CHAPTER 1 INTRODUCTION - TM-9-4940-568-34_19Figure 1-1. Forward Repair System - TM-9-4940-568-34_201-7. WARRANTY INFORMATION. - TM-9-4940-568-34_21SECTION II. EQUIPMENT DESCRIPTION AND DATA - TM-9-4940-568-34_221-12. ELECTRICAL SYSTEM1-13. HYDRAULIC SYSTEM - TM-9-4940-568-34_241-14. GENERATOR ENGINE SET1-15. GENERATOR FUEL SYSTEM1-16. COOLING SYSTEM. - TM-9-4940-568-34_271-17. AIR COMPRESSOR SYSTEM. - TM-9-4940-568-34_281-18. SOLAR AIR VENT. - TM-9-4940-568-34_291-19. SHELTER HEATER. - TM-9-4940-568-34_301-20. CRANE. - TM-9-4940-568-34_31CRANE (CONT). - TM-9-4940-568-34_32d. Overload Shutdown.CRANE (CONT). - TM-9-4940-568-34_34CHAPTER 2 TROUBLESHOOTING PROCEDURESTable 2-1. Troubleshooting Fault IndexTroubleshooting Fault Index (CONT). - TM-9-4940-568-34_37Table 2-2. Engine Fault IndexTable 2-3. Engine TroubleshootingEngine Troubleshooting (CONT). - TM-9-4940-568-34_40Engine Troubleshooting (CONT). - TM-9-4940-568-34_41Engine Troubleshooting (CONT). - TM-9-4940-568-34_42Engine Troubleshooting (CONT). - TM-9-4940-568-34_43Engine Troubleshooting (CONT). - TM-9-4940-568-34_44Table 2-4. Starter Motor Fault IndexTable 2-5. Starter Motor Troubleshooting.Starter Motor Troubleshooting (CONT).Table 2-6. Crane System Fault IndexFigure 2-1. Crane Electrical Wiring SchematicTable 2-7. Crane Troubleshooting.Crane Troubleshooting (CONT). - TM-9-4940-568-34_51Crane Troubleshooting (CONT). - TM-9-4940-568-34_52Crane Troubleshooting (CONT). - TM-9-4940-568-34_53Crane Troubleshooting (CONT). - TM-9-4940-568-34_54Crane Troubleshooting (CONT) - TM-9-4940-568-34_55Crane Troubleshooting (CONT). - TM-9-4940-568-34_56Crane Troubleshooting (CONT). - TM-9-4940-568-34_57Crane Troubleshooting (CONT). - TM-9-4940-568-34_58Crane Troubleshooting (CONT) - TM-9-4940-568-34_59Crane Troubleshooting (CONT). - TM-9-4940-568-34_60Crane Troubleshooting (CONT). - TM-9-4940-568-34_61Crane Troubleshooting (CONT). - TM-9-4940-568-34_62Crane Troubleshooting (CONT). - TM-9-4940-568-34_63Crane Troubleshooting (CONT). - TM-9-4940-568-34_64Crane Troubleshooting (CONT). - TM-9-4940-568-34_65Crane Troubleshooting (CONT)..Crane Troubleshooting (CONT). - TM-9-4940-568-34_67Crane Troubleshooting (CONT). - TM-9-4940-568-34_68Crane Troubleshooting (CONT). - TM-9-4940-568-34_69Crane Troubleshooting (CONT). - TM-9-4940-568-34_70Crane Troubleshooting (CONT). - TM-9-4940-568-34_71Crane Troubleshooting (CONT). - TM-9-4940-568-34_72Crane Troubleshooting (CONT). - TM-9-4940-568-34_73Crane Troubleshooting (CONT). - TM-9-4940-568-34_74Crane Troubleshooting (CONT). - TM-9-4940-568-34_75Crane Troubleshooting (CONT). - TM-9-4940-568-34_76Crane Troubleshooting (CONT). - TM-9-4940-568-34_77Crane Troubleshooting (CONT). - TM-9-4940-568-34_78Crane Troubleshooting (CONT). - TM-9-4940-568-34_79Crane Troubleshooting (CONT). - TM-9-4940-568-34_80Crane Troubleshooting (CONT). - TM-9-4940-568-34_81Crane Troubleshooting (CONT). - TM-9-4940-568-34_82Crane Troubleshooting (CONT). - TM-9-4940-568-34_83Crane Troubleshooting (CONT). - TM-9-4940-568-34_84Crane Troubleshooting (CONT). - TM-9-4940-568-34_85Crane Troubleshooting (CONT). - TM-9-4940-568-34_86Crane Troubleshooting (CONT). - TM-9-4940-568-34_87Crane Troubleshooting (CONT). - TM-9-4940-568-34_88Crane Troubleshooting (CONT). - TM-9-4940-568-34_89Crane Troubleshooting (CONT). - TM-9-4940-568-34_90Crane Troubleshooting (CONT). - TM-9-4940-568-34_91Crane Troubleshooting (CONT). - TM-9-4940-568-34_92Crane Troubleshooting (CONT). - TM-9-4940-568-34_93Crane Troubleshooting (CONT). - TM-9-4940-568-34_94Crane Troubleshooting (CONT). - TM-9-4940-568-34_95Crane Troubleshooting (CONT). - TM-9-4940-568-34_96Crane Troubleshooting (CONT). - TM-9-4940-568-34_97Crane Troubleshooting (CONT). - TM-9-4940-568-34_98Crane Troubleshooting (CONT). - TM-9-4940-568-34_99Crane Troubleshooting (CONT). - TM-9-4940-568-34_100Crane Troubleshooting (CONT). - TM-9-4940-568-34_101Crane Troubleshooting (CONT). - TM-9-4940-568-34_102Crane Troubleshooting (CONT). - TM-9-4940-568-34_103Crane Troubleshooting (CONT). - TM-9-4940-568-34_104Crane Troubleshooting (CONT). - TM-9-4940-568-34_105Crane Troubleshooting (CONT). - TM-9-4940-568-34_106CHAPTER 3 CRANE MAINTENANCE3-1. INTRODUCTION.3-3. CRANE PRINCIPLES OF OPERATIONCRANE PRINCIPLES OF OPERATION (Continued)Holding valvesc. Remote Control System.e. System Operation.3-4. CRANE REPLACEMENT.a. Removal. - TM-9-4940-568-34_115CRANE REPLACEMENT (CONT).b. Installation. - TM-9-4940-568-34_117c. Follow-On Maintenance - TM-9-4940-568-34_1183-5. CRANE LOAD TEST.CRANE LOAD TEST (CONT) - TM-9-4940-568-34_120CRANE LOAD TEST (CONT) - TM-9-4940-568-34_121b. Follow-On Maintenance - TM-9-4940-568-34_1223-6. TURNTABLE BEARING INSPECTION PROCEDURE.TURNTABLE BEARING INSPECTION PROCEDURE (CONT). (4) Position dial indicatorTURNTABLE BEARING INSPECTION PROCEDURE (CONT).b. Follow-On Maintenance - TM-9-4940-568-34_1273-7. THREE FUNCTION MANUAL CONTROL VALVE REPLACEMENTb. Installation - TM-9-4940-568-34_129THREE FUNCTION MANUAL CONTROL VALVE REPLACEMENT (Continued)3-8. OUTRIGGER EXTENSION CYLINDER REPLACEMENTOUTRIGGER EXTENSION CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_132b. Installation - TM-9-4940-568-34_133OUTRIGGER EXTENSION CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_1343-9. JACK CYLINDER REPLACEMENTJACK CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_136b. Cleaning/Inspection - TM-9-4940-568-34_137JACK CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_1383-10. OUTRIGGER BEAM MAINTENANCEOUTRIGGER BEAM MAINTENANCE (Continued) - TM-9-4940-568-34_140b. Installation - TM-9-4940-568-34_141OUTRIGGER BEAM MAINTENANCE (Continued) - TM-9-4940-568-34_142OUTRIGGER BEAM MAINTENANCE (Continued) - TM-9-4940-568-34_1433-11. THREE FUNCTION CONTROL VALVE MOUNTING BRACKET REPLACEMENTb. Installation - TM-9-4940-568-34_1453-12. SWING DRIVE ORBIT MOTOR REPLACEMENTSWING DRIVE ORBIT MOTOR REPLACEMENT -cont3-13. SWING DRIVE BRAKE REPLACEMENTb. Installation - TM-9-4940-568-34_1493-14. SWING DRIVE ASSEMBLY REPLACEMENTSWING DRIVE ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_151SWING DRIVE ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_152SWING DRIVE ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_153SWING DRIVE ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_154SWING DRIVE ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_155SWING DRIVE ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_1563-15. BOOM MID SECTION AND TELESCOPIC CYLINDER REPLACEMENT/ ADJUSTMENTBOOM MID SECTION AND TELESCOPIC CYLINDER REPLACEMENT/ ADJUSTMENT (Continued) - TM-9-4940-568-34_158b. Installation - TM-9-4940-568-34_159BOOM MID SECTION AND TELESCOPIC CYLINDER REPLACEMENT/ ADJUSTMENT (Continued) - TM-9-4940-568-34_160c. Adjustment - TM-9-4940-568-34_1613-16. BOOM FLY SECTION REPLACEMENT/ADJUSTMENTb. Installation - TM-9-4940-568-34_163BOOM FLY SECTION REPLACEMENT/ADJUSTMENT (Continued)c. Adjustment - TM-9-4940-568-34_1653-17. BOOM BASE SECTION REPLACEMENTBOOM BASE SECTION REPLACEMENT (Continued) - TM-9-4940-568-34_167b. Installation - TM-9-4940-568-34_168BOOM BASE SECTION REPLACEMENT (Continued) - TM-9-4940-568-34_169BOOM BASE SECTION REPLACEMENT (Continued) - TM-9-4940-568-34_1703-18. LIFT CYLINDER REPLACEMENTLIFT CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_172LIFT CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_173b. Installation - TM-9-4940-568-34_174LIFT CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_1753-19. ERECTION CYLINDER REPLACEMENT.ERECTION CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_177ERECTION CYLINDER REPLACEMENT (Continued) - TM-9-4940-568-34_1783-20. TENSION LINK REPLACEMENTTENSION LINK REPLACEMENT (Continued) - TM-9-4940-568-34_180TENSION LINK REPLACEMENT (Continued) - TM-9-4940-568-34_1813-21. MAST REPLACEMENTMAST REPLACEMENT (Continued) - TM-9-4940-568-34_183b. Installation - TM-9-4940-568-34_184MAST REPLACEMENT (Continued) - TM-9-4940-568-34_1853-22. CABLE FOLLOWER REPLACEMENT/REPAIRCABLE FOLLOWER REPLACEMENT/REPAIR (Continued) - TM-9-4940-568-34_187CABLE FOLLOWER REPLACEMENT/REPAIR (Continued) - TM-9-4940-568-34_1883-23. PROXIMITY SENSOR REPLACEMENTb. Installation - TM-9-4940-568-34_190c. Adjustment 3-24. HOIST HYDRAULIC MOTOR REPLACEMENTb. Installation - TM-9-4940-568-34_1933-25. OIL FILLED DISC BRAKE ASSEMBLY REPLACEMENTb. Installation - TM-9-4940-568-34_195OIL FILLED DISC BRAKE ASSEMBLY REPLACEMENT (Continued)3-26. HOIST ASSEMBLY REPLACEMENTHOIST ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_198HOIST ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_1993-27. OVERLOAD SHUTDOWN REPLACEMENTb. Installation - TM-9-4940-568-34_2013-28. TENSION LOAD CELL REPLACEMENTTENSION LOAD CELL REPLACEMENT (Continued) - TM-9-4940-568-34_203TENSION LOAD CELL REPLACEMENT (Continued) - TM-9-4940-568-34_204TENSION LOAD CELL REPLACEMENT (Continued) - TM-9-4940-568-34_205TENSION LOAD CELL REPLACEMENT (Continued) - TM-9-4940-568-34_2063-29. TURNTABLE BEARING REPLACEMENTTURNTABLE BEARING REPLACEMENT (Continued)3-30. TURNTABLE REPLACEMENTb. Installation - TM-9-4940-568-34_2103-31. FIVE FUNCTION CONTROL VALVE MOUNTING BRACKET REPLACEMENTFIVE FUNCTION CONTROL VALVE MOUNTING BRACKET REPLACEMENT (Continued) - TM-9-4940-568-34_212b. Installation - TM-9-4940-568-34_213FIVE FUNCTION CONTROL VALVE MOUNTING BRACKET REPLACEMENT (Continued) - TM-9-4940-568-34_2143-32. CROSS-RELIEF VALVE REPLACEMENTb. Installation - TM-9-4940-568-34_2163-33. FIVE FUNCTION CONTROL VALVE BANK REPLACEMENTFIVE FUNCTION CONTROL VALVE BANK REPLACEMENT (Continued) - TM-9-4940-568-34_218b. Installation - TM-9-4940-568-34_219FIVE FUNCTION CONTROL VALVE BANK REPLACEMENT (Continued) - TM-9-4940-568-34_2203-34. THREE FUNCTION MANUAL CONTROL VALVE REPAIRTHREE FUNCTION MANUAL CONTROL VALVE REPAIR (Continued)3-35. CRANE CONTROL VALVES REPAIRCRANE CONTROL VALVES REPAIR (Continued)c. Assembly - TM-9-4940-568-34_225d. Adjustment3-36. CRANE CONTROL VALVE REPLACEMENTb. Installation - TM-9-4940-568-34_2283-37. CRANE ELECTRIC SOLENOID VALVE REPLACEMENTb. Installation - TM-9-4940-568-34_2303-38. HOIST MOTOR CONTROL VALVE REPLACEMENTb. Installation - TM-9-4940-568-34_232HOIST MOTOR CONTROL VALVE REPLACEMENT (Continued)3-39. HOIST MOTOR HOLDING VALVE REPLACEMENTb. Installation - TM-9-4940-568-34_2353-40. BOOM ASSEMBLY REPLACEMENTBOOM ASSEMBLY REPLACEMENT -cont - TM-9-4940-568-34_237BOOM ASSEMBLY REPLACEMENT -cont - TM-9-4940-568-34_238b. Installation - TM-9-4940-568-34_239BOOM ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_240BOOM ASSEMBLY REPLACEMENT (Continued) - TM-9-4940-568-34_2413-41. HOIST HYDRAULIC PRESSURE ADJUSTMENTHOIST HYDRAULIC PRESSURE ADJUSTMENT -cont3-42. MAIN HYDRAULIC PRESSURE ADJUSTMENT3-43. CRANE TUBING REPLACEMENTCRANE TUBING REPLACEMENT (Continued) - TM-9-4940-568-34_246CRANE TUBING REPLACEMENT (Continued) - TM-9-4940-568-34_247CRANE TUBING REPLACEMENT (Continued) - TM-9-4940-568-34_2483-44. CRANE HOSES REPLACEMENTCRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_250CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_251CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_252CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_253CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_254CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_255CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_256CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_257CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_258CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_259CRANE HOSES REPLACEMENT (Continued) - TM-9-4940-568-34_2603-45. BOOM LIFT HOLDING VALVE REPLACEMENTb. Installation - TM-9-4940-568-34_2623-46. MANUAL OVERRIDE VALVE REPAIRMANUAL OVERRIDE VALVE REPAIR (Continued)b. Disassembly d. Assembly - TM-9-4940-568-34_266e. InstallationCHAPTER 4 HYDRAULIC MAINTENANCE4-2. HYDRAULIC PUMP REPLACEMENTb. Disassembly. - TM-9-4940-568-34_271d. Installation.e. Follow-On Maintenance4-3. HYDRAULIC PUMP ADJUSTMENT.HYDRAULIC PUMP ADJUSTMENT (CONT) - TM-9-4940-568-34_275HYDRAULIC PUMP ADJUSTMENT (CONT) - TM-9-4940-568-34_276HYDRAULIC PUMP ADJUSTMENT (CONT) - TM-9-4940-568-34_277HYDRAULIC PUMP ADJUSTMENT (CONT) - TM-9-4940-568-34_278CHAPTER 5 GENERATOR AND ENGINE MAINTENANCE5-2. GENERATOR HOUSING REPLACEMENT.GENERATOR HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_281GENERATOR HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_282b. Installation. - TM-9-4940-568-34_283GENERATOR HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_284c. Follow-On Maintenance - TM-9-4940-568-34_2855-3. GENERATOR SET REPLACEMENTa. Removal. - TM-9-4940-568-34_287GENERATOR SET REPLACEMENT (CONT). - TM-9-4940-568-34_288GENERATOR SET REPLACEMENT (CONT). - TM-9-4940-568-34_289GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_290GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_291GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_292b. Installation. - TM-9-4940-568-34_293GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_294GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_295GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_296GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_297GENERATOR SET REPLACEMENT (CONT) - TM-9-4940-568-34_2985-4. ENGINE REPLACEMENT.ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_300ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_301ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_302ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_303ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_304ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_305ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_306ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_307ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_308ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_309ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_310ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_311ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_312ENGINE REPLACEMENT (CONT) - TM-9-4940-568-34_3135-5. ENGINE MOUNT REPLACEMENT.b. Cleaning/Inspection. - TM-9-4940-568-34_3155-6. TIMING PIN REPLACEMENT.TIMING PIN REPLACEMENT (CONT). - TM-9-4940-568-34_317TIMING PIN REPLACEMENT (CONT). - TM-9-4940-568-34_3185-7. CYLINDER HEAD REPLACEMENT.CYLINDER HEAD REPLACEMENT (CONT). - TM-9-4940-568-34_320c. Installation. - TM-9-4940-568-34_321CYLINDER HEAD REPLACEMENT (CONT). - TM-9-4940-568-34_3225-8. ENGINE COMPRESSION CHECK.b. Valve Sealingc. Head Gasket Sealing.ENGINE COMPRESSION CHECK (CONT). 5-9. CRANKSHAFT FRONT SEAL REPLACEMENT.c. Installation5-10. CRANKSHAFT REAR SEAL REPLACEMENT.CRANKSHAFT REAR SEAL REPLACEMENT (CONT). - TM-9-4940-568-34_330b. Cleaning/Inspection. - TM-9-4940-568-34_331c. Installation. - TM-9-4940-568-34_332CRANKSHAFT REAR SEAL REPLACEMENT (CONT). - TM-9-4940-568-34_3335-11. FLYWHEEL RING/GEAR AND FLYWHEEL HOUSING REPLACEMENTb. Disassembly. - TM-9-4940-568-34_335c. Cleaning/Inspection. - TM-9-4940-568-34_336d. Assembly - TM-9-4940-568-34_337FLYWHEEL RING/GEAR AND FLYWHEEL HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_338f. Flywheel Housing Bore Alignment Check.FLYWHEEL RING/GEAR AND FLYWHEEL HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_340FLYWHEEL RING/GEAR AND FLYWHEEL HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_341g. Flywheel Housing Face Alignment Checkh. Follow-On Maintenance5-12. PUSH ROD COVER REPLACEMENT.c. Installation. - TM-9-4940-568-34_3455-13. LUBE OIL PUMP REPAIR.b. Disassembly. - TM-9-4940-568-34_347LUBE OIL PUMP REPAIR (CONT). - TM-9-4940-568-34_348LUBE OIL PUMP REPAIR (CONT). - TM-9-4940-568-34_349d. Assembly - TM-9-4940-568-34_350f. Follow-On Maintenance5-14. FRONT GEAR COVER REPLACEMENTb. Cleaning/Inspection - TM-9-4940-568-34_353FRONT GEAR COVER REPLACEMENT (CONT)5-15. FUEL TANK REPLACEMENTFUEL TANK REPLACEMENT (CONT) - TM-9-4940-568-34_356b. Cleaning/Inspection. - TM-9-4940-568-34_357c. Installation. - TM-9-4940-568-34_358FUEL TANK REPLACEMENT (CONT).d. Follow-On Maintenance5-16. FUEL INJECTOR REPLACEMENTFUEL INJECTOR REPLACEMENT (CONT). - TM-9-4940-568-34_362FUEL INJECTOR REPLACEMENT (CONT). - TM-9-4940-568-34_363c. Cleaning/Inspection. - TM-9-4940-568-34_364d. Testing.FUEL INJECTOR REPLACEMENT (CONT). - TM-9-4940-568-34_366f. Installation.FUEL INJECTOR REPLACEMENT (CONT)5-17. FUEL INJECTION PUMP REPLACEMENTFUEL INJECTION PUMP REPLACEMENT (CONT) - TM-9-4940-568-34_370FUEL INJECTION PUMP REPLACEMENT (CONT) - TM-9-4940-568-34_371FUEL INJECTION PUMP REPLACEMENT (CONT) - TM-9-4940-568-34_372b. Installation. - TM-9-4940-568-34_373FUEL INJECTION PUMP REPLACEMENT (CONT).c. Follow-On Maintenance - TM-9-4940-568-34_3755-18. FUEL INJECTION PUMP ADJUSTMENT.5-19. FUEL INJECTION PUMP TIMING.FUEL INJECTION PUMP TIMING (CONT). - TM-9-4940-568-34_378FUEL INJECTION PUMP TIMING (CONT). - TM-9-4940-568-34_379FUEL INJECTION PUMP TIMING (CONT). - TM-9-4940-568-34_380FUEL INJECTION PUMP TIMING (CONT). - TM-9-4940-568-34_3815-20. FUEL SHUTOFF VALVE REPLACEMENTb. Installation. - TM-9-4940-568-34_3835-21. GENERATOR REPLACEMENTGENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_385GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_386GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_387GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_388GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_389GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_390GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_391GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_392GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_393b. Installation. - TM-9-4940-568-34_394GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_395GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_396GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_397GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_398GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_399GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_400GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_401GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_402GENERATOR REPLACEMENT (CONT). - TM-9-4940-568-34_403c. Follow-On Maintenance - TM-9-4940-568-34_4045-22. GENERATOR TESTINGGENERATOR TESTING (CONT). - TM-9-4940-568-34_406GENERATOR TESTING (CONT). - TM-9-4940-568-34_407GENERATOR TESTING (CONT). - TM-9-4940-568-34_408GENERATOR TESTING (CONT). - TM-9-4940-568-34_409GENERATOR TESTING (CONT). - TM-9-4940-568-34_410GENERATOR TESTING (CONT). - TM-9-4940-568-34_411GENERATOR TESTING (CONT). - TM-9-4940-568-34_412HAZARDOUS VOLTAGE5-23. STARTER MOTOR REPAIR.a. Disassembly of Frame and Field AssemblySTARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_416b. Disassembly of Brush Holder Group.c. Disassembly of Gear Reduction and Drive Group.d. Disassembly of Drive Shaft and Clutch GroupSTARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_420e. Cleaning/InspectionSTARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_422f. Component Electrical TestingSTARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_424g. Assembly of Drive Shaft and Clutch Grouph. Assembly of Gear Reduction and Drive Group.STARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_427i. Assembly of Brush Holder GroupSTARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_429j. Assembly of Frame and Field Assembly.STARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_431STARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_432STARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_433k. Testing After Repair Or Overhaul.STARTER MOTOR REPAIR (CONT) - TM-9-4940-568-34_4355-24. GENERATOR ELECTRONIC CIRCUIT CARD (ECC) REPLACEMENT.b. Installation. - TM-9-4940-568-34_437c. Follow-On Maintenance - TM-9-4940-568-34_4385-25. GENERATOR VOLTAGE REGULATOR CARD (VR21) REPLACEMENT.b. Installation - TM-9-4940-568-34_440c. Follow-On Maintenance.CHAPTER 6 GENERAL SUPPORT CRANE MAINTENANCE6-2. OUTRIGGER EXTENSION CYLINDER REPAIROUTRIGGER EXTENSION CYLINDER REPAIR (Continued) - TM-9-4940-568-34_445b. Cleaning/Inspection - TM-9-4940-568-34_446c. Assembly - TM-9-4940-568-34_447OUTRIGGER EXTENSION CYLINDER REPAIR (Continued) - TM-9-4940-568-34_4486-3. JACK CYLINDER REPAIRa. DisassemblyJACK CYLINDER REPAIR (Continued) - TM-9-4940-568-34_451JACK CYLINDER REPAIR (Continued) - TM-9-4940-568-34_452b. Cleaning/Inspection - TM-9-4940-568-34_453c. Assembly JACK CYLINDER REPAIR (Continued) - TM-9-4940-568-34_455JACK CYLINDER REPAIR (Continued) - TM-9-4940-568-34_4566-4. SWING DRIVE ORBIT MOTOR REPAIRSWING DRIVE ORBIT MOTOR REPAIR (Continued) - TM-9-4940-568-34_458c. Assembly - TM-9-4940-568-34_459SWING DRIVE ORBIT MOTOR REPAIR (Continued) - TM-9-4940-568-34_460SWING DRIVE ORBIT MOTOR REPAIR (Continued) - TM-9-4940-568-34_4616-5. SWING DRIVE BRAKE REPAIRb. Cleaning/Inspection - TM-9-4940-568-34_4636-6. SWING DRIVE ASSEMBLY REPAIRSWING DRIVE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_465SWING DRIVE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_466SWING DRIVE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_467SWING DRIVE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_468SWING DRIVE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_469SWING DRIVE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_4706-7. GEAR SET REPAIRGEAR SET REPAIR (Continued) - TM-9-4940-568-34_472GEAR SET REPAIR (Continued) - TM-9-4940-568-34_473c. AssemblyGEAR SET REPAIR (Continued) - TM-9-4940-568-34_475GEAR SET REPAIR (Continued) - TM-9-4940-568-34_4766-8. OIL FILLED DISC BRAKE ASSEMBLY REPAIROIL FILLED DISC BRAKE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_478b. Cleaning/Inspection - TM-9-4940-568-34_479OIL FILLED DISC BRAKE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_480OIL FILLED DISC BRAKE ASSEMBLY REPAIR (Continued) - TM-9-4940-568-34_4816-9. LIFT CYLINDER REPAIRLIFT CYLINDER REPAIR (Continued) - TM-9-4940-568-34_483b. Cleaning/Inspection - TM-9-4940-568-34_484LIFT CYLINDER REPAIR (Continued) - TM-9-4940-568-34_4856-10. ERECTION CYLINDER REPAIRERECTION CYLINDER REPAIR (Continued) - TM-9-4940-568-34_487ERECTION CYLINDER REPAIR (Continued) - TM-9-4940-568-34_488ERECTION CYLINDER REPAIR (Continued) - TM-9-4940-568-34_489ERECTION CYLINDER REPAIR (Continued) - TM-9-4940-568-34_4906-11. BOOM TELESCOPIC CYLINDER REPAIRBOOM TELESCOPIC CYLINDER REPAIR (Continued) - TM-9-4940-568-34_492b. Cleaning/Inspection - TM-9-4940-568-34_493BOOM TELESCOPIC CYLINDER REPAIR (Continued) - TM-9-4940-568-34_4946-12. CROSS-RELIEF VALVE REPAIRb. Cleaning/Inspection - TM-9-4940-568-34_4966-13. FIVE FUNCTION CONTROL VALVE MANIFOLD REPAIRb. Assembly - TM-9-4940-568-34_4986-14. HOIST, BOOM, TELESCOPE, SWING SOLENOID PILOT VALVE REPAIRb. Cleaning/Inspection - TM-9-4940-568-34_500CHAPTER 7 GENERAL SUPPORT ENGINE AND GENERATOR MAINTENANCE7-2. INSTALLING/REMOVING ENGINE FROM STAND.b. Removing Engine From Engine Stand.c. Follow-On Maintenance - TM-9-4940-568-34_5047-3. CYLINDER BLOCK REPAIR AND DE-GLAZING INSTRUCTIONSa. Removal. - TM-9-4940-568-34_506CYLINDER BLOCK REPAIR AND DE-GLAZING INSTRUCTIONS (CONT) - TM-9-4940-568-34_507CYLINDER BLOCK REPAIR AND DE-GLAZING INSTRUCTIONS (CONT) - TM-9-4940-568-34_508CYLINDER BLOCK REPAIR AND DE-GLAZING INSTRUCTIONS (CONT) - TM-9-4940-568-34_509c. De-Glazing and HoningCYLINDER BLOCK REPAIR AND DE-GLAZING INSTRUCTIONS (CONT). d. Installatione. Follow-On Maintenance - TM-9-4940-568-34_5137-4. CYLINDER HEAD REPAIRa. Disassembly.b. Cleaning/Inspection. - TM-9-4940-568-34_516CYLINDER HEAD REPAIR (CONT) - TM-9-4940-568-34_517CYLINDER HEAD REPAIR (CONT) - TM-9-4940-568-34_518CYLINDER HEAD REPAIR (CONT) - TM-9-4940-568-34_519CYLINDER HEAD REPAIR (CONT) - TM-9-4940-568-34_520CYLINDER HEAD REPAIR (CONT) - TM-9-4940-568-34_521c. Valve Springs Inspectione. Follow-On Maintenance - TM-9-4940-568-34_5237-5. CRANKSHAFT AND BEARINGS REPLACEMENT.CRANKSHAFT AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_525CRANKSHAFT AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_526c. Cleaning/Inspection. - TM-9-4940-568-34_527CRANKSHAFT AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_528d. Assembly - TM-9-4940-568-34_529CRANKSHAFT AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_530CRANKSHAFT AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_531CRANKSHAFT AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_5327-6. PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT.PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_534PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_535PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_536PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_537PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_538b. Cleaning/Inspection. - TM-9-4940-568-34_539PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_540PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_541PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_542PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_543c. Installation. - TM-9-4940-568-34_544PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_545PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_546PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_547PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_548PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT). - TM-9-4940-568-34_549PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_550PISTONS, CONNECTING RODS, AND BEARINGS REPLACEMENT (CONT) - TM-9-4940-568-34_5517-7. CAMSHAFT AND VALVE TAPPETS REPLACEMENT.CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_553CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_554CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_555b. Cleaning/Inspection. - TM-9-4940-568-34_556CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_557CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_558CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_559CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_560d. Camshaft Bore Inspection.CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_562CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_563CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_564CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_565CAMSHAFT AND VALVE TAPPETS REPLACEMENT (CONT) - TM-9-4940-568-34_5667-8. CAMSHAFT GEAR REPLACEMENT.b. Cleaning/Inspection. - TM-9-4940-568-34_568c. Installation. - TM-9-4940-568-34_5697-9. FRONT GEAR HOUSING REPLACEMENT.b. Cleaning/Inspection - TM-9-4940-568-34_571FRONT GEAR HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_572FRONT GEAR HOUSING REPLACEMENT (CONT). - TM-9-4940-568-34_573d. Relocating The Timing Pin.FRONT GEAR HOUSING REPLACEMENT (CONT) - TM-9-4940-568-34_575FRONT GEAR HOUSING REPLACEMENT (CONT) - TM-9-4940-568-34_576FRONT GEAR HOUSING REPLACEMENT (CONT) - TM-9-4940-568-34_577e. Follow-On Maintenance - TM-9-4940-568-34_5787-10. GENERATOR REPAIRGENERATOR REPAIR (CONT). - TM-9-4940-568-34_580GENERATOR REPAIR (CONT). - TM-9-4940-568-34_581b. Assembly - TM-9-4940-568-34_582c. Follow-On Maintenance - TM-9-4940-568-34_583CHAPTER 8 GENERAL SUPPORT PNEUMATIC SYSTEM MAINTENANCE8-2. AIR COMPRESSOR REPAIR.AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_587AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_588AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_589AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_590AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_591AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_592AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_593AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_594AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_595AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_596AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_597AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_598AIR COMPRESSOR REPAIR (CONT). - TM-9-4940-568-34_599AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_600AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_601AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_602AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_603AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_604AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_605AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_606AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_607AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_608AIR COMPRESSOR REPAIR (CONT) - TM-9-4940-568-34_609APPENDIX A REFERENCES - TM-9-4940-568-34_611APPENDIX B EXPENDABLE SUPPLIES AND MATERIALS LISTSection II. EXPENDABLE SUPPLIES AND MATERIALS LIST - TM-9-4940-568-34_614EXPENDABLE SUPPLIES AND MATERIALS LIST (CONT) - TM-9-4940-568-34_615EXPENDABLE SUPPLIES AND MATERIALS LIST (CONT) - TM-9-4940-568-34_616APPENDIX C ILLUSTRATED LIST OF MANUFACTURED ITEMSSection II. MANUFACTURED ITEMS - TM-9-4940-568-34_618Table C-2. Wire And Wire AssembliesC-4. HOSES AND TUBESC-5. WOODEN BLOCKS.C-6. WOODEN DOWEL RODC-7. WOODEN DOWEL PINC-9. BEARING REMOVAL TOOL.C-10. ALIGNMENT PIN.C-11. SHUTTLE VALVE INSTALLATION/REMOVAL TOOL.APPENDIX D TORQUE LIMITSD-3. HOW TO USE TORQUE TABLE (CONT).b. Hoses and Fittings. - TM-9-4940-568-34_629Table D-3. Torque Limits For Dry FastenersTable D-4. Torque Limits For Wet FastenersTable D-5. Torque Limits For 37 Degree Flare Hose ConnectionsTable D-7. Torque Limits For ORS Preformed Packing Face Seal Hose ConnectionsAPPENDIX E MANDATORY REPLACEMENT PARTSSection II. MANDATORY REPLACEMENT PARTS LIST - TM-9-4940-568-34_636MANDATORY REPLACEMENT PARTS LIST (CONT) - TM-9-4940-568-34_637MANDATORY REPLACEMENT PARTS LIST (CONT) - TM-9-4940-568-34_638MANDATORY REPLACEMENT PARTS LIST (CONT) - TM-9-4940-568-34_639MANDATORY REPLACEMENT PARTS LIST (CONT) - TM-9-4940-568-34_640MANDATORY REPLACEMENT PARTS LIST (CONT) - TM-9-4940-568-34_641APPENDIX F TOOL IDENTIFICATION LISTSection II. COMMON TOOLS, TEST EQUIPMENT AND TOOL KITS (CONT) - TM-9-4940-568-34_644COMMON TOOLS, TEST EQUIPMENT AND TOOL KITS (CONT)FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 1 OF 19 - TM-9-4940-568-34_653FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 2 OF 19 - TM-9-4940-568-34_655FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 3 OF 19 - TM-9-4940-568-34_657FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 4 OF 19 - TM-9-4940-568-34_659FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 5 OF 19 - TM-9-4940-568-34_661FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 6 OF 19 - TM-9-4940-568-34_663FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 7 OF 19 - TM-9-4940-568-34_665FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 8 OF 19 - TM-9-4940-568-34_667FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 9 OF 19 - TM-9-4940-568-34_669FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 10 OF 19 - TM-9-4940-568-34_671FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 11 OF 19 - TM-9-4940-568-34_673FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 12 OF 19 - TM-9-4940-568-34_675FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 13 OF 19 - TM-9-4940-568-34_677FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 14 OF 19 - TM-9-4940-568-34_679FIGURE FO-1. ELECTRICAL SYSTEM SCHEMATIC FOLDOUT 15 OF 19 - TM-9-4940-568-34_681FIGURE FO-2. AIR COMPRESSOR HOSE SCHEMATIC FOLDOUT 16 OF 19 - TM-9-4940-568-34_683FIGURE FO-3. HYDRAULIC SYSTEM SCHEMATIC FOLDOUT 17 OF 19 - TM-9-4940-568-34_685FIGURE FO-3. HYDRAULIC SYSTEM SCHEMATIC FOLDOUT 18 OF 19 - TM-9-4940-568-34_687FIGURE FO-4. WELDING HOSE SCHEMATIC FOLDOUT 19 OF 19 - TM-9-4940-568-34_689