Chapter 1. INTRODUCTION - TM-5-3810-201-350009
Tabulated Data - TM-5-3810-201-350010
Table 1-1. Engine Repair and Replacement Standards For Engine Model D333TA - TM-5-3810-201-350011
Table 1-1. Engine Repair and Replacement Standards For Engine Model D333TA - continued - TM-5-3810-201-350012
Table 1-1. Engine Repair and Replacement Standards For Engine Model D333TA - continued - TM-5-3810-201-350013
Table 1-2Engine Repair and Replacement Standards For Engine Model 687C-18-ES
Personnel heater specifications
Chapter 2. GENERAL MAINTENANCE INSTRUCTIONS - TM-5-3810-201-350016
Figure 2-1. Specially designed (fabricated) tools (sheet 3 of 7). - TM-5-3810-201-350017
Figure 2-1. Specially designed (fabricated) tools (sheet 5 of 7). - TM-5-3810-201-350018
Figure 2-1. Specially designed (fabricated) tools (sheet 6 of 7).
Figure 2-1. Specially designed (fabricated) tools (sheet 7 of 7).
Section II. TROUBLESHOOTING - TM-5-3810-201-350021
Table 2-4. Troubleshooting - TM-5-3810-201-350022
Section III. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS OR AUXILIARIES - TM-5-3810-201-350023
Figure 2-3. Gantry, exploded view. - TM-5-3810-201-350024
Figure 2-4. Power take-off removal points.
Engine Removal or Installation
Chapter 3. ENGINE REPAIR INSTRUCTIONS - TM-5-3810-201-350027
Figure 3-1. Generator, exploded view. - TM-5-3810-201-350028
Figure 3-2. Alternator, disassembly and reassembly. - TM-5-3810-201-350029
Cleaning, Inspection, Test, and Repair.
Section II. STARTER MOTOR - TM-5-3810-201-350031
Figure 3-3. Starter motor, exploded view (for engine model 687C-18-ES)
Section III. POWER TAKE-OFF UNIT AND CLUTCH - TM-5-3810-201-350033
Figure 3-4. Backplate. removal and Installation.
Section IV. ENGINE GOVERNOR - TM-5-3810-201-350035
Figure 3-5. Power take-Off unit and clutch, exploded view (sheet 2 of 2).
Figure 3-6. Overspeed governor, exploded view.
Fuel Rack Setting.
Figure 3-10. Adjusting fuel rack setting.
Figure 3-11. Governor, cross-seectonal view.
Section V. FUEL INJECTOR FOR ENGINE MODEL 687C-18-ES
Section VI. BLOWER (SUPERCHARGER) OR TURBOCHARGER
Figure 3-14. Blowers, removal and installation. - TM-5-3810-201-350043
Figure 3-15. Blowers, exploded view (sheet 1 of 2 ).
Figure 3-15. Blowers, exploded view (continued) (sheet 2 of 2).
Turbocharger for Engine Model D333TA - TM-5-3810-201-350046
Figure 3-17. Turbocharger details (sheet 2 of 10). - TM-5-3810-201-350047
Figure 3-17. Turbocharger details (sheet 3 of 10). - TM-5-3810-201-350048
Figure 3-17. turbocharger details (sheet 4 of 10).
Figure 3-17. Turbocharger details (sheet 7 of 10). - TM-5-3810-201-350050
Figure 3-17. Turbocharger details (sheet 9 of 10). - TM-5-3810-201-350051
Figure 3-17. Turbocharger details (sheet 10 of 10). - TM-5-3810-201-350052
Figure 3-18. Fuel injection pump and drive mechanism, removal and installation.
Figure 3-19. Shutoff cam, removal and installation. - TM-5-3810-201-350054
Figure 3-20. Pump drive mechanism, exploded view. - TM-5-3810-201-350055
Figure 3-21. Fuel injection pump, exploded View (sheet 1 of 2)
Figure 3-21. Fuel injection pump, Exploded View (sheet 2 of 2)
Figure 3-22. End plate sleeve, removal points. - TM-5-3810-201-350058
Figure 3-24. Fuel transfer pump disassembly and reassembly.
Figure 3-25. Fuel injection valve, removal, disassembly, reassembly, and installation.
Figure 3-26. Fuel injection pumps, removal, disassembly, reassembly, and installation
Figure 3-27. Fuel injection pump housing and fuel pump, exploded view. - TM-5-3810-201-350062
Section VIII. COOLING SYSTEM - TM-5-3810-201-350063
Figure 3-29. Radiator for engine model 687-C18-ES exploded view.
Figure 3-30. Radiator for engine model 687-C18-ES exploded view
Figure 3-31. Fan assembly, for engine model 687C-18-ES exploded view.
Figure 3-32. Water pump, exploded view.
Figure 3-33. Water pump , for engine model D333TA, exploded view
Figure 3-34. Oil cooler cover and elbows, exploded view. - TM-5-3810-201-350069
Figure 3-35. Oil cooler core, hose, and elbow, exploded view. - TM-5-3810-201-350070
Figure 3-36. Aftercooler cover ad thermostat housing, exploded view.
Figure 3-37. Aftercooler core and related parts, exploded view.
Figure 3-38. Blower drive and idler gear, exploded view. - TM-5-3810-201-350073
Figure 3-39. Timing gear train and drive gears, installed view.
Rear Plate Removal.
Figure 3-40. Front cover, damper, pulley, and support, exploded view. - TM-5-3810-201-350076
Figure 3-41. Accessory drive, exploded view
Section X. VALVE OPERATING MECHANISM
Figure 3-43. Rocker arm, pushrod, and cam lever, exploded view. - TM-5-3810-201-350079
Figure 3-44. Valves, pushrods, rocker arm, and shaft, exploded view.
Section XI. FLYWHEEL AND HOUSING - TM-5-3810-201-350081
Figure 3-45. Flywheel housing and rear plate, exploded view. - TM-5-3810-201-350082
Figure 3-46. Flywheel and Flywheel Housing, exploded view. - TM-5-3810-201-350083
Section XII. LUBRICATION SYSTEM - TM-5-3810-201-350084
Figure 3-48. Oil pan and plate, exploded view. - TM-5-3810-201-350085
Figure 3-49. Oil pump and Crankshaft, installed view.
Figure 3-51. Oil pump and screen, for engine model D333TA with screen exploded. - TM-5-3810-201-350087
Figure 3-52. Oil pump for engine model D333TA, exploded view.
Section XIII. ENGINE FRONT COVER (MODEL 687C-18-ES) - TM-5-3810-201-350089
Figure 3-53. Front cover, support, and damper exploded view.
Figure 3-54. Camshaft for engine model 687C-18-ES exploded view.
Figure 3-55. Camshaft for engine model D333TA, exploded view.
Figure 3-56. Cylinder head, valve, and liner, removal.
Figure 3-58. Cylinder head and liner, disassembly and reassembly. - TM-5-3810-201-350094
Disassembly and Reassembly. - TM-5-3810-201-350095
Figure 3-59. Cylinder head and valves, exploded view (engine model D333TA). - TM-5-3810-201-350096
Figure 3-60. Cylinder block, cylinder sleeve, and main bearing caps, exploded view. - TM-5-3810-201-350097
Reassembly and Installation. - TM-5-3810-201-350098
Figure 3-62. Precombustion chamber positioning diagram.
Figure 3-63. Piston and connecting rod (for engine model 687C-18-ES), exploded view.
Figure 3-64. Piston and connecting rod for engine model D33TA, exploded view
Section XVII. CRANKSHAFT AND MAIN BEARINGS - TM-5-3810-201-350102
Figure 3-65. Crankshaft and flywheel for engine model 687C018-ES,erxploded
Section XVIII. ENGINE CRANKCASE - TM-5-3810-201-350104
Figure 3-67. Crankcase and exhaust manifold, exploded view.
Chapter 4. REVOLVING FRAME REPAIR INSTRUCTIONS - TM-5-3810-201-350106
Figure 4-1. Gantry sheave yoke and adapters, exploded view. - TM-5-3810-201-350107
Section III. COUNTERWEIGHT - TM-5-3810-201-350108
Figure 4-2. Steering wheel shaft, and vertical propel gear, installed view. - TM-5-3810-201-350109
Figure 4-3. Steering wheel and shafts, exploded view.
Section V. JACKSHAFT (HORIZONTAL SWING SHAFT) - TM-5-3810-201-350111
Figure 4-5. Main hoist shaft, left side installed view. - TM-5-3810-201-350112
Figure 4-6. Jackshaft (horizontal swing shaft), installed view. - TM-5-3810-201-350113
Figure 4-7. Horizontal swing (jackshaft), exploded view.
Cleaning, Inspection, and Repair. - TM-5-3810-201-350115
Section VI. INTERMEDIATE HOIST SHAFT - TM-5-3810-201-350116
Cleaning, Inspection, and Repair. - TM-5-3810-201-350117
Figure 4-9. Main drum (hoist) shaft, exploded view (sheet 1 of 2).
Figure 4-9. Main drum (hoist) shaft, exploded view (sheet 2 of 2)
Cleaning, Inspection and Repair. - TM-5-3810-201-350120
Section VIII. HOISTING, DIGGING, AND AUXILIARY CLUTCHES - TM-5-3810-201-350121
Section IX. VERTICAL INTERMEDIATE IDLER SHAFT - TM-5-3810-201-350122
Figure 4-11. Vertical wing shaft and intermediate idler shaft, installed view.
Section X. VERTICAL INTERMEDIATE SWING SHAFT - TM-5-3810-201-350124
Figure 4-14. Vertical intermediate swing shaft, exploded
Section XI. SWING BRAKE BAND AND OPERATING MECHANISM - TM-5-3810-201-350126
Figure 4-15. Swing broke band and linkage, exploded view.
Vertical Swing Shaft - TM-5-3810-201-350128
Cleaning, Inspection, and Repair. - TM-5-3810-201-350129
Cleaning, Inspection, and Repair. - TM-5-3810-201-350130
Section XIV. BOOM HOIST BRAKE - TM-5-3810-201-350131
Section XV. REVOLVING FRAME AND HOOK ROLLERS - TM-5-3810-201-350132
Figure 4-19. Front and rear hook roller, exploded view.
Figure 4-20. Revolving frame, exploded view.
Section XVI. HYDRAULIC BRAKE AND CLUTCH CYLINDERS
Figure 4-23. Clutch boom hoist, swing, hoist, and digging brake compensators, exploded view. - TM-5-3810-201-350136
Figure 4-24. Jackshaft and brakedrum hydraulic cylinder, exploded view.
Figure 4-25. Propel brake and planetary boom Hydraulic compensator, exploded view.
Figure 4-26. Pressure control valve, exploded view. - TM-5-3810-201-350139
Chapter 5. CRAWLER REPAIR INSTRUCTIONS - TM-5-3810-201-350140
Steering and Broke Lever Shaft
Figure 5-3. Steering and brake lever shaft, exploded view. - TM-5-3810-201-350142
Figure 5-4. Propelling brake and levers, exploded view. - TM-5-3810-201-350143
Section III. CRAWLER DRIVE SHAFT - TM-5-3810-201-350144
Figure 5-6. Crawler frame, exploded view. - TM-5-3810-201-350145
Cleaning, Inspection, and Repair. - TM-5-3810-201-350146
Figure 5-7. Crawler idler sprocket and idler shaft, exploded view.
Section V. HORIZONTAL PROPELLING SHAFT - TM-5-3810-201-350148
Figure 5-9. Horizontal propelling shaft,
Section VI. CRAWLER FRAME AND TRACKS - TM-5-3810-201-350150
Figure 5-10. Crawler track, disassembly and reassembly
Chapter 6. REPAIR INSTRUCTIONS FOR MATERIEL USED IN CONJUNCTION
Bridle Bar and Boom Point Sheaves
Figure 6-2. Bridle bar and boom point sheaves, exploded view
Figure 6-3. Crowd and retract mechanism, exploded view
Section II. SHOVEL DIPPER AND HANDLE - TM-5-3810-201-350156
Figure 6-5. Shovel dipper and bail, exploded view.
Bail and Sheave
Appendix A. REFERENCES - TM-5-3810-201-350159
TM-5-3810-201-35 Crane-Shovel Basic Unit Crawler Mounted 40 Ton 2 Cu Yd Diesel Driven Manual
Tabulated Data - TM-5-3810-201-350010
Table 1-1. Engine Repair and Replacement Standards For Engine Model D333TA - TM-5-3810-201-350011
Table 1-1. Engine Repair and Replacement Standards For Engine Model D333TA - continued - TM-5-3810-201-350012
Table 1-1. Engine Repair and Replacement Standards For Engine Model D333TA - continued - TM-5-3810-201-350013
Table 1-2Engine Repair and Replacement Standards For Engine Model 687C-18-ES
Personnel heater specifications
Chapter 2. GENERAL MAINTENANCE INSTRUCTIONS - TM-5-3810-201-350016
Figure 2-1. Specially designed (fabricated) tools (sheet 3 of 7). - TM-5-3810-201-350017
Figure 2-1. Specially designed (fabricated) tools (sheet 5 of 7). - TM-5-3810-201-350018
Figure 2-1. Specially designed (fabricated) tools (sheet 6 of 7).
Figure 2-1. Specially designed (fabricated) tools (sheet 7 of 7).
Section II. TROUBLESHOOTING - TM-5-3810-201-350021
Table 2-4. Troubleshooting - TM-5-3810-201-350022
Section III. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS OR AUXILIARIES - TM-5-3810-201-350023
Figure 2-3. Gantry, exploded view. - TM-5-3810-201-350024
Figure 2-4. Power take-off removal points.
Engine Removal or Installation
Chapter 3. ENGINE REPAIR INSTRUCTIONS - TM-5-3810-201-350027
Figure 3-1. Generator, exploded view. - TM-5-3810-201-350028
Figure 3-2. Alternator, disassembly and reassembly. - TM-5-3810-201-350029
Cleaning, Inspection, Test, and Repair.
Section II. STARTER MOTOR - TM-5-3810-201-350031
Figure 3-3. Starter motor, exploded view (for engine model 687C-18-ES)
Section III. POWER TAKE-OFF UNIT AND CLUTCH - TM-5-3810-201-350033
Figure 3-4. Backplate. removal and Installation.
Section IV. ENGINE GOVERNOR - TM-5-3810-201-350035
Figure 3-5. Power take-Off unit and clutch, exploded view (sheet 2 of 2).
Figure 3-6. Overspeed governor, exploded view.
Fuel Rack Setting.
Figure 3-10. Adjusting fuel rack setting.
Figure 3-11. Governor, cross-seectonal view.
Section V. FUEL INJECTOR FOR ENGINE MODEL 687C-18-ES
Section VI. BLOWER (SUPERCHARGER) OR TURBOCHARGER
Figure 3-14. Blowers, removal and installation. - TM-5-3810-201-350043
Figure 3-15. Blowers, exploded view (sheet 1 of 2 ).
Figure 3-15. Blowers, exploded view (continued) (sheet 2 of 2).
Turbocharger for Engine Model D333TA - TM-5-3810-201-350046
Figure 3-17. Turbocharger details (sheet 2 of 10). - TM-5-3810-201-350047
Figure 3-17. Turbocharger details (sheet 3 of 10). - TM-5-3810-201-350048
Figure 3-17. turbocharger details (sheet 4 of 10).
Figure 3-17. Turbocharger details (sheet 7 of 10). - TM-5-3810-201-350050
Figure 3-17. Turbocharger details (sheet 9 of 10). - TM-5-3810-201-350051
Figure 3-17. Turbocharger details (sheet 10 of 10). - TM-5-3810-201-350052
Figure 3-18. Fuel injection pump and drive mechanism, removal and installation.
Figure 3-19. Shutoff cam, removal and installation. - TM-5-3810-201-350054
Figure 3-20. Pump drive mechanism, exploded view. - TM-5-3810-201-350055
Figure 3-21. Fuel injection pump, exploded View (sheet 1 of 2)
Figure 3-21. Fuel injection pump, Exploded View (sheet 2 of 2)
Figure 3-22. End plate sleeve, removal points. - TM-5-3810-201-350058
Figure 3-24. Fuel transfer pump disassembly and reassembly.
Figure 3-25. Fuel injection valve, removal, disassembly, reassembly, and installation.
Figure 3-26. Fuel injection pumps, removal, disassembly, reassembly, and installation
Figure 3-27. Fuel injection pump housing and fuel pump, exploded view. - TM-5-3810-201-350062
Section VIII. COOLING SYSTEM - TM-5-3810-201-350063
Figure 3-29. Radiator for engine model 687-C18-ES exploded view.
Figure 3-30. Radiator for engine model 687-C18-ES exploded view
Figure 3-31. Fan assembly, for engine model 687C-18-ES exploded view.
Figure 3-32. Water pump, exploded view.
Figure 3-33. Water pump , for engine model D333TA, exploded view
Figure 3-34. Oil cooler cover and elbows, exploded view. - TM-5-3810-201-350069
Figure 3-35. Oil cooler core, hose, and elbow, exploded view. - TM-5-3810-201-350070
Figure 3-36. Aftercooler cover ad thermostat housing, exploded view.
Figure 3-37. Aftercooler core and related parts, exploded view.
Figure 3-38. Blower drive and idler gear, exploded view. - TM-5-3810-201-350073
Figure 3-39. Timing gear train and drive gears, installed view.
Rear Plate Removal.
Figure 3-40. Front cover, damper, pulley, and support, exploded view. - TM-5-3810-201-350076
Figure 3-41. Accessory drive, exploded view
Section X. VALVE OPERATING MECHANISM
Figure 3-43. Rocker arm, pushrod, and cam lever, exploded view. - TM-5-3810-201-350079
Figure 3-44. Valves, pushrods, rocker arm, and shaft, exploded view.
Section XI. FLYWHEEL AND HOUSING - TM-5-3810-201-350081
Figure 3-45. Flywheel housing and rear plate, exploded view. - TM-5-3810-201-350082
Figure 3-46. Flywheel and Flywheel Housing, exploded view. - TM-5-3810-201-350083
Section XII. LUBRICATION SYSTEM - TM-5-3810-201-350084
Figure 3-48. Oil pan and plate, exploded view. - TM-5-3810-201-350085
Figure 3-49. Oil pump and Crankshaft, installed view.
Figure 3-51. Oil pump and screen, for engine model D333TA with screen exploded. - TM-5-3810-201-350087
Figure 3-52. Oil pump for engine model D333TA, exploded view.
Section XIII. ENGINE FRONT COVER (MODEL 687C-18-ES) - TM-5-3810-201-350089
Figure 3-53. Front cover, support, and damper exploded view.
Figure 3-54. Camshaft for engine model 687C-18-ES exploded view.
Figure 3-55. Camshaft for engine model D333TA, exploded view.
Figure 3-56. Cylinder head, valve, and liner, removal.
Figure 3-58. Cylinder head and liner, disassembly and reassembly. - TM-5-3810-201-350094
Disassembly and Reassembly. - TM-5-3810-201-350095
Figure 3-59. Cylinder head and valves, exploded view (engine model D333TA). - TM-5-3810-201-350096
Figure 3-60. Cylinder block, cylinder sleeve, and main bearing caps, exploded view. - TM-5-3810-201-350097
Reassembly and Installation. - TM-5-3810-201-350098
Figure 3-62. Precombustion chamber positioning diagram.
Figure 3-63. Piston and connecting rod (for engine model 687C-18-ES), exploded view.
Figure 3-64. Piston and connecting rod for engine model D33TA, exploded view
Section XVII. CRANKSHAFT AND MAIN BEARINGS - TM-5-3810-201-350102
Figure 3-65. Crankshaft and flywheel for engine model 687C018-ES,erxploded
Section XVIII. ENGINE CRANKCASE - TM-5-3810-201-350104
Figure 3-67. Crankcase and exhaust manifold, exploded view.
Chapter 4. REVOLVING FRAME REPAIR INSTRUCTIONS - TM-5-3810-201-350106
Figure 4-1. Gantry sheave yoke and adapters, exploded view. - TM-5-3810-201-350107
Section III. COUNTERWEIGHT - TM-5-3810-201-350108
Figure 4-2. Steering wheel shaft, and vertical propel gear, installed view. - TM-5-3810-201-350109
Figure 4-3. Steering wheel and shafts, exploded view.
Section V. JACKSHAFT (HORIZONTAL SWING SHAFT) - TM-5-3810-201-350111
Figure 4-5. Main hoist shaft, left side installed view. - TM-5-3810-201-350112
Figure 4-6. Jackshaft (horizontal swing shaft), installed view. - TM-5-3810-201-350113
Figure 4-7. Horizontal swing (jackshaft), exploded view.
Cleaning, Inspection, and Repair. - TM-5-3810-201-350115
Section VI. INTERMEDIATE HOIST SHAFT - TM-5-3810-201-350116
Cleaning, Inspection, and Repair. - TM-5-3810-201-350117
Figure 4-9. Main drum (hoist) shaft, exploded view (sheet 1 of 2).
Figure 4-9. Main drum (hoist) shaft, exploded view (sheet 2 of 2)
Cleaning, Inspection and Repair. - TM-5-3810-201-350120
Section VIII. HOISTING, DIGGING, AND AUXILIARY CLUTCHES - TM-5-3810-201-350121
Section IX. VERTICAL INTERMEDIATE IDLER SHAFT - TM-5-3810-201-350122
Figure 4-11. Vertical wing shaft and intermediate idler shaft, installed view.
Section X. VERTICAL INTERMEDIATE SWING SHAFT - TM-5-3810-201-350124
Figure 4-14. Vertical intermediate swing shaft, exploded
Section XI. SWING BRAKE BAND AND OPERATING MECHANISM - TM-5-3810-201-350126
Figure 4-15. Swing broke band and linkage, exploded view.
Vertical Swing Shaft - TM-5-3810-201-350128
Cleaning, Inspection, and Repair. - TM-5-3810-201-350129
Cleaning, Inspection, and Repair. - TM-5-3810-201-350130
Section XIV. BOOM HOIST BRAKE - TM-5-3810-201-350131
Section XV. REVOLVING FRAME AND HOOK ROLLERS - TM-5-3810-201-350132
Figure 4-19. Front and rear hook roller, exploded view.
Figure 4-20. Revolving frame, exploded view.
Section XVI. HYDRAULIC BRAKE AND CLUTCH CYLINDERS
Figure 4-23. Clutch boom hoist, swing, hoist, and digging brake compensators, exploded view. - TM-5-3810-201-350136
Figure 4-24. Jackshaft and brakedrum hydraulic cylinder, exploded view.
Figure 4-25. Propel brake and planetary boom Hydraulic compensator, exploded view.
Figure 4-26. Pressure control valve, exploded view. - TM-5-3810-201-350139
Chapter 5. CRAWLER REPAIR INSTRUCTIONS - TM-5-3810-201-350140
Steering and Broke Lever Shaft
Figure 5-3. Steering and brake lever shaft, exploded view. - TM-5-3810-201-350142
Figure 5-4. Propelling brake and levers, exploded view. - TM-5-3810-201-350143
Section III. CRAWLER DRIVE SHAFT - TM-5-3810-201-350144
Figure 5-6. Crawler frame, exploded view. - TM-5-3810-201-350145
Cleaning, Inspection, and Repair. - TM-5-3810-201-350146
Figure 5-7. Crawler idler sprocket and idler shaft, exploded view.
Section V. HORIZONTAL PROPELLING SHAFT - TM-5-3810-201-350148
Figure 5-9. Horizontal propelling shaft,
Section VI. CRAWLER FRAME AND TRACKS - TM-5-3810-201-350150
Figure 5-10. Crawler track, disassembly and reassembly
Chapter 6. REPAIR INSTRUCTIONS FOR MATERIEL USED IN CONJUNCTION
Bridle Bar and Boom Point Sheaves
Figure 6-2. Bridle bar and boom point sheaves, exploded view
Figure 6-3. Crowd and retract mechanism, exploded view
Section II. SHOVEL DIPPER AND HANDLE - TM-5-3810-201-350156
Figure 6-5. Shovel dipper and bail, exploded view.
Bail and Sheave
Appendix A. REFERENCES - TM-5-3810-201-350159
TM-5-3810-201-35 Crane-Shovel Basic Unit Crawler Mounted 40 Ton 2 Cu Yd Diesel Driven Manual
