Maintenance Manual For All-Terrain Crane (ATEC) Diesel Driven, 22 Ton - Vol 2 - Pt2

Group System Exploded Diagram
Section i - Introduction
About the Manual
How to Use the Manual
Generic Symbols
Illustrations
General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Glossary of Terms
Glossary of Terms - Continued
Section E Engine and Component Identification
Engine Identification
Automotive/Industrial Engine Nomenclature
General Engine Specifications
Cooling System
Electrical System
Engine Diagram - Automotive Engine
Turbocharger Side View
Section 0 Engine Disassembly and Assembly Group 00
Section 0 Engine Disassembly and Assembly Group 00 - Continued
Section 0 Engine Disassembly and Assembly Group 00 - Continued
Engine Disassembly and Assembly
Engine Disassembly and Assembly - Service Tools
Engine Disassembly and Assembly - Service Tools - Continued
Engine Disassembly Check List
Engine Disassembly
Lifting Bracket Removal - Rear
Fan Pulley - Removal
Fan Hub - Removal
Thermostat - Removal
Turbocharger - Removal
Exhaust Manifold - Removal
Fuel Lines - Removal (0-20)
Fuel Drain Manifold - Removal (0-22)
Dipstick - Removal (0-24)
Valve Covers - Removal (0-27)
Rocker Levers - Removal (0-29)
Cylinder Head - Removal (0-31)
Water Pump - Removal (0-33)
Accessories - Removal (0-36)
Injection Pump - Removal (In-Line)
Fuel Transfer Pump - Removal
Water Inlet Connection Removal
Rear Seal Housing - Removal
Camshaft - Removal (0-52)
Lube Pump - Removal (0-55)
Timing Pin Housing - Removal (0-57)
Piston and Rod Assemblies Removal
Piston and Rod Assemblies Removal - Continued
Crankshaft - Removal (0-65)
Crankshaft - Removal (0-65) - Continued
Turbocharger Drain Removal
Valve Tappets - Installation (0-70)
Crankshaft - Installation (0-71)
Crankshaft - Installation (0-71) - Continued
Crankshaft - Installation (0-71) - Continued
Crankshaft - Installation (0-71) - Continued
Piston and Rod Assemblies Installation
Piston and Rod Assemblies Installation - Continued
Piston and Rod Assemblies Installation - Continued
PISTON PROTRUSION
Piston and Connecting Rod Assemblies - Installation
Piston and Connecting Rod Assemblies - Installation - Continued
Piston and Connecting Rod Assemblies - Installation - Continued
Gear Housing - Installation (0-73)
Lube Pump - Installation (0-74)
Camshaft - Installation (0-75)
Camshaft - Installation (0-75) - Continued
Camshaft - Installation (0-75) - Continued
Timing Pin - Installation (0-78)
Timing Pin - Installation (0-78) - Continued
Timing Pin - Installation (0-78) - Continued
Rear Seal - Installation (0-81)
Suction Tube - Installation (0-82)
Oil Pan - Installation (0-83)
Oil Cooler - Installation
Tappet Cover - Installation (0-87)
Injection Pump - Installation
Locked Timed Injection Pump - Installation
Locked Timed Injection Pump - Installation - Continued
P7100 Injection Pump Installation
P7100 Injection Pump Installation - Continued
P7100 Injection Pump Installation - Continued
P7100 Injection Pump Installation - Continued
P7100 Injection Pump Installation - Continued
Flywheel Housing - Installation
Water Pump - Installation
Front Cover - Installation (0-98)
Cylinder Head - Installation (0-99)
Push Rods - Installation (0-100)
Rocker Levers - Installation (0-101)
Cylinder Head - Tightening (0-102)
Cylinder Head - Tightening (0-102) - Continued
Valve Clearance - Adjustment
Feeler Gauge
Injector Nozzles - Installation
Valve Covers - Installation (0-105)
Fuel Drain Manifold - Installation (0-110)
Exhaust Manifold - Installation (0-113)
Turbocharger - Installation (0-116)
Turbocharger - Installation (0-116) - Continued
Turbocharger - Installation (0-116) - Continued
Thermostat - Installation (0-117)
Vibration Damper - Installation (0-118)
Belt Tensioner - Installation (0-120)
Alternator - Installation (0-122)
Drive Belt - Installation (0-123)
Starter - Installation (0-126)
Section 1 Cylinder Block Group 1
Section 1 Cylinder Block Group 1 - Continued
NOTES
Cylinder Block Exploded View
Cylinder Block Exploded View - Continued
Cylinder Block Exploded View - Continued
Cylinder Block General Information
Cylinder Block - Service Tools
Cylinder Block Group Inspection Checklist
Cylinder Block Precheck Disassembly (1-01)
Punch, Visegrips, Hammer
Universal Bushing Installation Tool
Gasket Scraper
Brush, 400 Grit Sandpaper, Diesel Fuel
Cylinder Block - Inspection (1-01)
Cylinder Block - Inspection (1-01) - Continued
Cylinder Block - De-Glazing (1-05)
Cylinder Block - De-Glazing (1-05) - Continued
Cylinder Block - De-Glazing (1-05) - Continued
Expansion and Installation
Expansion and Installation - Continued
Expansion and Installation - Continued
Expansion and Installation - Continued
Expansion and Installation - Continued
Dipstick Tube - Replacement (1-09)
Crankshaft - Cleaning (1-11)
Crankshaft Gear - Replacement (1-13)
Crankshaft Gear - Replacement (1-13) - Continued
Camshaft - Cleaning (1-14)
Camshaft and Gear - Inspection (1-15)
Camshaft Lobe Edge Deterioration (Breakdown) Criteria
Camshaft Lobe Edge Deterioration (Breakdown) Criteria - Continued
Camshaft Lobe Edge Deterioration (Breakdown) Criteria - Continued
Camshaft Gear - Replacement
Camshaft Gear - Replacement - Continued
Camshaft Gear - Installation (With Special Tool 3823589) (1-21)
Camshaft Gear - Installation (With Special Tool 3823589) (1-21) - Continued
Rubber Element Vibration Damper - Cleaning and Inspection (1-23)
Rubber Element Vibration Damper - Cleaning and Inspection (1-23) - Continued
Piston and Connecting Disassembly (1-24)
Piston, Pin and Connecting Rod - Cleaning (1-25)
Piston Pin - Inspection (1-27)
Connecting Rod - Inspection (1-28)
Piston and Connecting Rod - Assembly (1-30)
Piston Ring Gap - Checking (1-31)
Piston Rings - Installation (1-32)
Balancer - Disassembly (1-33)
Gear Housing and Timing Pin Assembly - Inspection (1-35)
Data Plate - Replacement (1-38)
Data Plate - Replacement (1-38) - Continued
Section 2 Cylinder Head Section 2
Cylinder Head - Service Tools
Cylinder Head Group 2
Cylinder Head Group 2 - Continued
Cylinder Head General Information
Cylinder Head - Precheck Before Disassembly (2-01)
Cylinder Head - Disassembly (2-02)
Cylinder Head - Cleaning (2-03)
Valve - Inspection (2-04)
Valve - Inspection (2-04) - Continued
Valve Guide Inspection (2-05)
Cylinder Head Cracks - Reuse Guidelines (2-08)
Cup Plug Replacement (2-10)
Cup Plug Replacement (2-10) - Continued
Valves - Grinding (2-11)
Valve Seats - Grinding (2-12)
Valve Seats - Grinding (2-12) - Continued
Valve Seats - Grinding (2-12) - Continued
Valve Seats - Grinding (2-12) - Continued
Valve Seats - Grinding (2-12) - Continued
Cylinder Head - Assembly (2-13)
Cylinder Head - Assembly (2-13) - Continued
Section 3 Rocker Levers Group 03
Rocker Lever Assembly Exploded View
Rocker Lever Assembly Exploded View - Continued
Rocker Lever Assembly - General Information
Rocker Levers - Disassembly (3-01)
Rocker Levers and Pedestals Cleaning (3-02)
Rocker Lever Pedestals - Inspection
Rocker Levers - Assembly (3-05)
Section 4 Tappets and Push Rods Group 04
Tappets and Push Rods - Exploded View
Tappets and Push Rods - General Information
Valve Tappets Inspection (4-01)
Push Rods - Inspection (4-02)
Section 5 Fuel System Group 05
Exploded View Fuel System
Injection Pump Repairs (5-21)
Injection Pump Repairs (5-21) - Continued
Fuel Inlet Banjo Connector Replacement, Bosch P7100 (5-31)
Fuel Shut Off Solenoid Adjustment, Bosch P7100 (5-33)
Fuel Shut Off Solenoid Bracket Replacement, Bosch P7100 (5-34)
Throttle Lever Replacement, Bosch P7100 (5-36)
Wiring Guidelines
NOTES
Section 6 Injectors and Fuel Lines Group 06
Injector - Service Tools
Injector Group - Exploded View
Fuel Transfer Pump General Information
Injector - Disassembly
Injector - Clean and Inspect
Nozzle Cleaning Kit 3376947
Injector - Assembly
Injector - Assembly - Continued
Injector - Testing
Fuel Transfer Pump - Piston Style Rebuild
Fuel Transfer Pump - Piston Style Rebuild - Continued
Fuel Lines - Clean and Inspect
Fuel Drain Manifold
Fuel Drain Manifold - Continued
Fuel Drain Manifold - Continued
Section 7 Lubricating System Group 7
Oil Pan and Suction Tube - Exploded View
Oil Pan and Suction Tube - General Information
Oil Pan and Suction Tube - Cleaning and Inspection (7-01)
Lubricating Oil Cooler Exploded View
Lubrication System - General Information
Pressure Regulator Valve - Disassembly (7-02)
Pressure Regulator Valve Assembly
Oil Cooler - Cleaning (7-06)
Oil Cooler - Inspection (7-07)
Lubricating Oil Pump Exploded View
Lubrication Oil Pump General Information
Oil Pump - Inspection (7-08)
Oil Pump - Inspection (7-08) - Continued
Oil Pump - Inspection (7-08) - Continued
NOTES
Section 8 Cooling System Group 8
Water Pump Exploded View
Water Pump - General Information
Water Pump - Inspection (8-01)
Belt Tensioner and Fan Hub Exploded View
Belt Tensioner and Fan Hub - General Information
Fan Hub - Inspection (8-02)
Fan Hub - Disassembly (8-03)
Fan Hub - Disassembly (8-03) - Continued
Belt Tensioner - Inspection (8-05)
Thermostat Housing Assembly - Exploded View
Thermostat Housing Assembly - General Information
Thermostat - Inspection (8-06)
Fans - General Information
Section 10 Air Intake System Group 10
Air Intake System Exploded View
Air Intake System Exploded View - Continued
Air Intake System - General Information
Turbocharger - Cleaning and Inspection for Reuse (10-01)
Aftercooler Assembly - Cleaning and Inspection for Reuse (10-02)
Aftercooler Assembly - Rebuild (10-03)
Air Crossover Tube - Cleaning and Inspection for Reuse (10-05)
Charge Air Cooler (CAC) - Pressure Testing (10-07)
Charge Air Cooler (CAC) - Pressure Testing (10-07) - Continued
Section 11 Exhaust System Group 11
Exhaust Manifold Exploded View
General Information
Exhaust Manifold Inspection (11-01)
Section 12 Air Equipment Group 12
Air Equipment - General Information
Air Compressor - Cleaning and Inspection for Reuse (12-01)
Air Compressor - Cleaning and Inspection for Reuse (12-01) - Continued
Section 13 Electrical Equipment Group 13
Electrical Equipment - General Information
Alternator Inspection (13-01)
Section 14 Engine Testing Group 14
Engine Testing - Service Tools
Engine Testing - Service Tools - Continued
Engine Testing Engine Side Views
Engine Testing Engine Side Views
Engine Testing - General Information
Blowby Measurement
Engine Dynamometer Test - Installation of the Engine (14-01)
Engine Dynamometer Test - Installation of the Engine (14-01) - Continued
Engine Dynamometer Test - Installation of the Engine (14-01) - Continued
Engine Dynamometer Test - Installation of the Engine (14-01) - Continued
Engine Dynamometer Test - Installation of the Engine (14-01) - Continued
Engine Dynamometer Test - Installation of the Engine (14-01) - Continued
Engine Dynamometer Test - Engine Run-In (14-02)
Engine Dynamometer Test - Engine Run-In (14-02) - Continued
Engine Dynamometer Test - Engine Run-In (14-02) - Continued
Engine Dynamometer Test - Engine Run-In (14-02) - Continued
Engine Dynamometer Test - Performance Checking (14-03)
Engine Dynamometer Test - Performance Checking (14-03) - Continued
Engine Dynamometer Test - Performance Checking (14-03) - Continued
Engine Run-In Procedure "In Chassis" - (On- and Off-Highway Vehicles) (14-07)
Engine - Painting (14-08)
Engine Storage - Short Term (14-09)
Engine Storage - Short Term (14-09) - Continued
Removing the Engine from Short-Term Storage
Removing the Engine from Short-Term Storage - Continued
Removing the Engine from Short-Term Storage - Continued
Removing the Engine from Long-Term Storage
Removing the Engine from Long-Term Storage - Continued
Removing the Engine from Long-Term Storage - Continued
Removing the Engine from Long-Term Storage - Continued
NOTES
Section 16 Mounting Adaptations Group 16
General Information
Flywheel and Ring Gear Inspection
Flywheel Housing Inspection (16-03)
Flywheel Housing Assembly (16-04)
Front Support - Cleaning and Inspection (16-05)
Section V Engine Component Specifications Group 18
Specifications General Information
Engine Component Torque Values
Engine Component Torque Values - Continued
Engine Component Torque Values - Continued
Component Specifications and Torque Values
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Component Specifications and Torque Values - Continued
Drive Belt Tension
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
Weight and Measures - Conversion Factors
Newton-Meter to Foot-Pound Conversion Chart
Capscrew Markings and Torque Values U.S. Customary
Capscrew Markings and Torque Values
Pipe Plug Torque Values
Tap-Drill Chart U.S. Customary & Metric
Section L Service Literature
Additional Service Literature

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