Komatsu 150A 150FA CRANE Shop Manual – PDF DOWNLOAD 

Description

Komatsu 150A 150FA CRANE Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu 150A 150FA CRANE Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 974
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 150A 150FA CRANE Shop Manual – PDF DOWNLOAD 

Serial Number
150A – 09695-10827
150FA – 09695-10827

MAIN MENU 0
COVER 1
TABLE OF CONTENTS 2
1 A-1 20 ROSS POWER STEERING GEAR (G-R-C) 3
CONTENTS 3
TORQUE SHEET 4
DISASSEMBLY 5
SERVICE TO CAM AND ACTUATOR ASSEMBLY 13
SERVICE TO LEVER SHAFT AND STUD ASSEMBLY 14
SERVICE TO VALVE ASSEMBLY 15
REASSEMBLY 18
INSTALLATION AND ADJUSTMENT OF VALVE ASSEMBLY 26
LUBRICANT SPECIFICATIONS 29
TROUBLESHOOTING 29
2 B-2 10 TORQUE CONVERTER (MODELS C272 & C273) (G-C) 33
CONTENTS 33
TORQUE SHEETS 34
SPECIAL TOOLS 69
DISASSEMBLY 35
REASSEMBLY 49
INSTALLATION 64
3 C-07 00 TRANSMISSION (MODEL 2420) (G-C) 71
CONTENTS 71
TORQUE SHEET 72
SPECIAL TOOLS 73
TRANSMISSION DISASSEMBLY 75
CLUTCH DISASSEMBLY 87
CLUTCH REASSEMBLY 92
CONTROL VALVE & OIL CIRCUIT PLATE DISASSEMBLY & ASSEMBLY 98
TRANSMISSION REASSEMBLY 100
PRESSURE CHECKS 114
4 C-10 00 ALLISION MODEL TT-2421-1 TRANSMISSION (C) 117
CONTENTS 117
GENERAL TORQUE VALUES 118
SCOPE OF MANUAL 119
SPECIFICATION, WEAR LIMITS, AND SPRING DATA 120
DESCRIPTION 124
OPERATION 126
TROUBLESHOOTING 129
SPECIAL TOOLS 132
REMOVAL FROM CRANE 133
DISASSEMBLY OF TRANSMISSION 135
INSPECTION AND CLEANING 145
REBUILD OF SUB-ASSEMBLIES 148
INSTALLATION IN CRANE 174
SERVICING TRANSMISSION 178
5 E-2 03 PRIMARY MANIFOLD & CONTROLS (C) 179
CONTENTS 179
TORQUE SHEET 180
DISASSEMBLY 181
REASSEMBLY 188
6 E-02 04 PRIMARY MANIFOLD (C) 195
CONTENTS 195
GENERAL TORQUE VALUES 196
SYSTEM APPLICATION 197
REMOVAL 199
DISASSEMBLY 202
CLEANING AND INSPECTION 206
REASSEMBLY 207
INSTALLATION 210
7 E-2 40 SECOND MANIFOLD (C) 213
CONTENTS 213
TORQUE SHEET 214
REMOVAL OF MANIFOLD 215
REMOVAL OF INDIVIDUAL VALVES 218
DISASSEMBLY OF VALVE COMPONENTS 220
CLEANING AND INSPECTION 223
REASSEMBLY OF VALVE COMPONENTS 224
INSTALLATION OF INDIVIDUAL VALVES 226
INSTALLATION OF MANIFOLD 228
TESTING AND TROUBLESHOOTING 230
8 E-3 10 HYDRAULIC CRANE CYLINDERS (C) 231
CONTENTS 231
TORQUE SHEET 232
PRECAUTIONS & SERVICE NOTES 233
SERIAL NUMBER RANGES BY CYLINDER 233
STEERING CYLINDERS 235
OUTRIGGER CYLINDERS 241
BOOM CROWD CYLINDERS 245
SWING & HOIST BRAKE CYLINDERS 251
SWING & HOIST BRAKE CHECKS AND ADJUSTMENTS 254
9 E-3 11 POLYURETHATNE ONE PEICE ROD SEAL USED ON BOOM CYLINDERS (C) 257
10 E-3 12 HYDRAULIC CRANE BOOM LIFT CYLINDER (C) 265
CONTENTS 265
TORQUE SHEET 266
DISASSEMBLY 271
REASSEMBLY 275
11 E-3 13 DUEL CROWD CYLINDER FOUR SECTION POWER BOOM (C) 285
CONTENTS 285
TORQUE SHEET 286
REMOVAL OF DUAL CROWD CYLINDER FROM CRANE 287
DISASSEMBLY OF DUAL CROWD CYLINDER 296
REASSEMBLY OF DUAL CROWD CYLINDER 301
INSTALLATION OF DUAL CROWD CYLINDER IN CRANE 311
12 E-10 10 HYDRAULIC WINCH MOTOR (COMMERCIAL SHEARING) (C) 321
CONTENTS 321
TORQUE SHEET 322
DESCRIPTION & IDENTIFICATION 323
TROUBLESHOOTING 324
DIASSEMBLY 325
INSPECTION & REPLACEMENT 328
CLEANING 330
SPECIAL TOOLS 331
REASSEMBLY 332
13 E-11 30 SWING DRIVE HYDRAULIC MOTOR (COMMERCIAL SHEARING) 337
CONTENTS 337
TORQUE SHEET 338
SWING DRIVE HYDRAULIC MOTOR REMOVAL 339
SWING DRIVE HYDRAULIC MOTOR DISASSEMBLY 340
CLEANING 343
INSPECTION 344
SWING DRIVE HYDRAULIC MOTOR REASSEMBLY 345
SWING DRIVE HYDRAULIC MOTOR INSTALLATION 349
START-UP PROCEDURE 350
SPECIAL TOOLS 351
14 E-12 01 TANDEM PUMP (COMMERCIAL SHEARING MODEL 25X) (C) 353
CONTENTS 353
END COVER REMOVAL 357
GEAR HOUSING REMOVAL 360
DRIVE & DRIVEN GEAR REMOVAL 361
DISASSEMBLY OF SHAFT END COVER 362
DISASSEMBLY OF SHAFT ASSEMBLY 364
DISASSEMBLY OF BEARING CARRIER 366
REASSEMBLY 367
TEST PROCEDURE FOR REBUILT PUMP 377
TORQUE SHEET 378
15 E-14 00 SWING COUNTERBALANCE VALVE (C) 379
CONTENTS 379
TORQUE SHEET 380
INTRODUCTION 381
REMOVAL 384
DISASSEMBLY 385
CLEANING AND INSPECTION 388
REASSEMBLY 389
INSTALLATION 392
16 E-15 00 HYDRAULIC CRANE TROUBLESHOOTING (C) 393
CONTENTS 393
TORQUE SHEET 394
SECTION I – HYDRAULIC PRESSURE & ENGINE SPEED CHARTS 399
SECTION II – HYDRAULIC SYSTEM INTRODUCTION 401
50 GPM CIRCUIT 406
TROUBLESHOOTING 50 GALLON PER MINUTE SYSTEM 406
50 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 30 GPM AND FRONT STEERING CIRCUITS ARE NORMAL 407
30 GPM CIRCUIT 408
TROUBLESHOOTING 30 GALLON PER MINUT SYSTEM 408
30 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 50 GPM AND FRONT STEERING CIRCUITS ARE NORMAL 409
FRONT STEERING – SLOW, HARD OR STOPPED WHEN 30 AND 50 GPM SYSTEMS ARE FUNCTIONING PROPERLY 410
RAPID WARMUP OF HYDRAULIC SYSTEM 412
SECTION III – TROUBLESHOOTING THE SWING DRIVE CIRCUIT 413
SWING DRIFTS AFTER CONTROL VALVE HAS BEEN RETURNED TO NEUTRAL 416
SWING RUNS AWAY WHILE SWINGING DOWN HILL WITH LOAD 417
SWING REFUSES TO ROTATE WHEN OTHER 30 GPM CONTROLS FUNCTION NORMALLY 417
SWING ERRATIC AND JERKY IN OPERATION 417
SECTION IV – TROUBLESHOOTING THE BOOM LIFT CYLINDER CIRCUIT 419
BOOM LIFT CYLINDER DRIFTS WITH HYDRAULIC CONTROL VALVE IN THE NEUTRAL POSITION 423
BOOM DROPS MOMENTARILY WHEN CONTROL IS MOVED FROM NEUTRAL TO RAISE 423
BOOM LIFT CYLINDER REFUSES TO LOWER 424
SECTION V – TROUBLESHOOTING THE CROWD CYLINDER(S) CIRCUIT 425
CROWD CYLINDER DRIFTS IN WITH OR WITHOUT LOAD 430
CROWD SECTION(S) CHATTERS OR REFUSES TO EXTEND UNDER HEAVY LOAD CONDITIONS 430
CROWD CYLINDERS OUT OF PHASE (3 AND 4 SECTION POWER BOOMS ONLY) 430
INSIDE CROWD CYLINDER CANNOT BE RETRACTED DUE TO BROKEN OIL SUPPLY LINE ON A THREE SECTION POWER BOOM 431
INSIDE CROWD CYLINDER CANNOT BE RETRACTED DUE TO BROKEN OIL SUPPLY LINE ON A FOUR SECTION POWER BOOM 432
REMOVAL OF THE INSIDE CROWD CYLINDER ON A THREE SECTION POWER BOOM 433
REMOVAL OF THE INSIDE DUAL CROWD CYLINDER ON A FOUR SECTION POWER BOOM 285
SECTION VI – TROUBLESHOOTING THE WINCH CIRCUIT 435
GALION HOIST WINCH OPERATION 440
HOIST WINCH DRIFTS WITH LOAD 440
HOIST WINCH CANNOT BE FEATHERED WHEN LOWERING A LOAD 444
HOST WINCH WON’T LOWER OR HESITATES BEFORE LOWERING 445
HOIST WINCH LOWERS IN A JERKY MANNER 446
HOIST WINCH WON’T LIFT LOAD 446
SECTION VII – TROUBLESHOOTING THE REAR STERRING CYLINDERS 449
REAR STEERING CYLINDER DRIFT 451
SECTION VIII – TROUBLESHOOTING THE OUTRIGGER CIRCUIT 453
OUTRIGGER CYLINDER DRIFT 456
OUTRIGGER CHATTER WHEN RAISING 457
17 F-6 20 BOOM WINCH ASSEMBLY (C) 459
CONTENTS 459
CONFIGURATION CHANGES 460
REMOVAL OF WINCH ASSEMBLY FROM CRANE 461
DISASSEMBLY 462
INSPECTION & CLEANING 469
REASSEMBLY 470
INSTALLING WINCH ASSEMBLY ON CRANE 476
TESTING 477
GENERAL TORQUE VALUES 478
18 F-10 SPRING MOTORS (C) 479
CONTENTS 479
TORQUE SHEET 480
DESCRIPTION 481
UNLOADING RETRACT MECHANISM 482
SERVICE TO OLD TYPE SPRING MOTOR 484
DISASSEMBLY 484
ASSEMBLY 492
SERVICE TO NEW TYPE SPRING MOTOR 503
SPRING CARTRIDGES 503
DISASSEMBLY 503
SHAFT BEARING S AND CABLE DRUM 508
ASSEMBLY 513
RELOADING RETRACT MECHANISM 517
ADJUSTMENT 518
LUBRICATION OF GLEASON REEL 520
19 G-06 00 PLANETARY DRIVE AXLE (CLARK SERIES DS-12152) (C) 521
CONTENTS 521
GENERAL TORQUE VALUES 522
SPECIAL TOOLS 523
DESCRIPTION 524
REMOVAL OF AXLE FROM CRANE 525
DISASSEMBLY 530
CLEANING AND INSPECTION 544
REASSEMBLY 546
INSTALLATION OF AXLE TO CRANE 560
TOOTH CONTACT SHEET 566
20 G-7 ROCKWELL AXLE ASSEMBLY (C) 567
CONTENTS 567
TORQUE SHEET 568
SPECIAL TOOLS 569
REMOVAL OF AXLES FROM CRANE 572
DISASSEMBLY 578
CLEANING AND INSPECTION 591
REASSEMBLY 593
INSTALLATION 607
BRAKE ADJUSTMENT, BLEEDING & BURNISHING 612
21 G-07 10 CLARK AXLE ASSEMBLIES (MODELS DS-13311 OR D1280736, AND DS-13550 OR D12S0840) (C) 617
TABLE OF CONTENTS 619
SPECIAL TOOLS 621
ADAPTOR BAR 621
DIFFERENTAL CARRIER SUPPORT PLATE 622
DIFFERENTIAL CARRIER SUPPORT PLATE LEGS 623
SPINDLE NUT WRENCH (FOR HUB RETAINING NUT P/N 1259 944 H1) 624
SPINDLE NUT WRENCH (FOR HUB RETAINING NUTS P/N 134701 134758 75491) 625
SPREADER BAR AND CHAINS 626
PLUG TOOL (FOR P/N 134705 1257 751 H91 AND 1260 021 H91) 627
MASTER CYLINDER BLEEDING ADAPTOR TOOL 628
AXLE HOUSING BUSHING AND OIL SEAL DRIVER 630
AXLE TRUNNION BUSHING DRIVER 631
SPINDLE BUSHING DRIVER 632
SPINDLE OIL SEAL DRIVER 633
INTRODUCTION 634
TROUBLESHOOTING 637
NOSPIN (FRONT AXLE ONLY) 638
SERVICING 639
REMOVAL 639
FRONT AXLE REMOVAL 641
REAR AXLE REMOVAL 643
GENERAL DISASSEMBLY 645
PLANETARY DISASSEMBLY 645
DIFFERENTAL DISASSEMBLY 650
CLEANING AND INSPECTION 651
GENERAL REASSEMBLY 653
DIFFERENTAL REASSEMBLY 654
PLANETARY REASSEMBLY 654
PLANETARY CARRIER ASSEMBLY (P/N 134705 1257 751 H91 AND 1260 021 H91) 663
DISASSEMBLY 663
REASSEMBLY 664
PLANETARY CARRIER BRAKE ASSEMBLY (P/N 81803 81804 81771 AND 81772) 665
DISASSEMBLY 665
REASSEMBLY 666
PLANETARY CARRIER BRAKE ASSEMBLY (P/N 1228 948 H91, 1228 949 H91, 1228 944 H91 AND 1228 943 H91) 667
DISASSEMBLY 667
REASSEMBLY 668
REAR AXLE DIFFERENTAL & CARRIER ASSEMBLY (P/N 134762 AND 1260 034 H91) 670
DISASSEMBLY 670
REASSEMBLY 673
PINION GEAR ROLLING TORQUE 673
PINION GEAR INSTALLATION 674
REASSEMBLY OF RING GEAR AND DIFFERENTIAL ASSEMBLY 676
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT 676
CHECK ROLLING PATTERN OF RING GEAR AND PINION 677
FINAL INSTALLATION OF DIFFERETIAL & CARRIER 678
FRONT AXLE DIFFERENTIAL & CARRIER ASSEMBLY (WITH PARKING BRAKE ASSEMBLY) (P/N 134728 AND 1260 025 H91) 679
DISASSEMLBY 679
REASSEMBLY 684
PINION GEAR ROLLING TORQUE 684
PINION GEAR INSTALLATION 685
REASSEMBLY OF RING GEAR AND DIFFERENTAL ASSEMBLY 688
RING GEAR PRELOAD AND BACKLASH ADJUSTMENT 689
CHECK ROLLING PATTERN OF RING GEAR AND PINION 690
FINAL INSTALLATION OF DIFFERENTAL & CARRIER 690
INSTALLATION 691
FRONT AXLE INSTALLATION 691
REAR AXLE INSTALLATION 693
TOOTH CONTACT CHARTS 695
STEERING ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES) 697
BRAKE SHOE ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES) 697
PARKING BRAKE ADJUSTMENT PROCEDURE (FRONT AXLE) 698
BRAKE BLEEDING PROCEDURE (FRONT AND REAR AXLES) 699
BURNISHING PROCEDURE (FRONT AND REAR AXLES) 701
REAR STEERING INDICATOR ADJUSTMENT PROCEDURE (REAR AXLE) 702
22 J-02 00 LUBRICATION SPECIFICATIONS (G-R-P-C-M) 705
CONTENTS 706
A ATF TRANSMISSION FLUID 713
B E050 SAE 50 HD ENGINE OIL 714
C EP80 EXTREME PRESSURE SAE 80 GEAR OIL 714
D EP90 EXTREME PRESSURE SAE 90 GEAR OIL 715
E WBL WORM GEAR LUBRICANT 715
F OGL OPEN GEAR LUBRICANT (SPECIAL PURPOSE) 716
G SAE80 STRAIGHT MINERAL SAE 80 GEAR OIL 717
H SAE90 STRAIGHT MINERAL SAE90 GEAR OIL 717
I SHC HIGH TEMPERATURE GEAR LUBRICANT (SYNTHESIZED HYDROCARBON BASE FLUID) 718
J C-2 TRANSMISSION FLUID 718
K C-3 TRANSMISSION FLUID 719
L HO HYDRAULIC OIL 719
M HO HYDRAULIC OIL 720
N MPG MULTI-PURPOSE LITHIUM BASE GREASE 721
0 BF HYDRAULIC BRAKE FLUID 721
P 10W30 SAE 10W30 ENGINE OIL 722
Q HO HYDRAULIC OIL – LOW TEMPERATURE 722
R 80W140 SAE 80W-140 723
S SAE40 SAE 40 ENGINE OIL 723
T 68 HYDRAULIC OIL – PETROLEUM BASE – ANTI-WEAR ADDITIVES 724
U SAE1OW SAE 10W ENGINE OIL 724
23 K-2 WAGNER POWER MASTER CYLINDER USED WITH FOUR WHEEL SERVICE BRAKES (G-C) 727
CONTENTS 727
POWER FUNCTION 731
MANUAL FUNCTION 731
DISASSEMBLY OF POWER UNIT 732
REASSEMBLY OF POWER UNIT 736
DISASSEMBLY OF OLD STYLE MASTER CYLINDER 739
REASSEMBLY OF OLD STYLE MASTER CYLINDER 741
DISASSEMBLY OF NEW STYLE MASTER CYLINDER 744
REASSEMBLY OF NEW STYLE MASTER CYLINDER 745
SPECIAL TOOLS 747
24 K-6 DELCO MORAINE HYDRAULIC MASTER BRAKE CYLINDER (C) 751
CONTENTS 751
TORQUE SHEET 752
SPECIAL TOOLS 753
REMOVAL 755
DISASSEMBLY 757
CLEANING AND INSPECTION 760
REASSEMBLY 761
INSTALLATION 764
BRAKE ADJUSTMENT AND BLEEDING 766
BURNISHING 771
25 K-06 5 BENDIX MASTER CYLINDER & POWER BOOSTER (C) 773
CONTENTS 773
SPECIAL TOOLS 775
REMOVAL 777
REMOVAL FROM 150A AND 150F 777
REMOVAL FROM 180S AND 220S 779
DISASSEMBLY 781
CLEANING AND INSPECTION 784
REASSEMBLY 785
INSTALLATION 788
INSTALLATION ON 150A AND 150FA 788
INSTALLATION ON 180S AND 220S 790
BLEEDING PROCEDURE – 180S AND 220S 791
BRAKE ADJUSTMENT -180S AND 220S 794
BURNISHING – 180S AND 220S 795
BRAKE ADJUSTMENT AND BLEEDING FOR 150 AND 150FA 796
BURNISHING – 150 AND 150FA 799
26 K-07 00 MINNESOTA BRAKE VALVE (G-P-C) 801
CONTENTS 802
GENERAL TORQUE VALUES 803
REMOVAL FROM MACHINE 805
DISASSEMBLY OF RESERVOIR 808
REASSEMBLY OF RESERVOIR SECTION 809
DISASSEMBLY OF POWER ASSIST SECTION 810
REASSEMBLY OF POWER ASSIST SECTION 811
INSTALLATION OF BRAKE VALVE ON MACHINE 814
BRAKE BLEEDING PROCEDURE 816
27 K-10 30 DELCO MORAINE POWER BOOSTER (C) 817
CONTENTS 817
TORQUE SHEET 818
INTRODUCTION 819
TROUBLESHOOTING 820
IDENTIFICATION 823
SERVICE CHART 825
SPECIAL TOOLS 826
PISTION ROD GAUGE 826
150A AND 150FA 827
180S AND 220S 829
SERVICING 831
REMOVAL 832
REMOVAL 150A AND 150FA 832
REMOVAL 180S AND 220S 834
DISASSEMBLY 836
GENERAL 836
DISASSEMBLY OF 124287 836
DISASSEMBLY OF 126448 842
DISASSEMBLY OF 138622 847
DISASSEMBLY OF 148399 851
CLEANING AND INSPECTION 855
REASSEMBLY 856
REASSEMBLY OF 124287 856
REASSEMLBY OF 126448 862
REASSEMBLY OF 138622 867
REASSEMBLY OF 148399 871
INSTALLATION 876
INSTALLATION 150A AND 150FA 876
INSTALLATION 180S AND 220S 878
BRAKE ADJUSTMENT AND BLEEDING 150A AND 150FA 879
BURNISHING 150A AND 150FA 884
BLEEDING PROCEDURE 180S AND 220S 885
BRAKE ADJUSTMENT 180S AND 220S 887
BURNINSHING 180S AND 220S 888
28 L-03 00 WIRING DIAGRAMS – CRANES (C) 889
CRANE MODEL 80 889
ENGINE DD 3-53N S/N 01710 THRU 03131 WIRING DIAGRAM NUMBER 111379 899
ENGINE DD 3-53N S/N 04001 AND UP WIRING DIAGRAM NUMBER 111379 899
ENGINE IH UB-264 S/N 01710 THRU 03131 WIRING DIAGRAM NUMBER 96962 891
ENGINE IH UB-264 S/N 04001 THRU 04638 WIRING DIAGRAM NUMBER 96962 891
ENGINE IH UB-264 S/N 04639 THRU 05644 WIRING DIAGRAM 109795 895
ENGINE IH UC-263 S/N 01710 THRU 03131 WIRING DIAGRAM 109795 895
ENGINE IH UC-263 S/N 05645 AND UP WIRING DIAGRAM 109795 895
ENGINE IH UD-282 S/N 01710 THRU 03131 WIRING DIAGRAM 92695 892
ENGINE IH UD-282 S/N 04001 AND UP WIRING DIAGRAM 109796 896
CRANE MODEL 90, 100, 110 & 125 889
ENGINE DD 3-53N S/N 05410 AND UP WIRING DIAGRAM 111379 899
ENGINE IH UB-264 S/N 01001-04677 EXCEPT 04655-04657 WIRING DIAGRAM 96962 891
ENGINE IH UB-264 S/N 04655 THRU 04657, 04678 AND UP WIRING DIAGRAM 109795 895
ENGINE IH UC-263 S/N 05563 AND UP WIRING DIAGRAM 109795 895
ENGINE IH UD-282 S/N 01001 THRU 04677 WIRING DIAGRAM 92695 892
ENGINE IH UD-282 S/N 04678 AND UP WIRING DIAGRAM 109796 896
CRANE MODEL 125F 889
ENGINE MODEL DD4-53N S/N 02965 AND UP WIRING DIAGRAM 109797 897
CRANE MODEL 90A, 100A, 110A & 125A 889
ENGINE MODEL CUM UV-352C S/N 02006 AND UP WIRING DIAGRAM 97869 894
ENGINE MODEL DD4-53N S/N 02006 AND UP WIRING DIAGRAM 109797 897
ENGINE MODEL IH UV-345 S/N 02006 THRU 04677 WIRING DIAGRAM 96704 893
ENGINE MODEL UV-345 S/N 04678 AND UP WIRING DIAGRAM 109798 898
CRANE MODEL 125FA 889
ENGINE MODEL IH UV-345 S/N 07990 AND UP WIRING DIAGRAM 109798 898
ENGINE MODEL DD 4-53N S/N 07990 AND UP WIRING DIAGRAM 109797 897
CRANE MODEL 140F 889
ENGINE MODEL DD 3-53N S/N 07571 AND UP WIRING DIAGRAM 111379 899
CRANE MODEL 150 & 150FA 889
ENGINE MODEL CUM UV-352C S/N 02832 THRU 04246 WIRING DIAGRAM 97869 894
ENGINE MODEL DD 4-53N S/N 02832 AND UP WIRING DIAGRAM 109797 897
ENGINE MODEL DEUTZ F6L-912 S/N 2832 AND UP WIRING DIAGRAM 122748 900
ENGINE MODEL IH UV-345 S/N 02832 THRU 04677 WIRING DIAGRAM 96704 893
ENGINE MODEL IH UV-345 S/N 04678 AND UP WIRING DIAGRAM 109798 898
CRANE MODEL 180S 889
ENGINE MODEL DD 6V-53N S/N 08502 AND UP WIRING DIAGRAM 138253 901
CRANE MODEL 200FA 890
ENGINE MODEL DD 4-53N S/N 09401 AND UP WIRING DIAGRAM 109797 897
CRANE MODEL 220A 890
ENGINE MODEL DD 4-53N S/N 07107 AND UP WIRING DIAGRAM 109797 897
CRANE MODEL 220S 890
ENGINE MODEL DD6V-53N S/N 07724 ABD UP WIRING DIAGRAM 138253 901
CRANE MODEL 125P 890
ENGINE MODEL ALL S/N 01001 AND UP 902
ENGINE MODEL ELECTRIC MOTOR S/N 01001 AND UP 903
CRANE MODEL 150P & 150T 890
ENGINE MODEL ALL S/N 01011 AND UP 904
ENGINE MODEL ELECTRIC MOTOR S/N 01011 AND UP 905
29 L-10 00 TROUBLESHOOTING & REMOVAL OF CRANKING MOTORS (M-P-G-R-C) 907
CONTENTS 907
TORQUE SHEETS 908
PRELIMINARY CHECKS 909
REMOVAL 913
BENCH TESTING 914
INSTALLATION 917
LUBRICATION 918
30 L-11 00 TROUBLESHOOTING & REMOVAL OF ALTERNATORS (M-G-P-R-C) 919
CONTENTS 919
TORQUES SHEET 920
PRELIMINARY CHECKS 921
REMOVAL 926
INSTALLATION 927
LUBRICATION 928
31 N-03 40 PREDELIVERY PROCEDURES (C) (NOT INCLUDED – LISTED FOR REFERENCE ONLY) 928
32 O-01 00 HEAD AND HOOK BLOCK (C) 929
CONTENTS 929
TORQUE SHEET 930
DISASSEMBLY 931
INSPECTION 934
REASSEMBLY 937
CARE OF WIRE ROPE 940
WIRE ROPE REPLACEMENT 941
METHODS OF LUBRICATION 942
33 O-03 00 DRESSER HYDRAULIC CRANE – WIRE ROPE SPECIFICATION (C) 945
MODEL BREAKDOWN 947
MODEL 80 947
MODEL 90, 100, 110 AND 125 947
MODEL 125F 948
MODEL 90A, 100A, 110A AND 125A 948
MODEL 125FA 949
MODEL 140F 949
MODEL 150A 949
MODEL 150FA 950
MODEL 180S 950
MODEL 220A 950
MODEL 200FA 952
MODEL 220S 951
MODEL 400S 951
MODEL 125P 951
MODEL 150P AND 150T 952
FRONT END WINCH (ALL MODELS 952
MANUFACTURERS DESCRIPTION 953
WIRE ROPE 955
WIRE ROPE SPECIFICATIONS 955
MAINTENANCE RECOMMENDATIONS 955
SERVICE AND INSPECTION OF WIRE ROPE 956
RESTING HOOK BLOCK 956
IMPORTANCE OF LUBRICATION 956
RECOMMENDED LUBRICANTS FOR WIRE ROPE 957
METHODS OF LUBRICATIONS 958
LUBRICATION IN STORAGE 959
IDLE ROPES 959
COMPONENT PARTS OF WIRE ROPE 960
INSPECTION OF WIRE ROPE SHEAVES & DRUM 960
WIRE ROPE 960
SHEAVES AND DRUM 962
WIRE ROPE REPLACEMENT 962
INSTALLATION OF WIRE ROPE 963
BREAKING IN WIRE ROPE 964
HOOK AND HEAD BLOCK REEVING 964
34 Y-01 00 GENERAL TORQUE VALUES (G-R-P-C-M) 965
CONTENTS 965
INTRODUCTION 967
TORQUES 968
TORQUE VALUES FOR STANDARD ENGLISH FASTENERS 968
BOLT IDENTIFICATION CHART 968
TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE 968
TYPE 8 PHOSPHATE COATED HARDWARE 970
TORQUE VALUES FOR STANDARD METRIC FASTENERS 971
TORQUE VALUES FOR HOSE CLAMPS 972
TORQUE VALUES FOR SPLIT FLANG CONNECTIONS 973
TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS 974

S.V 11/12/24