Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Cranes 150A, 150FA, with all the technical information to maintain, diagnose, repair, service like professional mechanics.
Komatsu Hydraulic Cranes 150A, 150FA workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBD001400 – Hydraulic Crane 150A, 150FA Shop Manual (SN 10828 & up).pdf
SMC-150FA – Hydraulic Crane 150A, 150FA Shop Manual (SN ~09695 – 10827).pdf
PRODUCT DETAILS:
Total Pages: 756 + 974 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
00 INTRODUCTION . . 00-1
01 GENERAL . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . 30-1
90 OTHER . . 90-1
CEBD001400 – Hydraulic Crane 150A, 150FA Shop Manual (SN 10828 & up)….2
COVER….2
CONTENTS….3
00 INTRODUCTION….2
SAFETY….6
SAFETY NOTICE….6
IMPORTANT SAFETY NOTICE….6
GENERAL PRECAUTIONS….6
PREPARATIONS FOR WORK….6
PRECAUTIONS DURING WORK….7
ASBESTOS AND NON-ASBESTOS FIBERS….8
GENERAL….11
HOW TO READ THE SHOP MANUAL….12
VOLUMES….12
DISTRIBUTION AND UPDATING….12
FILING METHOD….12
REVISED EDITION MARK….12
REVISIONS….12
SYMBOLS….12
GENERAL MACHINE HOISTING INSTRUCTIONS….13
GENERAL MACHINE HOISTING….13
GENERAL MACHINE WIRE ROPES….13
COATING MATERIALS….14
STANDARD TIGHTENING TORQUE FOR METRIC….16
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS….16
TIGHTENING TORQUE OF HOSE NUTS….17
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS….17
TIGHTENING TORQUE FOR FLARED NUTS….17
STANDARD TIGHTENING TORQUE FOR STANDARD ENGLISH….18
BOLT IDENTIFICATION CHART….18
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE….18
TYPE 8 PHOSPHATE COATED HARDWARE….20
TORQUE VALUES FOR HOSE CLAMPS….20
TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS….21
TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS….21
ELECTRIC WIRE CODE….22
CLASSIFICATION BY THICKNESS….22
CLASSIFICATION BY COLOR AND CODE….22
CONVERSION TABLES….23
METHOD OF USING THE CONVERSION TABLE….23
01 GENERAL….30
GENERAL ASSEMBLY DRAWING….31
FUEL, COOLANT, AND LUBRICANTS….34
ACCORDING TO AMBIENT TEMPERATURE….34
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….34
ENGINE OIL SPECIFICATIONS….36
NORMAL OPERATION….36
ARCTIC OPERATION….36
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, AND HYDRAULIC SYSTEM OIL SPECIFICATIONS….37
REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS….37
DIESEL FUEL SPECIFICATIONS….37
COOLANT SPECIFICATIONS….38
GENERAL….38
WATER….38
ANTIFREEZE….38
SUPPLEMENTAL COOLANT ADDITIVES….40
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES….40
COOLANT TESTING FOR CONDITIONER CONCENTRATION….40
REPLENISHING COOLANT CONDITIONER….40
SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE….41
COOLING SYSTEM TEST KIT….43
10 STRUCTURE AND FUNCTION….44
WIRE ROPE….46
WIRE ROPE SPECIFICATIONS….46
MAINTENANCE RECOMMENDATIONS….46
TRANSMISSION – T20000….47
SPECIFICATIONS….48
OPERATION….51
POWERFLOWS….56
GEAR AND CLUTCH LAY-OUT….62
SECTIONAL VIEWS….63
CONVERTER HOUSING….63
TRANSMISSION CASE AND REAR COVER….65
TURBINE SHAFT….67
DRIVE PLATE….69
TORQUE CONVERTER….71
AUXLIARY PUMP DRIVE….73
PUMP DRIVE….75
FORWARD SHAFT….77
REVERSE AND 2ND SHAFT….79
REVERSE IDLER….81
LOW SPEED SHAFT….83
3RD SHAFT….85
IDLER SHAFT….87
OUTPUT SHAFT….89
HI & LOW RANGE SHIFT CONTROL….91
CHARGING PUMP & FILTER….93
TRANSMISSION CONTROL VALVE (MANUAL)….95
TRANSMISSION – HR18000….97
SPECIFICATIONS….99
HR18000 CONVERTER….101
HR18000 LONG DROP CONVERTER AND TRANSMISSION CASE….103
CONTROL VALVE….105
6 SPEED CLUTCH AND GEAR….107
REAR VIEW….110
POWER FLOW….111
LOW RANGE….111
HIGH RANGE….112
CLUTCH AND GEAR ARRANGEMENT….114
STEERING CONTROL VALVE….115
TYPICAL OIL FLOW….117
OPERATION….118
DESIGN AND FUNCTION….119
CONTROL VALVE….120
METERING SECTION….120
ROTOR OPERATION IN THE ROTOR SET….120
POWER STEERING OPERATION….121
MANUAL STEERING OPERATION….121
BRAKE VALVE – MASTER….122
MASTER CYLINDER SECTION….122
POWER ASSIST SECTION….122
BRAKE VALVE – EXPLODED VIEW….123
HYDRAULIC PUMP….125
DUAL TANDEM….125
EXPLODED VIEW….125
DUAL TANDEM PUMP CUTAWAY VIEW….126
SWING DRIVE MOTOR….127
EXPLODED VIEW….127
HOIST/WINCH MOTOR….128
EXPLODED VIEW….128
AUXILIARY HOIST MOTOR….129
EXPLODED VIEW….129
PARKING BRAKE….131
SERVICE BRAKE….132
AXLES….133
DIFFERENTIAL….133
PLANETARY AXLE WHEEL ENDS….137
SENSORS….140
BACKUP ALARM PRESSURE SWITCH….140
FUEL LEVEL SENDER….140
TORQUE CONVERTER OIL TEMPERATURE SENDER….141
ENGINE WATER TEMPERATURE SENDER….141
ENGINE OIL PRESSURE SENDER….141
NEUTRAL START SWITCH….142
BRAKE LIGHT OIL PRESSURE SWITCH….142
ENGINE HIGH WATER TEMPERATURE SWITCH (OPTION)….143
ENGINE LOW OIL PRESSURE SWITCH (OPTION)….143
REAR STEERING INDICATOR LIGHT SWITCH….144
TOWING THE CRANE….145
FRONT DRIVELINE….145
REAR DRIVELINE….145
20 TESTING, ADJUSTING AND TROUBLESHOOTING….146
TANDEM PUMP….148
WEAR CONSIDERATIONS IN CS & S PUMPS….148
TEST PROCEDURE FOR REBUILT PUMP….148
WINCH MOTOR….150
INSPECTION & REPLACEMENT….150
CLEANING….151
WINCH SPOOLING ADJUSTMENT….151
PROCEDURE FOR CORRECTING WINCH SPOOLING BY ROTATING AND SHIMMING….152
ROTATING PROCEDURE:….152
SHIMMING PROCEDURE:….153
HOIST AND SWING BRAKE CHECKS AND ADJUSTMENTS….154
HOIST BRAKE CHECKS AND ADJUSTMENTS….154
PRIMARY MANIFOLD….156
CLEANING AND INSPECTION….156
SECONDARY MANIFOLD….156
CLEANING AND INSPECTION….156
TESTING AND TROUBLESHOOTING….156
SWING DRIVE BEARING & GEAR ASSEMBLY WEAR TOLERANCE….157
PERMISSIBLE BEARING CLEARANCES….157
PROCEDURE FOR CLEARANCE MEASUREMENT….158
STEERING CONTROL VALVE….161
INSPECTION AND REPLACEMENT….162
FILLING AND AIR BLEEDING THE SYSTEM WHEN DRAINED OF OIL….164
HYDRAULIC FLUID….164
TIPS FOR MAINTAINING THE HYDROSTATIC STEERING SYSTEM….165
BRAKE VALVE….166
PRESSURE BLEEDING INSTRUCTIONS….166
BENCH BLEEDING INSTRUCTIONS….167
SPRING MOTORS….168
ADJUSTMENT….168
HEAD & HOOK BLOCK INSPECTION….169
HEAD….169
SHEAVES AND DRUM….169
HOOK BLOCK INSPECTION….169
DAILY/10 HOUR INSPECTION….169
ANNUAL/500 HOUR INSPECTION….170
WIRE ROPE….171
RESTING HOOK BLOCK….171
IMPORTANCE OF LUBRICATION….171
RECONNECTED LUBRICANTS FOR WIRE ROPE….172
METHODS OF LUBRICATION….172
LUBRICATION IN STORAGE….173
IDLE ROPES….173
INSPECTION OF WIRE ROPE, SHEAVES AND DRUM….174
BREAKING IN WIRE ROPE….175
RESETTABLE CIRCUIT BREAKERS….176
TROUBLESHOOTING….178
ALTERNATORS….180
PRELIMINARY CHECKS….180
LUBRICATION….183
CRANKING MOTOR….184
PRELIMINARY CHECKS….184
LUBRICATION….186
WIRE ROPE….187
HR18000 TRANSMISSION….188
PRESSURE CHECK POINTS….189
3 SPEED CLUTCH AND GEAR ARRANGEMENT….190
T20000 TRANSMISSION….191
STALL TEST….191
PRESSURE CHECKS….191
MECHANICAL AND ELECTRICAL CHECKS….192
HYDRAULIC CHECKS….192
GUIDE….193
CHECK POINTS….194
HYDRAULIC….197
HYDRAULIC PEDESTAL CRANE….197
INTRODUCTION TO THE HYDRAULIC SYSTEM….197
50 GPM CIRCUIT….199
50 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 30 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….199
30 GPM CIRCUIT….200
30 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 50 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….201
FRONT STEERING – SLOW, HARD OR STOPPED WHEN 30 AND 50 GPM SYSTEMS ARE FUNCTIONING PROPERLY….202
RAPID WARMUP OF HYDRAULIC SYSTEM….202
SWING DRIVE CIRCUIT….203
SWING DRIFTS AFTER CONTROL VALVE HAS BEEN RETURNED TO NEUTRAL….203
SWING RUNS AWAY WHILE SWINGING DOWN HILL WITH LOAD….204
SWING REFUSES TO ROTATE, WHEN OTHER 30 GPM CONTROLS FUNCTION NORMALLY….204
SWING ERRATIC AND JERKY IN OPERATION….205
BOOM LIFT CYLINDER….206
BOOM LIFT CYLINDER DRIFTS WITH HYDRAULIC CONTROL VALVE IN THE NEUTRAL POSITION….206
BOOM DROPS MOMENTARILY WHEN CONTROL IS MOVED FROM NEUTRAL TO RAISE….207
BOOM LIFT CYLINDER REFUSES TO LOWER….207
CROWD CYLINDER(S)….208
CROWD CYLINDER DRIFTS IN WITH OR WITHOUT LOAD….209
CROWD SECTION(S) CHATTERS OR REFUSES TO EXTEND UNDER HEAVY LOAD CONDITIONS….209
INSIDE CROWD CYLINDER CANNOT BE RETRACTED, CAUSED BY BROKEN OIL SUPPLY LINE ON A THREE SECTION POWER BOOM….210
INSIDE CROWD CYLINDER CANNOT BE RETRACTED, CAUSED BY BROKEN OIL SUPPLY LINE ON A FOUR SECTION POWER BOOM….211
REMOVAL OF THE INSIDE CROWD CYLINDER ON A THREE SECTION POWER BOOM….212
HOIST WINCH CIRCUIT….213
HOIST WINCH CIRCUIT OPERATION….215
HOIST WINCH DRIFTS WITH LOAD….215
HOIST WINCH CANNOT BE FEATHERED WHEN LOWERING A LOAD….218
HOIST WINCH WON'T LOWER OR HESITATES BEFORE LOWERING….218
HOIST WINCH LOWERS IN AN UNEVEN OR JERKY MANNER….219
HOIST WINCH WILL NOT LIFT LOAD….219
REAR STEERING….220
REAR STEERING CYLINDERS DRIFT….220
OUTRIGGERS….221
OUTRIGGER CYLINDER DRIFT….221
OUTRIGGERS CHATTER WHEN RAISING….222
SERVICE BRAKES….223
ADJUST BRAKE….223
WHEEL CYLINDER MAINTENANCE….223
WHEEL CYLINDER DIAGNOSTICS….224
BLEED HYDRAULIC SYSTEM….224
MAINTENANCE SCHEDULES….225
MINOR INSPECTION: HYDRAULIC BRAKES….225
MAJOR INSPECTION: HYDRAULIC BRAKES….226
PARKING BRAKE….227
ADJUST BRAKE….227
MAINTENANCE SCHEDULES….227
MINOR INSPECTION: MECHANICAL BRAKES….227
MAJOR INSPECTION: MECHANICAL BRAKES….227
PRE-DELIVERY PROCEDURE….228
PRE-UNLOADING CHECKS….230
EXAMPLE OF SERVICE REPORT ON DELIVERY….231
RECORD SERIAL NUMBERS….232
LUBRICATION….234
TORQUES….240
SPECIFIC BOLT TORQUES….241
ENGINE CHECKS….242
HYDRAULIC PRESSURE TEST….244
TRANSMISSION CHECKS….246
ADJUSTMENTS….248
ROTARY DRIVE SCREWS CLEARANCE….248
RETRACT REEL – SPRING MOTOR….248
BOOM ROLLERS….248
BOOM WEAR PLATES….248
SWING AND HOIST BRAKE ROD AND SPRING….249
CRANE OPERATION….250
TIRE INFLATION….250
REAR STEERING INDICATOR….250
TESTING….251
YARD TEST CRANE….251
ROAD TEST CRANE….251
ELECTRICAL SYSTEM CHECKS….251
30 DISASSEMBLY AND ASSEMBLY….252
METHOD OF USING MANUAL….258
PRECAUTIONS DURING OPERATION….259
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK….259
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK….260
PRECAUTIONS WHEN COMPLETING THE OPERATIONS….261
OTHER PRECAUTIONS….261
SKETCHES OF SPECIAL TOOLS….263
REVERSE IDLER SHAFT NUT SOCKET (TG 1304 – 54)….263
HYDRAULIC MOTOR….264
STEEL SLEEVE….264
SEAL RETAINER TOOL….264
CHECK VALVE TOOL….265
SEAL RETAINER TOOL….265
DIFFERENTIAL CARRIER….266
REPAIR STAND….266
TRANSMISSION T20000 POWERSHIFT 6 SPEED….268
SERVICING MACHINE AFTER COMPONENTS OVERHAUL….268
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE….269
CLEANING AND INSPECTION….270
CLEANING….270
INSPECTION….270
DISASSEMBLY….272
LOW (1ST) CLUTCH….286
REVERSE CLUTCH….294
2ND CLUTCH….302
3RD CLUTCH….306
FORWARD CLUTCH….311
CONVERTER HOUSING….319
IDLER SHAFT….330
OUTPUT SHAFT….334
ASSEMBLY….338
CONVERTER DRIVE COUPLING INSTALLATION DETAILS….361
HYDRAULIC ACTUATED AXLE DISCONNECT….363
SECTIONAL VIEWS AND PARTS IDENTICATION….363
OUTPUT SHAFT WITH AXLE DISCONNECT….366
AXLE DISCONNECT….371
TOWING OR PUSHING….379
TRANSMISSION 18000 SERIES 6 SPEED….380
DISASSEMBLY….380
FREEWHEEL DISASSEMBLY….384
TRANSMISSION CASE DISASSEMBLY….389
LOW CLUTCH….395
REVERSE AND 2nd CLUTCH….401
3RD CLUTCH….408
FORWARD CLUTCH….413
LOCK NUT TYPE IDLER SHAFT….420
TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS….425
CONVERTER HOUSING….426
ASSEMBLY….429
FREEWHEEL ASSEMBLY….429
CONVERTER HOUSING….435
18000 SERIES TRANSMISSION CONVERTER DRIVE PLATE KIT….442
CLUTCH SHAFT OIL SEALING RING (PISTON RING)….443
INSTALLATION….443
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE….445
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL….446
TOWING OR PUSH STARTING….446
PEDESTAL, ROTEK BEARING & SWING DRIVE SYSTEM….447
REMOVAL….447
DRIVE MOTOR AND BRAKE….448
DISASSEMBLY….448
ASSEMBLY….454
INSTALLATION….463
SWING DRIVE MOTOR….465
REMOVAL….465
DISASSEMBLY….465
CLEANING….466
INSPECTION….467
ASSEMBLY….468
INSTALLATION….470
START-UP PROCEDURE….470
WINCH MOTOR….471
DISASSEMBLY….471
ASSEMBLY….475
BOOM WINCH….478
REMOVAL OF WINCH ASSEMBLY FROM CRANE….478
DISASSEMBLY….479
INSPECTION & CLEANING….484
ASSEMBLY….485
INSTALLING WINCH ASSEMBLY ON CRANE….490
JIB AND GANTRY….491
JIB EXTENSION PROCEDURE….491
JIB STOWAGE PROCEDURE….499
HEAD & HOOK BLOCK….500
DISASSEMBLY….500
ASSEMBLY….503
CARE OF WIRE ROPE….505
WIRE ROPE REPLACEMENT….505
HOOK & HEAD BLOCK REEVING….507
METHODS OF LUBRICATION….508
LUBRICATION IN STORAGE….508
SPRING MOTORS….509
UNLOADING RETRACT MECHANISM….509
DISASSEMBLY….511
SHAFT BEARINGS AND CABLE DRUM….515
ASSEMBLY….519
LOADING RETRACT MECHANISM….522
SETTING SPRING TENSION….522
LUBRICATION….523
BRAKE VALVE….524
MASTER CYLINDER SECTION….524
REMOVE AND SEPARATE INTO SECTIONS….524
DISASSEMBLY….525
ASSEMBLY….526
CONNECTING SECTIONS AND MOUNTING BRAKE VALVE ON VEHICLE….526
POWER ASSIST SECTION….528
REMOVE AND SEPARATE INTO SECTIONS….528
DISASSEMBLY….529
ASSEMBLY….530
CONNECTING SECTIONS AND MOUNTING BRAKE VALVE ON VEHICLE….531
STEERING CONTROL VALVE….533
SERVICING….534
DISASSEMBLY….534
ASSEMBLY….537
TANDEM PUMP….543
REMOVAL….543
DISASSEMBLY….545
ASSEMBLY….553
INSTALLATION….560
PRIMARY MANIFOLD & CONTROLS….561
REMOVAL….561
DISASSEMBLY….561
OPERATING CABLES….564
ASSEMBLY….567
OPERATING CABLES….567
INSTALLATION….572
PRIMARY MANIFOLD….573
REMOVAL….573
DISASSEMBLY….575
ASSEMBLY….577
INSTALLATION….579
SECOND MANIFOLD….581
REMOVAL….581
REMOVAL OF INDIVIDUAL VALVES….583
DISASSEMBLY….585
ASSEMBLY….587
INSTALLATION OF INDIVIDUAL VALVES….588
INSTALLATION….590
HYDRAULIC CYLINDERS….592
BOOM LIFT CYLINDER….592
DISASSEMBLY….592
ASSEMBLY….595
BOOM CROWD CYLINDER ROD SEAL….603
DUAL CROWD CYLINDER FOUR SECTION POWER BOOM….607
REMOVEAL….607
DISASSEMBLY….614
ASSEMBLY….618
INSTALLATION….626
STEERING CYLINDER….633
DISASSEMBLY….634
ASSEMBLY….634
OUTRIGGER CYLINDER….635
DISASSEMBLY….636
ASSEMBLY….636
LOWER CROWD CYLINDER….637
DISASSEMBLY….638
ASSEMBLY….638
SWING & HOIST BRAKE CYLINDER….639
DISASSEMBLY….640
ASSEMBLY….640
PARKING BRAKE….641
DISASSEMBLY….641
ASSEMBLY….642
SERVICE BRAKE….643
DISASSEMBLY….643
ASSEMBLY….644
WHEEL CYLINDER….646
DISASSEMBLY….646
ASSEMBLY….647
AXLES….648
DIFFERENTIAL….648
DISASSEMBLY….648
PREPARING PARTS FOR ASSEMBLY….660
ASSEMBLY….675
LUBRICANT….707
FASTENER TORQUE INFORMATION….709
ADJUSTMENTS AND SPECIFICATIONS….713
PLANETARY AXLE WHEEL ENDS….715
REMOVAL….715
PREPARE PARTS FOR ASSEMBLY….723
ASSEMBLY….723
90 OTHERS….734
HYDRAULIC….736
150A – SHEET 1 OF 2, PART 1 OF 2….736
150A – SHEET 1 0F 2, PART 2 OF 2….738
150A – SHEET 2 OF 2, PART 1 OF 2….740
150A – SHEET 2 OF 2, PART 2 OF 2….742
150FA – SHEET 1 OF 2, PART 1 OF 2….744
150FA – SHEET 1 OF 2, PART 2 OF 2….746
150FA – SHEET 2 OF 2, PART 1 OF 2….748
150FA – SHEET 2 OF 2, PART 2 OF 2….750
ELECTRICAL….752
150A/FA – SHEET 1 OF 1, PART 1 OF 2….752
150A/FA – SHEET 1 OF 1, PART 2 OF 2….754
SMC-150FA – Hydraulic Crane 150A, 150FA Shop Manual (SN ~09695 – 10827)….758
COVER….758
TABLE OF CONTENTS….759
1 A-1.20 ROSS POWER STEERING GEAR (G-R-C)….760
CONTENTS….760
TORQUE SHEET….761
DISASSEMBLY….762
SERVICE TO CAM AND ACTUATOR ASSEMBLY….770
SERVICE TO LEVER SHAFT AND STUD ASSEMBLY….771
SERVICE TO VALVE ASSEMBLY….772
REASSEMBLY….775
INSTALLATION AND ADJUSTMENT OF VALVE ASSEMBLY….783
LUBRICANT SPECIFICATIONS ….786
TROUBLESHOOTING….786
2 B-2.10 TORQUE CONVERTER (MODELS C272 & C273) (G-C)….790
CONTENTS….790
TORQUE SHEETS….791
SPECIAL TOOLS….826
DISASSEMBLY….792
REASSEMBLY….806
INSTALLATION….821
3 C-07.00 TRANSMISSION (MODEL 2420) (G-C)….828
CONTENTS….828
TORQUE SHEET….829
SPECIAL TOOLS….830
TRANSMISSION DISASSEMBLY….832
CLUTCH DISASSEMBLY….844
CLUTCH REASSEMBLY….849
CONTROL VALVE & OIL CIRCUIT PLATE DISASSEMBLY & ASSEMBLY….855
TRANSMISSION REASSEMBLY….857
PRESSURE CHECKS….871
4 C-10.00 ALLISION MODEL TT-2421-1 TRANSMISSION (C)….874
CONTENTS….874
GENERAL TORQUE VALUES….875
SCOPE OF MANUAL….876
SPECIFICATION, WEAR LIMITS, AND SPRING DATA….877
DESCRIPTION….881
OPERATION….883
TROUBLESHOOTING ….886
SPECIAL TOOLS….889
REMOVAL FROM CRANE….890
DISASSEMBLY OF TRANSMISSION….892
INSPECTION AND CLEANING….902
REBUILD OF SUB-ASSEMBLIES….905
INSTALLATION IN CRANE….931
SERVICING TRANSMISSION….935
5 E-2.03 PRIMARY MANIFOLD & CONTROLS (C)….936
CONTENTS….936
TORQUE SHEET….937
DISASSEMBLY….938
REASSEMBLY….945
6 E-02.04 PRIMARY MANIFOLD (C)….952
CONTENTS….952
GENERAL TORQUE VALUES….953
SYSTEM APPLICATION….954
REMOVAL….956
DISASSEMBLY….959
CLEANING AND INSPECTION….963
REASSEMBLY….964
INSTALLATION….967
7 E-2.40 SECOND MANIFOLD (C)….970
CONTENTS….970
TORQUE SHEET….971
REMOVAL OF MANIFOLD….972
REMOVAL OF INDIVIDUAL VALVES….975
DISASSEMBLY OF VALVE COMPONENTS….977
CLEANING AND INSPECTION….980
REASSEMBLY OF VALVE COMPONENTS….981
INSTALLATION OF INDIVIDUAL VALVES….983
INSTALLATION OF MANIFOLD….985
TESTING AND TROUBLESHOOTING….987
8 E-3.10 HYDRAULIC CRANE CYLINDERS (C)….988
CONTENTS….988
TORQUE SHEET….989
PRECAUTIONS & SERVICE NOTES….990
SERIAL NUMBER RANGES BY CYLINDER….990
STEERING CYLINDERS ….992
OUTRIGGER CYLINDERS….998
BOOM CROWD CYLINDERS….1002
SWING & HOIST BRAKE CYLINDERS….1008
SWING & HOIST BRAKE CHECKS AND ADJUSTMENTS….1011
9 E-3.11 POLYURETHATNE ONE PEICE ROD SEAL USED ON BOOM CYLINDERS (C)….1014
10 E-3.12 HYDRAULIC CRANE BOOM LIFT CYLINDER (C)….1022
CONTENTS….1022
TORQUE SHEET ….1023
DISASSEMBLY….1028
REASSEMBLY….1032
11 E-3.13 DUEL CROWD CYLINDER FOUR SECTION POWER BOOM (C)….1042
CONTENTS….1042
TORQUE SHEET….1043
REMOVAL OF DUAL CROWD CYLINDER FROM CRANE….1044
DISASSEMBLY OF DUAL CROWD CYLINDER….1053
REASSEMBLY OF DUAL CROWD CYLINDER….1058
INSTALLATION OF DUAL CROWD CYLINDER IN CRANE….1068
12 E-10.10 HYDRAULIC WINCH MOTOR (COMMERCIAL SHEARING) (C)….1078
CONTENTS….1078
TORQUE SHEET….1079
DESCRIPTION & IDENTIFICATION….1080
TROUBLESHOOTING ….1081
DIASSEMBLY….1082
INSPECTION & REPLACEMENT….1085
CLEANING….1087
SPECIAL TOOLS….1088
REASSEMBLY….1089
13 E-11.30 SWING DRIVE HYDRAULIC MOTOR (COMMERCIAL SHEARING)….1094
CONTENTS….1094
TORQUE SHEET….1095
SWING DRIVE HYDRAULIC MOTOR REMOVAL….1096
SWING DRIVE HYDRAULIC MOTOR DISASSEMBLY….1097
CLEANING ….1100
INSPECTION….1101
SWING DRIVE HYDRAULIC MOTOR REASSEMBLY….1102
SWING DRIVE HYDRAULIC MOTOR INSTALLATION….1106
START-UP PROCEDURE….1107
SPECIAL TOOLS….1108
14 E-12.01 TANDEM PUMP (COMMERCIAL SHEARING MODEL 25X) (C)….1110
CONTENTS….1110
END COVER REMOVAL….1114
GEAR HOUSING REMOVAL….1117
DRIVE & DRIVEN GEAR REMOVAL….1118
DISASSEMBLY OF SHAFT END COVER….1119
DISASSEMBLY OF SHAFT ASSEMBLY….1121
DISASSEMBLY OF BEARING CARRIER….1123
REASSEMBLY….1124
TEST PROCEDURE FOR REBUILT PUMP….1134
TORQUE SHEET….1135
15 E-14.00 SWING COUNTERBALANCE VALVE (C)….1136
CONTENTS….1136
TORQUE SHEET….1137
INTRODUCTION….1138
REMOVAL….1141
DISASSEMBLY….1142
CLEANING AND INSPECTION….1145
REASSEMBLY….1146
INSTALLATION….1149
16 E-15.00 HYDRAULIC CRANE TROUBLESHOOTING (C)….1150
CONTENTS….1150
TORQUE SHEET….1151
SECTION I – HYDRAULIC PRESSURE & ENGINE SPEED CHARTS….1156
SECTION II – HYDRAULIC SYSTEM INTRODUCTION….1158
50 GPM CIRCUIT….1163
TROUBLESHOOTING 50 GALLON PER MINUTE SYSTEM….1163
50 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 30 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….1164
30 GPM CIRCUIT….1165
TROUBLESHOOTING 30 GALLON PER MINUT SYSTEM….1165
30 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 50 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….1166
FRONT STEERING – SLOW, HARD OR STOPPED WHEN 30 AND 50 GPM SYSTEMS ARE FUNCTIONING PROPERLY….1167
RAPID WARMUP OF HYDRAULIC SYSTEM….1169
SECTION III – TROUBLESHOOTING THE SWING DRIVE CIRCUIT….1170
SWING DRIFTS AFTER CONTROL VALVE HAS BEEN RETURNED TO NEUTRAL….1173
SWING RUNS AWAY WHILE SWINGING DOWN HILL WITH LOAD….1174
SWING REFUSES TO ROTATE WHEN OTHER 30 GPM CONTROLS FUNCTION NORMALLY….1174
SWING ERRATIC AND JERKY IN OPERATION….1174
SECTION IV – TROUBLESHOOTING THE BOOM LIFT CYLINDER CIRCUIT….1176
BOOM LIFT CYLINDER DRIFTS WITH HYDRAULIC CONTROL VALVE IN THE NEUTRAL POSITION….1180
BOOM DROPS MOMENTARILY WHEN CONTROL IS MOVED FROM NEUTRAL TO RAISE….1180
BOOM LIFT CYLINDER REFUSES TO LOWER….1181
SECTION V – TROUBLESHOOTING THE CROWD CYLINDER(S) CIRCUIT….1182
CROWD CYLINDER DRIFTS IN WITH OR WITHOUT LOAD….1187
CROWD SECTION(S) CHATTERS OR REFUSES TO EXTEND UNDER HEAVY LOAD CONDITIONS….1187
CROWD CYLINDERS OUT OF PHASE .(3 AND 4 SECTION POWER BOOMS ONLY)….1187
INSIDE CROWD CYLINDER CANNOT BE RETRACTED DUE TO BROKEN OIL SUPPLY LINE ON A THREE SECTION POWER BOOM….1188
INSIDE CROWD CYLINDER CANNOT BE RETRACTED DUE TO BROKEN OIL SUPPLY LINE ON A FOUR SECTION POWER BOOM….1189
REMOVAL OF THE INSIDE CROWD CYLINDER ON A THREE SECTION POWER BOOM….1190
REMOVAL OF THE INSIDE DUAL CROWD CYLINDER ON A FOUR SECTION POWER BOOM….1042
SECTION VI – TROUBLESHOOTING THE WINCH CIRCUIT….1192
GALION HOIST WINCH OPERATION….1197
HOIST WINCH DRIFTS WITH LOAD….1197
HOIST WINCH CANNOT BE FEATHERED WHEN LOWERING A LOAD….1201
HOST WINCH WON'T LOWER OR HESITATES BEFORE LOWERING….1202
HOIST WINCH LOWERS IN A JERKY MANNER….1203
HOIST WINCH WON'T LIFT LOAD….1203
SECTION VII – TROUBLESHOOTING THE REAR STERRING CYLINDERS….1206
REAR STEERING CYLINDER DRIFT….1208
SECTION VIII – TROUBLESHOOTING THE OUTRIGGER CIRCUIT….1210
OUTRIGGER CYLINDER DRIFT….1213
OUTRIGGER CHATTER WHEN RAISING….1214
17 F-6.20 BOOM WINCH ASSEMBLY (C)….1216
CONTENTS….1216
CONFIGURATION CHANGES….1217
REMOVAL OF WINCH ASSEMBLY FROM CRANE….1218
DISASSEMBLY….1219
INSPECTION & CLEANING….1226
REASSEMBLY….1227
INSTALLING WINCH ASSEMBLY ON CRANE….1233
TESTING….1234
GENERAL TORQUE VALUES….1235
18 F-10 SPRING MOTORS (C)….1236
CONTENTS….1236
TORQUE SHEET….1237
DESCRIPTION….1238
UNLOADING RETRACT MECHANISM….1239
SERVICE TO OLD TYPE SPRING MOTOR….1241
DISASSEMBLY….1241
ASSEMBLY….1249
SERVICE TO NEW TYPE SPRING MOTOR….1260
SPRING CARTRIDGES….1260
DISASSEMBLY….1260
SHAFT BEARING S AND CABLE DRUM….1265
ASSEMBLY….1270
RELOADING RETRACT MECHANISM….1274
ADJUSTMENT ….1275
LUBRICATION OF GLEASON REEL….1277
19 G-06.00 PLANETARY DRIVE AXLE (CLARK SERIES DS-12152) (C)….1278
CONTENTS….1278
GENERAL TORQUE VALUES….1279
SPECIAL TOOLS….1280
DESCRIPTION….1281
REMOVAL OF AXLE FROM CRANE….1282
DISASSEMBLY….1287
CLEANING AND INSPECTION….1301
REASSEMBLY….1303
INSTALLATION OF AXLE TO CRANE….1317
TOOTH CONTACT SHEET….1323
20 G-7 ROCKWELL AXLE ASSEMBLY (C)….1324
CONTENTS….1324
TORQUE SHEET….1325
SPECIAL TOOLS….1326
REMOVAL OF AXLES FROM CRANE….1329
DISASSEMBLY….1335
CLEANING AND INSPECTION….1348
REASSEMBLY….1350
INSTALLATION….1364
BRAKE ADJUSTMENT, BLEEDING & BURNISHING….1369
21 G-07.10 CLARK AXLE ASSEMBLIES (MODELS DS-13311 OR D1280736, AND DS-13550 OR D12S0840) (C)….1374
TABLE OF CONTENTS….1376
SPECIAL TOOLS….1378
ADAPTOR BAR….1378
DIFFERENTAL CARRIER SUPPORT PLATE….1379
DIFFERENTIAL CARRIER SUPPORT PLATE LEGS….1380
SPINDLE NUT WRENCH (FOR HUB RETAINING NUT P/N 1259 944 H1)….1381
SPINDLE NUT WRENCH (FOR HUB RETAINING NUTS P/N 134701. 134758. 75491)….1382
SPREADER BAR AND CHAINS….1383
PLUG TOOL (FOR P/N 134705. 1257 751 H91 AND 1260 021 H91)….1384
MASTER CYLINDER BLEEDING ADAPTOR TOOL….1385
AXLE HOUSING BUSHING AND OIL SEAL DRIVER….1387
AXLE TRUNNION BUSHING DRIVER….1388
SPINDLE BUSHING DRIVER….1389
SPINDLE OIL SEAL DRIVER….1390
INTRODUCTION….1391
TROUBLESHOOTING ….1394
NOSPIN (FRONT AXLE ONLY)….1395
SERVICING ….1396
REMOVAL….1396
FRONT AXLE REMOVAL….1398
REAR AXLE REMOVAL….1400
GENERAL DISASSEMBLY….1402
PLANETARY DISASSEMBLY….1402
DIFFERENTAL DISASSEMBLY….1407
CLEANING AND INSPECTION….1408
GENERAL REASSEMBLY….1410
DIFFERENTAL REASSEMBLY….1411
PLANETARY REASSEMBLY….1411
PLANETARY CARRIER ASSEMBLY (P/N 134705. 1257 751 H91 AND 1260 021 H91)….1420
DISASSEMBLY….1420
REASSEMBLY….1421
PLANETARY CARRIER BRAKE ASSEMBLY (P/N 81803. 81804. 81771 AND 81772)….1422
DISASSEMBLY….1422
REASSEMBLY….1423
PLANETARY CARRIER BRAKE ASSEMBLY (P/N 1228 948 H91, 1228 949 H91, 1228 944 H91 AND 1228 943 H91)….1424
DISASSEMBLY….1424
REASSEMBLY….1425
REAR AXLE DIFFERENTAL & CARRIER ASSEMBLY (P/N 134762 AND 1260 034 H91)….1427
DISASSEMBLY….1427
REASSEMBLY….1430
PINION GEAR ROLLING TORQUE….1430
PINION GEAR INSTALLATION….1431
REASSEMBLY OF RING GEAR AND DIFFERENTIAL ASSEMBLY….1433
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT….1433
CHECK ROLLING PATTERN OF RING GEAR AND PINION….1434
FINAL INSTALLATION OF DIFFERETIAL & CARRIER….1435
FRONT AXLE DIFFERENTIAL & CARRIER ASSEMBLY (WITH PARKING BRAKE ASSEMBLY) (P/N 134728 AND 1260 025 H91)….1436
DISASSEMLBY….1436
REASSEMBLY….1441
PINION GEAR ROLLING TORQUE….1441
PINION GEAR INSTALLATION….1442
REASSEMBLY OF RING GEAR AND DIFFERENTAL ASSEMBLY….1445
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT….1446
CHECK ROLLING PATTERN OF RING GEAR AND PINION ….1447
FINAL INSTALLATION OF DIFFERENTAL & CARRIER….1447
INSTALLATION….1448
FRONT AXLE INSTALLATION….1448
REAR AXLE INSTALLATION….1450
TOOTH CONTACT CHARTS….1452
STEERING ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES)….1454
BRAKE SHOE ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES)….1454
PARKING BRAKE ADJUSTMENT PROCEDURE (FRONT AXLE)….1455
BRAKE BLEEDING PROCEDURE (FRONT AND REAR AXLES)….1456
BURNISHING PROCEDURE (FRONT AND REAR AXLES)….1458
REAR STEERING INDICATOR ADJUSTMENT PROCEDURE (REAR AXLE)….1459
22 J-02.00 LUBRICATION SPECIFICATIONS (G-R-P-C-M)….1462
CONTENTS….1463
A ATF TRANSMISSION FLUID….1470
B E050 SAE 50 HD ENGINE OIL….1471
C EP80 EXTREME PRESSURE SAE 80 GEAR OIL….1471
D EP90 EXTREME PRESSURE SAE 90 GEAR OIL….1472
E WBL WORM GEAR LUBRICANT….1472
F OGL OPEN GEAR LUBRICANT (SPECIAL PURPOSE)….1473
G SAE80 STRAIGHT MINERAL SAE 80 GEAR OIL….1474
H SAE90 STRAIGHT MINERAL SAE90 GEAR OIL….1474
I SHC HIGH TEMPERATURE GEAR LUBRICANT (SYNTHESIZED HYDROCARBON BASE FLUID)….1475
J C-2 TRANSMISSION FLUID….1475
K C-3 TRANSMISSION FLUID….1476
L HO HYDRAULIC OIL….1476
M HO HYDRAULIC OIL….1477
N MPG MULTI-PURPOSE LITHIUM BASE GREASE….1478
0 BF HYDRAULIC BRAKE FLUID….1478
P 10W30 SAE 10W30 ENGINE OIL….1479
Q HO HYDRAULIC OIL – LOW TEMPERATURE….1479
R 80W140 SAE 80W-140….1480
S SAE40 SAE 40 ENGINE OIL….1480
T 68 HYDRAULIC OIL – PETROLEUM BASE – ANTI-WEAR ADDITIVES….1481
U SAE1OW SAE 10W ENGINE OIL….1481
23 K-2 WAGNER POWER MASTER CYLINDER USED WITH FOUR WHEEL SERVICE BRAKES (G-C)….1484
CONTENTS….1484
POWER FUNCTION….1488
MANUAL FUNCTION….1488
DISASSEMBLY OF POWER UNIT….1489
REASSEMBLY OF POWER UNIT….1493
DISASSEMBLY OF OLD STYLE MASTER CYLINDER….1496
REASSEMBLY OF OLD STYLE MASTER CYLINDER….1498
DISASSEMBLY OF NEW STYLE MASTER CYLINDER….1501
REASSEMBLY OF NEW STYLE MASTER CYLINDER….1502
SPECIAL TOOLS….1504
24 K-6 DELCO MORAINE HYDRAULIC MASTER BRAKE CYLINDER (C)….1508
CONTENTS….1508
TORQUE SHEET….1509
SPECIAL TOOLS….1510
REMOVAL….1512
DISASSEMBLY….1514
CLEANING AND INSPECTION….1517
REASSEMBLY….1518
INSTALLATION….1521
BRAKE ADJUSTMENT AND BLEEDING….1523
BURNISHING….1528
25 K-06.5 BENDIX MASTER CYLINDER & POWER BOOSTER (C)….1530
CONTENTS….1530
SPECIAL TOOLS….1532
REMOVAL….1534
REMOVAL FROM 150A AND 150F ….1534
REMOVAL FROM 180S AND 220S….1536
DISASSEMBLY….1538
CLEANING AND INSPECTION….1541
REASSEMBLY….1542
INSTALLATION….1545
INSTALLATION ON 150A AND 150FA….1545
INSTALLATION ON 180S AND 220S….1547
BLEEDING PROCEDURE – 180S AND 220S….1548
BRAKE ADJUSTMENT -180S AND 220S….1551
BURNISHING – 180S AND 220S….1552
BRAKE ADJUSTMENT AND BLEEDING FOR 150 AND 150FA….1553
BURNISHING – 150 AND 150FA….1556
26 K-07.00 MINNESOTA BRAKE VALVE (G-P-C)….1558
CONTENTS….1559
GENERAL TORQUE VALUES….1560
REMOVAL FROM MACHINE….1562
DISASSEMBLY OF RESERVOIR….1565
REASSEMBLY OF RESERVOIR SECTION….1566
DISASSEMBLY OF POWER ASSIST SECTION….1567
REASSEMBLY OF POWER ASSIST SECTION….1568
INSTALLATION OF BRAKE VALVE ON MACHINE….1571
BRAKE BLEEDING PROCEDURE….1573
27 K-10.30 DELCO MORAINE POWER BOOSTER (C)….1574
CONTENTS….1574
TORQUE SHEET….1575
INTRODUCTION….1576
TROUBLESHOOTING ….1577
IDENTIFICATION….1580
SERVICE CHART….1582
SPECIAL TOOLS….1583
PISTION ROD GAUGE….1583
150A AND 150FA….1584
180S AND 220S….1586
SERVICING ….1588
REMOVAL….1589
REMOVAL 150A AND 150FA….1589
REMOVAL 180S AND 220S….1591
DISASSEMBLY….1593
GENERAL ….1593
DISASSEMBLY OF 124287….1593
DISASSEMBLY OF 126448….1599
DISASSEMBLY OF 138622….1604
DISASSEMBLY OF 148399….1608
CLEANING AND INSPECTION….1612
REASSEMBLY….1613
REASSEMBLY OF 124287….1613
REASSEMLBY OF 126448….1619
REASSEMBLY OF 138622….1624
REASSEMBLY OF 148399….1628
INSTALLATION….1633
INSTALLATION 150A AND 150FA….1633
INSTALLATION 180S AND 220S….1635
BRAKE ADJUSTMENT AND BLEEDING 150A AND 150FA….1636
BURNISHING 150A AND 150FA….1641
BLEEDING PROCEDURE 180S AND 220S….1642
BRAKE ADJUSTMENT 180S AND 220S….1644
BURNINSHING 180S AND 220S….1645
28 L-03.00 WIRING DIAGRAMS – CRANES (C)….1646
CRANE MODEL 80….1646
ENGINE DD 3-53N S/N 01710 THRU 03131 WIRING DIAGRAM NUMBER 111379….1656
ENGINE DD 3-53N S/N 04001 AND UP WIRING DIAGRAM NUMBER 111379….1656
ENGINE IH UB-264 S/N 01710 THRU 03131 WIRING DIAGRAM NUMBER 96962….1648
ENGINE IH UB-264 S/N 04001 THRU 04638 WIRING DIAGRAM NUMBER 96962….1648
ENGINE IH UB-264 S/N 04639 THRU 05644 WIRING DIAGRAM 109795….1652
ENGINE IH UC-263 S/N 01710 THRU 03131 WIRING DIAGRAM 109795….1652
ENGINE IH UC-263 S/N 05645 AND UP WIRING DIAGRAM 109795….1652
ENGINE IH UD-282 S/N 01710 THRU 03131 WIRING DIAGRAM 92695….1649
ENGINE IH UD-282 S/N 04001 AND UP WIRING DIAGRAM 109796….1653
CRANE MODEL 90, 100, 110 & 125….1646
ENGINE DD 3-53N S/N 05410 AND UP WIRING DIAGRAM 111379….1656
ENGINE IH UB-264 S/N 01001-04677 EXCEPT 04655-04657 WIRING DIAGRAM 96962….1648
ENGINE IH UB-264 S/N 04655 THRU 04657, 04678 AND UP WIRING DIAGRAM 109795….1652
ENGINE IH UC-263 S/N 05563 AND UP WIRING DIAGRAM 109795….1652
ENGINE IH UD-282 S/N 01001 THRU 04677 WIRING DIAGRAM 92695….1649
ENGINE IH UD-282 S/N 04678 AND UP WIRING DIAGRAM 109796….1653
CRANE MODEL 125F….1646
ENGINE MODEL DD4-53N S/N 02965 AND UP WIRING DIAGRAM 109797….1654
CRANE MODEL 90A, 100A, 110A & 125A….1646
ENGINE MODEL CUM UV-352C S/N 02006 AND UP WIRING DIAGRAM 97869….1651
ENGINE MODEL DD4-53N S/N 02006 AND UP WIRING DIAGRAM 109797….1654
ENGINE MODEL IH UV-345 S/N 02006 THRU 04677 WIRING DIAGRAM 96704….1650
ENGINE MODEL UV-345 S/N 04678 AND UP WIRING DIAGRAM 109798….1655
CRANE MODEL 125FA….1646
ENGINE MODEL IH UV-345 S/N 07990 AND UP WIRING DIAGRAM 109798….1655
ENGINE MODEL DD 4-53N S/N 07990 AND UP WIRING DIAGRAM 109797….1654
CRANE MODEL 140F….1646
ENGINE MODEL DD 3-53N S/N 07571 AND UP WIRING DIAGRAM 111379….1656
CRANE MODEL 150 & 150FA….1646
ENGINE MODEL CUM UV-352C S/N 02832 THRU 04246 WIRING DIAGRAM 97869….1651
ENGINE MODEL DD 4-53N S/N 02832 AND UP WIRING DIAGRAM 109797….1654
ENGINE MODEL DEUTZ F6L-912 S/N 2832 AND UP WIRING DIAGRAM 122748….1657
ENGINE MODEL IH UV-345 S/N 02832 THRU 04677 WIRING DIAGRAM 96704….1650
ENGINE MODEL IH UV-345 S/N 04678 AND UP WIRING DIAGRAM 109798….1655
CRANE MODEL 180S….1646
ENGINE MODEL DD 6V-53N S/N 08502 AND UP WIRING DIAGRAM 138253….1658
CRANE MODEL 200FA ….1647
ENGINE MODEL DD 4-53N S/N 09401 AND UP WIRING DIAGRAM 109797….1654
CRANE MODEL 220A ….1647
ENGINE MODEL DD 4-53N S/N 07107 AND UP WIRING DIAGRAM 109797….1654
CRANE MODEL 220S ….1647
ENGINE MODEL DD6V-53N S/N 07724 ABD UP WIRING DIAGRAM 138253….1658
CRANE MODEL 125P….1647
ENGINE MODEL ALL S/N 01001 AND UP….1659
ENGINE MODEL ELECTRIC MOTOR S/N 01001 AND UP….1660
CRANE MODEL 150P & 150T….1647
ENGINE MODEL ALL S/N 01011 AND UP….1661
ENGINE MODEL ELECTRIC MOTOR S/N 01011 AND UP….1662
29 L-10.00 TROUBLESHOOTING & REMOVAL OF CRANKING MOTORS (M-P-G-R-C)….1664
CONTENTS….1664
TORQUE SHEETS….1665
PRELIMINARY CHECKS….1666
REMOVAL ….1670
BENCH TESTING ….1671
INSTALLATION….1674
LUBRICATION….1675
30 L-11.00 TROUBLESHOOTING & REMOVAL OF ALTERNATORS (M-G-P-R-C)….1676
CONTENTS….1676
TORQUES SHEET….1677
PRELIMINARY CHECKS ….1678
REMOVAL ….1683
INSTALLATION….1684
LUBRICATION….1685
31 N-03.40 PREDELIVERY PROCEDURES (C) (NOT INCLUDED – LISTED FOR REFERENCE ONLY)….1685
32 O-01.00 HEAD AND HOOK BLOCK (C)….1686
CONTENTS….1686
TORQUE SHEET….1687
DISASSEMBLY….1688
INSPECTION….1691
REASSEMBLY….1694
CARE OF WIRE ROPE….1697
WIRE ROPE REPLACEMENT….1698
METHODS OF LUBRICATION….1699
33 O-03.00 DRESSER HYDRAULIC CRANE – WIRE ROPE SPECIFICATION (C)….1702
MODEL BREAKDOWN….1704
MODEL 80….1704
MODEL 90, 100, 110 AND 125….1704
MODEL 125F….1705
MODEL 90A, 100A, 110A AND 125A….1705
MODEL 125FA….1706
MODEL 140F….1706
MODEL 150A….1706
MODEL 150FA….1707
MODEL 180S….1707
MODEL 220A….1707
MODEL 200FA….1709
MODEL 220S….1708
MODEL 400S….1708
MODEL 125P….1708
MODEL 150P AND 150T….1709
FRONT END WINCH (ALL MODELS….1709
MANUFACTURERS DESCRIPTION….1710
WIRE ROPE….1712
WIRE ROPE SPECIFICATIONS….1712
MAINTENANCE RECOMMENDATIONS….1712
SERVICE AND INSPECTION OF WIRE ROPE….1713
RESTING HOOK BLOCK….1713
IMPORTANCE OF LUBRICATION….1713
RECOMMENDED LUBRICANTS FOR WIRE ROPE….1714
METHODS OF LUBRICATIONS….1715
LUBRICATION IN STORAGE….1716
IDLE ROPES….1716
COMPONENT PARTS OF WIRE ROPE….1717
INSPECTION OF WIRE ROPE SHEAVES & DRUM….1717
WIRE ROPE….1717
SHEAVES AND DRUM….1719
WIRE ROPE REPLACEMENT ….1719
INSTALLATION OF WIRE ROPE….1720
BREAKING IN WIRE ROPE….1721
HOOK AND HEAD BLOCK REEVING….1721
34 Y-01.00 GENERAL TORQUE VALUES (G-R-P-C-M)….1722
CONTENTS….1722
INTRODUCTION….1724
TORQUES….1725
TORQUE VALUES FOR STANDARD ENGLISH FASTENERS….1725
BOLT IDENTIFICATION CHART….1725
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE….1725
TYPE 8 PHOSPHATE COATED HARDWARE….1727
TORQUE VALUES FOR STANDARD METRIC FASTENERS….1728
TORQUE VALUES FOR HOSE CLAMPS….1729
TORQUE VALUES FOR SPLIT FLANG CONNECTIONS….1730
TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS….1731
Komatsu Hydraulic Crane 150A / 150FA Repair Service Manuals