 14). - TM-5-3810-201-120075
Figure 3-1. Lubricating point identification (sheet 3 of 14). - TM-5-3810-201-120076
Figure 3-1. Lubricating point identification (sheet 4 of 14).
Figure 3-1. Lubricating point identification (sheet 5 of 14). - TM-5-3810-201-120078
Figure 3-1. Lubricating point identification (sheet 6 of 14). - TM-5-3810-201-120079
Figure 3-1. Lubricating point identification (sheet 7 of 14). - TM-5-3810-201-120080
Figure 3-1. Lubricating point identification (sheet 8 of 14). - TM-5-3810-201-120081
Figure 3-1. Lubricating point identification (sheet 9 of 14). - TM-5-3810-201-120082
Figure 3-1. Lubricating point identification (sheet 10 of 14). - TM-5-3810-201-120083
Figure 3-1. Lubricating point identification (sheet 11 of 14). - TM-5-3810-201-120084
Figure 3-1. Lubricating point identification (sheet 12 of 14). - TM-5-3810-201-120085
Figure 3-1. Lubricating point identification (sheet 13 of 14). - TM-5-3810-201-120086
Figure 3-1. Lubricating point identification (sheet 14 of 14). - TM-5-3810-201-120087
Figure 3-2. Air cleaner service (crane-shovel model 855BG2).'
Engine Oil Filter Service.
Figure 3-5. Engine oil filter service for engine model D333TA.
Figure 3-6. Engine oil strainer service (model 687C-18-ES only).
Figure 3-7. Chain case fill cap and breather service.
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-3810-201-120093
Table 3-2. Preventive Maintenance Checks and Services - TM-5-3810-201-120094
Table 3-2. Preventive Maintenance Checks and Services - continued - TM-5-3810-201-120095
Table 3-2. Preventive Maintenance Checks and Services - continued - TM-5-3810-201-120096
Figure 3-9. Engine clutch adjustment.
Figure 3-11. Primary fuel filter service. (model 687C-18-ES).
Figure 3-13. Fuel filter service on engine model D333TA.
Figure 3-15. Filler cap and filter service, model 855BG3.
Figure 3-16. Fuel tank breather service, model 855BG3.
Figure 3-19. Battery service (non-winterized models).
Battery Service (Winterized Models)
Radiator Service - TM-5-3810-201-120104
Generator Drive Belt Adjustment (Engine Model 687C-18-ES Only)
Heater Fuel Strainer Service (Winterized Models)
Swing ( jackshaft) Clutch Adjustment
Figure 3-28. Hoist clutch shoes adjustment and removal points.
Positioning Clutch and Brake Bands on Hoist Drum
Hoist Clutch and Digging Clutch Adjustment - TM-5-3810-201-120110
Figure 3-32. Steering linkage and propel brake adjustment.
Steering Linkage, Swing Broke and Propel Brake Adjustment
Figure 3-34. Boom hoist brake adjustment points.
Crowd Chain Adjustment
Figure 3-37. Trip cable adjustment.
Figure 3-38. Hook roller adjustment points
Figure 3-39. Propel chain adjustment.
Figure 3-40. Track adjustment.
Section V. TROUBLESHOOTING - TM-5-3810-201-120119
Table 3-3. Troubleshooting
Table 3-3. Troubleshooting - continued
Section VI. FIELD EXPEDIENT REPAIRS - TM-5-3810-201-120122
Testing of Radio Interference Suppression Components
Section VIII. ORGANIZATIONAL MAINTENANCE PROCEDURES - TM-5-3810-201-120124
Figure 3-42. Valve (rocker arm) adjustment, model 687C-18-ES engine.
Section X. ENGINE LUBRICATION SYSTEM
Engine Oil Level Gage (Dipstick)
Figure 3-45. Engine oil filters (Model 887C-18-ES) disassembly, and reassembly, and oil filter pipe removal and installation.
Figure 3-46. Oil filters, removal, disassembly, reassembly and installation for engine Model D333TA (sheet 1 of 2).
Figure 3-46. Oil filters, removal, disassembly, reassembly, and installation for engine Model D333TA (sheet 2 of 2).
Figure 3-47. Engine oil strainer (for engine Model 687C-18-ES), removal, disassembly, reassembly and installation.
Figure 3-49. External oil and ventilation lines, removal and installation.
Figure 3-50. Crankcase breather and oil filler (engine model D333TA), removal, disassembly, reassembly and installation.
Section XI. FULL SYSTEM
Figure 3-51. Fuel injector and fuel line removal and installation (engine model 687C-18-ES).
Fuel Tanks, Lines, and Fittings - TM-5-3810-201-120136
Figure 3-53. Air cleaner and mounting bracket, removal, disassembly and installation (on Crane model 855BG with engine 687C-18-ES).
Figure 3-54. Air cleaner, disassembly and reassembly (on crane models 855BGs with engine model 687C-18-ES).
Figure 3-55. Air cleaner, dry type, removal, disassembly, reassembly, and installation (for engine mode D333TA).
Figure 3-56. Air manifold and blower adapters, installed view.
Figure 3-57. Fuel tank, lines, and fittings (on crane models 855-BG2), removal and installation.
Figure 3-58. Filler pipe and fuel level gage (crane model 855Bg only), removal and installation.
Figure 3-59. Fuel line and breather (crane model/855BG3), installed view.
Figure 3-60. Primary fuel filter (on engine model 687C-18 ES only) removal, disassembly, reassembly and installation.
Figure 3-61. Fuel filter (secondary), removal, disassembly , reassembly and installation (engine model 687C-18-ES).
Governor Throttle Control Linkage
Figure 3-62. Fuel filter (for engine model D333TA), removal, disassembly, reassembly, and installation.
Figure 3-64. Primer pump (for engine model 687C-18-ES) removal and installation.
Figure 3-65. Primer pump (for engine model D333TA) removal, disassembly, reassembly and installation (sheet 1 of 2).
Figure 3-65. Primer pump (for engine Model D333TA) removal, disassembly, reassembly and installation (sheet 2 of 2).
Figure 3-66. Engine shutoff control, removal and installation.
Figure 3-67. Blower Adapters, removal and installation (Engine Model 687C-18-ES).
Section XII. ELECTRICAL SYSTEM - TM-5-3810-201-120153
Figure 3-68. Battery and Battery Box removal and installation (nonwinterized units).
On Equipment Test. - TM-5-3810-201-120155
Generator Regulator (For Engine Model 687C-18-ES).
Figure 3-70. Insulation panels and temperature controls, removal and installation (winterized units)
Figure 3-71. Generator and voltage regulator test points
Figure 3-72. Generator test connections.
Figure 3-73. Alternator test connections.
Figure 3-74. Generator voltage regulator test connections.
Figure 3-75. Generator voltage regulator and shock mounts, removal and installation.
Water Temperature Transmitter
Figure 3-77. Starter motor, relay solenoid, and inspection band, removal and installation.
Figure 3-78. Starter motor brush replacement
Replacement.
Figure 3-81 Water temperature transmitter, and water high temperature switch, removal and installation.
Figure 3-82. Low Oil pressure switch, removal and installation.
Figure 3-83. Overspeed governor, removal, installation, and speed adjustment (engine model 687C-18-ES).
Section XIII. EXHAUST SYSTEM - TM-5-3810-201-120170
Figure 3-85. Exhaust pipe, hood, cap, and elbow, removal and installation (engine model D333TA).
Radiator, Shroud, and Fan Shroud
Figure 3-87. Fan guard and shroud (engine model 687C-18-ES), removal and installation.
Figure 3-88. Fan guard (engine model DS33TA) removal and installation.
Figure 3-89. Radiator, removal and installation.
Figure 3-90. Fan and support bracket (engine model 687C-18-ES), removal and installation.
Figure 3-92. Fan idler pulley, fan hub, and fan belt removal, disassembly, reassembly, installation, and adjustment.
Section XV. ENGINE CLUTCH
Section XVI. POWER TRANSFER - TM-5-3810-201-120179
Figure 3-96. Transfer chain case cover, removal and installation.
Figure 3-97. Transfer chain, removal and installation.
Section XVII. HYDRAULIC SYSTEM - TM-5-3810-201-120182
Hydraulic, Hose, Lines, Tubes and Fittings
Compensators (Cylinders)
Figure 3-100. Lever stand showing compensator, lever, pedal, and linkage removal and adjustment points (sheet 2 of 2).
Swing and Propel Shifter Lever and Linkage
Figure 3-102. Swing brake hydraulic control, removal and installation.
Hydraulic Clutch and Brake Cylinders and Linkage
Figure 3-104. Hydraulic clutch cylinder, removal and installation.
Section XVIII. ROTATING BASE (REVOLVING FRAME) - TM-5-3810-201-120190
Figure 3-106. Front hook rollers, removal and installation.
Figure 3-107. Rear hook rollers, removal and installation.
Figure 3-108. Jackshaft clutch shoes, removal and installation.
Figure 3-109. Main hoist clutch shoes, removal and installation.
Figure 3-110. Planetary clutch band and brake band, removal and installation.
Figure 3-111. Drum lagging, removal and installation.
Gear and Dirt Guards or Shields
Figure 3-114. Shovel sprocket and planetary pinion gear, removal and installation.
Figure 3-115. Swing brake dirt guard, removal and installation
Figure 3-117. Hoist gear guard, removal and installation.
Figure 3-119. Intermediate hoist and jackshaft cover, removal and installation.
Figure 3-121. Swing brake band, removal and installation.
Figure 3-122. Boom planetary of hoist brake band, removal and installation.
Figure 3-123. Boom hoist holding pawl, removal and installation.
Figure 3-124. Propel brake band and linkage, removal and installation.
Figure 3-125. Steering wheel adjustment.
Section XIX. TRACKS - TM-5-3810-201-120207
Upper Track Support Rollers - TM-5-3810-201-120208
Section XX. INSTRUMENTS AND CONTROLS - TM-5-3810-201-120209
Figure 3-128. Tachometer-time totalizing meter, oil pressure indicator, fuel lever indicator, and ammeter, removal and installation
Ammeter
Figure 3-129. Indicator light and switch, removal and installation.
Water Temperature Indicator - TM-5-3810-201-120213
Figure 3-130. Counterweight extension, removal and installation.
Figure 3-131. Handrail, panel, window frame, and cab, removal and installation.
Figure 3-132. Panels and swinging door, removal and installation.
Figure 3-133. Sliding and winterized doors, removal and installation.
Figure 3-134. Front doors on winterized model.
Figure 3-135. Panel, covers, and doors, removal and installation.
Figure 3-136. Upper and lower doors (winterized models) removal and installations.
Figure 3-137. Operator's seat, removal and installation (Model 855BG-2).
Figure 3-138. Operator's seat, removal and installation (Model 855BG-3).
Figure 3-139. Floodlight, disassembly and assembly.
Figure 3-140. Light enclosure and components, removal and installation.
Figure 3-141. Gun case and tool box, removal and installation.
Figure 4-1. Shovel front end attachment, cribbed for removal or installation.
Figure 4-2. Revolving frame component relationship. - TM-5-3810-201-120227
Figure 4-3. Crowd and retract chain, removal, installation, and adjustment. - TM-5-3810-201-120228
Figure 4-4. Shovel dipper, removal, disassembly, reassembly, and installation.
Shovel Dipper a. Removal.
Figure 4-5. Dipper teeth, removal and installation.
Dipper Trip Mechanism and Trip Lines
Figure 4-8. Dipper trip clutch mechanism, disassembly and reassembly. - TM-5-3810-201-120233
Figure 4-9. Clutch brakeshoes, removal and installation.
Section II. CLAMSHELL, CRANE, AND DRAGLINE FRONT AND ATTACHMENTS
Figure 4-10. Boom disassembly and reassembly. - TM-5-3810-201-120236
Figure 4-11. Boom (extension) section, removal and installation.
Figure 4-12. Tagline winder, removal and installation.
Figure 4-14. Fair lead and sheaves, disassembly and reassembly. - TM-5-3810-201-120239
Clamshell Bucket and Teeth
Figure 4-16. Dragline bucket, teeth replacement. - TM-5-3810-201-120241
Figure 4-18. Boom point and idler sheaves, removal and installation.
Figure 4-20. Crane boom with jib, installed view.
Figure 4-21. Jib boom, disassembly or reassembly. - TM-5-3810-201-120244
Boom Backstop
Figure 4-23. Radius (boom angle) indicator, removal, disassembly, reassembly, and installation
Section III. BACKHOE FRONT END ATTACHMENT - TM-5-3810-201-120247
Figure 4-24. Backhoe front end attachment, installed view. - TM-5-3810-201-120248
Figure 4-25. Auxiliary gantry and boom foot adapters. - TM-5-3810-201-120249
Figure 4-26. Auxiliary gantry sheaves. - TM-5-3810-201-120250
Figure 4-27. Backhoe bucket, disassembly and reassembly. - TM-5-3810-201-120251
Figure 4-28. Backhoe bucket stick, disassembly and reassembly. - TM-5-3810-201-120252
Backhoe Safety Backstop
Figure 4-30. Backhoe boom disassembly and reassembly. - TM-5-3810-201-120254
Section IV. PILEDRIVER FRONT END ATTACHMENT - TM-5-3810-201-120255
Figure 4-31. Pile leads, cribs for removal or installation.
Figure 4-32. Pile lead attaching hardware
Section V. ACCESSORIES - TM-5-3810-201-120258
Section VI. WINTERIZATION EQUIPMENT
Figure 4-35. Personnel heater removal and installation.
Figure 4-36. Personnel or engine heater, disassembly and reassembly.
Figure 4-37. Personnel and engine heater control, disassembly and reassembly.
Figure 4-38. Engine heater and battery heater, removal and installation (sheet I of 2).
Figure 4-39. Battery heater, disassembly and reassembly.
Figure 4-40. Battery heater control, disassembly and reassembly.
Figure 4-41. Heater fuel tank, strainers, and fuel pump group, removal and installation.
Figure 4-42. Heater control panel, removal, disassembly, reassembly and installation (sheet 1 of 2).
Figure 4-42. Heater control panel, removal, disassembly, reassembly, and installation (Sheet 2 of 2).
Winterfront
Figure 4-44. Defroster, hose, and manifold group, removal and installation.
Figure 4-45. Pressure Primer discharge, removal and installation
Figure 4-47. Glow plug, removal and installation.
Figure 4-48. Winterfront, removal, disassembly, reassembly, and installation
Chapter 5. SHIPMENT AND LIMITED STORAGE, AND DEMOLITION TO PREVENT ENEMY USE - TM-5-3810-201-120274
Demolition by Explosives or Weapons Fire - TM-5-3810-201-120275
Appendix A. REFERENCES - TM-5-3810-201-120276
Appendix B. BASIC ISSUE ITEMS LIST - TM-5-3810-201-120277
Section II. BASIC ISSUE ITEMS - TM-5-3810-201-120278
Section III. MAINTENANCE AND OPERATING SUPPLIES - TM-5-3810-201-120279
Appendix C. MAINTENANCE ALLOCATION CHART - TM-5-3810-201-120280
Section II. MAINTENANCE ALLOCATION CHART - TM-5-3810-201-120281
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120282
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120283
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120284
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-201-120285
Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS - TM-5-3810-201-120286
TM-5-3810-201-12 Crane-Shovel Basic Unit Crawler Mounted 40 Ton 2 Cu Yd Diesel Driven Manual
