OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL - TM-5-3810-231-120001
SAFETY PRECAUTIONS - TM-5-3810-231-120002
Operator and Organizational Maintenance Manual - TM-5-3810-231-120003
Table II. Maintenance and Operating Supplies
Table II. Maintenance and Operating Supplies - continued
Section I. INTRODUCTION - TM-5-3810-231-120006
Chapter 1. INTRODUCTION - TM-5-3810-231-120008
Figure 1. Crane, left front, three quarter view.
Figure 2. Crane, right-rear, three-quarter view, with shipping dimensions.
Tabulated Data. - TM-5-3810-231-120011
Figure 3. Wiring diagram.
Figure 3. Wiring diagram - continued - TM-5-3810-231-120013
Figure 3. Wiring diagram - continued - TM-5-3810-231-120014
Figure 4. Base plan.
Adjustment data. - TM-5-3810-231-120016
Chapter 2. INSTALLATION AND OPERATION INSTRUCTIONS - TM-5-3810-231-120017
Table 1. Freezing Points, Composition and Specific Gravities of Military Antifreeze Materials
Figure 5. Block and tie-down removal.
Section II. MOVEMENT TO A NEW WORKSITE - TM-5-3810-231-120020
Controls and Instruments - TM-5-3810-231-120021
Figure 7. Controls and instruments.
Figure 7. Controls and instruments - continued
Section IV. OPERATION OF EQUIPMENT
Figure 10. Gantry in lowered position.
Operation in Extreme Cold (below 0F .)
Operation in Dusty or Sandy Areas - TM-5-3810-231-120027
Figure 12. Cold weather starting aid and moisture evaporator kit.
Maintenance - TM-5-3810-231-120029
Chapter 3. OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS - TM-5-3810-231-120030
Figure 13. Lubrication Order.
Figure 13. Lubrication Order - continued - TM-5-3810-231-120032
Figure 13. Lubrication Order - continued - TM-5-3810-231-120033
Figure 13. Lubrication Order - continued - TM-5-3810-231-120034
Figure 13. Lubrication Order - continued - TM-5-3810-231-120035
Figure 13. Lubrication Order - continued - TM-5-3810-231-120036
Figure 13. Lubrication Order - continued - TM-5-3810-231-120037
Figure 13. Lubrication Order - continued - TM-5-3810-231-120038
Figure 13. Lubrication Order - continued - TM-5-3810-231-120039
Figure 13. Lubrication Order - continued - TM-5-3810-231-120040
Figure 13. Lubrication Order - continued - TM-5-3810-231-120041
Figure 13. Lubrication Order - continued - TM-5-3810-231-120042
Figure 15. Engine air cleaner service.
Section III. PREVENTIVE MAINTENANCE SERVICES
PREVENTIVE MAINTENANCE SERVICES - TM-5-3810-231-120045
HARNISCHFEGER MODEL - TM-5-3810-231-120046
HARNISCHFEGER MODEL - TM-5-3810-231-120047
CONTROLS AND INSTRUMENTS - TM-5-3810-231-120048
ENGINE CLUTCH
Section IV. OPERATOR'S MAINTENANCE - TM-5-3810-231-120050
Figure 20. V-belt adjustments.
Figure 20. V-belt adjustments - continued
Figure 21. Light or lamp, removal and installation
Figure 22. Counterweight reeving.
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables.
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables - continued - TM-5-3810-231-120056
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables - continued - TM-5-3810-231-120057
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables - continued - TM-5-3810-231-120058
Section V. TROUBLESHOOTING - TM-5-3810-231-120059
Engine Hard to Start or Fails to Start
Hoist Shaft Gears Noisy
Section VI. RADIO INTERFERENCE SUPPRESSION
Section VII. ENGINE FUEL SYSTEM
Fuel Tanks, Lines, and Fittings - TM-5-3810-231-120064
Figure 28. Fuel tanks, lines, and fittings, removal and installation.
Figure 28. Fuel tanks, lines, and fittings, removal and installation - continued
Figure 29. Fuel injectors, removal, cleaning, adjustment, and installation.
Valve Adjustment - TM-5-3810-231-120068
Figure 31. Throttle and governor controls, removal and installation.
Air Cleaner - TM-5-3810-231-120070
Figure 32. Oil filter, removal and installation.
Figure 33. Oil cooler.
Section IX. AIR INDUCTION AND EXHAUST SYSTEM
Figure 36. Turbocharger, exhaust stack and rain cap, removal and installation.
Section X. ENGINE COOLING SYSTEM
Fan Guard and Fan
Section XI. ENGINE ELECTRICAL SYSTEM, CONTROL AND INSTRUMENTS
Aneroid Control and Overspeed Governor
Figure 44. Aneroid control and overspeed governor, adjustment, renewal and installation.
Figure 45. Starter and solenoid test wiring diagram
Figure 47. Starter brush, replacement.
Figure 48. Batteries, cables, and battery box, removal and installation.
Figure 49. Instrument panel gages, controls, and sending units, removal and installation
Figure 49. Instrument panel gages, controls, and sending units, removal and installation - continued
Section XII. ENGINE V-BELT DRIVES
Figure 51. V-belt drives, removal and installation.
Water Pump Drive Belt
Section XIV. ENGINE CLUTCH ASSEMBLY
Section XV. CRANE LOWER CRAWLER SECTION
Propel Chain
Section XVI. HOOK ROLLER ASSEMBLIES
Section XVII. CRANE BRAKE AND CLUTCH ASSEMBLIES
Figure 60. Location of brakes and clutches.
Figure 61. Main hoist brake and Secondary hoist brake adjustment, removal and installation.
Figure 62. Boom hoist brake adjustment, removal and installation.
Figure 63. Swing brake adjustment, removal and installation.
Figure 64. Main hoist and secondary hoist clutch, adjustment, removal and installation.
Figure 65. Magnetic clutch jack shaft assembly.
Figure 66. Schematic wiring diagram.
Figure 66. Schematic wiring diagram - continued
Section XVIII. HYDRAULIC SYSTEM
Figure 68. Control stand hydraulic compensators, removal and installation.
Figure 69. Bleeding compensator.
Section XIX. CRANE AIR SYSTEM
Figure 74. Air system controls, valves and gages, removal and installation.
Swing Brake Lock Valve
Figure 76. Air cylinder and air chamber assemblies, removal and installation.
Section XX. CRANE CAB AND COMPONENTS
Figure 77. Crane cab assembly.
Figure 78. Door and window glass, replacement.
Figure 80. Windshield wiper motor, arm and blade, removal and installation.
Section XXI. BOOM ASSEMBLY AND COMPONENTS
Figure 82. Boom assembly and components.
Boom Jib Assembly
Figure 83. Boom jib and components, disassembly and reassembly.
Hook Block Assembly
Figure 85. Boom equalizer and spreader assembly, exploded view.
Section XXII. CRANE ELECTRICAL CONTROL SYSTEM
Swing Controller
Figure 88. Swing controller assembly shown with cover removed.
Figure 89. Swing controller, removal and installation
Chapter 4. WINTERIZATION EQUIPMENT
Figure 92. Heater control panel.
Engine Coolant Heater
Radiator Winter Front Shutter
Section II. OPERATOR'S SERVICE
Section III. ORGANIZATIONAL MAINTENANCE
Fuel Filters
Cab or Component Fresh Air Heater
Figure 101. Heater fuel lines, fitting, and valves, removal and installation
Figure 101. Heater fuel lines, fitting, and valves, removal and installation - continued
Figure 102. Radiator winter front shutters, removal and installation
Figure 103. Winterized wiring diagram.
Figure 103. Winterized wiring diagram - continued
Appendix I. REFERENCES - TM-5-3810-231-120135
Appendix II. BASIC ISSUE ITEMS AND MAINTENANCE AND OPERATING SUPPLIES
Section II. BASIC ISSUE ITEMS LIST - TM-5-3810-231-120137
Section II. BASIC ISSUE ITEMS LIST - continued - TM-5-3810-231-120138
Section II. BASIC ISSUE ITEMS LIST - continued - TM-5-3810-231-120139
Section III. Maintenance and Operating Supplies - TM-5-3810-231-120140
Section III. Maintenance and Operating Supplies - continued
Appendix III. MAINTENANCE ALLOCATION CHART
Explanation of Columns in Section III - TM-5-3810-231-120143
Section II. MAINTENANCE ALLOCATION CHART - TM-5-3810-231-120144
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120145
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120146
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120147
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120148
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120149
Section IV. REMARKS - TM-5-3810-231-120150
TM-5-3810-231-12 Crane Crawler Mounted 60 Ton Diesel Driven Manual
SAFETY PRECAUTIONS - TM-5-3810-231-120002
Operator and Organizational Maintenance Manual - TM-5-3810-231-120003
Table II. Maintenance and Operating Supplies
Table II. Maintenance and Operating Supplies - continued
Section I. INTRODUCTION - TM-5-3810-231-120006
Chapter 1. INTRODUCTION - TM-5-3810-231-120008
Figure 1. Crane, left front, three quarter view.
Figure 2. Crane, right-rear, three-quarter view, with shipping dimensions.
Tabulated Data. - TM-5-3810-231-120011
Figure 3. Wiring diagram.
Figure 3. Wiring diagram - continued - TM-5-3810-231-120013
Figure 3. Wiring diagram - continued - TM-5-3810-231-120014
Figure 4. Base plan.
Adjustment data. - TM-5-3810-231-120016
Chapter 2. INSTALLATION AND OPERATION INSTRUCTIONS - TM-5-3810-231-120017
Table 1. Freezing Points, Composition and Specific Gravities of Military Antifreeze Materials
Figure 5. Block and tie-down removal.
Section II. MOVEMENT TO A NEW WORKSITE - TM-5-3810-231-120020
Controls and Instruments - TM-5-3810-231-120021
Figure 7. Controls and instruments.
Figure 7. Controls and instruments - continued
Section IV. OPERATION OF EQUIPMENT
Figure 10. Gantry in lowered position.
Operation in Extreme Cold (below 0F .)
Operation in Dusty or Sandy Areas - TM-5-3810-231-120027
Figure 12. Cold weather starting aid and moisture evaporator kit.
Maintenance - TM-5-3810-231-120029
Chapter 3. OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS - TM-5-3810-231-120030
Figure 13. Lubrication Order.
Figure 13. Lubrication Order - continued - TM-5-3810-231-120032
Figure 13. Lubrication Order - continued - TM-5-3810-231-120033
Figure 13. Lubrication Order - continued - TM-5-3810-231-120034
Figure 13. Lubrication Order - continued - TM-5-3810-231-120035
Figure 13. Lubrication Order - continued - TM-5-3810-231-120036
Figure 13. Lubrication Order - continued - TM-5-3810-231-120037
Figure 13. Lubrication Order - continued - TM-5-3810-231-120038
Figure 13. Lubrication Order - continued - TM-5-3810-231-120039
Figure 13. Lubrication Order - continued - TM-5-3810-231-120040
Figure 13. Lubrication Order - continued - TM-5-3810-231-120041
Figure 13. Lubrication Order - continued - TM-5-3810-231-120042
Figure 15. Engine air cleaner service.
Section III. PREVENTIVE MAINTENANCE SERVICES
PREVENTIVE MAINTENANCE SERVICES - TM-5-3810-231-120045
HARNISCHFEGER MODEL - TM-5-3810-231-120046
HARNISCHFEGER MODEL - TM-5-3810-231-120047
CONTROLS AND INSTRUMENTS - TM-5-3810-231-120048
ENGINE CLUTCH
Section IV. OPERATOR'S MAINTENANCE - TM-5-3810-231-120050
Figure 20. V-belt adjustments.
Figure 20. V-belt adjustments - continued
Figure 21. Light or lamp, removal and installation
Figure 22. Counterweight reeving.
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables.
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables - continued - TM-5-3810-231-120056
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables - continued - TM-5-3810-231-120057
Figure 23. Reeving diagram, crane boom and jib removal and installation, and load rating tables - continued - TM-5-3810-231-120058
Section V. TROUBLESHOOTING - TM-5-3810-231-120059
Engine Hard to Start or Fails to Start
Hoist Shaft Gears Noisy
Section VI. RADIO INTERFERENCE SUPPRESSION
Section VII. ENGINE FUEL SYSTEM
Fuel Tanks, Lines, and Fittings - TM-5-3810-231-120064
Figure 28. Fuel tanks, lines, and fittings, removal and installation.
Figure 28. Fuel tanks, lines, and fittings, removal and installation - continued
Figure 29. Fuel injectors, removal, cleaning, adjustment, and installation.
Valve Adjustment - TM-5-3810-231-120068
Figure 31. Throttle and governor controls, removal and installation.
Air Cleaner - TM-5-3810-231-120070
Figure 32. Oil filter, removal and installation.
Figure 33. Oil cooler.
Section IX. AIR INDUCTION AND EXHAUST SYSTEM
Figure 36. Turbocharger, exhaust stack and rain cap, removal and installation.
Section X. ENGINE COOLING SYSTEM
Fan Guard and Fan
Section XI. ENGINE ELECTRICAL SYSTEM, CONTROL AND INSTRUMENTS
Aneroid Control and Overspeed Governor
Figure 44. Aneroid control and overspeed governor, adjustment, renewal and installation.
Figure 45. Starter and solenoid test wiring diagram
Figure 47. Starter brush, replacement.
Figure 48. Batteries, cables, and battery box, removal and installation.
Figure 49. Instrument panel gages, controls, and sending units, removal and installation
Figure 49. Instrument panel gages, controls, and sending units, removal and installation - continued
Section XII. ENGINE V-BELT DRIVES
Figure 51. V-belt drives, removal and installation.
Water Pump Drive Belt
Section XIV. ENGINE CLUTCH ASSEMBLY
Section XV. CRANE LOWER CRAWLER SECTION
Propel Chain
Section XVI. HOOK ROLLER ASSEMBLIES
Section XVII. CRANE BRAKE AND CLUTCH ASSEMBLIES
Figure 60. Location of brakes and clutches.
Figure 61. Main hoist brake and Secondary hoist brake adjustment, removal and installation.
Figure 62. Boom hoist brake adjustment, removal and installation.
Figure 63. Swing brake adjustment, removal and installation.
Figure 64. Main hoist and secondary hoist clutch, adjustment, removal and installation.
Figure 65. Magnetic clutch jack shaft assembly.
Figure 66. Schematic wiring diagram.
Figure 66. Schematic wiring diagram - continued
Section XVIII. HYDRAULIC SYSTEM
Figure 68. Control stand hydraulic compensators, removal and installation.
Figure 69. Bleeding compensator.
Section XIX. CRANE AIR SYSTEM
Figure 74. Air system controls, valves and gages, removal and installation.
Swing Brake Lock Valve
Figure 76. Air cylinder and air chamber assemblies, removal and installation.
Section XX. CRANE CAB AND COMPONENTS
Figure 77. Crane cab assembly.
Figure 78. Door and window glass, replacement.
Figure 80. Windshield wiper motor, arm and blade, removal and installation.
Section XXI. BOOM ASSEMBLY AND COMPONENTS
Figure 82. Boom assembly and components.
Boom Jib Assembly
Figure 83. Boom jib and components, disassembly and reassembly.
Hook Block Assembly
Figure 85. Boom equalizer and spreader assembly, exploded view.
Section XXII. CRANE ELECTRICAL CONTROL SYSTEM
Swing Controller
Figure 88. Swing controller assembly shown with cover removed.
Figure 89. Swing controller, removal and installation
Chapter 4. WINTERIZATION EQUIPMENT
Figure 92. Heater control panel.
Engine Coolant Heater
Radiator Winter Front Shutter
Section II. OPERATOR'S SERVICE
Section III. ORGANIZATIONAL MAINTENANCE
Fuel Filters
Cab or Component Fresh Air Heater
Figure 101. Heater fuel lines, fitting, and valves, removal and installation
Figure 101. Heater fuel lines, fitting, and valves, removal and installation - continued
Figure 102. Radiator winter front shutters, removal and installation
Figure 103. Winterized wiring diagram.
Figure 103. Winterized wiring diagram - continued
Appendix I. REFERENCES - TM-5-3810-231-120135
Appendix II. BASIC ISSUE ITEMS AND MAINTENANCE AND OPERATING SUPPLIES
Section II. BASIC ISSUE ITEMS LIST - TM-5-3810-231-120137
Section II. BASIC ISSUE ITEMS LIST - continued - TM-5-3810-231-120138
Section II. BASIC ISSUE ITEMS LIST - continued - TM-5-3810-231-120139
Section III. Maintenance and Operating Supplies - TM-5-3810-231-120140
Section III. Maintenance and Operating Supplies - continued
Appendix III. MAINTENANCE ALLOCATION CHART
Explanation of Columns in Section III - TM-5-3810-231-120143
Section II. MAINTENANCE ALLOCATION CHART - TM-5-3810-231-120144
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120145
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120146
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120147
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120148
Section II. MAINTENANCE ALLOCATION CHART - continued - TM-5-3810-231-120149
Section IV. REMARKS - TM-5-3810-231-120150
TM-5-3810-231-12 Crane Crawler Mounted 60 Ton Diesel Driven Manual
