CHAPTER 1 INTRODUCTION - TM-5-3810-289-340033
CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Table 2-1. Special tools and equipment
Section III. GENERAL MAINTENANCE INSTRUCTIONS
Maintenance of Gears and Bearings
Table 2-2. Reference Data
Table 2-2. Reference Data-Continued - TM-5-3810-289-340039
Table 2-2. Reference Data-Continued - TM-5-3810-289-340040
Table 2-2. Reference Data-Continued - TM-5-3810-289-340041
Table 2-2. Reference Data-Continued - TM-5-3810-289-340042
Table 2-2. Reference Data-Continued - TM-5-3810-289-340043
Table 2-2. Reference Data-Continued - TM-5-3810-289-340044
Table 2-2. Reference Data-Continued - TM-5-3810-289-340045
Table 2-2. Reference Data-Continued - TM-5-3810-289-340046
Table 2-2. Reference Data-Continued - TM-5-3810-289-340047
Table 2-2. Reference Data-Continued - TM-5-3810-289-340048
Table 2-2. Reference Data-Continued - TM-5-3810-289-340049
Table 2-2. Reference Data-Continued - TM-5-3810-289-340050
Table 2-2. Reference Data-Continued - TM-5-3810-289-340051
Table 2-2. Reference Data-Continued - TM-5-3810-289-340052
Table 2-2. Reference Data-Continued - TM-5-3810-289-340053
Table 2-2. Reference Data-Continued - TM-5-3810-289-340054
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS - TM-5-3810-289-340055
Figure 2-2. Engine assembly removal and installation.
CHAPTER 3 REPAIR OF ENGINE AND ACCESSORIES
Figure 3-1. Alternator assembly, exploded view.
Figure 3-2. Alternator test connections.
Figure 3-4. Fuel pump return line removal
Figure 3-6. Fuel pump removal
Figure 3-9. Pulsation damper removal and installation.
Figure 3-8. Shut down valve removal
Figure 3-12. Governor plunger removal
Figure 3-16. Spring pack assembly removal.
Figure 3-21. Washer being installed over plunger.
Figure 3-24. Spring pack snap ring installation.
Figure 3-30. Governor plunger, installation.
Figure 3-32. Nylon buffer installation.
Figure 3-35. "Plate type" valve inspection
Figure 3-38. Valve assembly
Figure 3-40. Drive shaft bushing reaming
Figure 3-44. Snap ring removal from groove
Figure 3-46. Gear removal from weight carrier.
Figure 3-50. Drive cover oil seal installation.
Figure 3-56. Governor plunger driver removal.
Figure 3-57. Clearance check between washer and driver.
Figure 3-61. Locating notches.
Figure 3-65. Fuel filter scree - MVS governor type.
Figure 3-66. Governor plunger being lapped to burrel.
Figure 3-70. Current PT (type G) governor plunger
Figure 3-72. Tachometer gear begin pressed
Figure 3-74. Injector removal
Figure 3-78. Corroded injector cup tip
Figure 3-83. Pulling link with a tap holder
Figure 3-89. Size markings on injector body
Figure 3-96. Sleeve seat bead and chamfer location.
Figure 3-96. Sleeve seat bead and chamfer location
Figure 3-99. Sealing lower end of injector sleeve
Figure 3-101. Clutch assembly, cutaway view.
Figure 3-103. Primer unit: lines, fittings, exploded view.
Section II. ENGINE COMPONENTS
Figure 3-107. Bearing and shaft assembly being pressed in.
Figure 3-108. Mandrel being placed on seal driving lip.
Figure 3-110. Fan hub assembly removal and installation.
Figure 3-111. Fan hub assembly, exploded view
Figure 3-112. Accessory drive pulley removal
Figure 3-114. Accessory drive assembly, exploded view.
Figure 3-115. Accessory drive pulley installation.
Figure 3-118. Cylinder head removal
Figure 3-121. Install injector sleeve holding tool ST-383.
Figure 3-125. Setting reamer depth
Figure 3-129. Regroove cylinder head.
Figure 3-130. Installing grommets and retainers
Figure 3-134. Loosening rocker arm lever jam nuts.
Figure 3-138. Magnetic inspection crack indication.
Figure 3-141. Rocker arm assembly, exploded view.
Figure 3-142. Rocker arm assembly.
Figure 3-145. Torquing cylinder head capscrews.
Figure 3-150. Minimum valve head rim thickness.
Figure 3-152. Valve guide measurement.
Figure 3-155. Pencil marks on valves.
Figure 3-158. Tappet guide screw removal and installation.
Figure 3-162. Tappet installation.
Figure 3-164. Flywheel indicator gage installation.
Figure 3-167. Camshaft counterbore gasket installation.
Figure 3-170. Oil pan, exploded view.
Figure 3-171. Oil pan installation.
Figure 3-175. Oil pump and suction tube installation.
Figure 3-179. Crankshaft hub installation
Figure 3-182. Gear cover removal and installation
Figure 3-184. Gear cover mounting plate removal
Figure 3-187. Camshaft removal
Figure 3-191. Checking camshaft gear backlash
oFigure 3-192. Checking camshaft end play
Figure 3-198. Connecting rod cap removal
Figure 3-201. Connecting rod crank journal bore check
Figure 3-202. Connecting rod piston pin bushing check
Figure 3-206. Piston check points
Figure 3-208. Piston pin bushing installation
Figure 3-210. Installing pin in piston and rod
Figure 3-212. Piston and rod assemblies installation
Figure 3-216. Prying main bearing caps loose
Figure 3-219. Drilling dowel hole in rear main bearing
Figure 3-224. Cleaning drilled oil passages.
Figure 3-226. Crankshaft dimension points
Figure 3-228. Upper main bearing shells installation.
Figure 3-230. Main bearing cap with thrust ring in place.
Figure 3-232. Checking crankshaft end play.
Figure 3-235. Air bleed hole.
Figure 3-238. Cylinder liner counterbore dimensions.
Figure 3-241. Inspecting cylinder liner clearance.
Figure 3-245. Tappet bore inside diameter check
Figure 3-247. Camshaft bushing installation
Figure 3-251. Standard and oversize counterbore diameters.
Figure 3-255. Valve seat insert cross-section.
Figure 3-257. Refacing valve seat.
Figure 3-259. Valve crossheads removal.
Figure 3-264. Pulling cylinder liner with ST-777 puller.
Figure 3-266. Cylinder liner bore inspection.
Figure 3-268. Honing Liner.
Figure 3-269. Initial honing stone expansion.
Figure 3-270. Cylinder liner counterbore inspection.
Figure 3-271. Cylinder liner flange inspection.
CHAPTER 4 REPAIR OF CRANE-SHOVEL UPPER WORKS AND LOWER WORKS
Figure 4-1. Transmission shaft, exploded view.
Figure 4-3. Gear case sump
FIGURE 4-4. VERTICAL SWING SHAFT
Prepare Upper Works for Installation.
Figure 4-6. Vertical propel shaft, exploded view (sheet 1 of 3).
Figure 4-6. Vertical propel shaft, exploded view (sheet 2 of 3).
Figure 4-6. Vertical propel shaft, exploded view (sheet 3 of 3)
Figure 4-7. Vertical swing shaft repair and replacement.
Figure 4-8. Horizontal swing shift, cutaway view.
Figure 4-10. Re drum shift shifter bridge and yoke
Rear Drum Shaft Assembly
Figure 4-11. Rear and front drum shaft assembly exploded view (sheet 1 of 3).
Figure 4-11. Rear end front drum shaft assembly exploded view (sheet 2 of 3)
Figure 4-11. Rear and front drum shaft assembly, exploded view (sheet 3 of 3).
Figure 4-12. Rear drum shaft assembly (left side).
Figure 4-13. Rear drum shaft assembly (right side).
Figure 4-15. Front drum shaft removal
Figure 4-16. Boom hoist clutch and brake band removal and installations.
Figure 4-17. Front drum shaft assembly (right side)
Figure 4-18. Boom hoist safety pawl.
Figure 4-19. Control levers - TM-5-3810-289-340176
Figure 4-20. Independent boom hoist assembly, exploded view.
Main Clutches
Section II. LOWER WORKS
Center Propelling Shaft - TM-5-3810-289-340180
Center Gudgeon Bushing
Figure 4-21. Track drive sprocket replacement
APPENDIX A REFERENCES - TM-5-3810-289-340183
TM-5-3810-289-34 Crane-Shovel Crawler Mounted; 12 Ton - Cu Yd; Diesel Engine Driven Manual
CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Table 2-1. Special tools and equipment
Section III. GENERAL MAINTENANCE INSTRUCTIONS
Maintenance of Gears and Bearings
Table 2-2. Reference Data
Table 2-2. Reference Data-Continued - TM-5-3810-289-340039
Table 2-2. Reference Data-Continued - TM-5-3810-289-340040
Table 2-2. Reference Data-Continued - TM-5-3810-289-340041
Table 2-2. Reference Data-Continued - TM-5-3810-289-340042
Table 2-2. Reference Data-Continued - TM-5-3810-289-340043
Table 2-2. Reference Data-Continued - TM-5-3810-289-340044
Table 2-2. Reference Data-Continued - TM-5-3810-289-340045
Table 2-2. Reference Data-Continued - TM-5-3810-289-340046
Table 2-2. Reference Data-Continued - TM-5-3810-289-340047
Table 2-2. Reference Data-Continued - TM-5-3810-289-340048
Table 2-2. Reference Data-Continued - TM-5-3810-289-340049
Table 2-2. Reference Data-Continued - TM-5-3810-289-340050
Table 2-2. Reference Data-Continued - TM-5-3810-289-340051
Table 2-2. Reference Data-Continued - TM-5-3810-289-340052
Table 2-2. Reference Data-Continued - TM-5-3810-289-340053
Table 2-2. Reference Data-Continued - TM-5-3810-289-340054
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS - TM-5-3810-289-340055
Figure 2-2. Engine assembly removal and installation.
CHAPTER 3 REPAIR OF ENGINE AND ACCESSORIES
Figure 3-1. Alternator assembly, exploded view.
Figure 3-2. Alternator test connections.
Figure 3-4. Fuel pump return line removal
Figure 3-6. Fuel pump removal
Figure 3-9. Pulsation damper removal and installation.
Figure 3-8. Shut down valve removal
Figure 3-12. Governor plunger removal
Figure 3-16. Spring pack assembly removal.
Figure 3-21. Washer being installed over plunger.
Figure 3-24. Spring pack snap ring installation.
Figure 3-30. Governor plunger, installation.
Figure 3-32. Nylon buffer installation.
Figure 3-35. "Plate type" valve inspection
Figure 3-38. Valve assembly
Figure 3-40. Drive shaft bushing reaming
Figure 3-44. Snap ring removal from groove
Figure 3-46. Gear removal from weight carrier.
Figure 3-50. Drive cover oil seal installation.
Figure 3-56. Governor plunger driver removal.
Figure 3-57. Clearance check between washer and driver.
Figure 3-61. Locating notches.
Figure 3-65. Fuel filter scree - MVS governor type.
Figure 3-66. Governor plunger being lapped to burrel.
Figure 3-70. Current PT (type G) governor plunger
Figure 3-72. Tachometer gear begin pressed
Figure 3-74. Injector removal
Figure 3-78. Corroded injector cup tip
Figure 3-83. Pulling link with a tap holder
Figure 3-89. Size markings on injector body
Figure 3-96. Sleeve seat bead and chamfer location.
Figure 3-96. Sleeve seat bead and chamfer location
Figure 3-99. Sealing lower end of injector sleeve
Figure 3-101. Clutch assembly, cutaway view.
Figure 3-103. Primer unit: lines, fittings, exploded view.
Section II. ENGINE COMPONENTS
Figure 3-107. Bearing and shaft assembly being pressed in.
Figure 3-108. Mandrel being placed on seal driving lip.
Figure 3-110. Fan hub assembly removal and installation.
Figure 3-111. Fan hub assembly, exploded view
Figure 3-112. Accessory drive pulley removal
Figure 3-114. Accessory drive assembly, exploded view.
Figure 3-115. Accessory drive pulley installation.
Figure 3-118. Cylinder head removal
Figure 3-121. Install injector sleeve holding tool ST-383.
Figure 3-125. Setting reamer depth
Figure 3-129. Regroove cylinder head.
Figure 3-130. Installing grommets and retainers
Figure 3-134. Loosening rocker arm lever jam nuts.
Figure 3-138. Magnetic inspection crack indication.
Figure 3-141. Rocker arm assembly, exploded view.
Figure 3-142. Rocker arm assembly.
Figure 3-145. Torquing cylinder head capscrews.
Figure 3-150. Minimum valve head rim thickness.
Figure 3-152. Valve guide measurement.
Figure 3-155. Pencil marks on valves.
Figure 3-158. Tappet guide screw removal and installation.
Figure 3-162. Tappet installation.
Figure 3-164. Flywheel indicator gage installation.
Figure 3-167. Camshaft counterbore gasket installation.
Figure 3-170. Oil pan, exploded view.
Figure 3-171. Oil pan installation.
Figure 3-175. Oil pump and suction tube installation.
Figure 3-179. Crankshaft hub installation
Figure 3-182. Gear cover removal and installation
Figure 3-184. Gear cover mounting plate removal
Figure 3-187. Camshaft removal
Figure 3-191. Checking camshaft gear backlash
oFigure 3-192. Checking camshaft end play
Figure 3-198. Connecting rod cap removal
Figure 3-201. Connecting rod crank journal bore check
Figure 3-202. Connecting rod piston pin bushing check
Figure 3-206. Piston check points
Figure 3-208. Piston pin bushing installation
Figure 3-210. Installing pin in piston and rod
Figure 3-212. Piston and rod assemblies installation
Figure 3-216. Prying main bearing caps loose
Figure 3-219. Drilling dowel hole in rear main bearing
Figure 3-224. Cleaning drilled oil passages.
Figure 3-226. Crankshaft dimension points
Figure 3-228. Upper main bearing shells installation.
Figure 3-230. Main bearing cap with thrust ring in place.
Figure 3-232. Checking crankshaft end play.
Figure 3-235. Air bleed hole.
Figure 3-238. Cylinder liner counterbore dimensions.
Figure 3-241. Inspecting cylinder liner clearance.
Figure 3-245. Tappet bore inside diameter check
Figure 3-247. Camshaft bushing installation
Figure 3-251. Standard and oversize counterbore diameters.
Figure 3-255. Valve seat insert cross-section.
Figure 3-257. Refacing valve seat.
Figure 3-259. Valve crossheads removal.
Figure 3-264. Pulling cylinder liner with ST-777 puller.
Figure 3-266. Cylinder liner bore inspection.
Figure 3-268. Honing Liner.
Figure 3-269. Initial honing stone expansion.
Figure 3-270. Cylinder liner counterbore inspection.
Figure 3-271. Cylinder liner flange inspection.
CHAPTER 4 REPAIR OF CRANE-SHOVEL UPPER WORKS AND LOWER WORKS
Figure 4-1. Transmission shaft, exploded view.
Figure 4-3. Gear case sump
FIGURE 4-4. VERTICAL SWING SHAFT
Prepare Upper Works for Installation.
Figure 4-6. Vertical propel shaft, exploded view (sheet 1 of 3).
Figure 4-6. Vertical propel shaft, exploded view (sheet 2 of 3).
Figure 4-6. Vertical propel shaft, exploded view (sheet 3 of 3)
Figure 4-7. Vertical swing shaft repair and replacement.
Figure 4-8. Horizontal swing shift, cutaway view.
Figure 4-10. Re drum shift shifter bridge and yoke
Rear Drum Shaft Assembly
Figure 4-11. Rear and front drum shaft assembly exploded view (sheet 1 of 3).
Figure 4-11. Rear end front drum shaft assembly exploded view (sheet 2 of 3)
Figure 4-11. Rear and front drum shaft assembly, exploded view (sheet 3 of 3).
Figure 4-12. Rear drum shaft assembly (left side).
Figure 4-13. Rear drum shaft assembly (right side).
Figure 4-15. Front drum shaft removal
Figure 4-16. Boom hoist clutch and brake band removal and installations.
Figure 4-17. Front drum shaft assembly (right side)
Figure 4-18. Boom hoist safety pawl.
Figure 4-19. Control levers - TM-5-3810-289-340176
Figure 4-20. Independent boom hoist assembly, exploded view.
Main Clutches
Section II. LOWER WORKS
Center Propelling Shaft - TM-5-3810-289-340180
Center Gudgeon Bushing
Figure 4-21. Track drive sprocket replacement
APPENDIX A REFERENCES - TM-5-3810-289-340183
TM-5-3810-289-34 Crane-Shovel Crawler Mounted; 12 Ton - Cu Yd; Diesel Engine Driven Manual
