Figure 1-1. Machine Serial Number
Figure 1-2. Crane Terminology
MAIN WINCH DATA
LIGHT BULBS
Figure 1-3. Range Diagram - 80' Boom (105x75-A)
Figure 1-4. Range Diagram - 100' Boom (105J83)
Figure 1-5. Dimensions and Clearance
Section II. CONTROLS AND OPERATION
Figure 2-1. Carrier Controls
Figure 2-2. Voltmeter Operation
STEERING WHEEL.
Figure 2-4. Emergency Engine Shutoff
CARRIER OPERATION
OUTRIGGER OPERATION
Figure 2-5. Outrigger Locks
Figure 2-7. Upper Controls
Figure 2-8. Winch Lever Positions
BOOM HOIST LEVER AND PEDAL
CRANE OPERATION
CRANE OPERATING CYCLE
Figure 2-9. Crane Operating Cycle
Figure 2-10. Crane Operating Cycle
CARRIER REMOTE CONTROLS
HAND SIGNALS
Figure 2-12. Hand Signal for Crane Operation
CONTROLS AND OPERATION
OPERATION IN HUMIDITY OR SALT WATER AREAS.
Figure 2-13. Securing Rope to Drum
Figure 2.16. Installing a Rope Socket
Figure 2-16. Jib Storage
Figure 2-17. Jib Suspension (911591)
Figure 2-18. Manual Fly Section (105J681)
COUNTERWEIGHT
Section III. LUBRICATION
MULTIPURPOSE GREASE
PETROLEUM GEAR OIL
POWER TRANSMISSION FLUID AND GEAR OIL
OPEN GEAR AND WIRE ROPE LUBRICANT
HEAVY DUTY MOTOR OIL
HYDRAULIC OIL
HIGH TEMPERATURE GREASE
Figure 3-1. Upper Lubrication Chart
Figure 3-2. Crane Lubrication Chart
Section IV. HYDRAULIC SYSTEM AND COMPONENTS
SUB-SECTION 4A - HYDRAULIC SYSTEM
GENERAL MAINTENANCE
TROUBLESHOOTING GUIDE
Chart 1. Excessive Noise
Chart 2. Excessive Heat
Chart 3. Incorrect Flow
Chart 4. lncorrect Pressure
Chart 5. Faulty Operation
SYSTEM DESCRIPTIONS
Figure 4A-1. hydrau;ic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH GEARMATIC MAIN AND AUXILIARY WINCHES
Figure 4A-2. Hydrau;ic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH GEARMATIC FREE-FALL MAIN AND NON FREE-FALL AUXILIARY WINCHES
Figure 4A-3. Hydraulic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH FREE-FALL MAIN AND AUXILIARY WINCHES
Figure 4A-4. Hydraulic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH P&H MAIN AND AUXILIARY WINCHES
Figure 4A-5. Hydraulic System Schematic
AUXILIARY WINCH CIRCUIT
Figure 4B-1. Dual Pumps (41Z55 and 41Z56)
Figure 4B-2. Pump Cartridge Operation
Figure 4B-3. Pressure Feed to Vanes
Figure 4B-5. Exploded View of Dual Pump
Figure 4B-7. Removing Pump Cover
INSPECTION AND REPAIR
Figure 4B-10. Installing Rotor
Figure 4B-14. Single Pump (41Z57)
Figure 4B-15. Pump Cartridge Operation
Figure 4B-16. Pressure Feed to Vanes
Figure 4B-18. Exploded View of Single Pump
Figure 4B-19. Installing Rotor
Figure 4B-20. Intaliing Ring
Figure 4B-23. Dual Pumps (41Z102 and 41Z103)
Figure 4B-24. Pump Cartridge Operation
Figure 4B-25. Pressure Feed to Vanes
Figure 4B-27. Exploded View of Dual Pump
Figure 4B-28. Beginning Disassembly
OVERHAUL
Figure 4B- 32. Installing Rotor
SINGLE PUMP (41Z104)
Figure 4B-36. Single Pump (41Z57)
Figure 4B-38. Pressure Feed to Vanes
Figure 4B-40. Exploded View of Single Pump
OVERHAUL
Figure 4B-42. Installing Ring
Figure 4C-1. Rotary Joint (979J24)
ROTARY JOINT (979J30)
Figure 4C-2. Rotary Joint (979J30)
INSTALLATION
Figure 4D-1. Control Valve Operation (36Z724)
TABLE 4D-1. TROUBLE, CAUSE AND REMEDY CHART
Figure 4D-2. Control Valve (36Z724)
Figure 4D-3. Control Valve Operation (36Z725)
TABLE 4D-2. TROUBLE, CAUSE AND REMEDY CHART (CONTINUED)
Figure 4D-4. Control Valve (36Z725)
Figure 4D-5. Control Valve Operation (36Z726)
Figure 4D-6. Control Valve (36Z726)
Figure 4D-7. Control Valve Operation (36Z727)
TABLE 4D-4. TROUBLE, CAUSE AND REMEDY CHART
Figure 4D-8. Control Valve (36Z727)
Figure 4D-9. Control Valve Operation (36Z986)
TABLE 4D-5. TROUBLE, CAUSE AND REMEDY CHART
Figure 4D-10. Control Valve (36Z986)
Figure 4D-11. Control Valve Operation (36Q70)
TABLE 4D-6. TROUBLE, CAUSE AND REMEDY CHART
CONTROL VALVES
Figure 4D-13. Control Valve (36Z840)
Figure 4D-14. Gauge Ports
TABLE 4D-7. TROUBLE, CAUSE AND REMEDY CHART
TABLE 4D-7. TROUBLE, CAUSE AND REMEDY CHART - Continued
Figure 4D-15. Control Valve (36Z840)
Figure 4D-16. Control Spool Disassembly
INSTALLATION
Figure 4E-1. Filter Operation
Section V. BOOM AND WINCH SYSTEMS AND COMPONENTS
SUB-SECTION 5A. BOOM AND WINCH SYSTEMS
Figure 5A-1. Boom Installation
Figure 5A-2. Boom Assembly
Figure 5A-3. Boom Alignment (1100P154)
Figure 5B-1. Boom Hoist Cylinder (38Z231)
BOOM HOIST CYLINDER (38U92)
Figure 5B-2 Boom Hoist Cylinder (38U92)
SUB-SECTION 5C. BOOM TELESCOPE CYLINDERS
Figure 5C-2. Hose Loop Assembly (100J3870)
Figure 5C-3. Boom Telescope Cylinder (38R32)
BOOM TELESCOPE CYLINDERS
Figure 5D-1. Flow Divider Operation
Figure 5D-2. Flow Divider (36Z680)
Figure 5D-3. Flow Divider Operation
Figure 5D-4. Flow Divider (36Q46)
SUB-SECTION 5E. HOSE REELS
Figure 5E-1. Hose Reel (36Z691)
Figure 5E-2. Hose Reel Spring Motor
Figure 5E-4. Seat Arrangement
Figure 5E-5. Hose Replacement
SUBSECTION 5F. COUNTERBALANCE VALVES
Figure 5F-1. Counterbalance Valve Operation
Figure 5F-2. Counterbalance Valve Removal
COUNTERBALANCE VALVE (36Z838)
Figure 5F-4. Counterbalance Valve Operation
Figure 5F-5. Counterbalance Valve Removal
Figure 5F-7. Counterbalance Valve Operation
REPAIR
MAINTENANCE
VELOCITY FUSES
Figure 5G-1. Velocity Fuse Operation
Figure 5G-2. Velocity Fuse (1036Z403)
VELOCITY FUSES
Figure 5H-1. Winch Brake Valve (36Q76)
Figure 5H-2. Linkage Adjustment
Figure 5H-4. Linkage Adjustment
Figure 5J-1. Winch Clearances
DISASSEMBLY OF PRIMARY DRIVE
Figure 5J-2. The P&H Winch
Figure 5J-3. Brake Mounting Bolts
Figure 5J-7. Removing Sleeve Bearing
Figure 5J-11. Location of Breather, Level, and Drain Plugs
Figure 5J-15. Removing Outer Ring Gear
Figure 5J-18. Installing Sprag Clutch
Figure 5J-21. Winch Brake Assembly
Figure 5J-22. Dimensions for Spring Setting
Figure 5J-23. Brake Assembly
Figure 5K-1. Winch Motor (41Q6)
Figure 5K-2. Motor Operation
Figure 5K-3. Motor (41Q6)
Figure 5K-4. Pressure Plate
Figure 5K-5. Motor (41Q7)
Figure 5K-6. Motor Operation
Figure 5K-7. Motor (41Q7)
MOTOR (41U13)
WINCH MOTOR
DISASSEMBLY
Figure 5K-9. Motor (41U13)
INSPECTION
SECTION VI. SWING SYSTEM AND COMPONENTS
TABLE 6A-1. SWING CIRCUIT TROUBLESHOOTING
TABLE 6A-1. SWING CIRCUIT TROUBLESHOOTING - Continued
Figure 6B-1. Swing Reducer (53Z373)
Figure 6B-2. Swing Reducer Removal
Table 6B-1 Swing Reducer Troubleshooting
SWING REDUCERS
Figure 6B-3. Swing Reducer (53Z373)
Figure 6B-4. Removing Planet Pins
REASSEMBLY
SWING REDUCERS
Figure 6B-5. Adjusting Brake Piston Clearance
INSTALLATION
Figure 6C-1. Swing Motor Operation
SWING MOTORS
Figure 6C-4. Swing Motor (41Z125)
Figure 6D-1. Swing Transmission (53R3)
SWING TRANSMISSION
Figure 6D-3. Swing Transmission (53R3)
SWING TRANSMISSION
SWING TRANSMISSION - Continued
INSTALLATION
SUB-SECTION 6E. SLEWING RINGS
Figure 6E-1. Slewing Ring Installation
SLEWING RINGS
SUBSECTION 6F. SWING BRAKE VALVES
Figure 6F-2. Brake Pedal Stop Adjustment (100J4194-1-A)
SUB-SECTION 6G. SWING BRAKE LOCK VALVES
Figure 6G-1. Swing Brake Lock Valve (36Z361)
SECTION VII. OUTRIGGER SYSTEM
SECTION VII. OUTRIGGER SYSTEM
Figure 7-2. Hydraulic Outrigger Control System
Figure 7-3. Outrigger Hydraulic Schematic (8100J3980)
SOLENOID VALVES (36Z341)
OUTRIGGER EXTENSION CYLINDERS
Figure 7-5. Outrigger Extension Cylinder (10053305)
Figure 7-6. Outrigger Extension Cylinder (38489 & 38491)
OUTRlGGER SYSTEM
Figure 7-7. Vertical List Cylinder (100J4208)
INSTALLATION
SECTION VIII. POWER TRAIN
SECTION VIII. POWER TRAIN
Figure 8-2. Remote Control Assembly
Figure 8-3. Engine Clutch Assembly
Figure 8-4. Clutch Disassembly
Figure 8-6. Clutch Assembly
Figure 8-8. Clutch Adjustment
Figure 8-9. Engine and Transmission Mounting
Figure 8-10. Propeller Shaft (810N37 & 10U49)
Figure 8-11. Propeller Shaft (20Q17)
Figure 8-12. Rear Suspension
Figure 8-13. Hydraulic Pump Drive Assembly (53U13)
Figure 8-14. Power Steering Pump Installation
Figure 8-15. Power Steering Pump Installation
Figure 8-16. Hydraulic Pump Drive Assembly
Figure B-17. Carrier Electrical Schematic
SECTION IX. AIR SYSTEM AND COMPONENTS
SUB-SECTION 9A. AIR SYSTEM
CARRIER REMOTE CONTROL DESCRIPTION
UNEVEN BRAKES
TROUBLESHOOTING
Figure 9A-1. Air System Schematic
Figure 9A-2. Air Diagram Schematic
SUB-SECTION 9B. AIR COMPRESSORS
INSTALLATION
SUB-SECTION 9C. AIR SYSTEM COMPONENTS
AIR SYSTEM COMPONENTS
ROUTINE INSPECTION
Figure 9C-3. Treadle Valve (38Z225)
Figure 9C-4. Quick Release Valve (36Z254)
Figure 9C.5. Relay Valve (36Z291)
Figure 9C-6. Relay Valve (36Z650)
Figure 9C-7. Exhaust & Pressure Retaining Valve
Figure 9C-8. Maxibrake Control Valve (36Z222)
Figure 9C-9. Emergency Release Valve (362362)
Figure 9C-10. Differential Lockout Valve (36Z289)
Figure 9C-11. Differential Lookout Valve (36Z1025)
Figure 9C-12. Throttle Selector Valve (36Z971)
Figure 9C-13. Throttle Arrangements
LEAKAGE TEST
AIR SYSTEM COMPONENTS
Figure 9C-15. Throttle Valve (36U29)
HAND THROTTLE VALVE (36U54)
Figure 9C-16. Throttle Valve
AIR SYSTEM COMPONENTS
Figure 9C-17. Hand Throttle Valve (36U54)
Figure 90-1. Front Brake Mechanism
Figure 9D-2. Brake Chamber (1038Z170)
Figure 9D-3. Maxibrake Chamber 38Q18)
Figure 9D-4. Maxibrake Tools
Figure 9D-5. Exploded View - Maxibrake Chamber
Figure 9D-6. Service Bracket
Figure 9D-10. Removing Piston Assembly
Figure 9D-13. Installing Piston Assembly
SECTION X. POWER STEERING SYSTEM
SECTION X. POWER STEERING SYSTEM
Figure 10-1. Steering System Schematic
Figure 10-2. High Pressure Filter (46Z133)
Figure 10-4. Steering Gear and Column Mounting
Figure 10-5. Steering Column (20Z1144)
Figure 10-6. Steering Gear (53Z341)
Figure 10-7. Steering Gear (53Z341)
MINIMUM HACKLASH ADJUSTMENT
Figure 10-8. Hydraulic Pump and Pump Cartridge Operation
TABLE 10-1 TROUBLESHOOTING CHART
Figure 10B-2. Relief Valve Operation
Figure 10-10. Hydraulic Pump
Figure 10-12. Ring Positions
Figure 10-13. Drag Link Valve (6Z197)
TABLE 10-2. DRAG LINK VALVE TROUBLESHOOTING
REPAIR AND INSPECTION
Figure 10-14. Adjusting End Plug Gap
Figure 10-15 Steering Cylinder
Figure 10-16. Toe-In Adjustment
HOW TO USE THIS BOOK
HOW TO USE THIS BOOK - Continued
GROUP ONE - ATTACHMENT
GROUP Two - BASIC UPPER
GROUP Two - BASIC UPPER - Continued
GROUP THREE - CARRIER
GROUP FOUR - POWER PLANT
GROUP ONE - ATTACHMENT
GROUP TWO - BASIC UPPER
GROUP TWO - BASIC UPPER - Continued
GROUP THREE - CARRIER
GROUP FOUR - POWER PLANT
ATTACHMENT
BASIC UPPER
BASIC UPPER - Continued
CARRIER
CARRIER - Continued
POWER PLANT
ATTACHMENT
BASIC UPPER
BASIC UPPER - Continued
CARRIER
POWER PLANT
BOOM INSTALLATION - 80 FOOT
BOOM INSTALLATION - 80 FOOT - Continued
BOOM HOIST CYLINDER
BOOM HOIST CYLINDER (Continued)
(BASE SECTION)
80 FOOT BOOM ASSEMBLY - (MIDSECTION)
80 FOOT BOOM ASSEMBLY - (FLY SECTION)
80 FOOT BOOM ASSEMBLY (Continued)
80 FOOT BOOM ASSEMBLY (Continued)
80 FOOT BOOM ASSEMBLY (Continued)
EXPORT SHEAVE MODIFICATION
LOWER TELESCOPE CYLINDER ASSEMBLY
TELESCOPE CYLINDER ASSEMBLY
TELESCOPE CYLINDER ASSEMBLY (Continued)
BOOM TELESCOPE CYLINDER
BOOM TELESCOPE CYLINDER - Continued
HOOK BLOCK ASSEMBLY
HOOK BLOCK ASSEMBLY (Continued)
HOOK BLOCK
BOOM ANGLE INDICATOR
JIB ASSEMBLY STORAGE. MOUNTING & SUSPENSION
JIB ASSEMBLY STORAGE, MOUNTING & SUSPENSION (Continued)
TAGLINE INSTALLATION
TAGLINE INSTALLATION (Continued)
TAGLINE WINDER ASSEMBLY
TAGLINE WINDER ASSEMBLY (Continued)
PILE DRIVER INSTALLATION
REVOLVING FRAME GROUP
REVOLVING FRAME GROUP (Continued)
SWING TRANSMISSION INSTALLATION
SWING TRANSMISSION ASSEMBLY
SWING TRANSMISSION ASSEMBLY (Continued)
SWING TRANSMISSION ASSEMBLY (Continued)
MOTOR, SWlNG
OPERATORS SEAT ASSEMBLY
OPERATORS SEAT ASSEMBLY - Continued
UPPER CAB GROUP
UPPER CAB GROUP (Continued)
UPPER OUTRIGGER LEVEL ASSEMBLY
UPPER CAB GLASS
HIGH MORTALITY HEATER PARTS
UPPER AIR THROTTLE ASSEMBLY
UPPER AIR THROTTLE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
HAND THROTTLE CONTROL VALVE
HAND THROTTLE CONTROL VALVE (Continual)
UPPER ELECTRICAL ASSEMBLY
UPPER ELECTRICAL ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY
UPPER ELECTRICAL ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY (Continued)
COLLECTOR RING & SWIVEL ASSEMBLY
COLLECTOR RING & SWIVEL ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (BOOM HOIST AND TELESCOPE CIRCUITS MAIN AND AUXILIARY WINCH VALVE RETURN)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH-SWIVEL TO VALVE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (BOOM HOIST AND TELESCOPE CIRCUITS MAIN AND AUXILIARY WINCH VALVE RETURN)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT)
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH-SWIVEL TO VALVE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH-SWIVEL TO VALVE CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT) - Continued
WINCH HOLDING VALVE ASSEMBLY
WINCH HOLDING VALVE INSTALLATION (Continued)
SOLENOID VALVE INSTALLATION
SOLENOID VALVE INSTALLATION - Continued
EXPORT MODIFICATION - WINCH TUBE CONVERSION
FLOW DIVIDER VALVE ASSEMBLY
PRIORITY VALVE SUB ASSEMBLY
UPPER CONTROL ASSEMBLY
UPPER CONTROL ASSEMBLY (Continued)
UPPER CONTROL ASSEMBLY (Continued)
SWING & HOIST CONTROL VALVES
TELESCOPE CONTROL VALVE
TELESCOPE CONTROL VALVE (Continued))
TELESCOPE CONTROL VALVE (Continued))
MAIN & AUXILIARY WINCH CONTROL VALVE
MAIN AND AUXILlARY WINCH INSTALLATIONS
MAIN AND AUXILIARY WINCH INSTALLATIONS (Continued))
WINCH ASSEMBLY
WINCH ASSEMBLY (Continued))
WINCH MOTOR ASSEMBLY
WINCH BRAKE ASSEMBLY
WINCH BRAKE ASSEMBLY (Continued))
PLANETARY DRIVE ASSEMBLY
PLANETARY DRIVE ASSEMBLY (Continued))
DRUM TURN INDICATOR GROUP
DRUM TURN INDICATOR GROUP (Continued))
WINCH INDICATOR BRACKET ASSEMBLY
TRADEMARKS AND NAMEPLATES (Continued))
TRADEMARKS AND NAMEPLATES (Continued))
TOOLS
FLOODLIGHT INSTALLATION
SAFELOAD ASSEMBLY
SAFELOAD INDICATOR ASSEMBLY (Continued))
SAFELOAD INDICATOR ASSEMBLY (Continued))
CAB AND BODY ASSEMBLY
SAFELOAD INDICATOR ASSEMBLY
CARRIER CAB ASSEMBLY
CARRIER CAB ASSEMBLY (Continued))
CARRIER CAB GLASS
CARRIER SEAT AND SAFETY BELT ASSEMBLY
CARRIER SEAT AND SAFETY BELT ASSEMBLY
HEADER and DEFROSTER INSTALLATION
TRANSMISSION CONTROL ASSEMBLY
TRANSMISSION CONTROL ASSEMBLY - Continued
MAIN TRANSMISSION SHIFT LEVER ASSEMBLY
MAIN TRANSMISSION SHIFT LEVEL ASSEMBLY (Continued))
AUXILIARY TRANSMISSION CONTROL LEVER ASSEMBLY
CARRIER CAB DASH PANEL GROUP
CARRIER CAB DASH GROUP (Continued))
CARRIER CAB DASH GROUP (Continued))
METRIC SPEEDOMETER INSTALLATION
TANK - SUCTION MANIFOLD AND LINES ASSEMBLY
TANK-SUCTION MANIFOLD AND LINES ASSEMBLY (Continued))
TANK-SUCTION MANIFOLD AND LINES ASSEMBLY (Continued))
PUMP DRIVE ASSEMBLY
PUMP DRIVE ASSEMBLY (Continued))
HYDRAULIC PUMP ASSEMBLIES
AUILIARY WINCH PUMP
CARRIER WIRING HARNESS GROUP
CARRIER WIRING HARNESS GROUP (Continued)
CARRIER WIRING HARNESS GROUP (Continued)
CARRIER WIRING HARNESS GROUP (Continued)
OUTRIGGER CONTROL BOX ASSEMBLY
HYDRAULIC ASSEMBLY - OUTRIGGERS
HYDRAULIC ASSEMBLY - OUTRIGGERS (Continued)
OUTRIGGER SOLENOID VALVE BANK ASSEMBLY
OUTRIGGER ASSEMBLY
OUTRIGGER ASSEMBLY (Continued)
OUTRIGGER ASSEMBLY (Continued)
HORIZONTAL OUTRIGGER CYLINDER
VERTICAL CYLINDER ASSEMBLY
VERTICAL CYLINDER ASSEMBLY - Continued
FRONT 5TH FLOAT ASSEMBLY
CARRIER AIR BRAKE ASSEMBLY - (SUPPLY CIRCUITS)
CARRIER AIR BRAKE ASSEMBLY (Continued)
CARRIER AIR BRAKE ASSEMBLY (Continued)
CARRIER AIR ASSEMBLY (Continued) - (FUNCTION CIRCUITS)
CARRIER AIR BRAKE ASSEMBLY (Continued)
CARRIER AIR BRAKE ASSEMBLY (Continued)
DUAL BRAKE VALVE INSTALLATION
FRONT SUSPENSION ASSEMBLY
FRONT SUSPENSION ASSEMBLY (Continued)
FRONT AXLE ASSEMBLY
FRONT AXLE ASSEMBLY (Continued)
FRONT AXLE ASSEMBLY (Continued)
BRAKE GROUP - FRONT AXLE
BRAKE GROUP - FRONT AXLE (Continued)
FRONT AXLE ASSEMBLY
FRONT AXLE ASSEMBLY (Continued)
FRONT AXLE ASSEMBLY (Continued)
BRAKE ASSEMBLY - FRONT AXLE
BRAKE ASSEMBLY - FRONT AXLE (Continued)
WHEEL AND RIM ASSEMBLY
PROPELLER SHAFTS AND AUXILIARY TRANSMISSION ASSEMBLY
REAR SUSPENSION ASSEMBLY
REAR SUSPENSION ASSEMBLY (Continued)
REAR SUSPENSION ASSEMBLY (Continued)
REAR SUSPENSION ASSEMBLY (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL ASSEMBLY
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL ASSEMBLY
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
REAR AXLE MAXIBRAKE CHAMBER
BACK-UP WARNING DEVICE ASSEMBLY
SUN VISOR INSTALLATION
SPARE TIRE AND RACK ASSEMBLY
POWER PLANT ASSEMBLY
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
ENGINE WIRING HARNESS ASSEMBLY
CLUTCH GROUP - HYDRAULIC
CLUTCH GROUP - HYDRAULIC (Continued)
CLUTCH ASSEMBLY
CLUTCH ASSEMBLY (Continued)
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP (Continued)
MAIN TRANSMISSION GEAR AND SHAFT GROUP
MAIN TRANSMISSION GEAR AND SHAFT GROUP (Continued)
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP (Continued)
AUXILIARY TRANSMlSSlON CASE, GASKET & COVER GROUP
AUXILIARY TRANSMISSION GEAR AND SHAFT (Continued)
AUXILIARY TRANSMISSION GEAR & SHAFT GROUP
AUXILIARY TRANSMISSION GEAR AND SHAFT (Continued)
AUXILIARY TRANSMISSION SIDE SHIFT HOUSING GROUP
CARRIER AIR THROTTLE ASSEMBLY
CARRIER AIR THROTTLE ASSEMBLY (Continued))
CARRIER AIR THROTTLE ASSEMBLY (Continued))
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
ENGINE COVERING SHEET METAL ASSEMBLY
ENGINE COVERING SHEET METAL ASSEMBLY (Continued)
ENGINE COVERING SHEET METAL ASSEMBLY (Continued)
FUEL SYSTEM ASSEMBLY
POWER STEERING AND OUTRIGGER PUMP
POWER STEERING ASSEMBLY
POWER STEERING ASSEMBLY (Continued)
POWER STEERING ASSEMBLY (Continued)
POWER STEERING ASSEMBLY (Continued)
POWER STEERING ASSEMBLY (Continued)
POWER STEERING AND OUTRIGGER SELECTOR VALVE ASSEMBLY
POWER STEERING AND OUTRIGGER SELECTOR VALVE ASSEMBLY (Continued)
STEERING COLUMN
STEERING COLUMN (Continued)
STEERING GEAR
STEERING GEAR (Continued)
POWER STEERING VALVE ASSEMBLY
POWER STEERING VALVE ASSEMBLY (Continued)
POWER STEERING CYLINDER
POWER STEERING CYLINDER (Continued)
PUMP CONTROL ASSEMBLY
PUMP CONTROL ASSEMBLY (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
ETHER STARTING AID ASSEMBLY
EDITING SECTION E
EDITING SECTION E - Continued
EDITING SECTION E - Continued
EDITING SECTION E - Continued
EDITING SECTION E - Continued
ATTACHMENT
BASIC UPPER
BASIC UPPER - Continued
CARRIER
POWER PLANT
GUARDS AND COVERS
GUARDS AND COVERS - Continued
CAB, OPERATOR'S
CAB, OPERATOR'S - Continued
UPPER AIR THROTTLE ASSEMBLY
UPPER AIR THROTTLE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
COLLECTOR RING & SWIVEL ASSEMBLY
COLLECTROR RING AND SWIVEL ASSEMBLY (Continued)
MAIN AND AUXILIARY WINCH INSTALLATIONS
MAIN AND AUXILIARY WINCH INSTALLATION (Continued)
WINCH ASSEMBLY
WINCH ASSEMBLY (Continued)
WINCH BRAKE
WINCH BRAKE ASSEMBLY (Continued)
REAR SUSPENSION ASSEMBLY
REAR SUSPENSION ASSEMBLY (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL ASSEMBLY
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
POWER PLANT ASSEMBLY
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
ALTERNATOR
ALTERNATOR (Continued)
MAIN TRANSMISSION GEAR AND SHAFT GROUP
MAIN TRANSMISSION GEAR AND SHAFT GROUP (Continued)
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP (Continued)
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP (Continued)
CARRIER AIR THROTTLE ASSEMBLY
CARRIER AIR THROTTLE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
ETHER STARTING AID ASSEMBLY
Figure 1-2. Crane Terminology
MAIN WINCH DATA
LIGHT BULBS
Figure 1-3. Range Diagram - 80' Boom (105x75-A)
Figure 1-4. Range Diagram - 100' Boom (105J83)
Figure 1-5. Dimensions and Clearance
Section II. CONTROLS AND OPERATION
Figure 2-1. Carrier Controls
Figure 2-2. Voltmeter Operation
STEERING WHEEL.
Figure 2-4. Emergency Engine Shutoff
CARRIER OPERATION
OUTRIGGER OPERATION
Figure 2-5. Outrigger Locks
Figure 2-7. Upper Controls
Figure 2-8. Winch Lever Positions
BOOM HOIST LEVER AND PEDAL
CRANE OPERATION
CRANE OPERATING CYCLE
Figure 2-9. Crane Operating Cycle
Figure 2-10. Crane Operating Cycle
CARRIER REMOTE CONTROLS
HAND SIGNALS
Figure 2-12. Hand Signal for Crane Operation
CONTROLS AND OPERATION
OPERATION IN HUMIDITY OR SALT WATER AREAS.
Figure 2-13. Securing Rope to Drum
Figure 2.16. Installing a Rope Socket
Figure 2-16. Jib Storage
Figure 2-17. Jib Suspension (911591)
Figure 2-18. Manual Fly Section (105J681)
COUNTERWEIGHT
Section III. LUBRICATION
MULTIPURPOSE GREASE
PETROLEUM GEAR OIL
POWER TRANSMISSION FLUID AND GEAR OIL
OPEN GEAR AND WIRE ROPE LUBRICANT
HEAVY DUTY MOTOR OIL
HYDRAULIC OIL
HIGH TEMPERATURE GREASE
Figure 3-1. Upper Lubrication Chart
Figure 3-2. Crane Lubrication Chart
Section IV. HYDRAULIC SYSTEM AND COMPONENTS
SUB-SECTION 4A - HYDRAULIC SYSTEM
GENERAL MAINTENANCE
TROUBLESHOOTING GUIDE
Chart 1. Excessive Noise
Chart 2. Excessive Heat
Chart 3. Incorrect Flow
Chart 4. lncorrect Pressure
Chart 5. Faulty Operation
SYSTEM DESCRIPTIONS
Figure 4A-1. hydrau;ic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH GEARMATIC MAIN AND AUXILIARY WINCHES
Figure 4A-2. Hydrau;ic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH GEARMATIC FREE-FALL MAIN AND NON FREE-FALL AUXILIARY WINCHES
Figure 4A-3. Hydraulic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH FREE-FALL MAIN AND AUXILIARY WINCHES
Figure 4A-4. Hydraulic System Schematic
MAIN WINCH CIRCUIT
BASIC MACHINE WITH P&H MAIN AND AUXILIARY WINCHES
Figure 4A-5. Hydraulic System Schematic
AUXILIARY WINCH CIRCUIT
Figure 4B-1. Dual Pumps (41Z55 and 41Z56)
Figure 4B-2. Pump Cartridge Operation
Figure 4B-3. Pressure Feed to Vanes
Figure 4B-5. Exploded View of Dual Pump
Figure 4B-7. Removing Pump Cover
INSPECTION AND REPAIR
Figure 4B-10. Installing Rotor
Figure 4B-14. Single Pump (41Z57)
Figure 4B-15. Pump Cartridge Operation
Figure 4B-16. Pressure Feed to Vanes
Figure 4B-18. Exploded View of Single Pump
Figure 4B-19. Installing Rotor
Figure 4B-20. Intaliing Ring
Figure 4B-23. Dual Pumps (41Z102 and 41Z103)
Figure 4B-24. Pump Cartridge Operation
Figure 4B-25. Pressure Feed to Vanes
Figure 4B-27. Exploded View of Dual Pump
Figure 4B-28. Beginning Disassembly
OVERHAUL
Figure 4B- 32. Installing Rotor
SINGLE PUMP (41Z104)
Figure 4B-36. Single Pump (41Z57)
Figure 4B-38. Pressure Feed to Vanes
Figure 4B-40. Exploded View of Single Pump
OVERHAUL
Figure 4B-42. Installing Ring
Figure 4C-1. Rotary Joint (979J24)
ROTARY JOINT (979J30)
Figure 4C-2. Rotary Joint (979J30)
INSTALLATION
Figure 4D-1. Control Valve Operation (36Z724)
TABLE 4D-1. TROUBLE, CAUSE AND REMEDY CHART
Figure 4D-2. Control Valve (36Z724)
Figure 4D-3. Control Valve Operation (36Z725)
TABLE 4D-2. TROUBLE, CAUSE AND REMEDY CHART (CONTINUED)
Figure 4D-4. Control Valve (36Z725)
Figure 4D-5. Control Valve Operation (36Z726)
Figure 4D-6. Control Valve (36Z726)
Figure 4D-7. Control Valve Operation (36Z727)
TABLE 4D-4. TROUBLE, CAUSE AND REMEDY CHART
Figure 4D-8. Control Valve (36Z727)
Figure 4D-9. Control Valve Operation (36Z986)
TABLE 4D-5. TROUBLE, CAUSE AND REMEDY CHART
Figure 4D-10. Control Valve (36Z986)
Figure 4D-11. Control Valve Operation (36Q70)
TABLE 4D-6. TROUBLE, CAUSE AND REMEDY CHART
CONTROL VALVES
Figure 4D-13. Control Valve (36Z840)
Figure 4D-14. Gauge Ports
TABLE 4D-7. TROUBLE, CAUSE AND REMEDY CHART
TABLE 4D-7. TROUBLE, CAUSE AND REMEDY CHART - Continued
Figure 4D-15. Control Valve (36Z840)
Figure 4D-16. Control Spool Disassembly
INSTALLATION
Figure 4E-1. Filter Operation
Section V. BOOM AND WINCH SYSTEMS AND COMPONENTS
SUB-SECTION 5A. BOOM AND WINCH SYSTEMS
Figure 5A-1. Boom Installation
Figure 5A-2. Boom Assembly
Figure 5A-3. Boom Alignment (1100P154)
Figure 5B-1. Boom Hoist Cylinder (38Z231)
BOOM HOIST CYLINDER (38U92)
Figure 5B-2 Boom Hoist Cylinder (38U92)
SUB-SECTION 5C. BOOM TELESCOPE CYLINDERS
Figure 5C-2. Hose Loop Assembly (100J3870)
Figure 5C-3. Boom Telescope Cylinder (38R32)
BOOM TELESCOPE CYLINDERS
Figure 5D-1. Flow Divider Operation
Figure 5D-2. Flow Divider (36Z680)
Figure 5D-3. Flow Divider Operation
Figure 5D-4. Flow Divider (36Q46)
SUB-SECTION 5E. HOSE REELS
Figure 5E-1. Hose Reel (36Z691)
Figure 5E-2. Hose Reel Spring Motor
Figure 5E-4. Seat Arrangement
Figure 5E-5. Hose Replacement
SUBSECTION 5F. COUNTERBALANCE VALVES
Figure 5F-1. Counterbalance Valve Operation
Figure 5F-2. Counterbalance Valve Removal
COUNTERBALANCE VALVE (36Z838)
Figure 5F-4. Counterbalance Valve Operation
Figure 5F-5. Counterbalance Valve Removal
Figure 5F-7. Counterbalance Valve Operation
REPAIR
MAINTENANCE
VELOCITY FUSES
Figure 5G-1. Velocity Fuse Operation
Figure 5G-2. Velocity Fuse (1036Z403)
VELOCITY FUSES
Figure 5H-1. Winch Brake Valve (36Q76)
Figure 5H-2. Linkage Adjustment
Figure 5H-4. Linkage Adjustment
Figure 5J-1. Winch Clearances
DISASSEMBLY OF PRIMARY DRIVE
Figure 5J-2. The P&H Winch
Figure 5J-3. Brake Mounting Bolts
Figure 5J-7. Removing Sleeve Bearing
Figure 5J-11. Location of Breather, Level, and Drain Plugs
Figure 5J-15. Removing Outer Ring Gear
Figure 5J-18. Installing Sprag Clutch
Figure 5J-21. Winch Brake Assembly
Figure 5J-22. Dimensions for Spring Setting
Figure 5J-23. Brake Assembly
Figure 5K-1. Winch Motor (41Q6)
Figure 5K-2. Motor Operation
Figure 5K-3. Motor (41Q6)
Figure 5K-4. Pressure Plate
Figure 5K-5. Motor (41Q7)
Figure 5K-6. Motor Operation
Figure 5K-7. Motor (41Q7)
MOTOR (41U13)
WINCH MOTOR
DISASSEMBLY
Figure 5K-9. Motor (41U13)
INSPECTION
SECTION VI. SWING SYSTEM AND COMPONENTS
TABLE 6A-1. SWING CIRCUIT TROUBLESHOOTING
TABLE 6A-1. SWING CIRCUIT TROUBLESHOOTING - Continued
Figure 6B-1. Swing Reducer (53Z373)
Figure 6B-2. Swing Reducer Removal
Table 6B-1 Swing Reducer Troubleshooting
SWING REDUCERS
Figure 6B-3. Swing Reducer (53Z373)
Figure 6B-4. Removing Planet Pins
REASSEMBLY
SWING REDUCERS
Figure 6B-5. Adjusting Brake Piston Clearance
INSTALLATION
Figure 6C-1. Swing Motor Operation
SWING MOTORS
Figure 6C-4. Swing Motor (41Z125)
Figure 6D-1. Swing Transmission (53R3)
SWING TRANSMISSION
Figure 6D-3. Swing Transmission (53R3)
SWING TRANSMISSION
SWING TRANSMISSION - Continued
INSTALLATION
SUB-SECTION 6E. SLEWING RINGS
Figure 6E-1. Slewing Ring Installation
SLEWING RINGS
SUBSECTION 6F. SWING BRAKE VALVES
Figure 6F-2. Brake Pedal Stop Adjustment (100J4194-1-A)
SUB-SECTION 6G. SWING BRAKE LOCK VALVES
Figure 6G-1. Swing Brake Lock Valve (36Z361)
SECTION VII. OUTRIGGER SYSTEM
SECTION VII. OUTRIGGER SYSTEM
Figure 7-2. Hydraulic Outrigger Control System
Figure 7-3. Outrigger Hydraulic Schematic (8100J3980)
SOLENOID VALVES (36Z341)
OUTRIGGER EXTENSION CYLINDERS
Figure 7-5. Outrigger Extension Cylinder (10053305)
Figure 7-6. Outrigger Extension Cylinder (38489 & 38491)
OUTRlGGER SYSTEM
Figure 7-7. Vertical List Cylinder (100J4208)
INSTALLATION
SECTION VIII. POWER TRAIN
SECTION VIII. POWER TRAIN
Figure 8-2. Remote Control Assembly
Figure 8-3. Engine Clutch Assembly
Figure 8-4. Clutch Disassembly
Figure 8-6. Clutch Assembly
Figure 8-8. Clutch Adjustment
Figure 8-9. Engine and Transmission Mounting
Figure 8-10. Propeller Shaft (810N37 & 10U49)
Figure 8-11. Propeller Shaft (20Q17)
Figure 8-12. Rear Suspension
Figure 8-13. Hydraulic Pump Drive Assembly (53U13)
Figure 8-14. Power Steering Pump Installation
Figure 8-15. Power Steering Pump Installation
Figure 8-16. Hydraulic Pump Drive Assembly
Figure B-17. Carrier Electrical Schematic
SECTION IX. AIR SYSTEM AND COMPONENTS
SUB-SECTION 9A. AIR SYSTEM
CARRIER REMOTE CONTROL DESCRIPTION
UNEVEN BRAKES
TROUBLESHOOTING
Figure 9A-1. Air System Schematic
Figure 9A-2. Air Diagram Schematic
SUB-SECTION 9B. AIR COMPRESSORS
INSTALLATION
SUB-SECTION 9C. AIR SYSTEM COMPONENTS
AIR SYSTEM COMPONENTS
ROUTINE INSPECTION
Figure 9C-3. Treadle Valve (38Z225)
Figure 9C-4. Quick Release Valve (36Z254)
Figure 9C.5. Relay Valve (36Z291)
Figure 9C-6. Relay Valve (36Z650)
Figure 9C-7. Exhaust & Pressure Retaining Valve
Figure 9C-8. Maxibrake Control Valve (36Z222)
Figure 9C-9. Emergency Release Valve (362362)
Figure 9C-10. Differential Lockout Valve (36Z289)
Figure 9C-11. Differential Lookout Valve (36Z1025)
Figure 9C-12. Throttle Selector Valve (36Z971)
Figure 9C-13. Throttle Arrangements
LEAKAGE TEST
AIR SYSTEM COMPONENTS
Figure 9C-15. Throttle Valve (36U29)
HAND THROTTLE VALVE (36U54)
Figure 9C-16. Throttle Valve
AIR SYSTEM COMPONENTS
Figure 9C-17. Hand Throttle Valve (36U54)
Figure 90-1. Front Brake Mechanism
Figure 9D-2. Brake Chamber (1038Z170)
Figure 9D-3. Maxibrake Chamber 38Q18)
Figure 9D-4. Maxibrake Tools
Figure 9D-5. Exploded View - Maxibrake Chamber
Figure 9D-6. Service Bracket
Figure 9D-10. Removing Piston Assembly
Figure 9D-13. Installing Piston Assembly
SECTION X. POWER STEERING SYSTEM
SECTION X. POWER STEERING SYSTEM
Figure 10-1. Steering System Schematic
Figure 10-2. High Pressure Filter (46Z133)
Figure 10-4. Steering Gear and Column Mounting
Figure 10-5. Steering Column (20Z1144)
Figure 10-6. Steering Gear (53Z341)
Figure 10-7. Steering Gear (53Z341)
MINIMUM HACKLASH ADJUSTMENT
Figure 10-8. Hydraulic Pump and Pump Cartridge Operation
TABLE 10-1 TROUBLESHOOTING CHART
Figure 10B-2. Relief Valve Operation
Figure 10-10. Hydraulic Pump
Figure 10-12. Ring Positions
Figure 10-13. Drag Link Valve (6Z197)
TABLE 10-2. DRAG LINK VALVE TROUBLESHOOTING
REPAIR AND INSPECTION
Figure 10-14. Adjusting End Plug Gap
Figure 10-15 Steering Cylinder
Figure 10-16. Toe-In Adjustment
HOW TO USE THIS BOOK
HOW TO USE THIS BOOK - Continued
GROUP ONE - ATTACHMENT
GROUP Two - BASIC UPPER
GROUP Two - BASIC UPPER - Continued
GROUP THREE - CARRIER
GROUP FOUR - POWER PLANT
GROUP ONE - ATTACHMENT
GROUP TWO - BASIC UPPER
GROUP TWO - BASIC UPPER - Continued
GROUP THREE - CARRIER
GROUP FOUR - POWER PLANT
ATTACHMENT
BASIC UPPER
BASIC UPPER - Continued
CARRIER
CARRIER - Continued
POWER PLANT
ATTACHMENT
BASIC UPPER
BASIC UPPER - Continued
CARRIER
POWER PLANT
BOOM INSTALLATION - 80 FOOT
BOOM INSTALLATION - 80 FOOT - Continued
BOOM HOIST CYLINDER
BOOM HOIST CYLINDER (Continued)
(BASE SECTION)
80 FOOT BOOM ASSEMBLY - (MIDSECTION)
80 FOOT BOOM ASSEMBLY - (FLY SECTION)
80 FOOT BOOM ASSEMBLY (Continued)
80 FOOT BOOM ASSEMBLY (Continued)
80 FOOT BOOM ASSEMBLY (Continued)
EXPORT SHEAVE MODIFICATION
LOWER TELESCOPE CYLINDER ASSEMBLY
TELESCOPE CYLINDER ASSEMBLY
TELESCOPE CYLINDER ASSEMBLY (Continued)
BOOM TELESCOPE CYLINDER
BOOM TELESCOPE CYLINDER - Continued
HOOK BLOCK ASSEMBLY
HOOK BLOCK ASSEMBLY (Continued)
HOOK BLOCK
BOOM ANGLE INDICATOR
JIB ASSEMBLY STORAGE. MOUNTING & SUSPENSION
JIB ASSEMBLY STORAGE, MOUNTING & SUSPENSION (Continued)
TAGLINE INSTALLATION
TAGLINE INSTALLATION (Continued)
TAGLINE WINDER ASSEMBLY
TAGLINE WINDER ASSEMBLY (Continued)
PILE DRIVER INSTALLATION
REVOLVING FRAME GROUP
REVOLVING FRAME GROUP (Continued)
SWING TRANSMISSION INSTALLATION
SWING TRANSMISSION ASSEMBLY
SWING TRANSMISSION ASSEMBLY (Continued)
SWING TRANSMISSION ASSEMBLY (Continued)
MOTOR, SWlNG
OPERATORS SEAT ASSEMBLY
OPERATORS SEAT ASSEMBLY - Continued
UPPER CAB GROUP
UPPER CAB GROUP (Continued)
UPPER OUTRIGGER LEVEL ASSEMBLY
UPPER CAB GLASS
HIGH MORTALITY HEATER PARTS
UPPER AIR THROTTLE ASSEMBLY
UPPER AIR THROTTLE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
HAND THROTTLE CONTROL VALVE
HAND THROTTLE CONTROL VALVE (Continual)
UPPER ELECTRICAL ASSEMBLY
UPPER ELECTRICAL ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY
UPPER ELECTRICAL ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY (Continued)
COLLECTOR RING & SWIVEL ASSEMBLY
COLLECTOR RING & SWIVEL ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (BOOM HOIST AND TELESCOPE CIRCUITS MAIN AND AUXILIARY WINCH VALVE RETURN)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH-SWIVEL TO VALVE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (BOOM HOIST AND TELESCOPE CIRCUITS MAIN AND AUXILIARY WINCH VALVE RETURN)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY (Continued)
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT)
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (SWING AND SWING BRAKE CONTROL CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH-SWIVEL TO VALVE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH-SWIVEL TO VALVE CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT)
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT) - Continued
UPPER HYDRAULIC ASSEMBLY - (MAIN AND AUXILIARY WINCH VALVE AND WINCH BRAKE CIRCUIT) - Continued
WINCH HOLDING VALVE ASSEMBLY
WINCH HOLDING VALVE INSTALLATION (Continued)
SOLENOID VALVE INSTALLATION
SOLENOID VALVE INSTALLATION - Continued
EXPORT MODIFICATION - WINCH TUBE CONVERSION
FLOW DIVIDER VALVE ASSEMBLY
PRIORITY VALVE SUB ASSEMBLY
UPPER CONTROL ASSEMBLY
UPPER CONTROL ASSEMBLY (Continued)
UPPER CONTROL ASSEMBLY (Continued)
SWING & HOIST CONTROL VALVES
TELESCOPE CONTROL VALVE
TELESCOPE CONTROL VALVE (Continued))
TELESCOPE CONTROL VALVE (Continued))
MAIN & AUXILIARY WINCH CONTROL VALVE
MAIN AND AUXILlARY WINCH INSTALLATIONS
MAIN AND AUXILIARY WINCH INSTALLATIONS (Continued))
WINCH ASSEMBLY
WINCH ASSEMBLY (Continued))
WINCH MOTOR ASSEMBLY
WINCH BRAKE ASSEMBLY
WINCH BRAKE ASSEMBLY (Continued))
PLANETARY DRIVE ASSEMBLY
PLANETARY DRIVE ASSEMBLY (Continued))
DRUM TURN INDICATOR GROUP
DRUM TURN INDICATOR GROUP (Continued))
WINCH INDICATOR BRACKET ASSEMBLY
TRADEMARKS AND NAMEPLATES (Continued))
TRADEMARKS AND NAMEPLATES (Continued))
TOOLS
FLOODLIGHT INSTALLATION
SAFELOAD ASSEMBLY
SAFELOAD INDICATOR ASSEMBLY (Continued))
SAFELOAD INDICATOR ASSEMBLY (Continued))
CAB AND BODY ASSEMBLY
SAFELOAD INDICATOR ASSEMBLY
CARRIER CAB ASSEMBLY
CARRIER CAB ASSEMBLY (Continued))
CARRIER CAB GLASS
CARRIER SEAT AND SAFETY BELT ASSEMBLY
CARRIER SEAT AND SAFETY BELT ASSEMBLY
HEADER and DEFROSTER INSTALLATION
TRANSMISSION CONTROL ASSEMBLY
TRANSMISSION CONTROL ASSEMBLY - Continued
MAIN TRANSMISSION SHIFT LEVER ASSEMBLY
MAIN TRANSMISSION SHIFT LEVEL ASSEMBLY (Continued))
AUXILIARY TRANSMISSION CONTROL LEVER ASSEMBLY
CARRIER CAB DASH PANEL GROUP
CARRIER CAB DASH GROUP (Continued))
CARRIER CAB DASH GROUP (Continued))
METRIC SPEEDOMETER INSTALLATION
TANK - SUCTION MANIFOLD AND LINES ASSEMBLY
TANK-SUCTION MANIFOLD AND LINES ASSEMBLY (Continued))
TANK-SUCTION MANIFOLD AND LINES ASSEMBLY (Continued))
PUMP DRIVE ASSEMBLY
PUMP DRIVE ASSEMBLY (Continued))
HYDRAULIC PUMP ASSEMBLIES
AUILIARY WINCH PUMP
CARRIER WIRING HARNESS GROUP
CARRIER WIRING HARNESS GROUP (Continued)
CARRIER WIRING HARNESS GROUP (Continued)
CARRIER WIRING HARNESS GROUP (Continued)
OUTRIGGER CONTROL BOX ASSEMBLY
HYDRAULIC ASSEMBLY - OUTRIGGERS
HYDRAULIC ASSEMBLY - OUTRIGGERS (Continued)
OUTRIGGER SOLENOID VALVE BANK ASSEMBLY
OUTRIGGER ASSEMBLY
OUTRIGGER ASSEMBLY (Continued)
OUTRIGGER ASSEMBLY (Continued)
HORIZONTAL OUTRIGGER CYLINDER
VERTICAL CYLINDER ASSEMBLY
VERTICAL CYLINDER ASSEMBLY - Continued
FRONT 5TH FLOAT ASSEMBLY
CARRIER AIR BRAKE ASSEMBLY - (SUPPLY CIRCUITS)
CARRIER AIR BRAKE ASSEMBLY (Continued)
CARRIER AIR BRAKE ASSEMBLY (Continued)
CARRIER AIR ASSEMBLY (Continued) - (FUNCTION CIRCUITS)
CARRIER AIR BRAKE ASSEMBLY (Continued)
CARRIER AIR BRAKE ASSEMBLY (Continued)
DUAL BRAKE VALVE INSTALLATION
FRONT SUSPENSION ASSEMBLY
FRONT SUSPENSION ASSEMBLY (Continued)
FRONT AXLE ASSEMBLY
FRONT AXLE ASSEMBLY (Continued)
FRONT AXLE ASSEMBLY (Continued)
BRAKE GROUP - FRONT AXLE
BRAKE GROUP - FRONT AXLE (Continued)
FRONT AXLE ASSEMBLY
FRONT AXLE ASSEMBLY (Continued)
FRONT AXLE ASSEMBLY (Continued)
BRAKE ASSEMBLY - FRONT AXLE
BRAKE ASSEMBLY - FRONT AXLE (Continued)
WHEEL AND RIM ASSEMBLY
PROPELLER SHAFTS AND AUXILIARY TRANSMISSION ASSEMBLY
REAR SUSPENSION ASSEMBLY
REAR SUSPENSION ASSEMBLY (Continued)
REAR SUSPENSION ASSEMBLY (Continued)
REAR SUSPENSION ASSEMBLY (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL ASSEMBLY
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL ASSEMBLY
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY
REAR REAR AXLE DIFFERENTIAL CARRIER ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
FORWARD AND REAR REAR AXLE BRAKE GROUP (Continued)
REAR AXLE MAXIBRAKE CHAMBER
BACK-UP WARNING DEVICE ASSEMBLY
SUN VISOR INSTALLATION
SPARE TIRE AND RACK ASSEMBLY
POWER PLANT ASSEMBLY
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
ENGINE WIRING HARNESS ASSEMBLY
CLUTCH GROUP - HYDRAULIC
CLUTCH GROUP - HYDRAULIC (Continued)
CLUTCH ASSEMBLY
CLUTCH ASSEMBLY (Continued)
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP (Continued)
MAIN TRANSMISSION GEAR AND SHAFT GROUP
MAIN TRANSMISSION GEAR AND SHAFT GROUP (Continued)
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP (Continued)
AUXILIARY TRANSMlSSlON CASE, GASKET & COVER GROUP
AUXILIARY TRANSMISSION GEAR AND SHAFT (Continued)
AUXILIARY TRANSMISSION GEAR & SHAFT GROUP
AUXILIARY TRANSMISSION GEAR AND SHAFT (Continued)
AUXILIARY TRANSMISSION SIDE SHIFT HOUSING GROUP
CARRIER AIR THROTTLE ASSEMBLY
CARRIER AIR THROTTLE ASSEMBLY (Continued))
CARRIER AIR THROTTLE ASSEMBLY (Continued))
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
ENGINE COVERING SHEET METAL ASSEMBLY
ENGINE COVERING SHEET METAL ASSEMBLY (Continued)
ENGINE COVERING SHEET METAL ASSEMBLY (Continued)
FUEL SYSTEM ASSEMBLY
POWER STEERING AND OUTRIGGER PUMP
POWER STEERING ASSEMBLY
POWER STEERING ASSEMBLY (Continued)
POWER STEERING ASSEMBLY (Continued)
POWER STEERING ASSEMBLY (Continued)
POWER STEERING ASSEMBLY (Continued)
POWER STEERING AND OUTRIGGER SELECTOR VALVE ASSEMBLY
POWER STEERING AND OUTRIGGER SELECTOR VALVE ASSEMBLY (Continued)
STEERING COLUMN
STEERING COLUMN (Continued)
STEERING GEAR
STEERING GEAR (Continued)
POWER STEERING VALVE ASSEMBLY
POWER STEERING VALVE ASSEMBLY (Continued)
POWER STEERING CYLINDER
POWER STEERING CYLINDER (Continued)
PUMP CONTROL ASSEMBLY
PUMP CONTROL ASSEMBLY (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
HYDRAULIC ASSEMBLY - FROM PUMPS TO SWIVEL AND RETURN (Continued)
ETHER STARTING AID ASSEMBLY
EDITING SECTION E
EDITING SECTION E - Continued
EDITING SECTION E - Continued
EDITING SECTION E - Continued
EDITING SECTION E - Continued
ATTACHMENT
BASIC UPPER
BASIC UPPER - Continued
CARRIER
POWER PLANT
GUARDS AND COVERS
GUARDS AND COVERS - Continued
CAB, OPERATOR'S
CAB, OPERATOR'S - Continued
UPPER AIR THROTTLE ASSEMBLY
UPPER AIR THROTTLE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
UPPER ELECTRICAL ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
COLLECTOR RING & SWIVEL ASSEMBLY
COLLECTROR RING AND SWIVEL ASSEMBLY (Continued)
MAIN AND AUXILIARY WINCH INSTALLATIONS
MAIN AND AUXILIARY WINCH INSTALLATION (Continued)
WINCH ASSEMBLY
WINCH ASSEMBLY (Continued)
WINCH BRAKE
WINCH BRAKE ASSEMBLY (Continued)
REAR SUSPENSION ASSEMBLY
REAR SUSPENSION ASSEMBLY (Continued)
FORWARD REAR AXLE GROUP
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD REAR AXLE GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
FORWARD AND REAR REAR AXLE HUB AND DRUM GROUP (Continued)
REAR REAR AXLE DIFFERENTIAL ASSEMBLY
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
FORWARD AND REAR REAR AXLE BRAKE GROUP
REAR REAR AXLE DIFFERENTIAL ASSEMBLY (Continued)
POWER PLANT ASSEMBLY
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
POWER PLANT ASSEMBLY (Continued)
ALTERNATOR
ALTERNATOR (Continued)
MAIN TRANSMISSION GEAR AND SHAFT GROUP
MAIN TRANSMISSION GEAR AND SHAFT GROUP (Continued)
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP
MAIN TRANSMISSION CASE AND CLUTCH HOUSING GROUP (Continued)
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP
MAIN TRANSMISSION YOKES, BAR AND REMOTE CONTROL GROUP (Continued)
CARRIER AIR THROTTLE ASSEMBLY
CARRIER AIR THROTTLE ASSEMBLY (Continued)
AIR THROTTLE PEDAL AND VALVE ASSEMBLY
AIR THROTTLE PEDAL AND VALVE ASSEMBLY (Continued)
ETHER STARTING AID ASSEMBLY
