SECTION I. INTRODUCTION
WARRANTY
Figure 1-2. Mechanical Train Schematic
Figure 1-3. Crane Terminology
Table 1-2. Liquid Capacity Chart
Figure 1-4. General Dimensions (2105J170)
Table 1-1. English to Metric Conversions
ENGINE SPECIFICATIONS
TABLE 1-2. DRUM PERFORMANCE DATA
TABLE 1-2. DRUM PERFORMANCE DATA (Cont.)
Section II. CONTROLS AND OPERATION
Section II. CONTROLS AND OPERATION
Figure 2-1. Operator's Controls
LEFT DRUM PAWL SWITCH
LEFT DRUM BRAKE SWITCH
Figure 2-2. Load Weighing System
Figure 2-3 Voltmeter Operation
Figure 2-5. Anti-Rotation Bar (2100J1046)
Figure 2-7. Drum Cover
STARTING THE ENGINE
Figure 2-8. Propelling the Machine
Figure 2-9. Axle Locking Bolts and Keepers
Figure 2-10. Liftcrane Operating Cycle
Figure 2-11. Hand Signals for Crane Operation
Figure 2-11.1. Connect Leads
Figure 2-11.3. Raising Hammer
Figure 2-12. Antifreeze Concentration and Temperature
CONTROLS AND OPERATION
Figure 2-14. Angle Meter and Control Panel
TABLE 2-1. PROGRAM SELECTOR SWITCHES
Section III. LUBRICATION
Section IV. UPPER POWER TRAIN
ENGINES
TROUBLESHOOTING PROCEDURES
Figure 4A-1. Locating a Misfiring Cylinder
Table 4A-1. Compression Pressure Comparison
Air Box Pressure
Figure 4A-4. Comparison of Column Height for Mercury and Water Manometers
Troubleshooting Guide
Troubleshooting Guide - Continued
Troubleshooting Guide - Continued
TABLE OF CONTENTS
CLUTCHES
Figure 4B-1. Clutch Adjustment
Table 4B-1. Clutch Actuator Troubleshooting
Figure 4B-2. Clutch Actuator (88U24D1)
TABLE OF CONTENTS
TRANSMISSIONS
Figure 4C-1. Pump Drive (53U84)
CLEANING, INSPECTION AND REPAIR
TORQUE CONVERTER (53Z659)
Figure 4C-2. Oil System - Schematic
Preventative Maintenance
Figure 4C-4. Checking Converter-in Pressure
Table 4C-1. Converter Troubleshooting (Part 1 of 2)
Table 4C-1. Converter Troubleshooting (Part 2 of 2)
Figure 4C-5. Special Tools for Torque Converter Overhaul
Figure 4C-6. Converter Overhaul Stand
Figure 4C-7. Spanner Wrench for Input Disconnect Clutch Lock Nut
Figure 4C-9. Sketch of Puller and Sleeve
Table 4C-3. Special Tools
INSPECTING BUSHING, THRUST WASHERS
Figure 4C-10. Torque Specifications
Figure 4C-12. Removing (or Installing) Freewheel Roller Race Retaining Nut
Figure 4C-13. Removing (or Installing) Lock Strips
Figure 4C-15. Removing Converter Pump Hub and Bearing
Figure 4C-21. Removing Oil Pump Idler Gear Shaft
Figure 4C-22. Removing (or Installing) Oil Pump Idler Gear
Figure 4C-25. Installing Stator Springs and Rollers
Figure 4C-28. Removing (or Installing) Converter Pressure Regulating Valve
Figure 4C-29. Removing (or Installing) Clutch Pressure Regulating Valve
Figure 4C-33. Removing Oil Pump Bearing Sleeve
Figure 4C-34. Exploded View of Input Disconnect Clutch
Assembly
Figure 4C-35. Idler Gear and Bearing Assembly
Figure 4C-37. Checking End Play - Weight Suspended
INSTALLATION
Wear Limits Data
Table 4C-4. Wear Limits Data
Figure 4C-38. Exploded View Converter Housing
Figure 4C-39. Exploded View of Torque Converter
Figure 4C-40. Exploded View of Converter Drive and Sprag Clutch
Figure 4C-41. Exploded View of Charging Oil Pump
Figure 4D-1. Propeller Shaft (10Z563)
Figure 4D-2. Propeller Shaft (10Z553)
PROPELLER SHAFTS
SUBSECTION 4E. CHAINS AND IDLER SHAFTS
Figure 4E-1. Chain Case and Idler Shaft (2100J1389 and 2100J515F1)
Figure 4E-2. Idler Shaft (2100N515F1)
CHAIN TROUBLESHOOTING GUIDE
SECTION V. HYDRAULIC CONTROL SYSTEM
SUBSECTION 5A. HYDRAULIC SYSTEM
GENERAL MAINTENANCE
Chart 5A-1 Excessive Noise
Chart 5A-2 Excessive Heat
Chart 5A-3. Incorrect Flow
Chart 5A-4. Incorrect Pressure
Chart 5A-5. Faulty Operation
SYSTEM DESCRIPTION
PROPEL BRAKE CIRCUIT
Figure 5A-1. Hydraulic Control Schematic (2105J238)
PROPEL BRAKE CIRCUIT
SUBSECTION 5B. PUMPS
Table 5B-1. Pump Troubleshooting
Figure 5B-1. Control Pump (37Z317)
Figure 5B-2. Bushing Assembly Installation
PUMPS
Figure 5A-1. hydraulic Control Schematic (2105J238)
CONTROL VALVE (36Q384)
Figure 5C- 1. Control Valve Assembly
Figure 5C-2. Control Valve (36Q384)
Figure 5C-4. Control Valve (36Z1077)
Figure 5C-5. Swing Control Valve (36Z1384)
Figure 5C-6. Brake Valve lnstallation (2100J1129)
Figure 5C-7. Brake Valve (36U259)
PRESSURE REGULATING VALVE (36U258)
Figure 5C-8. Pressure Regulating Valve (36U258)
Figure 5C-9. Third Drum Control Valve (36Q372)
COMBINATION CONTROL VALVE (36Q327)
Figure 5D-1. Hydraulic Accumulator and Combination Valve Installation
Figure 5D-2. Accumulator (45U47D1)
Figure 5D-3. Gauging Head lnstallation
Table 5D-1. Troubleshooting Chart
Figure 5D-4. Solenoid Valves (3621349, 36Z1528 and 36Z1423)
SHUTTLE VALVE (36Z1171)
CRAWLER EXTENSION/RETRACTION CYLINDER (38U113)
Figure 5D-5. Actuating Cylinders
Figure 5D-6. Crawler Extension Cylinder (38U113)
Figure 5D-7. Swivel Removal
Figure 5D-8. Swivel (45Z453)
Figure 5D-9. Swing Lock Cylinder (36Z434)
Section VI. SWING SYSTEM AND COMPONENTS
SUBSECTION 6A. SWING SYSTEM
SUBSECTION 6B. HORIZONTAL SWING SHAFTS
Figure 6B-1. Checking Backlash
Figure 6B. Horizontal Swing Shaft (2910J30-5)
Figure 6C-1. Intermediate Swing Shaft (9210J60-3)
ASSEMBLY AND INSTALLATION
TABLE OF CONTENTS
SUBSECTION 6D VERTICAL SWING SHAFTS
Figure 6D-1. Vertical Swing Shaft (2100J1334-1)
ASSEMBLY AND INSTALLATION
Figure 6E-1. Swing Brake Adjustment
360 SWING LOCK (2100J1405)
Figure 6E-2. Swing Brake (2100J992-3)
Figure 6E-3. 360 Swing Lock (2100J1405)
TABLE OF CONTENTS
Figure 6F-1. Swing Clutch (2100J1346-1)
ADJUSTMENT
Figure 6F-2. Swing Clutch Adjustment
SUBSECTION 6G SLEWING RINGS
Figure 6G-1. Slewing Ring (2100J950)
SECTION VII. HOIST SYSTEM AND COMPONENTS
Figure 7A-1. Hoist System
SUBSECTION 7B. DRUMSHAFTS
THIRD DRUMSHAFT (2100J1132-9)
Figure 7B-2. Third Drum (2100J1132-9)
Figure 7B-2. Third Drum (2100J1132-9)
INSPECTION AND REPAIR
SUBSECTION 7C. DRUM BRAKES
Figure 7C-1. Left and Right Drum Brakes (9215J107)
Figure 7C-2. Left and Right Drum Brakes (9215J107)
ADJUSTMENT CHECK
PLANETARY BRAKES (9215J107-14)
Figure 7C-4. Planetary Brake (9215J107-14)
Figure 7C-5. Planetary Brakes (9215J107-14)
Figure 7C-6. Third Drum Brake (2100N464)
ASSEMBLY AND INSTALLATION
Figure 7D-1, Main Drum Clutch (2915J64)
Figure 7D-2. Third Drum Clutch (9215J105-2)
INSPECTION AND REPAIR
TABLE OF CONTENTS
SUBSECTION 7E. DRUM PAWLS
Figure 7E-2. Drum Pawls (2100J1320-1)
Section VIII. BOOM HOIST SYSTEM AND COMPONENTS
SUBSECTION 8A. BOOM HOIST SYSTEM
Figure 8A-2. Boom Hoist Planetary Operation
BOOM HOIST SYSTEM
SUBSECTION 8B. WORM SHAFTS
Figure 8B-1. Worm Shaft (2100H503-1)
BOOM HOIST SHAFT (2100J1132-1 & 5)
ASSEMBLY AND INSTALLATION
Figure 8C-1. Boom Hoist Shaft
Figure 8C-2. Assembly Tool (218T1470)
Figure 8D-1. Boom Hoist Drum Brake (2100N457)
Figure 8D-2. Boom Hoist Planetary Brake (2100N458)
Figure 8D-4. Assembly Bolt
Figure 8D-5. Boom Hoist Brakes (2100J1008-2)
ADJUSTMENTS
SUBSECTION 8E. BOOM HOIST CLUTCHES
Figure 8E-1. Boom Hoist Clutch (9215J105-1)
Figure 8F-1. Spring Bracket Assembly (2100N404)
INSPECTION AND REPAIR
Figure 8F-2. Boom Hoist Pawls (2100J1008-2)
Figure 8F-3. Adjust Boom Hoist Pawls (2100J1008)
ADJUSTMENTS
Section IX. PROPEL SYSTEM AND COMPONENTS
Figure 9A-1. Propel System Components
Figure 9B-1. Propel Transmission with Gauges
Figure 9B-3 Propel Motor
CONTROLLER
TROUBLESHOOTING PROCEDURES
Figure 9B-6. Charge Pump Removal
Figure 9B-9 Motor Charge Relief Valve
Figure 9B-10. Propel Hydraulic Schematic (2105J171)
Table 9B-1. Propel Transmission Troubleshooting
Table 9B-1. Propel Transmission Troubleshooting (Continued)
Figure 9B-13. Removing Bronze Sealrng Ring
Figure 9B-15. Installing Bronze Ring
Figure 9B-19. Relief Valve Removal
Figure 9B-22 High Pressure Relief Valve
Figure 9B-24. Charge Relief Valve Removal
Figure 9B-28. Tension Spring and Capscrew Removal
Figure 9B-29. Cleaning the Air Gap
Figure 9B-30. Propel Controller (45Q39)
Figure 9B-31. Spool installation
Figure 9B-32. Controller Null Adjustment
Figure 9B-33. Pressure Override Valve
Figure 9C-1. Propel Brake Location
Figure 9C-2. Propel Brake (15Z499)
Figure 9C-3. Piston Installation
Figure 9D-1. Propel Gear Case
Figure 9D-2. Bull Gear Removal
Figure 9D-3. Bearing Measurement
Figure 9D-6. Housing Dimension Location
Figure 9D-9. Gear Adapter Assembly Dimension
Figure 9D-11 Bull Gear lnstallation
Figure 9D-12. Propel Gear Case (14Q121)
Figure 9D-13. Propel Gear Case
Figure 9E-1. Crawler Track Adjustment
Figure 9E-2. Crawler Track
Figure 9E-3. Idler Sprocket (2100J968)
CLEANING AND INSPECTION
Figure 9E-4. Drive Sprocket Assembly (2100J2969)
Figure 9E-6. Side Frame Removal
Figure 9E-7. Crawler and Axle Assembly (2100J949)
CRAWLER ROLLER (13Q18D1)
Figure 9E-8, Crawler Roller (13Q18D1)
INSTALLATION
Setion X. ELECTRICAL SYSTEM
SUBSECTION 1OA. ELECTRICAL SYSTEMS
Figure 10A-1 Machinery Electrical Schematic (2101J44 1 of 2)
Figure 10A-1. Machinery Electrical Schematic (2101J44 2 of 2)
Figure 1OA-2. Engine Electrical Schematic (2100J1165-1) DDA4-71T
Figure 10A-3. Floodlight Electrical Schematic (2105J235)
Figure 10B-1. Boom Hoist Limit Switch Adjustment (2100J1005)
KRUEGER LOAD SYSTEM
SUBSECTION 1OC. PROPEL ANTI-STALL CONTROL SYSTEM
Table 10C-1. Propel Anti-Stall Control Troubleshooting
Figure 10C-1. Anti-Stall Control Electrical Schematic
Figure 10C-2 Propel Control Station
Figure 10C-3. Pump Controller
TABLE OF CONTENTS
Figure 10D-1. Starting Motor Cross-sectional View
Troubleshooting
Figure 10D-2. Starting Motor Overcrank Protection
Figure 10D-3. No L o a d T e s t C i r c u i t
Figure 10D-4. Internal Motor Circuit
Figure 10D-5. Internal Solenoid Circuit
Figure 10D-7. Checking Solenoid Pull-in Winding
Figure 10D-8. Checking Pinion Clearance Circuit
Figure 10D-10. Alternator Wiring
Figure 10D-11. Alternator
Figure 10D-12. Output Check
Figure 10D-13. Adjusting Voltage Setting
Figure 10D-14. End View, Cover Removed
REGULATOR REPLACEMENT
Figure 10D-16. Panel Board Assembly
Figure 10D-18. Checking Transistor TR1
Figure 10D-20. Bearing Assembled Between Shaft and Housing
REPAIRS
Figure 10D-21. Throttle Shut Down Solenoid
TABLE OF CONTENTS
SUBSECTION 11A. GENERAL INFORMATION
GENERAL DESCRIPTION
Figure 11A-3. Option Plate
SOLVENT TANK CLEANING
Assembly
Assembly - Continued
OPERATING SPECIFICATIONS
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
SUBSECTION 11B. ENGINE (LESS MAJOR ASSEMBLIES)
Figure 11B-2. Cutaway of Cylinder Block Showing Air and Water Passages
Figure 11B-3. Air Box Covers and Air Inlet Ports
Figure 11B-7. Cleaning Cylinder block
Figure 11B-9. Cylinder Block Prepared for Pressure Test
Figure 11B-10. Honing Bore of Cylinder block
Figure 11B-11. High Pressure Areas on Cylinder Liners
Figure 11B-14. Block Bore Measurement Form
Table 11B-1. Cylinder Bore Clearances
Figure 11B-17. Centerline of Crankshaft to Top of Block
Inspect Cylinder Block
Figure 11B-19. Cylinder Block Markings
Figure 11B-20. Installing Front End Plate
Figure 11B-22. Air Box Drain Tank Installation
Figure 11B-23. Cylinder Head Assembly
Figure 11B-24. Mounting of Cylinder Head
Remove Cylinder Head
Figure 11B-28. Removing or Installing Injector Control Tube
Figure 11B-30. Cylinder Head Prepared for Pressure Test
Figure 11B-31. Checking Bottom Face of Cylinder Head
Figure 11B-33. Correct Installation of Water Nozzles
Figure 11B-34. Cylinder Head Seals and Gaskets
Figure 11B-35. Compression Gasket Mounting in Cylinder Block
Assemble Cylinder Head
Figure 11B-36. Cylinder Head Bolt Tightening Sequence
VALVE AND INJECTOR OPERATING MECHANISM
Remove Rocker Arms and Shaft
Figure 11B-39. Removing Push Rod from Upper Side of Cylinder Head
Figure 11B-42. Push Rod and Lower Spring Seat
Figure 11B-44. Removing or Installing Cam Follower Roller
Figure 11B45. Valve Operating Mechanism
Figure 11B-47. Checking Cam Followerto Guide Clearance
Figure 11B-49. Location of Exhaust Valves
Figure 11B-50. Assembly of Exhaust Valves and Guides
Figure 11B-51. Removing Exhaust Valve Spring
Figure 11B-52. Testing Exhaust Valve Spring
Figure 11B-54. Removing Exhaust Valve Guide
Figure 11B-58. Removing Broken Exhaust Valve Bridge
Figure 11B-60. Installing Valve Seat
Figure 11B-63. Reconditioning Valve Seat Insert
Figure 11B-64. Grinding Wheel Dressing Tool
Exhaust Valve Bridge Adjustment
ENGINE LIFTER BRACKETS
VALVE ROCKER COVER
Figure 11B-69. Valve Rocker Cover Assembly
Inspection
Figure 11B-70. Ridging of Crankshaft
Figure 11B-71. Critical Crankshaft Loading Zones
Figure 11B-72. Crankshaft Fatigue Cracks
Figure 11B-74. Crankshaft Journal Fillets
Figure 11B-77. Checking Crankshaft End Play
CRANKSHAFT OIL SEALS
Figure 11B-79. Crankshaft Front Oil Seal
Figure 11B-82. Crankshaft Rear Oil Seal Mounting
Figure 11B - 83. Use of Rear Oil Seal Spacer or Sleeve on Grooved Crankshaft
CRANKSHAFT MAIN BEARINGS
Figure 11B-87. Removing Main Bearing Cap
Figure 11B-88. Removing Upper Main Bearing Shell
Figure 11B-91. Main Bearing Measurements
Install Main Bearing Shells (Crankshaft in Place)
Figure 11B-94. Main Bearing Cap Marking
Remove Crankshaft Front Cover
Figure 11B-98. Front Cover Tightening Sequence
Inspect Vibration Damper
CRANKSHAFT PULLEY
FLYWHEEL
FLYWHEEL HOUSING
Figure 11B-106. Removing or Installing Flywheel Housing
Figure 11B-107. Flywheel Housing Tightening Sequence (Operation 1)
CROSS-HEAD PISTON
Inspect Piston Rings
Figure 11B-113. Removing or Installing Piston Rings
Figure 11B-114. Checking Fire Ring Groove Using J 24599
Figure 11B-116. Installing Piston Pin
Figure 11B-119. Checking Piston Pin Retainer for Proper Sealing
Install Piston Rings
Figure 11B-124. Piston Ring Installation Instructions
Figure 11B-125. Connecting Rod Details
Figure 11B-126. Magnetic Particle Inspection Limits for Connecting Rod
Figure 11B-127. Dimensional Inspection of Connecting Rods
CONNECTING ROD BEARINGS
Inspection
Description
Figure 11B-129. Cylinder Liner
Liner Measurement
Figure 11B-133. Cylinder Liner Ridge Due to Wear
Fitting Cylinder Liner in Block Bore
Fitting Cylinder Liner in Block Bore - Continued
Figure 11B-136. Cylinder Liner Mounting in Block
Figure 11B-139. Connecting Rod Markings
Figure 11B-140. Installing Cylinder Liner in Cylinder Block
Figure 11B-141. Front Balance Weight Mounting
Gear Train
Engine timing
Figure 11B-145. Pointer Installation for Marking Top-Dead Center
Figure 11B-146. Checking Engine Timing by Measuring Injector Depression
Figure 11B-148. Woodruff Keys for Camshafts
Figure 11B-151. Removing or Installing Shaft Bearing Retainer Bolts
Figure 11B-152. Removing Camshaft With Puller
Figure 11B-154. Checking Cam Lobe Wear
Assemble Camshaft and Balance Balance Shaft
Figure 11B - 157. Comparison of End Bearings and Thrust Washers
Figure 11B-158. Camshaft Plug Installation
CAMSHAFT AND BALANCE SHAFT GEARS
Install Camshaft and Balance Shaft Gears
Figure 11B-161. Replacing Camshaft Gear
Assemble Idler Gear Assembly
Figure 11B-163. Idler Gear Parts
Figure 11B-165. Fixture for Testing Bearing Pre-Load
Install Idler Gear Assembly
CRANKSHAFT TIMING GEAR
Remove and Install Blower Drive Shaft
Figure 11B-170. Blower Drive Support
Assemble Blower Drive Gear and Support
Figure 11B-173. Blower Drive Gear Parts
Figure 11B-176. Balance Weight Cover Mounting
Figure 118-178. Accessory Drive Locations
Figure 11B-180. Accessory Drives
Figure 11B-181. Location of Oil Seal Spacer
Figure 11B-182. Comparison of Current and Former Design Accessory Drive Plates
SHOP NOTE - TROUBLESHOOTING
Figure 11B-183. Using Plastic Strip to Measure Clearances
TROUBLE SHOOTING
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
STUD TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
CYLINDER BLOCK PLUGGING INSTRUCTIONS
CYLINDER BLOCK PLUGGING INSTRUCTIONS - Continued
SERIES 71 FOUR VALVE HEAD PLUGGING CHART
SERIES 71 TWO VALVE CYLINDER HEAD ASSEMBLY INSTRUCTIONS
TABLE OF CONTENTS
SUBSECTION 11C. FUEL SYSTEM AND GOVERNOR
Figure 11C-2. Fuel Injector Assembly
Figure 11C-4. Fuel Metering from No-Load to Full-load
Figure 11C-6. Injector Identification Chart
Figure 11C-8. Removing Injector from Cylinder Head
Figure 11C-9. Check Rack and Plunger for Free Movement
Figure 11C-11. Unusable Injector Plungers
Figure 11C-13. Injector Installed in Tester J 23010
Figure 11C-14. Injector in Position for Testing with J 23010
Figure 11C-15. Injector on Tip Test Adaptor
Figure 11C-16. Adaptor and Tube on Injector Tester
Figure 11C-18. Injector Needle Tester with Auxiliary Tester J 22640
Figure 11C-19. Injector Parts on Auxiliary Tester
Figure 11C-22. Setting Calibrator Stroke Counter
Figure 11C-23. Removing or Installing Filter Cap
Figure 11C-25. Removing Injector Nut
Figure 11C-27. Cleaning Injector Spray Tip
Figure 11C-29. Cleaning Injector Body Ring
Figure 11C-31. Sealing Surfaces which may Require Lapping
Figure 11C-33. Lapping Spray Tips on Lapping Blocks
Figure 11C-36. Detailed Parts of Injector
Figure 11C-37. Injector Plunger and Follower
Figure 11C-39. Tightening Injector Nut with Torque Wrench
Figure 11C-41. Checking Injector Tip Concentricity
Figure 11C-43. Installing Injector Tube
Figure 11C-44. Upsetting Injector Tube
Figure 11C-46. Reaming Injector Tube for Injector Nut
Operation
Figure 11C-50. Typical Fuel Pump Mounting and Drive
Figure 11C-52. Fuel Pump Oil Seal
Figure 11C-54. Removing Oil Seals
Figure 11C-56. Installing Inner Oil Seal
Figure 11C-58. Install Drive Shaft and Gear
Figure 11C-59. Cylinder Head with Integral Fuel Manifolds
VARIABLE SPEED MECHANICAL GOVERNOR
Figure 11C-60. Variable Speed Mechanical Governor
Figure 11C-62. Governor Cover Details
Figure 11C-63. Removing Bearings from Cover Using J 23967-01
Figure 11C-65. Removing Variable Speed Spring Plunger Guide
Figure 11C-68 Governor Weight Housing Details
Figure 11C-70. Installing Needle Bearing in Cover
Assemble Governor Weight Housing
Figure 11C-72. Variable Speed Spring Housing Details
Figure 11C-73. Installing Speed Control Shaft Bearings
Install Governor
Figure 11C-74. Checking Fuel Output
Figure 11C-75. Refreshing Lapping
Figure 11C-76. Injector Rack-To-Gear Timing
Figure 11C-78. Injector Follower
TROUBLESHOOTING
Figure 11C-79. Measuring Fuel Flow
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
TABLE OF CONTENTS
SUBSECTION 11D. AIR INTAKE SYSTEM
Figure 11D-2. Air Flow Through Turbocharger and Blower
Figure 11D-3. Blower Assembly
Remove Blower
Figure 11D-4. Blower Mounting
Figure 11D-6. Removing Blower Rotor Gears
Figure 11D-8. Removing Oil Seal Ring from Carrier
Figure 11D-11. Blower Details
Figure 11D-12. Upper and Lower Rotors and Gears
Figure 11D-14. Installing Oil Seal Ring Carrier on Blower Rotor
Figure 11D-15. Installing Blower Rotor in Rear End Plate
Figure 11D-16. Installing Front End Plate
Figure 11D-18. Installing Ball Bearings on Rotor Shaft
Timing Blower Rotors
Figure 11D-20. Measuring " C C " and "C" Clearances Between Blower Lobes
Figure 11D-22. Shim Locations for Correct Lobe Clearances
Attach Blower to Engine
Figure 11D-24. Turbocharger Assembly
Figure 11D-26. Schematic Air Flow Diagram
Figure 11D-28. Turbocharger Oil Flow Diagram
Figure 11D-29. Inspection Checks for Turbocharger
Periodic Inspection
Disassemble Turbocharger
Figure 11D-30. Turbocharger Details
Figure 11D-31. Turbocharger Holding Fixture
Inspection
Figure 11D-32. Checking Bearing Axial End Play
Figure 11D-33. Checking Shaft Radial Movement
Install Turbocharger
Install Turbocharger - Continued
TROUBLE SHOOTING
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
TABLE OF CONTENTS
SUBSECTION 11E. LUBRICATION SYSTEM
Figure 11E-1. Schematic Diagram of Lubrication System
Figure 11E-2. Blower Lubrication
Figure 11E-3. Oil Pump Mounting
Figure 11E-4. Oil Pump Assembly
Inspect Oil Pump Parts
Figure 1 1 E - 7 . Diameter and Location of Bushing in Oil Pump
Remove Oil Pump Driving Gear from Crankshaft
Figure 11E-11. Measuring Clearance Between Teeth of Oil Pump Gears
LUBRICATING OIL PRESSURE REGULATOR
Assemble Oil Pressure Regulator
Remove Lubricating Oil Cooler
Install Lubricating Oil Cooler
Figure 11E-16. Lubricating Oil Cooler Parts
VENTILATING SYSTEM
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STUD TORQUE SPECIFICATIONS
TABLE OF CONTENTS
SUBSECTION 11F. COOLING SYSTEM
Figure 11F-1. Cooling System With Radiator And Fan
Fill Cooling System
Contaminated Engine
LUBRICATION SYSTEM
Figure 11F-2. Water Pump With Ceramic Insert in Impeller
Figure 11F-6. Removing Pump Drive Coupling with Tool J 1930
Figure 11F-7. Installing Pump Impeller
Figure 11F-8. Impeller Clearance
Figure 11F-9. Water Manifold Mounting
Remove Thermostat
RADIATOR
Remove Radiator
COOLANT PRESSURE CONTROL CAP
Figure 11F-14. Fan and Fan Hub Assembly
Figure 11F-15. Fan Mounting
Figure 11F-17. Fan Hub and Adjusting Bracket Details
Install Fan, Hub and Bracket
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
TABLE OF CONTENTS
SECTION 11G. EXHAUST SYSTEM
Install Exhaust Manifold
TABLE OF CONTENTS
SUBSECTION 11H. ENGINE TUNE-UP
Tune-Up Sequence
Figure 11H-1. Adjusting Valve Clearance
Figure 11H-2. Timing Fuel Injector
Figure 11H-4. Positioning No. 1 Injector Rack Control Lever
Figure 11H-6. Checking Rotating Movement Of Injector Control Rack
Figure 11H-8. Locating of Stops and Shims
ENGINE RUN-IN INSTRUCTIONS
Dynamometer Test and Run-In Procedures
RUN-IN PROCEDURE
Basic Run-In Inspection
ENGINGE OPERATING INSTRUCTIONS
TORQUE CONVERTER
TURBOCHARGER
NORMAL STOPPING
ENGINE TEST REPORT
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI)
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
Section I. GENERAL
Publications
Common Hardware
Section II. MAINTENANCE
Lubrication
Quality Deficiency Report (QDR)
Wire Rope Specification MS132.1T (P&H)
Troops Installed Item List
SECTION III. REPAIR PARTS SUPPLY
Requisitioning Repair Parts
APPENDIX A. MAINTENANCE ALLOCATION CHART FOR CRANE, CRAWLER, 40 TON HARNISCHFEGER MODEL 5060
APPENDIX A. MAINTENANCE ALLOCATION CHART FOR CRANE, CRAWLER, 40 TON HARNISCHFEGER MODEL 5060 - Continued
APPENDIX A, PART 1 MAINTENANCE ALLOCATION CHART CRANE, 40 TON CRAWLER, MDL 5060 P&H 3810-01-145-8288
MAINTENANCE ALLOCATION CHART
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
TOOL AND TEST EQUIPMENT REQUIREMENTS
TOOL AND TEST EQUIPMENT REQUIREMENTS
TOOL AND TEST EQUIPMENT REQUIREMENTS - Continued
APPENDIX B. PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
APPENDIX B. PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONTINUED
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONTINUED
APPENDIX C. ITEMS FURNISHED WITH CRANE
APPENDIX C. Anti-Freeze Collant Require* (in Quarters)
APPENDIX E. MAINTENANCE AND OPERATING SUPPLY LIST
APPENDIX E. MAINTENANCE AND OPERATING SUPPLY LIST - Continued
APPENDIX F. PETROLEUM SUPPLY LIST
Cooling System Treatment
Open Gear and Wire Rope Lubricant (OG)
CONVERSION CHART
Appendix G. Tap Drill Sizes
Appendix G.
APPENDIX H
APPENDIX I. EQUIPMENT PUBLICATIONS
INITIAL RECOMMENDATION PRESCRIBLE LOAD LIST (PLL) AUTHORIZED STOCKAGE LIST (ASL)
INITIAL RECOMMENDATION PRESCRIBLE LOAD LIST (PLL) AUTHORIZED STOCKAGE LIST (ASL) - Continued
APPENDIX K. WARRANTY GUIDELINES
APPENDIX K. WARRANTY GUIDELINES - Continued
APPENDIX K. WARRANTY GUIDELINES - Continued
APPENDIX K. WARRANTY GUIDELINES - Continued
Appendix L. Sample Format - DA Form 2765 Part Number Request
Appendix M. DSS PROJECT CODES
APPENDIX N. SAMPLE FORMAT - MILSTRIP REQUISITION (NSN)
APPENDIX O. SAMPLE FORMAT MILSTRIP REQUISITION FOR (NONNSN)
APPENDIX O. SAMPLE FORMAT MILSTRIP REQUISITION FOR (NONNSN) - Continued
APPENDIX P. SAMPLE FORMAT - MILSTRIP REQUISITION (NON-NSN) (MANUAL)
APPENDIX P. SAMPLE FORMAT - MILSTRIP REQUISITION (NON-NSN) (MANUAL) - Continued
APPENDIX Q. REQUISITION FORMAT
APPENDIX R. NSN FORMAT
APPENDIX S
APPENDIX S - Continued
APPENDIX T
APPENDIX T - Continued
MODEL 5060 LOWER LUBRICATION CHART
APPENDIX T
APPENDIX T - Continued
MODEL 5060 ATTACHMENTS LUBRICATION CHART
APPENDIX T - Continued
WARRANTY
Figure 1-2. Mechanical Train Schematic
Figure 1-3. Crane Terminology
Table 1-2. Liquid Capacity Chart
Figure 1-4. General Dimensions (2105J170)
Table 1-1. English to Metric Conversions
ENGINE SPECIFICATIONS
TABLE 1-2. DRUM PERFORMANCE DATA
TABLE 1-2. DRUM PERFORMANCE DATA (Cont.)
Section II. CONTROLS AND OPERATION
Section II. CONTROLS AND OPERATION
Figure 2-1. Operator's Controls
LEFT DRUM PAWL SWITCH
LEFT DRUM BRAKE SWITCH
Figure 2-2. Load Weighing System
Figure 2-3 Voltmeter Operation
Figure 2-5. Anti-Rotation Bar (2100J1046)
Figure 2-7. Drum Cover
STARTING THE ENGINE
Figure 2-8. Propelling the Machine
Figure 2-9. Axle Locking Bolts and Keepers
Figure 2-10. Liftcrane Operating Cycle
Figure 2-11. Hand Signals for Crane Operation
Figure 2-11.1. Connect Leads
Figure 2-11.3. Raising Hammer
Figure 2-12. Antifreeze Concentration and Temperature
CONTROLS AND OPERATION
Figure 2-14. Angle Meter and Control Panel
TABLE 2-1. PROGRAM SELECTOR SWITCHES
Section III. LUBRICATION
Section IV. UPPER POWER TRAIN
ENGINES
TROUBLESHOOTING PROCEDURES
Figure 4A-1. Locating a Misfiring Cylinder
Table 4A-1. Compression Pressure Comparison
Air Box Pressure
Figure 4A-4. Comparison of Column Height for Mercury and Water Manometers
Troubleshooting Guide
Troubleshooting Guide - Continued
Troubleshooting Guide - Continued
TABLE OF CONTENTS
CLUTCHES
Figure 4B-1. Clutch Adjustment
Table 4B-1. Clutch Actuator Troubleshooting
Figure 4B-2. Clutch Actuator (88U24D1)
TABLE OF CONTENTS
TRANSMISSIONS
Figure 4C-1. Pump Drive (53U84)
CLEANING, INSPECTION AND REPAIR
TORQUE CONVERTER (53Z659)
Figure 4C-2. Oil System - Schematic
Preventative Maintenance
Figure 4C-4. Checking Converter-in Pressure
Table 4C-1. Converter Troubleshooting (Part 1 of 2)
Table 4C-1. Converter Troubleshooting (Part 2 of 2)
Figure 4C-5. Special Tools for Torque Converter Overhaul
Figure 4C-6. Converter Overhaul Stand
Figure 4C-7. Spanner Wrench for Input Disconnect Clutch Lock Nut
Figure 4C-9. Sketch of Puller and Sleeve
Table 4C-3. Special Tools
INSPECTING BUSHING, THRUST WASHERS
Figure 4C-10. Torque Specifications
Figure 4C-12. Removing (or Installing) Freewheel Roller Race Retaining Nut
Figure 4C-13. Removing (or Installing) Lock Strips
Figure 4C-15. Removing Converter Pump Hub and Bearing
Figure 4C-21. Removing Oil Pump Idler Gear Shaft
Figure 4C-22. Removing (or Installing) Oil Pump Idler Gear
Figure 4C-25. Installing Stator Springs and Rollers
Figure 4C-28. Removing (or Installing) Converter Pressure Regulating Valve
Figure 4C-29. Removing (or Installing) Clutch Pressure Regulating Valve
Figure 4C-33. Removing Oil Pump Bearing Sleeve
Figure 4C-34. Exploded View of Input Disconnect Clutch
Assembly
Figure 4C-35. Idler Gear and Bearing Assembly
Figure 4C-37. Checking End Play - Weight Suspended
INSTALLATION
Wear Limits Data
Table 4C-4. Wear Limits Data
Figure 4C-38. Exploded View Converter Housing
Figure 4C-39. Exploded View of Torque Converter
Figure 4C-40. Exploded View of Converter Drive and Sprag Clutch
Figure 4C-41. Exploded View of Charging Oil Pump
Figure 4D-1. Propeller Shaft (10Z563)
Figure 4D-2. Propeller Shaft (10Z553)
PROPELLER SHAFTS
SUBSECTION 4E. CHAINS AND IDLER SHAFTS
Figure 4E-1. Chain Case and Idler Shaft (2100J1389 and 2100J515F1)
Figure 4E-2. Idler Shaft (2100N515F1)
CHAIN TROUBLESHOOTING GUIDE
SECTION V. HYDRAULIC CONTROL SYSTEM
SUBSECTION 5A. HYDRAULIC SYSTEM
GENERAL MAINTENANCE
Chart 5A-1 Excessive Noise
Chart 5A-2 Excessive Heat
Chart 5A-3. Incorrect Flow
Chart 5A-4. Incorrect Pressure
Chart 5A-5. Faulty Operation
SYSTEM DESCRIPTION
PROPEL BRAKE CIRCUIT
Figure 5A-1. Hydraulic Control Schematic (2105J238)
PROPEL BRAKE CIRCUIT
SUBSECTION 5B. PUMPS
Table 5B-1. Pump Troubleshooting
Figure 5B-1. Control Pump (37Z317)
Figure 5B-2. Bushing Assembly Installation
PUMPS
Figure 5A-1. hydraulic Control Schematic (2105J238)
CONTROL VALVE (36Q384)
Figure 5C- 1. Control Valve Assembly
Figure 5C-2. Control Valve (36Q384)
Figure 5C-4. Control Valve (36Z1077)
Figure 5C-5. Swing Control Valve (36Z1384)
Figure 5C-6. Brake Valve lnstallation (2100J1129)
Figure 5C-7. Brake Valve (36U259)
PRESSURE REGULATING VALVE (36U258)
Figure 5C-8. Pressure Regulating Valve (36U258)
Figure 5C-9. Third Drum Control Valve (36Q372)
COMBINATION CONTROL VALVE (36Q327)
Figure 5D-1. Hydraulic Accumulator and Combination Valve Installation
Figure 5D-2. Accumulator (45U47D1)
Figure 5D-3. Gauging Head lnstallation
Table 5D-1. Troubleshooting Chart
Figure 5D-4. Solenoid Valves (3621349, 36Z1528 and 36Z1423)
SHUTTLE VALVE (36Z1171)
CRAWLER EXTENSION/RETRACTION CYLINDER (38U113)
Figure 5D-5. Actuating Cylinders
Figure 5D-6. Crawler Extension Cylinder (38U113)
Figure 5D-7. Swivel Removal
Figure 5D-8. Swivel (45Z453)
Figure 5D-9. Swing Lock Cylinder (36Z434)
Section VI. SWING SYSTEM AND COMPONENTS
SUBSECTION 6A. SWING SYSTEM
SUBSECTION 6B. HORIZONTAL SWING SHAFTS
Figure 6B-1. Checking Backlash
Figure 6B. Horizontal Swing Shaft (2910J30-5)
Figure 6C-1. Intermediate Swing Shaft (9210J60-3)
ASSEMBLY AND INSTALLATION
TABLE OF CONTENTS
SUBSECTION 6D VERTICAL SWING SHAFTS
Figure 6D-1. Vertical Swing Shaft (2100J1334-1)
ASSEMBLY AND INSTALLATION
Figure 6E-1. Swing Brake Adjustment
360 SWING LOCK (2100J1405)
Figure 6E-2. Swing Brake (2100J992-3)
Figure 6E-3. 360 Swing Lock (2100J1405)
TABLE OF CONTENTS
Figure 6F-1. Swing Clutch (2100J1346-1)
ADJUSTMENT
Figure 6F-2. Swing Clutch Adjustment
SUBSECTION 6G SLEWING RINGS
Figure 6G-1. Slewing Ring (2100J950)
SECTION VII. HOIST SYSTEM AND COMPONENTS
Figure 7A-1. Hoist System
SUBSECTION 7B. DRUMSHAFTS
THIRD DRUMSHAFT (2100J1132-9)
Figure 7B-2. Third Drum (2100J1132-9)
Figure 7B-2. Third Drum (2100J1132-9)
INSPECTION AND REPAIR
SUBSECTION 7C. DRUM BRAKES
Figure 7C-1. Left and Right Drum Brakes (9215J107)
Figure 7C-2. Left and Right Drum Brakes (9215J107)
ADJUSTMENT CHECK
PLANETARY BRAKES (9215J107-14)
Figure 7C-4. Planetary Brake (9215J107-14)
Figure 7C-5. Planetary Brakes (9215J107-14)
Figure 7C-6. Third Drum Brake (2100N464)
ASSEMBLY AND INSTALLATION
Figure 7D-1, Main Drum Clutch (2915J64)
Figure 7D-2. Third Drum Clutch (9215J105-2)
INSPECTION AND REPAIR
TABLE OF CONTENTS
SUBSECTION 7E. DRUM PAWLS
Figure 7E-2. Drum Pawls (2100J1320-1)
Section VIII. BOOM HOIST SYSTEM AND COMPONENTS
SUBSECTION 8A. BOOM HOIST SYSTEM
Figure 8A-2. Boom Hoist Planetary Operation
BOOM HOIST SYSTEM
SUBSECTION 8B. WORM SHAFTS
Figure 8B-1. Worm Shaft (2100H503-1)
BOOM HOIST SHAFT (2100J1132-1 & 5)
ASSEMBLY AND INSTALLATION
Figure 8C-1. Boom Hoist Shaft
Figure 8C-2. Assembly Tool (218T1470)
Figure 8D-1. Boom Hoist Drum Brake (2100N457)
Figure 8D-2. Boom Hoist Planetary Brake (2100N458)
Figure 8D-4. Assembly Bolt
Figure 8D-5. Boom Hoist Brakes (2100J1008-2)
ADJUSTMENTS
SUBSECTION 8E. BOOM HOIST CLUTCHES
Figure 8E-1. Boom Hoist Clutch (9215J105-1)
Figure 8F-1. Spring Bracket Assembly (2100N404)
INSPECTION AND REPAIR
Figure 8F-2. Boom Hoist Pawls (2100J1008-2)
Figure 8F-3. Adjust Boom Hoist Pawls (2100J1008)
ADJUSTMENTS
Section IX. PROPEL SYSTEM AND COMPONENTS
Figure 9A-1. Propel System Components
Figure 9B-1. Propel Transmission with Gauges
Figure 9B-3 Propel Motor
CONTROLLER
TROUBLESHOOTING PROCEDURES
Figure 9B-6. Charge Pump Removal
Figure 9B-9 Motor Charge Relief Valve
Figure 9B-10. Propel Hydraulic Schematic (2105J171)
Table 9B-1. Propel Transmission Troubleshooting
Table 9B-1. Propel Transmission Troubleshooting (Continued)
Figure 9B-13. Removing Bronze Sealrng Ring
Figure 9B-15. Installing Bronze Ring
Figure 9B-19. Relief Valve Removal
Figure 9B-22 High Pressure Relief Valve
Figure 9B-24. Charge Relief Valve Removal
Figure 9B-28. Tension Spring and Capscrew Removal
Figure 9B-29. Cleaning the Air Gap
Figure 9B-30. Propel Controller (45Q39)
Figure 9B-31. Spool installation
Figure 9B-32. Controller Null Adjustment
Figure 9B-33. Pressure Override Valve
Figure 9C-1. Propel Brake Location
Figure 9C-2. Propel Brake (15Z499)
Figure 9C-3. Piston Installation
Figure 9D-1. Propel Gear Case
Figure 9D-2. Bull Gear Removal
Figure 9D-3. Bearing Measurement
Figure 9D-6. Housing Dimension Location
Figure 9D-9. Gear Adapter Assembly Dimension
Figure 9D-11 Bull Gear lnstallation
Figure 9D-12. Propel Gear Case (14Q121)
Figure 9D-13. Propel Gear Case
Figure 9E-1. Crawler Track Adjustment
Figure 9E-2. Crawler Track
Figure 9E-3. Idler Sprocket (2100J968)
CLEANING AND INSPECTION
Figure 9E-4. Drive Sprocket Assembly (2100J2969)
Figure 9E-6. Side Frame Removal
Figure 9E-7. Crawler and Axle Assembly (2100J949)
CRAWLER ROLLER (13Q18D1)
Figure 9E-8, Crawler Roller (13Q18D1)
INSTALLATION
Setion X. ELECTRICAL SYSTEM
SUBSECTION 1OA. ELECTRICAL SYSTEMS
Figure 10A-1 Machinery Electrical Schematic (2101J44 1 of 2)
Figure 10A-1. Machinery Electrical Schematic (2101J44 2 of 2)
Figure 1OA-2. Engine Electrical Schematic (2100J1165-1) DDA4-71T
Figure 10A-3. Floodlight Electrical Schematic (2105J235)
Figure 10B-1. Boom Hoist Limit Switch Adjustment (2100J1005)
KRUEGER LOAD SYSTEM
SUBSECTION 1OC. PROPEL ANTI-STALL CONTROL SYSTEM
Table 10C-1. Propel Anti-Stall Control Troubleshooting
Figure 10C-1. Anti-Stall Control Electrical Schematic
Figure 10C-2 Propel Control Station
Figure 10C-3. Pump Controller
TABLE OF CONTENTS
Figure 10D-1. Starting Motor Cross-sectional View
Troubleshooting
Figure 10D-2. Starting Motor Overcrank Protection
Figure 10D-3. No L o a d T e s t C i r c u i t
Figure 10D-4. Internal Motor Circuit
Figure 10D-5. Internal Solenoid Circuit
Figure 10D-7. Checking Solenoid Pull-in Winding
Figure 10D-8. Checking Pinion Clearance Circuit
Figure 10D-10. Alternator Wiring
Figure 10D-11. Alternator
Figure 10D-12. Output Check
Figure 10D-13. Adjusting Voltage Setting
Figure 10D-14. End View, Cover Removed
REGULATOR REPLACEMENT
Figure 10D-16. Panel Board Assembly
Figure 10D-18. Checking Transistor TR1
Figure 10D-20. Bearing Assembled Between Shaft and Housing
REPAIRS
Figure 10D-21. Throttle Shut Down Solenoid
TABLE OF CONTENTS
SUBSECTION 11A. GENERAL INFORMATION
GENERAL DESCRIPTION
Figure 11A-3. Option Plate
SOLVENT TANK CLEANING
Assembly
Assembly - Continued
OPERATING SPECIFICATIONS
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
SUBSECTION 11B. ENGINE (LESS MAJOR ASSEMBLIES)
Figure 11B-2. Cutaway of Cylinder Block Showing Air and Water Passages
Figure 11B-3. Air Box Covers and Air Inlet Ports
Figure 11B-7. Cleaning Cylinder block
Figure 11B-9. Cylinder Block Prepared for Pressure Test
Figure 11B-10. Honing Bore of Cylinder block
Figure 11B-11. High Pressure Areas on Cylinder Liners
Figure 11B-14. Block Bore Measurement Form
Table 11B-1. Cylinder Bore Clearances
Figure 11B-17. Centerline of Crankshaft to Top of Block
Inspect Cylinder Block
Figure 11B-19. Cylinder Block Markings
Figure 11B-20. Installing Front End Plate
Figure 11B-22. Air Box Drain Tank Installation
Figure 11B-23. Cylinder Head Assembly
Figure 11B-24. Mounting of Cylinder Head
Remove Cylinder Head
Figure 11B-28. Removing or Installing Injector Control Tube
Figure 11B-30. Cylinder Head Prepared for Pressure Test
Figure 11B-31. Checking Bottom Face of Cylinder Head
Figure 11B-33. Correct Installation of Water Nozzles
Figure 11B-34. Cylinder Head Seals and Gaskets
Figure 11B-35. Compression Gasket Mounting in Cylinder Block
Assemble Cylinder Head
Figure 11B-36. Cylinder Head Bolt Tightening Sequence
VALVE AND INJECTOR OPERATING MECHANISM
Remove Rocker Arms and Shaft
Figure 11B-39. Removing Push Rod from Upper Side of Cylinder Head
Figure 11B-42. Push Rod and Lower Spring Seat
Figure 11B-44. Removing or Installing Cam Follower Roller
Figure 11B45. Valve Operating Mechanism
Figure 11B-47. Checking Cam Followerto Guide Clearance
Figure 11B-49. Location of Exhaust Valves
Figure 11B-50. Assembly of Exhaust Valves and Guides
Figure 11B-51. Removing Exhaust Valve Spring
Figure 11B-52. Testing Exhaust Valve Spring
Figure 11B-54. Removing Exhaust Valve Guide
Figure 11B-58. Removing Broken Exhaust Valve Bridge
Figure 11B-60. Installing Valve Seat
Figure 11B-63. Reconditioning Valve Seat Insert
Figure 11B-64. Grinding Wheel Dressing Tool
Exhaust Valve Bridge Adjustment
ENGINE LIFTER BRACKETS
VALVE ROCKER COVER
Figure 11B-69. Valve Rocker Cover Assembly
Inspection
Figure 11B-70. Ridging of Crankshaft
Figure 11B-71. Critical Crankshaft Loading Zones
Figure 11B-72. Crankshaft Fatigue Cracks
Figure 11B-74. Crankshaft Journal Fillets
Figure 11B-77. Checking Crankshaft End Play
CRANKSHAFT OIL SEALS
Figure 11B-79. Crankshaft Front Oil Seal
Figure 11B-82. Crankshaft Rear Oil Seal Mounting
Figure 11B - 83. Use of Rear Oil Seal Spacer or Sleeve on Grooved Crankshaft
CRANKSHAFT MAIN BEARINGS
Figure 11B-87. Removing Main Bearing Cap
Figure 11B-88. Removing Upper Main Bearing Shell
Figure 11B-91. Main Bearing Measurements
Install Main Bearing Shells (Crankshaft in Place)
Figure 11B-94. Main Bearing Cap Marking
Remove Crankshaft Front Cover
Figure 11B-98. Front Cover Tightening Sequence
Inspect Vibration Damper
CRANKSHAFT PULLEY
FLYWHEEL
FLYWHEEL HOUSING
Figure 11B-106. Removing or Installing Flywheel Housing
Figure 11B-107. Flywheel Housing Tightening Sequence (Operation 1)
CROSS-HEAD PISTON
Inspect Piston Rings
Figure 11B-113. Removing or Installing Piston Rings
Figure 11B-114. Checking Fire Ring Groove Using J 24599
Figure 11B-116. Installing Piston Pin
Figure 11B-119. Checking Piston Pin Retainer for Proper Sealing
Install Piston Rings
Figure 11B-124. Piston Ring Installation Instructions
Figure 11B-125. Connecting Rod Details
Figure 11B-126. Magnetic Particle Inspection Limits for Connecting Rod
Figure 11B-127. Dimensional Inspection of Connecting Rods
CONNECTING ROD BEARINGS
Inspection
Description
Figure 11B-129. Cylinder Liner
Liner Measurement
Figure 11B-133. Cylinder Liner Ridge Due to Wear
Fitting Cylinder Liner in Block Bore
Fitting Cylinder Liner in Block Bore - Continued
Figure 11B-136. Cylinder Liner Mounting in Block
Figure 11B-139. Connecting Rod Markings
Figure 11B-140. Installing Cylinder Liner in Cylinder Block
Figure 11B-141. Front Balance Weight Mounting
Gear Train
Engine timing
Figure 11B-145. Pointer Installation for Marking Top-Dead Center
Figure 11B-146. Checking Engine Timing by Measuring Injector Depression
Figure 11B-148. Woodruff Keys for Camshafts
Figure 11B-151. Removing or Installing Shaft Bearing Retainer Bolts
Figure 11B-152. Removing Camshaft With Puller
Figure 11B-154. Checking Cam Lobe Wear
Assemble Camshaft and Balance Balance Shaft
Figure 11B - 157. Comparison of End Bearings and Thrust Washers
Figure 11B-158. Camshaft Plug Installation
CAMSHAFT AND BALANCE SHAFT GEARS
Install Camshaft and Balance Shaft Gears
Figure 11B-161. Replacing Camshaft Gear
Assemble Idler Gear Assembly
Figure 11B-163. Idler Gear Parts
Figure 11B-165. Fixture for Testing Bearing Pre-Load
Install Idler Gear Assembly
CRANKSHAFT TIMING GEAR
Remove and Install Blower Drive Shaft
Figure 11B-170. Blower Drive Support
Assemble Blower Drive Gear and Support
Figure 11B-173. Blower Drive Gear Parts
Figure 11B-176. Balance Weight Cover Mounting
Figure 118-178. Accessory Drive Locations
Figure 11B-180. Accessory Drives
Figure 11B-181. Location of Oil Seal Spacer
Figure 11B-182. Comparison of Current and Former Design Accessory Drive Plates
SHOP NOTE - TROUBLESHOOTING
Figure 11B-183. Using Plastic Strip to Measure Clearances
TROUBLE SHOOTING
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
STUD TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
CYLINDER BLOCK PLUGGING INSTRUCTIONS
CYLINDER BLOCK PLUGGING INSTRUCTIONS - Continued
SERIES 71 FOUR VALVE HEAD PLUGGING CHART
SERIES 71 TWO VALVE CYLINDER HEAD ASSEMBLY INSTRUCTIONS
TABLE OF CONTENTS
SUBSECTION 11C. FUEL SYSTEM AND GOVERNOR
Figure 11C-2. Fuel Injector Assembly
Figure 11C-4. Fuel Metering from No-Load to Full-load
Figure 11C-6. Injector Identification Chart
Figure 11C-8. Removing Injector from Cylinder Head
Figure 11C-9. Check Rack and Plunger for Free Movement
Figure 11C-11. Unusable Injector Plungers
Figure 11C-13. Injector Installed in Tester J 23010
Figure 11C-14. Injector in Position for Testing with J 23010
Figure 11C-15. Injector on Tip Test Adaptor
Figure 11C-16. Adaptor and Tube on Injector Tester
Figure 11C-18. Injector Needle Tester with Auxiliary Tester J 22640
Figure 11C-19. Injector Parts on Auxiliary Tester
Figure 11C-22. Setting Calibrator Stroke Counter
Figure 11C-23. Removing or Installing Filter Cap
Figure 11C-25. Removing Injector Nut
Figure 11C-27. Cleaning Injector Spray Tip
Figure 11C-29. Cleaning Injector Body Ring
Figure 11C-31. Sealing Surfaces which may Require Lapping
Figure 11C-33. Lapping Spray Tips on Lapping Blocks
Figure 11C-36. Detailed Parts of Injector
Figure 11C-37. Injector Plunger and Follower
Figure 11C-39. Tightening Injector Nut with Torque Wrench
Figure 11C-41. Checking Injector Tip Concentricity
Figure 11C-43. Installing Injector Tube
Figure 11C-44. Upsetting Injector Tube
Figure 11C-46. Reaming Injector Tube for Injector Nut
Operation
Figure 11C-50. Typical Fuel Pump Mounting and Drive
Figure 11C-52. Fuel Pump Oil Seal
Figure 11C-54. Removing Oil Seals
Figure 11C-56. Installing Inner Oil Seal
Figure 11C-58. Install Drive Shaft and Gear
Figure 11C-59. Cylinder Head with Integral Fuel Manifolds
VARIABLE SPEED MECHANICAL GOVERNOR
Figure 11C-60. Variable Speed Mechanical Governor
Figure 11C-62. Governor Cover Details
Figure 11C-63. Removing Bearings from Cover Using J 23967-01
Figure 11C-65. Removing Variable Speed Spring Plunger Guide
Figure 11C-68 Governor Weight Housing Details
Figure 11C-70. Installing Needle Bearing in Cover
Assemble Governor Weight Housing
Figure 11C-72. Variable Speed Spring Housing Details
Figure 11C-73. Installing Speed Control Shaft Bearings
Install Governor
Figure 11C-74. Checking Fuel Output
Figure 11C-75. Refreshing Lapping
Figure 11C-76. Injector Rack-To-Gear Timing
Figure 11C-78. Injector Follower
TROUBLESHOOTING
Figure 11C-79. Measuring Fuel Flow
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
TABLE OF CONTENTS
SUBSECTION 11D. AIR INTAKE SYSTEM
Figure 11D-2. Air Flow Through Turbocharger and Blower
Figure 11D-3. Blower Assembly
Remove Blower
Figure 11D-4. Blower Mounting
Figure 11D-6. Removing Blower Rotor Gears
Figure 11D-8. Removing Oil Seal Ring from Carrier
Figure 11D-11. Blower Details
Figure 11D-12. Upper and Lower Rotors and Gears
Figure 11D-14. Installing Oil Seal Ring Carrier on Blower Rotor
Figure 11D-15. Installing Blower Rotor in Rear End Plate
Figure 11D-16. Installing Front End Plate
Figure 11D-18. Installing Ball Bearings on Rotor Shaft
Timing Blower Rotors
Figure 11D-20. Measuring " C C " and "C" Clearances Between Blower Lobes
Figure 11D-22. Shim Locations for Correct Lobe Clearances
Attach Blower to Engine
Figure 11D-24. Turbocharger Assembly
Figure 11D-26. Schematic Air Flow Diagram
Figure 11D-28. Turbocharger Oil Flow Diagram
Figure 11D-29. Inspection Checks for Turbocharger
Periodic Inspection
Disassemble Turbocharger
Figure 11D-30. Turbocharger Details
Figure 11D-31. Turbocharger Holding Fixture
Inspection
Figure 11D-32. Checking Bearing Axial End Play
Figure 11D-33. Checking Shaft Radial Movement
Install Turbocharger
Install Turbocharger - Continued
TROUBLE SHOOTING
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
TABLE OF CONTENTS
SUBSECTION 11E. LUBRICATION SYSTEM
Figure 11E-1. Schematic Diagram of Lubrication System
Figure 11E-2. Blower Lubrication
Figure 11E-3. Oil Pump Mounting
Figure 11E-4. Oil Pump Assembly
Inspect Oil Pump Parts
Figure 1 1 E - 7 . Diameter and Location of Bushing in Oil Pump
Remove Oil Pump Driving Gear from Crankshaft
Figure 11E-11. Measuring Clearance Between Teeth of Oil Pump Gears
LUBRICATING OIL PRESSURE REGULATOR
Assemble Oil Pressure Regulator
Remove Lubricating Oil Cooler
Install Lubricating Oil Cooler
Figure 11E-16. Lubricating Oil Cooler Parts
VENTILATING SYSTEM
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STUD TORQUE SPECIFICATIONS
TABLE OF CONTENTS
SUBSECTION 11F. COOLING SYSTEM
Figure 11F-1. Cooling System With Radiator And Fan
Fill Cooling System
Contaminated Engine
LUBRICATION SYSTEM
Figure 11F-2. Water Pump With Ceramic Insert in Impeller
Figure 11F-6. Removing Pump Drive Coupling with Tool J 1930
Figure 11F-7. Installing Pump Impeller
Figure 11F-8. Impeller Clearance
Figure 11F-9. Water Manifold Mounting
Remove Thermostat
RADIATOR
Remove Radiator
COOLANT PRESSURE CONTROL CAP
Figure 11F-14. Fan and Fan Hub Assembly
Figure 11F-15. Fan Mounting
Figure 11F-17. Fan Hub and Adjusting Bracket Details
Install Fan, Hub and Bracket
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
TABLE OF CONTENTS
SECTION 11G. EXHAUST SYSTEM
Install Exhaust Manifold
TABLE OF CONTENTS
SUBSECTION 11H. ENGINE TUNE-UP
Tune-Up Sequence
Figure 11H-1. Adjusting Valve Clearance
Figure 11H-2. Timing Fuel Injector
Figure 11H-4. Positioning No. 1 Injector Rack Control Lever
Figure 11H-6. Checking Rotating Movement Of Injector Control Rack
Figure 11H-8. Locating of Stops and Shims
ENGINE RUN-IN INSTRUCTIONS
Dynamometer Test and Run-In Procedures
RUN-IN PROCEDURE
Basic Run-In Inspection
ENGINGE OPERATING INSTRUCTIONS
TORQUE CONVERTER
TURBOCHARGER
NORMAL STOPPING
ENGINE TEST REPORT
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI)
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
SECTION XII. SUPPLEMENTAL OPERATING, MAINTENANCE AND REPAIR PARTS INSTRUCTIONS (SOMARPI) - Continued
Section I. GENERAL
Publications
Common Hardware
Section II. MAINTENANCE
Lubrication
Quality Deficiency Report (QDR)
Wire Rope Specification MS132.1T (P&H)
Troops Installed Item List
SECTION III. REPAIR PARTS SUPPLY
Requisitioning Repair Parts
APPENDIX A. MAINTENANCE ALLOCATION CHART FOR CRANE, CRAWLER, 40 TON HARNISCHFEGER MODEL 5060
APPENDIX A. MAINTENANCE ALLOCATION CHART FOR CRANE, CRAWLER, 40 TON HARNISCHFEGER MODEL 5060 - Continued
APPENDIX A, PART 1 MAINTENANCE ALLOCATION CHART CRANE, 40 TON CRAWLER, MDL 5060 P&H 3810-01-145-8288
MAINTENANCE ALLOCATION CHART
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
MAINTENANCE ALLOCATION CHART - Continued
TOOL AND TEST EQUIPMENT REQUIREMENTS
TOOL AND TEST EQUIPMENT REQUIREMENTS
TOOL AND TEST EQUIPMENT REQUIREMENTS - Continued
APPENDIX B. PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
APPENDIX B. PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES - Continued
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONTINUED
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONTINUED
APPENDIX C. ITEMS FURNISHED WITH CRANE
APPENDIX C. Anti-Freeze Collant Require* (in Quarters)
APPENDIX E. MAINTENANCE AND OPERATING SUPPLY LIST
APPENDIX E. MAINTENANCE AND OPERATING SUPPLY LIST - Continued
APPENDIX F. PETROLEUM SUPPLY LIST
Cooling System Treatment
Open Gear and Wire Rope Lubricant (OG)
CONVERSION CHART
Appendix G. Tap Drill Sizes
Appendix G.
APPENDIX H
APPENDIX I. EQUIPMENT PUBLICATIONS
INITIAL RECOMMENDATION PRESCRIBLE LOAD LIST (PLL) AUTHORIZED STOCKAGE LIST (ASL)
INITIAL RECOMMENDATION PRESCRIBLE LOAD LIST (PLL) AUTHORIZED STOCKAGE LIST (ASL) - Continued
APPENDIX K. WARRANTY GUIDELINES
APPENDIX K. WARRANTY GUIDELINES - Continued
APPENDIX K. WARRANTY GUIDELINES - Continued
APPENDIX K. WARRANTY GUIDELINES - Continued
Appendix L. Sample Format - DA Form 2765 Part Number Request
Appendix M. DSS PROJECT CODES
APPENDIX N. SAMPLE FORMAT - MILSTRIP REQUISITION (NSN)
APPENDIX O. SAMPLE FORMAT MILSTRIP REQUISITION FOR (NONNSN)
APPENDIX O. SAMPLE FORMAT MILSTRIP REQUISITION FOR (NONNSN) - Continued
APPENDIX P. SAMPLE FORMAT - MILSTRIP REQUISITION (NON-NSN) (MANUAL)
APPENDIX P. SAMPLE FORMAT - MILSTRIP REQUISITION (NON-NSN) (MANUAL) - Continued
APPENDIX Q. REQUISITION FORMAT
APPENDIX R. NSN FORMAT
APPENDIX S
APPENDIX S - Continued
APPENDIX T
APPENDIX T - Continued
MODEL 5060 LOWER LUBRICATION CHART
APPENDIX T
APPENDIX T - Continued
MODEL 5060 ATTACHMENTS LUBRICATION CHART
APPENDIX T - Continued
