TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR ALL-TERRAIN CRANE (ATEC) AT422T DIESEL ENGINE DRIVEN, 22 TON CAPACITY TRUCK MOUNTED WITH CAB NSN 3810-01-448-2619 DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY August 2000
WARNING OPERATIONS ADJACENT TO OVERHEAD LINES ARE PROHIBITED UNLESS ONE OF THE FOLLOWING CONDITIONS ARE SATISFIED. 1 POWER HAS BEEN SHUT OFF AND POSITIVE MEANS TAKEN TO PREVENT LINES FROM BEING ENERGIZED. 2 POSITION AND BLOCK EQUIPMENT INSURING NO PARTS, INCLUDING CABLE, CAN COME WITHIN THE FOLLOWING CLEARANCES: VOLTAGE REQD CLEARANCE UNDER 50 KV - 10 FEET 69 KV - 12 FEET 115-161 KV - 15 FEET 230-285 KV - 20 FEET 345 KV - 25 FEET 500 KV - 35 FEET CHECK WITH YOUR LOCAL POWER SUPPLIER FOR CORRECT LINE VOLTAGE NOTE READ AND UNDERSTAND ALL OF THE SAFETY WARNINGS AND CAUTIONS CONTAINED IN SECTION 2 OF THE OPERATOR'S MANUAL BEFORE OPERATING OR MAINTAINING THE CRANE, DIRECT ANY QUESTIONS THAT YOU MAY HAVE TO YOUR SUPERVISOR FOR CLARIFICATION. a
CHANGE HEADQUARTERS, DEPARTMENT OF THE ARMY NO. 1 WASHINGTON, D.C. 1 July 2006 TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR All-Terrain Crane (ATEC) Diesel Engine Driven, 22 Ton Capacity Truck Mounted With Cab NSN 3810-01-448-2619 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. TM 5-3810-307-24-1-1, 1 August 2000, is updated as follows: 1. File this sheet in front of the manual for reference. 2. This change is a result of changes documented against the configuration of the crane. Extreme weather equipment including engine coolant and hydraulic reservoir heaters have been added as an option. 3. New or updated test is indicated by a vertical bar in the outer margin of the page. 4. Added illustrations are indicated by a vertical bar adjacent to the figure number. Changed illustrations are indicated by change bars in the outside margin adjacent to the updated area and a change bar adjacent to the figure number. 5. Remove old pages and insert new pages as indicated below: Remove Pages Insert Pages List of Effective Pages List of Effective Pages i thru ix i thru ix 1-1-3 and 1-1-4 1-1-3 and 1-1-4 1-1-7 and 1-1-8 1-1-7 and 1-1-8 1-2-5 and 1-2-6 1-2-5 and 1-2-6 1-3-5 thru 1-3-10 1-3-5 thru 1-3-10 1-4-5 thru 1-4-8 1-4-5 thru 1-4-8 2-1-3 and 2-1-4 2-1-3 and 2-1-4 2-1-25 and 2-1-26 2-1-25 and 2-1-26 2-1-31 thru 2-1-34 2-1-31 thru 2-1-34 None 2-1-101 and 2-1-102 2-2-27 thru 2-2-30 2-2-27 thru 2-2-30 2-5-1 and 2-5-2 2-5-1 and 2-5-2 None 2-7-1 thru 2-7-4 2-5-23/(2-5-24 blank) 2-7-1 thru 2-7-4 2-7-11 and 2-7-12 2-7-11 and 2-7-12 2-7-17 and 2-7-18 2-7-17 and 2-7-18 2-7-21 thru 2-7-36 2-7-21 thru 2-7-36 None 2-7-37/(2-7-38 blank) 2-8-1 and 2-8-2 None 2-8-1 and 2-8-2 2-8-18a/(2-8-18b blank)
Remove Pages Insert Pages 2-8-21 and 2-8-22 2-8-21 and 2-8-22 2-8-29 and 2-8-30 2-8-29 and 2-8-30 2-8-31 and 2-8-32 2-8-31 and 2-8-32 2-8-37 and 2-8-38 2-8-37 and 2-8-38 2-8-43 and 2-8-44 2-8-43 and 2-8-44 2-8-47 and 2-8-48 2-8-47 and 2-8-48 2-8-53 and 2-8-54 2-8-53 and 2-8-54 2-8-61 thru 2-8-64 2-8-61 thru 2-8-64 2-9-5 and 2-9-6 2-9-5 and 2-9-6 2-9-17 and 2-9-18 2-9-17 and 2-9-18 2-10-3 and 2-10-4 2-10-3 and 2-10-4 2-10-11 and 2-10-12 2-10-11 and 2-10-12 2-16-1 and 2-16-2 2-16-1 and 2-16-2 Appendix A (A-1 thru A-21/(A-22 blank) Appendix A (A-1 thru A-21/(A-22 blank) Index-1 and Index-22 Index-1 and Index-20
By Order of the Secretary of the Army: Official: PETER J. SCHOOMAKER General, United States Army Chief of Staff JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 0615301 Distribution: To be distributed in accordance with the initial distribution number (IDN) 256626, requirements for TM 5-3810-307-24-1-1.
INSERT LATEST CHANGED PAGES. DESTROY SUPERCEDED DATA. LIST OF EFFECTIVE PAGES NOTE: The portion of text affected by the changes is indicated by a vertical line in the outer margins of the pages. Changes to illustrations are also indicated by vertical lines in the outer margins. Original: 01 August 2000; Change 1: 01 July 2006 Dates of issue for original and changed pages are: TOTAL NUMBER OF PAGES FOR THIS MANUAL IS 644 CONSISTING OF THE FOLLOWING: Page No. *Change No. Page No. *Change No. Page No. *Change No. Cover 0 Divider 0 2-7-22 0 Blank 0 Blank 0 2-7-23 1 Warning 0 2-1-1 2-1-2 0 2-7-24 2-7-25 0 Blank 0 2-1-3 1 2-7-26 2-7-27 1 i ii 1 2-1-4 2-1-24 0 2-7-28 2-7-29 0 iii 0 2-1-25 1 2-7-30 2-7-38 1 iv vi 1 2-1-26 2-1-31 0 2-8-1 1 vii 0 2-1-32 1 2-8-2 2-8-18 0 viii x 1 2-1-33 0 2-8-18a 2-8-18b 1 Divider 0 2-1-34 1 2-8-19 2-8-20 0 Blank 0 2-1-35 2-1-100 0 2-8-21 1 1-1-1 1-1-2 0 2-1-101 2-1-102 1 2-8-22 2-8-29 0 1-1-3 1 2-2-1 2-2-26 0 2-8-30 1 1-1-4 1-1-6 0 2-2-27 1 2-8-31 0 1-1-7 1 2-2-28 2-2-29 0 2-8-32 1 1-1-8 1-1-10 0 2-2-30 1 2-8-33 2-8-36 0 1-2-1 1-2-5 0 2-2-31 2-2-42 0 2-8-37 1 1-2-6 1 2-3-1 2-3-36 0 2-8-38 2-8-42 0 1-2-7 1-2-10 0 2-4-1 2-4-36 0 2-8-43 1 1-3-1 1-3-4 0 2-5-1 0 2-8-44 2-8-46 0 1-3-5 1-3-6 1 2-5-2 1 2-8-47 1 1-3-7 0 2-5-3 2-5-22 0 2-8-48 2-8-52 0 1-3-8 1 2-5-23 2-5-24 1 2-8-53 1 1-3-9 0 2-6-1 2-6-6 0 2-8-54 2-8-60 0 1-3-10 1 2-7-1 2-7-4 1 2-8-61 2-8-63 1 1-3-11 1-3-12 0 2-7-5 2-7-10 0 2-8-64 2-8-78 0 1-4-1 1-4-4 0 2-7-11 2-7-12 1 2-9-1 2-9-5 0 1-4-5 1-4-6 1 2-7-13 2-7-17 0 2-9-6 1 1-4-7 0 2-7-18 1 2-9-7 2-9-17 0 1-4-8 1 2-7-19 2-7-20 0 2-9-18 1 1-4-9 1-1-14 0 2-7-21 1 1-5-1 1-5-34 0 * Zero in this column indicates an original page. A C-1
LIST OF EFFECTIVE PAGES - Continued Page No. *Change No. Page No. *Change No. Page No. *Change No. 2-10-1 2-10-3 0 2-10-4 1 2-10-5 2-10-10 0 2-10-11 1 2-10-12 2-10-22 0 2-11-1 2-11-16 0 2-12-1 2-12-14 0 2-13-1 2-13-12 0 2-14-1 2-14-30 0 2-15-1 2-15-10 0 2-16-1 2-16-2 1 2-16-3 2-16-4 0 A-1 A-22 1 Index-1 Index-20 1 FO-1 FO-14 0 * Zero in this column indicates an original page. C-1 B
HEADQUARTERS, DEPARTMENT OF THE ARMY WASHINGTON D.C., 1 AUGUST 2000 COMMERCIAL SERVICE MANUAL ALL-TERRAIN CRANE (ATEC) DIESEL ENGINE DRIVEN, 22 TON CAPACITY TRUCK MOUNTED WITH CAB GROVE MODEL AT422T CONTRACT NO. DAAE07-97-D-X001 NSN 3810-01-448-2619 CAGE 12361 PART NUMBER 1140000513 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical Publications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to: AMSTA-LC-LPIT / TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The email address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726. TABLE OF CONTENTS VOLUME 1 Page HOW TO USE THIS MANUAL... vii CHAPTER ONE - GENERAL DESCRIPTION AND MAINTENANCE SECTION 1 - GENERAL DESCRIPTION...1-1-1 SECTION 2 - GENERAL MAINTENANCE...1-2-1 SECTION 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...1-3-1 SECTION 4 - LUBRICATION...1-4-1 SECTION 5 - TROUBLESHOOTING...1-5-1 W i C-1
TABLE OF CONTENTS - Continued Page CHAPTER TWO - DETAILED DESCRIPTION AND MAINTENANCE SECTION 1 - CABS...2-1-1 Cabs...2-1-7 Carrier Cab...2-1-8 Superstructure Cab...2-1-8 Maintenance...2-1-9 SECTION 2 - ENGINE...2-2-1 Engine...2-2-5 Fuel System... 2-2-19 Air Intake System... 2-2-25 Water Cooling System... 2-2-32 Exhaust System.... 2-2-38 SECTION 3 - DRIVE TRAIN...2-3-1 Drive Train...2-3-5 Transmission/Torque Converter...2-3-7 Transmission Control Valve... 2-3-10 Transmission Oil Cooler... 2-3-11 Automatic Powershift Control (APC 100)... 2-3-13 SECTION 4 AXLES AND BRAKE SYSTEM...2-4-1 Axles...2-4-5 Axle Proximity Sensor Assemblies... 2-4-13 Rear Axle Steering Unlock Switch... 2-4-20 Wheels and Tires.... 2-4-22 Brake System... 2-4-23 Service Brakes... 2-4-24 Brake Chamber (Front Wheels)... 2-4-27 Brake Chamber (Rear Wheels)... 2-4-33 Air Valves... 2-4-36 SECTION 5 - STEERING SYSTEMS....2-5-1 Steering Systems...2-5-3 Steering Gear...2-5-6 Miter Gear... 2-5-10 Selector Valves... 2-5-12 Steering Pump... 2-5-14 Integrated Outrigger Valve.... 2-5-16 Steer Cylinders... 2-5-17 Emergency (Standby) Steering Valve and Pump... 2-5-19 Steering System Filter Check Valve... 2-5-23 ii C-1
TABLE OF CONTENTS - Continued Page SECTION 6 - AXLE OSCILLATION SYSTEM...2-6-1 Axle Oscillation System....2-6-3 Lockout Cylinders...2-6-4 Double Solenoid Valves...2-6-6 SECTION 7 - AIR SYSTEM...2-7-1 Air System...2-7-5 Air System Components...2-7-8 SECTION 8 - HYDRAULIC SYSTEM....2-8-1 Hydraulic System...2-8-9 Supply Pressure and Return Circuit... 2-8-14 Hydraulic Pump... 2-8-19 Hydraulic Pump Disconnect... 2-8-21 Valves... 2-8-23 Cylinders... 2-8-56 SECTION 9 - SWING SYSTEM...2-9-1 Swing System...2-9-5 Swing Motor...2-9-6 Swing Gearbox and Brake....2-9-8 Swing Bearing... 2-9-11 SECTION 10 - BOOM... 2-10-1 Boom... 2-10-5 Boom Extension and Retraction Cable... 2-10-12 Telescope Circuit... 2-10-14 Lift Circuit... 2-10-15 Hook Block... 2-10-18 Boom Hose Reel... 2-10-19 SECTION 11 - HOISTS... 2-11-1 Hoists... 2-11-3 Vane Type Motor... 2-11-7 Cable Idler Drum and Follower... 2-11-9 Hoist to Boom Alignment... 2-11-12 Hoist Drum Rotation Indicator... 2-11-14 SECTION 12 - OUTRIGGERS... 2-12-1 Outrigger Circuit... 2-12-3 Outrigger Box Assembly... 2-12-5 Extension Cylinder... 2-12-8 Stabilizer Cylinder... 2-12-10 Integrated Outrigger Valve.... 2-12-12 Solenoid Valve Stack... 2-12-13 Pilot Operated Check Valve... 2-12-14 iii
TABLE OF CONTENTS - Continued Page SECTION 13 - SWIVELS... 2-13-1 Swivels... 2-13-3 14 Port Air/Hydraulic Swivel... 2-13-5 Electrical Swivel... 2-13-9 SECTION 14 - ELECTRICAL SYSTEM... 2-14-1 Electrical System... 2-14-5 SECTION 15 - EMERGENCY STOWAGE SYSTEM... 2-15-1 Emergency Stowage System... 2-15-3 3-Way Valve Assembly... 2-15-4 Pump/Motor Assembly... 2-15-6 Electrical Control Box Assembly... 2-15-8 SECTION 16 - PREPARATION FOR SHIPMENT AND STORAGE... 2-16-1 APPENDICES A Maintenance Allocation Chart (MAC) FOLDOUTS Page FO-1 Electrical Schematic... FO-1 FO-2 Hydraulic Schematic... FO-9 FO-3 Air System Schematic... FO-13 iv C-1
TABLE OF CONTENTS - Continued VOLUME 2 SERVICE MAINTENANCE PACKAGES SM01-001-0 SM01-002-0 SM02-025-0 SM02-027-0 SM03-026-0 SM04-019-0 SM04-020-0 SM07-005-0 SM07-006-0 SM07-008-0 SM07-012-0 SM07-014-0 SM07-017-0 SM08-015-1 SM08-017-1 SM08-018-0 SM08-041-0 SM09-004-0 SM11-010-1 SM11-011-0 SM13-006-0 SM13-007-0 SM14-001-0 Air Intake System Water Cooling System Transmission/Torque Converter Torque Converter with Lockup Kessler Axle Steering Pump Miter Gear Reservoirs Low Pressure Indicating Switch Throttle Control Cylinder Pressure Protection Valve R-12 Relay Valve Stop Light Switch Hydraulic Pump Integrated Outrigger Valve Outrigger Solenoid Valve Stack Holding Valve Swing Gearbox and Brake Grove Model HO-15 Hoist Vane Type Motor (HO-15C Hoist) Swivel Assembly Electrical Swivel Diesel Heater v C-1
TABLE OF CONTENTS - Continued APPENDICES B Red Dot Heavy Duty Air Conditioning and Heating Service Training Manual (P/N RD-5-5900-0) C Cummins Master Repair Manual - Holset Air Compressors, Bulletin No. 3810321-01 D Delco Remy 21-S1 Delctron Generator (Alternator), Service Manual 1G-286 E Delco Remy Cranking Motors, Service Bulletin 1M-157 and Delco Remy Service Test Specifications, Service Bulletin 1M-188 F Not Used G PAT DS350 LMI Troubleshooting Handbook for Grove AT422T H ZF Semi-Integral Power Steering Gear, Type 7421 Instructions for Operation, Maintenance, and Inspection I Cummins Field Service Procedures for Wabco Air Compressor J Winterizing the ATEC Crane AT422T K Berminghammer Pile Driver System, Instructions for Maintenance, Troubleshooting, and Repair vi C-1
HOW TO USE THIS MANUAL This manual contains troubleshooting and maintenance instructions for the Army's AT422T, 22-ton All- Terrain Crane (ATEC). Other manuals in the set contain operation instructions and operator maintenance and diesel engine maintenance. Although these manuals do not conform with the format specified for other Army vehicles, the technical data presented herein is essential for properly operating and maintaining the vehicle. These manuals were developed to help you operate and maintain the equipment. All task descriptions will take you step-by-step through the procedure. Don't take shortcuts. Before you begin any task, you should read through the complete procedure, make sure you know what needs to be done, then go back and follow the steps as written. Pay particular attention to WARNINGS, CAUTIONS, and NOTES. This will prevent injury to personnel, damage to equipment, and provide clear instructions. Use the alphabetical index at the back of the manual to find a topic not listed in the tables of contents. The definitions of WARNING, CAUTION, and NOTE as used in this manual apply as follows: WARNING A warning or danger is used to emphasize that if an operation, procedure, or practice is not followed exactly, death or injury to personnel may result. CAUTION A caution is used to emphasize that if an operation, procedure, or practice is not followed exactly, equipment damage may result. NOTE A note is used to emphasize an important procedure or condition. The following paragraphs provide a general description of each ATEC technical manual. TM 5-3810-307-10 - Operator's Manual. Contains general theory of operations, operator safety, instructions for driving and operating the crane, operator troubleshooting, and operator maintenance. The manual also contains appendices for: (1) APPENDIX A. References - Forms and Publications, (2) APPENDIX B. Components of End Item and Basic Issue Items List (COEI/BII), (3) APPENDIX C. Additional Authorization List (AAL), (4) APPENDIX D. Expendable/Durable Supplies and Materials List (EDSML), (5) APPENDIX E. Load Chart, (6) APPENDIX F. Location/Description of Signs/Decals/Data Plates, (7) APPENDIX G. Load Moment Indicator (LMI) Operator's Handbook, vii
(8) APPENDIX H. Instructions for Installation/Operation of Pile Driver System (Berminghammer), (9) APPENDIX I. Determination of ATEC Weight Distribution, (10) APPENDIX J. Transportability Guidance, (11) APPENDIX K. Winterizing the ATEC Crane, (12) APPENDIX L. Instructions for Installation/Operation of Pile Driver (Linkbelt), (13) APPENDIX M. Lubrication, (14) Alphabetical Index. TM 5-3810-307-24-1 - Maintenance Manual with Supplemental Data. This manual consists of two volumes: Volume one is the basic service manual and Volume two is the Service Maintenance (SM) packages. Volume one, the service manual, is divided into chapters and sections. Chapter One contains 5 sections that cover: general maintenance information; preventive maintenance; lubrication; and troubleshooting. Chapter Two, divided into 16 sections, covers specific vehicle component removal/replacement procedures. At the beginning of each section is a Table of Contents listing the specific system/components contained in the section. Where vehicle components are repairable, the replacement procedure may refer to an SM package for repair. Volume One also contains the Maintenance Allocation Chart (MAC) as Appendix A. Volume Two, the SM packages, contains repair procedures for selected components of the vehicle. Each SM package is complete with its own Table of Contents. Any requirements for tools and materials to perform each repair task are also listed. Volume Two also includes Appendices consisting of vendor repair data for components not addressed elsewhere in the manual and instructions for winterizing the ATEC (AT422T). TM 5-3810-307-24-2 - Diesel Engine Operation and Maintenance Manual. This manual also consists of two volumes: Volume one is the Cummins operation and maintenance handbook while volume two contains engine repair information. Each manual has been edited specifically for the ATEC. Included are preventive maintenance, troubleshooting, adjustment/repair/replacement specifications/torques values, and warranty data. TM 5-3810-307-24P Repair Parts and Special Tools List (RPSTL). Contains a complete illustrated parts breakdown for the ATEC. Also included are: (1) Introduction Work Package, (2) Repair Parts List Work Package, (3) Special Tools Work Package, (4) Cross-Reference Index Work Packages. viii C-1
WARNINGS GENERAL It is mandatory that all hydraulic hoses and fittings be correctly tagged and identified before they are disconnected to effect repairs or service. Failure to correctly tag and identify hoses and fittings can cause wrong reconnection, which can result in death or injury to personnel. Review warning summaries included at the beginning of each section. Structural repairs and/or modifications must be approved by the manufacturer. Repair requests should be submitted to Manitowoc Crane CARE, P.O. Box 21, Shady Grove, PA 17256-0021, USA. Any unauthorized repairs and/or modification could void any remaining crane warranty and/or result in serious injury and equipment damage. ix/(x Blank) C-1