Figure 1-1. General View, Model HDS-E Standard Pulvi-Mixer With Asphalt Emulsion Handling System
Figure 1-2. Number Plate
Figure 1-3. Two-Stroke Cycle Operation
GENERAL SPECIFICATIONS
Figure 1-4. Model Number Coding
Figure 1-5. Typical Engine Serial Number and Model Number as Stamped on Cylinder Block Option Plate
Lubrication System
CROSS SECTION OF ENGINE MODEL VH4D
Shipping and Lifting
Service Classification of Oil
Figure 1-8. Operating Controls
Water Temperature Gage
Starter Switch
TABLE 1-1. Oil Pressures For Various Engine
Cooling System
Figure 1-9. Hood and Rotor Assembly Nomenclature
Figure 1-10. Rotor Operation
Figure 1-11. Instant Depth Check
V.P.I. Fluid Handling System
Table 1-3. Pulvi-Mixer Reference Application Chart
Warm-Up Period
Figure 1-13. Spray bar Nozzle Assembly
Figure 1-15. Wash Down System
Figure 1-17. Standard Rotor
DIESEL ENGINE AND RELATED COMPONENTS
MAIN VEHICLE WIRING DIAGRAM
Tailboard Wearplate
ROTOR TINE REPLACEMENT
ROTOR AND JACK AXLE REMOVAL
SHEAR COUPLING REPAIR
SUBSECTION 2 EMULSION PUMP AND WASH DOWN PUMP
Troubleshooting
SUBSECTION 2 EMULSION PUMP AND WASH DOWN PUMP
HYDRAULIC BRAKE LAYOUT
DISASSEMBLY
BRAKE MASTER CYLINDER
Figure 7. Wheel Cylinder Exploded View
Figure 1. Sectional View of Type DPB Single Plate Clutch
GENERAL DESCRIPTION
Figure 2. Checking Dimension `A'
COMMON SERVICE PROBLEMS
COMMON SERVICE PROBLEMS (Cont.)
CHECKING FOR MISALIGNMENT
Figure 5. Knocking Out Drive Gear Assembly
Figure 8. Sectional and Exploded View of Rotor Drive transmission
FIGURE 9. Removing Drive Gear Bearing
FIGURE 12. Pressing on Countershaft Rear Bearing
TWO SPEED ROTOR DRIVE TRANSMISSION
DISASSEMBLE DRIVE UNIT
EXPLOSION VIEW OF UNIT HOUSING DRIVE AXLE
DISASSEMBLE PINION AND CAGE ASSEMBLY
COMPLETE ASSEMBLIES
REASSEMBLE PINION AND CAGE ASSEMBLY
REASSEMBLE PINION AND CAGE ASSEMBLY - Continued
ASSEMBLE DIFFERENTIAL AND BEVEL GEAR
ADJUST DIFFERENTIAL BEARING PRE-LOAD
TORQUE SPECIFICATIONS
SUBSECTION 5 REAR AXLE ASSEMBLY AND FINAL DRIVE
DISASSEMBLE PLANETARY SPIDER ASSEMBLY
REMOVE THE FLOATING RING GEAR ASSEMBLY
DISASSEMBLE BRAKE SHOE AND LINER ASSEMBLY
WHEEL BEARING ADJUSTMENT
REASSEMBLE PLANETARY SPIDER ASSEMBLY
INSTALL PLANETARY SPIDER ASSEMBLY
TWO SPEED NOSE BOX TRANSMISSION
TWO SPEED NOSE BOX TRANSMISSION
ASSEMBLY
TRACTION DRIVE AXLE
DISASSEMBLE DRIVE UNIT
PREPARE FOR REASSEMBLY
COMPLETE ASSEMBLIES
REASSEMBLE AXLE
REASSEMBLE PINION AND CAGE ASSEMBLY
ASSEMBLE DIFFERENTIAL AND BEVEL GEAR
ADJUST DIFFERENTIAL BEARING PRE-LOAD
TORQUE SPECIFICATIONS
SUBSECTION 6 HYDROSTATIC PUMP AND MOTOR
SCHEMATIC HYDROSTATIC DRIVE
HYDROSTATIC TRACTION DRIVE AND GEARING ARRANGEMENT DIAGRAM
Manual Displacement Control
Start Up Procedure
HYDROSTATIC PUMP AND MOTOR
HYDRAULIC SUPPORT SYSTEM
System Relief Valves
MOTOR REPLACEMENT
TROUBLESHOOTING GAUGE ISTALLATION AND INFORMATION
SYSTEM OPERATING HOT
SYSTEM RESPONSE IS SLUGGISH
Inspect Manual Displacement Control
Inspect Charge Check Valves
CONTROL ADJUSTMENTS
Centering Spring
MINOR REPAIRS
Shaft Seal
System Relief Valve
Motor Manifold
Installation
Control
FIXED DISPLACEMENT MOTOR
Special Tools
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
VARIABLE DISPLACEMENT PUMP
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
INSTALLATION TORQUE VALUES
SUBSECTION 7 HYDRAULIC PUMP
FIGURE 4 Marking of the Gears for Location
PUMP ASSEMBLY
FIGURE 12 Use of India Stone on Gears
FIGURE 17 Drive Shaft, Inner Wear Plate and Seal Assembly being Installed in Adapter
BREAK-IN OF REPAIRED PUMPS
FIGURE 1 Valve Section
REPLACING SPOOL SEALS IN CONTROL VALVE
REPLACING SPOOL SEALS IN CONTROL VALVE - Continued
FIGURE 4 Model V20 Directional Control Valve, Typical Main Assembly
TAILBOARD HYDRAULIC CYLINDER
SPRAY BAR HYDRAULIC CYLINDER
SPRAY BAR HYDRAULIC CYLINDER - Continued
SUBSECTION 10 - DIESEL ENGINE
SCOPE AND USE OF THE MANUAL
GENERAL PROCEDURES
GENERAL PROCEDURES - Continued
WORK SAFELY
CONTENTS
CYLINDER BLOCK
Fig. 2 - Cutaway View of Cylinder Block Showing Air and Water Passages
Fig. 5 - Engine Mounted on Overhaul Stand
Fig. 7 - Cleaning Cylinder Block
Fig. 9 - Cylinder Block Prepared for Pressure Test
Fig. 10 - Honing Bore of Cylinder Block
Fig. 12. Checking Bore of Cylinder Block
Fig. 14. Block Bore Measurement Record Form
Fig. 16. Checking Top Face of Cylinder Block
Fig. 18. Checking Depth of Counterbore for Cylinder Liner with Tool J 22273
Assemble and Install Engine
Assemble and Install Engine - Continued
CYLINDER BLOCK END PLATES
CYLINDER BLOCK END PLATES - Continued
Fig. 1. Air Box Drain Tubes
CYLINDER HEAD
Fig. 3. Typical Mounting of Cylinder Head
Cylinder Head Maintenance
Fig. 5. Removing or Installing Injector Control Tube
Fig. 7. Cylinder Head Prepared for Pressure Test using Tool J 28454
Non-Fluorescent Penetrant Method
Fig. 9- Minimum Distance Between Top and Bottom Faces of Cylinder Head
Assemble Cylinder Head
Fig. 11 Cylinder Head Seals and Gaskets
Fig. 13 Cylinder Head Bolt Tightening Sequence
Pre-lnstallation Inspection
VALVE AND INJECTOR OPERATING MECHANISM
Remove Rocker Arms and Shaft
Fig. 4. Cam Followers and Guide
Fig. 5. Cam Roller Clearances
Fig. 7. Testing Cam Follower Spring using Tool J 22738-02
Fig. 8. Removing or Installing Cam Follower Roller using Tool J 5840-01
Fig. 11. Checking Cam Follower to Guide
Fig. 12. Adjusting Cam Follower Guide
Fig. 2. Assembly of Exhaust Valves and Guides
Remove Exhaust Valve Spring (Cylinder Head Installed)
Fig. 4. Testing Exhaust Valve Spring using Tool J 22738-02
Fig. 6. Removing Exhaust Valve Guide
Fig. 9. Removing Valve Seat Insert
Fig. 11. Refacing Exhaust Valve
Fig. 14 - Relationship Between New Exhaust Valve, Insert and Cylinder Head
Fig. 16. Checking Pressure Required to Open the Exhaust Valve in Cylinder Head
Install Engine Lifter Bracket
Fig. 1. Typical Valve Rocker Cover Assembly (Current)
Remove and Install Valve Rocker Cover
Fig. 1. Typical Six Cylinder Crankshaft (Former)
Fig. 2. Typical Crankshaft, Timing Gear and Oil Pump Drive Gear Assembly-Four Cylinder Engine
Crankshaft Measurements
Fig. 4. Critical Crankshaft Loading Zones
Fig. 6. Dimensions of Crankshaft Journals
Fig. 8. New or Morco Remanufactured Crankshaft
Fig. 10. Checking Crankshaft End Play
Install Crankshaft
Fig. 1. Crankshaft Front Oil Seal
Fig. 4. Crankshaft Rear Oil Seal Mounting
Install Crankshaft Front Oil Seal
Fig. 1. Main Bearing Shells, Bearing Caps and Crankshaft Thrust Washers
Fig. 4. Removing Upper Rear Main Bearing Shell
Fig. 5. Comparison of Main Bearing Shells Minimum
Fig. 8. Crankshaft Thrust Washers in Place
Fig. 9 - Main Bearing Cap Marking
Fig. 1. Crankshaft Front Cover Mounting (Vibration Damper Removed)
Install Crankshaft Front Cover
CRANKSHAFT VIBRATION DAMPER
Fig. 3. Vibration Damper and Crankshaft Pulley Assembly Mounting
Install Vibration Damper on Crankshaft
Fig. 1. Removing Rubber Mounted Pulley from Crankshaft using Tool J 5356
Install Crankshaft Pulley
Remove Flywheel (Transmission Removed)
Remove Ring Gear
Fig. 4. Torque - Turn Limits
CLUTCH PILOT BEARING
Fig. 1. Typical Flywheel Housing Mounting
Fig. 3. Flywheel Housing Bolt Tightening Sequence (Operation 1)
Fig. 4. Flywheel Housing Bolt Tightening Sequence (Operation 2)
Fig. 1. Cross-Head Piston and Connecting Rod Assembly
Inspect Piston Rings
Fig. 5. Checking Fire Ring Groove in Piston Crown using Tool J 24599
Fig. 7. Installing Piston Pin
Fig. 9. Installing Piston Pin Retainer using Tool J 23762
Fig. 11 - Measuring Piston-to-Liner Clearance using Tool J 5438-01
Fig. 14 - Measuring Piston Ring Gap
Fig. 16. Piston Ring Installation Instructions.
CONNECTING ROD
Fig. 2. Magnetic Particle Inspection Limits for Connecting Rod.
Fig. 3 - Dimensional Inspection of Cross-Head Piston Connecting Rods
Assemble Connecting Rod to Piston
Fig. 1 - Connecting Rod and Bearing Shells
Install Connecting Rod Bearing Shells
Fig. 1. Typical Cylinder Liner.
Fig. 2 -Cylinder Liner
Fig. 6. Cylinder Liner Ridge Due to Wear.
Fig. 8 - Checking Bore of Cylinder Line Using Tool J 5347-01
NEW CYLINDER LINER TO NEW CYLINDER BLOCK BORE FITS
Fig. 9. Cylinder Liner Classification
Fig. 11. Checking Distance of Liner Flange Below Top Face of Block
Fig. 13. Typical Connecting Rod Markings
Install Cylinder Liner, Piston and Connecting Rod Assembly
Fig. 2. Loosening Nut on Camshaft or Balance
Install Front Balance Weights
Fig. 1. Gear Train and Timing Marks-Right-Hand Rotation Engine (Standard Timing Shown)
Fig. 2. Pointer Installation for Marking Top-Dead-Center
Fig. 3. Checking Engine Timing By Measuring Injector Depression
Fig. 1. Camshaft and Balance Shaft Assemblies
Fig. 2. Woodruff Keys for Current Camshafts
Fig. 5. Removing or Installing Shaft Bearing Retainer Bolts
Fig. 7. Removing Gear (Camshaft or Balance Shaft Gear Puller J 1902-01)
Fig. 9. Camshaft and Balance Shaft Journal Fillets
Fig. 10. Typical Camshaft and Balance Shaft Details and Relative Location of Parts
Fig. 11. Comparison of End Bearings and Thrust Washers
Fig. 12. Camshaft Plug Installation
Fig. 13. Camshaft Intermediate Bearing Lock Screws
Fig. 2. Removing Gear (Camshaft or Balance Shaft)
Fig. 3. Replacing Gear (Camshaft Shown)
Fig. 1. Idler Gear Mounting Typical
ig. 2. Pressing Hub Out of Bearing
Fig. 4. Idler Gear Details and Relative Location of Parts
Fig. 6. Fixture for Testing Bearing Pre-Load
Fig. 8. Checking Pre-Load of Idler Gear Bearing
Install Idler Gear, Hub and Bearing Assembly
Fig. 1. Removing Crankshaft Timing Gear
Fig. 1. Typical Blower Drive Gear and Support Assembly
Fig. 4. Bower Drive Shaft Mounting
Fig. 5. Typical Blower Drive Gear Details and Relative Location of Parts
Fig. 6. Inserting Blower Drive Cam
Fig. 1. Typical Components of Accessory Drive For Direct-Driven Accessories
ACCESSORY DRIVE
Fig. 1. Balance Weight Cover Mounting
CHECKING BEARING CLEARANCES
TROUBLE SHOOTING
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
uEXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
SPECIAL PLUG TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
Fig. 1. Schematic Diagram of Typical Fuel System
Fig. 2. Cutaway View of Fuel Injector
Fig. 3 Fuel Metering from No-Load to Full-Load
Fig. 6 Fuel Injector Mounting
Fig. 9. Removing Injector Follower Stop Pin
Fig. 11. Injector Tester J 23010 Clamping Heads
Fig. 12. Injector Installed in Tester J 23010 with clamping Head
Visual Inspection of Plunger
Fig. 15. Adaptor and Tube Assembly on Injector Tester J 23010
Unclamping the Injector
Fig. 16. Checking Needle Valve Lift
Fig. 17 - Injector Needle Valve Tester J 23010 with Auxiliary Tester J 22640
Fig. 20 - Position of Calibrator Fuel Flow Pipes
Fig. 22 Setting Calibrator Stroke Counter
Fig. 27. Cleaning injector Spray Tip
Fig. 31. Sealing Surfaces which may Require Lapping
Fig. 34. Location of Filter in Injector Body
Fig. 36. Injector Rack, Gear, Spray Tip and Valve Assembly Details and Relative Location of Parts
Fig. 37. Injector Plunger, Follower and Relative Location of Parts
Fig. 39. Spray Tip Sealing Surface Identification
Fig. 42. Installing Injector Follower Stop Pin
Fig. 43. Checking Injector Spray Tip Concentricity using Tool J 29584
Check Spray Tip Concentricity
Install Injector
Install Injector Tube
Fig. 3 - Upsetting Injector Tube
Fig. 5 - Reaming Injector Tube for Injector Nut
Ream Injector Tube
Fig. 1 - Typical Fuel Pump Assembly
Fig. 2 - Typical Fuel Pump Mounting and Drive
Fig. 3 - Fuel Pump Valving and Rotation (Right-Hand Pump)
Fig. 5 - Removing Pump Cover
Fig. 7 - Fuel Pump Details and Relative Location of Parts
Fig. 9 - Installing Outer Oil Seal
Fig. 10 Installing Drive Shaft and Gear Assembly
Fig. 1 - Typical Spin-On Filter Mounting
Fig. 1 - Cylinder Head with Integral Fuel Manifolds
MECHANICAL GOVERNOR
Remove Governor
Fig. 1 - Variable Speed Mechanical Governor
Fig. 2 - Variable Speed Governor Mounting
Fig. 5 Governor Control Housing Details and Relative Location of Parts
Fig. 7. Removing Operating Shaft from Operating Fork
Fig. 9. Governor Weight Housing Details and Relative Location of Parts
Fig. 11 Installing Needle Bearing in Governor Cover using Tool J 21068
Fig. 12. Cross Section of Governor Variable Speed Spring Housing
Fig. 13. Variable Speed Spring Housing and Shaft Details and Relative Location of Parts
Fig. 15. Governor Weight Housing
Install Governor
FUEL INJECTOR CONTROL TUBE
Install Injector Control Tube
Fig. 1. Checking Fuel Output
REFINISH LAPPING BLOCKS
EFFECT OF PRE-IGNITION ON FUEL INJECTOR
REFINISHING INJECTOR FOLLOWER FACE
PRESSURIZE FUEL SYSTEM CHECK FOR LEAKS
CHECKING FUEL FLOW
CHECKING FUEL FLOW - Continued
SHOOTING CHARTS (Needle Valve Injectors)
SHOOTING CHARTS (Needle Valve Injectors) - Continued
SHOOTING CHARTS (Needle Valve Injectors) - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
Fig. 1 - Air Flow Through Blower and Engine
Air Cleaner Mounting
Fig. 1 - Dry Type Air Cleaner (Heavy Duty)
Service
AIR SHUTDOWN HOUSING
Fig. 2 - Air Shutdown Housing Mounting and Bolt Location
BLOWER
Fig. 1 - Blower and Drive Assembly and Accessories including Mechanical Governor Attached to blower
Fig. 2 Typical Blower Mounting (71 Engine)
Fig. 4 Removing Blower Rotor Gears from Blower Rotor Shafts with Tool Set J 6270-F
Fig 5 - Removing Blower End Plate using Tool Set J 6270-F
Fig. 7 - Typical Details and Relative Location of Parts
Fig. 8 - Installing Oil Seal in Blower End Plate using Tool J 6270-3.
Fig. 10 - Position of Blower Front End Plate on Housing
Fig. 13 - Installing Roller Bearing on Rotor Shaft and in Front End Plate using Tool J 6270-4.
Fig. 14 - Installing Ball Bearing on Rotor Shaft and in Rear End Plate using Tool J 6270-7.
Fig. 16 - Measuring "CC" and "C" Clearances Between Blower Rotor Lobes.
Fig. 17 - Chart of Minimum Clearances for Blowers.
Fig. 18 - Diagram Showing Proper Location of Shims for Correct Rotor Lobe Clearances.
Attach Accessories to Blower
Fig. 1 - Removing Rotor Stub Shaft.
Install Service Rotor Front Stub Shaft
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
LUBRICATION SYSTEM
Fig. 1 - Schematic Diagram of Typical Lubrication System.
Fig. 2 - Blower Lubrication.
Fig. 1 - Oil Pump Assembly.
Fig. 2 - Typical Oil Pump Mounting.
Fig. 3 - Oil Pump Details and Relative Location of Parts.
Fig. 5 - Removing Oil Pump Drive Gear form Shaft.
Fig. 6 - Diameter and Location of Bushing in Oil Pump.
Fig. 8 - Removing Oil Pump Driving Gear from Crankshaft
Fig. 9 - Installing Oil Pump Driving Gear on Crankshaft
Install Oil Pump Driving Gear on Crankshaft
Fig. 1 - Lubricating Oil Pressure Regulator Details and Relative Location of Parts.
Assemble Oil Pressure Regulator
Fig. 1 - Typical Oil Filter Mounting.
Fig. 3- Bypass Valve
Figure 1. Typical Lubricating Oil Cooler Mounting-Radiator Cooled Engine
Fig. 2 Oil Cooler Core Prepared for Pressure Check
Install Lubricating Oil Cooler
LUBRICATING OIL COOLER BYPASS VALVE
Figure 1. Typical Dipstick Mounting
Figure 1. Typical Deep Sump Type Oil Pan
Figure 1. Breather Mounted on Cylinder Block
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
RADIATOR AND COOLING FAN
Fig. 1 - Typical Cooling System with Radiator and Fan
Cooling System Capacity
Miscellaneous Cooling System
LUBRICATION SYSTEM
Fig. 1 - Water Pump With Ceramic Insert in Impeller
Fig. 4 Pressing Pump Shaft from Impeller
Fig. 6 - Water Pump Details and Relative Location of Parts
Fig. 7 - Installing Pump Impeller
Fig. 1 - Typical Water Manifold Mounting Industrial Unit
Fig. 1 - Typical thermostat Housing Mounting (Radiator Cooling System)
Fig. 2 - Method of Checking Thermostat Operation
Cleaning Radiator
Fig. 1 Removing Radiator, Shell and Shroud with Lifting Hook (Typical)
COOLANT PRESSURE CONTROL CAP
Fig. 1 . Typical Fan and Fan Hub Assembly
Fig. 2 - Shaft Type Fan Hub Assembly Details for Compact Front End Engine.
Fig. 3 - Shaft Type Fan Hub Assembly.
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXHAUST SYSTEM
Fig. 1 - Typical Air-Cooled Exhaust Manifold Mounting.
Remove Exhaust Manifold
ELECTRICAL SYSTEM
Fig.1 - Hinge-Mounted Alternator.
Fig. 4 - Terminal Connections.
Fig. 6 - Charging Circuit.
ABNORMAL CHARGING SYSTEM OPERATION
Fig. 10 - Testing Diode Trio.
Fig. 11 - Testing Rectifier Bridge.
Fig. 13 - Drive End Bearing Assembly.
Fig. 16 - Tighten Alternator Pulley Retaining Nut
Fig. 17 - Battery Connecting Diagram.
Battery Safety Precautions
Fig. 2 - Cross-section of Starting Motor with Sprag Heavy-Duty Clutch Drive.
TROUBLESHOOTING
Interpreting Results of Tests
Fig. 5 - Checking Solenoid Hold-In Winding.
Fig. 6 - Checking Solenoid Pull-In Winding.
Fig. 8 - Measuring Pinion Clearance.
Fig. 1 - Typical Instrument Panel.
Fig. 3 - Tachometer Mounting.
Fig. 5 - Tachometer Head.
MANUAL SHUTDOWN SYSTEM
COLD WEATHER STARTING
ALIGNMENT TOOLS FOR TACHOMETER DRIVE COVERS AND ADAPTORS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
ENGINE OPERATING CONDITIONS
DYNAMOMETER TEST AND RUN-IN PROCEDURES
Dynamometer
ENGINE TEST REPORT
BASIC RUN-IN INSPECTION
INSPECTION AFTER FINAL RUN-IN
FUEL OILS FOR DETROIT DIESEL ENGINES
DIESEL FUEL LINE DE-ICER
LUBRICATING OILS FOR DETROIT DIESEL ENGINES
USED LUBE OIL ANALYSIS PROGRAM
LUBE OIL FILTER CHANGE INTERVAL
STATEMENT OF POLICY ON FUEL AND LUBRICANT ADDITIVES
COOLANT REQUIREMENTS
Fig. 1 - Heat Transfer Capacity
Fig. 2 Coolant Freezing and Boiling Temperatures vs. Antifreeze Concentration (Sea Level)
GENERAL RECOMMENDATIONS
GENERAL RECOMMENDATIONS - Continued
ENGINE TUNE-UP PROCEDURES
Fig. 1 - Adjusting Valve Clearance (Two Valve Head)
Fig. 1 - Timing Fuel Injector
Fig. 1 - Adjusting Governor Cap
Fig. 3 - Buffer and Idle Speed Adjusting Screw
Fig. 6 - Location of Stops and Shims
Adjust Booster Spring
PREVENTIVE MAINTENANCE TROUBLE SHOOTING - STORAGE - PLUGGING CHARTS
ENGINE OIL CHANGE INTERVALS
Diesel Fuel Contamination
Throttle and Clutch Controls
Exhaust System
Engine and Transmission Mounts
Crankcase Breather
Fig. 1 - Locating a Misfiring Cylinder
Fig. 2 - Checking Compression Pressure
Fig. 3 - Inspecting Piston Rings
PROPER USE OF MANOMETER
PRESSURE CONVERSION CHART
EXHAUST SMOKE ANALYSIS
EXHAUST SMOKE ANALYSIS - Continued
HARD STARTING
HARD STARTING - Continued
ABNORMAL ENGINE OPERATION
ABNORMAL ENGINE OPERATION - Continued
NO FUEL OR INSUFFICIENT FUEL
NO FUEL OR INSUFFICIENT FUEL - Continued
ABNORMAL ENGINE COOLANT OPERATING TEMPERATURE
EXCESSIVE CRANKCASE PRESSURE
LOW OIL PRESSURE
LOW OIL PRESSURE- CONTINUED
HIGH LUBRICATING OIL CONSUMPTION
HIGH LUBRICATING OIL CONSUMPTION - CONTINUED
PREPARING ENGINE FOR STORAGE
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
PLUGGING CHARTS - LC and RC ENGINES
PLUGGING CHARTS - LC and RC ENGINES - Continued
SUBSECTION 11 FRONT AXLE AND STEERING
INSTALLATION AND OPERATION
HYDRAULIC FLUID RECOMMENDATIONS
TABLE II - TROUBLE SHOOTING CHART
TABLE II. - TROUBLE SHOOTING CHART (CONTINUED)
Control Valve Sub-Assembly
STEERING GEAR REPLACEMENT
FRONT AXLE REPAIR
SUBSECTION 12 STEERING CYLINDER
POWER STEERING VALVE UNIT ON STEERING COLUMN
SUBSECTION 13 V.P.I. FLUID HANDLING SYSTEM
CALIBRATING THE V.P.I. SYSTEM-METER RECORDING UNIT
CALIBRATING THE V.P.I. SYSTEM-METER RECORDING UNIT - Continued
TRAVEL SPEED UNIT
PROPORTIONING SYSTEM UNIT
SUGGESTED EXTERNAL POWER SOURCE CIRCUITRY
V.P.I. TROUBLE SHOOTING
SUBSECTION 14 GASOLINE PUMP ENGINE
MAGNETO BREAKER POINT ADJUSTMENT
FIGURE 6. MAGNETO TIMING DIAGRAM
FIGURE 7. WIRING DIAGRAM
TROUBLES CAUSES AND REMEDIES
ENGINE SURGES OR GALLOPS
TESTING REBUILT ENGINE
CARBURETOR AND MANIFOLD
IDLER GEAR AND SHAFT
PISTONS and CONNECTING RODS
CYLINDER BLOCKS
VALVE TAPPETS
GOVERNOR ADJUSTMENT
WALBRO CARBURETOR
FIGURE 30. FLOAT SETTING
FIGURE 31. EXPLODED VIEW Instructions and Service Parts Illustration
LUBRICATION CHART 1 - GENERAL
LUBRICATION CHART 1 - GENERAL (Continued)
LUBRICATION CHART 2 - EMULSION HANDLING SYSTEM
FIG. 1. ROTOR HOOD, TAILBOARD, LIFT ARMS, HOOD ARMS, JACK AXLE ARMR AND SKIS
ROTOR HOOD-CRANE-TAILBOARD-LIFT ARMS - HOOD ARMS-JACK AXLE ARMS & SKIS - REX SELF-PROPELLED PULVI MIXERS
ROTOR ASSEMBLY WITH SOLID TUBE AND BEYEL EDGE TINES REX ASSEMBLY NO. 602.2720, COMPLETE
FIG. 3. ROTOR DRIVE CHAIN CASE (LEFT AND RIGHT REQUIRED)
ROTOR DRIVE CHAIN CASE
FIG. 4. ROTOR DRIVE LINE
ROTOR DRIVELINES
FIG. 5. EMULSION PUMP ASSEMBLY PEABODY - BARNES MODELS: 30CCG, 30CCG-1, 30CCG-2
EMULSION PUMP ASSEMBLY
FIG. 6. PUMP FOR WASH-DOWN SYSTEM
FIG. 7. EMULSION HANDLING UNIT PIPING, CONTROLS HYDRAULIC LINES AND FITTINGS
EMULSION HANDLING UNIT PIPING - CONTROLS - HYDRAULIC LINES & FITTINGS
EMULSION HANDLING UNIT PIPING - CONTROLS - HYDRAULIC LINES & FITTINGS - Continued
EMULSION HANDLING UNIT PIPING - CONTROLS - HYDRAULIC LINES & FITTINGS - Continued
FIG. 8. FLOW METER
FLOW METER AND TACHOMETER GENERATOR ASSY. 4' MODEL 4MLFT- SGH
FLOW METER AND TACHOMETER GENERATOR ASSY. 4' MODEL 4MLFT- SGH
FIG. 9. WATER AND ASPHALT SPRAY BARS AND ROTOR HOOD COVERS
WATER AND ASPHALT SPRAY BARS AND ROTOR HOOD COVERS REX SELF PROPELLED PULVI MIXERS
FIG. 10. TRACTION DRIVE WHEEL ENDS AND BRAKES
TRACTION DRIVE WHEEL ENDS INCLUDED IN AXLE ASSEMBLY 102-6168-1 ROCKWELL MODEL TA-279-HXI EFFECTIVE HK-381
TRACTION DRIVE WHEEL ENDS INCLUDED IN AXLE ASSEMBLY 102-6168-1 ROCKWELL MODEL TA-279-HXI EFFECTIVE HK-381 - Continued
FIG. 11. TWO SPEED TRANSMISSION - ROTOR DRIVE
ROTOR DRIVE TWO-SPEED TRANSMISSION REX PART NO. 602-10224-2 ROTOR DRIVE CLUTCH ASSEMBLY
ROTOR DRIVE TWO-SPEED TRANSMISSION REX PART NO. 602-10224-2 ROTOR DRIVE CLUTCH ASSEMBLY - Continued
FIG. 12. TRACTION DRIVE TRANSMISSION (2 SPEED)
TRACTION DRIVE TWO-SPEED TRANSMISSION INCLUDED IN AXLE ASSEMBLY 102-11053-1
FIG. 13. TRACTION DRIVE AXLE
DIFFERENTIAL, CASE AND HOUSING INCLUDED IN AXLE ASSEMBLY 102-11053-1
FIG. 14. ROTOR DRIVE AXLE
ROTOR DRIVE AXLE ROCKWELL STANDARD MODEL JH-150-X-48 DWG. 35-1019
ROTOR DRIVE AXLE ROCKWELL STANDARD MODEL JH-150-X-48 DWG. 35-1019
ROTOR DRIVE AXLE ROCKWELL STANDARD MODEL JH-150-X-48 DWG. 35-1019
LEFT HAND ROTATION TRACTION DRIVE HYDROSTATIC PUMP
HYDROSTATIC PUMP - TRACTION DRIVE UNIVERSAL JOINT & CONNECTIONS TO PUMP AND ENGINE PUSH PULL UNIT - FORWARD - REVERSE NEUTRAL START SWITCH
FIG. 17. TRACTION DRIVE MOTOR
FIG. 18. TRACTION DRIVE HYDRAULIC LINES
HYDRAULIC LINES & FITTINGS - TRACTION DRIVE WHEELS & TIRES REX HYDROSTATIC DRIVE PULVI MIXER
HYDRAULIC LINES & FITTINGS - TRACTION DRIVE WHEELS & TIRES REX HYDROSTATIC DRIVE PULVI MIXER - Continued
FIG. 19. HYDRAULIC PUMP FOR TAILBOARD - SPRAY BAR AND CRANE RAMS
FIG. 20. HYDRAULIC CONTROL VALVE FOR TAILBOARD AND ROTOR LIFT RAMS
HYDRAULIC CONTROL VALVE FOR ROTOR HOIST RAM AND TAILBOARD CONTROL RAM (GRESEN MFG. CO. "CP4" - 2 SPOOL)
FIG. 21. MODEL V20 DIRECTIONAL CONTROL VALVE TYPICAL MAIN ASSEMBLY
FIG. 22. 4-WAY, 3-POSITION VALVE SECTION
FIG. 23. STANDARD SPOOL POSITIONER
FIG. 25. OPTIONAL VERTICAL HANDLE AND BRACKET ASSEMBLY
FIG. 26. LOAD CHECK PLUG ASSEMBLY
FIG. 27. MODEL RDSON MAIN RELIEF VALVE (NON-ADJUSTABLE)
Standard Buna-N Seals and O-Rings
FIG. 28. HYDRAULIC LINES - VALVE TO SPRAY BAR
FIG. 29. HYDRAULIC LINES SCHEMATIC FOR ROTOR AND TAILBOARD
HYDRAULIC LINES SCHEMATIC ROTOR & TAILBOARD LIFT FOR G.M. DIESEL POWER ONLY REX DWG. NO. 602-2750
FIG. 30. HYDRAULIC CYLINDER FOR SPRAY BAR AND FIFTH WHEEL
FIG. 31. HYDRAULIC CYLINDER RAM FOR ROTOR LIFT
FIG. 32. HYDRAULIC CYLINDER FOR SPRAY BAR AND FIFTH WHEEL
FIG. 33. HYDRAULIC CYLINDER FOR TAILBOARD
FIG. 34. GENERAL MOTORS DIESEL POWER UNIT
GENERAL MOTORS DIESEL POWER UNIT - CONTINUED
GENERAL MOTORS DIESEL POWER UNIT - CONTINUED
GENERAL MOTORS DIESEL POWER UNIT - CONTINUED
FIG. 35. POWER STEERING PUMP
FIG. 36. POWER STEERING CYLINDER
POWER STEERING CYLINDER ASSEMBLY ROSS GEAR DIVISION PART NO. C36531-A4-50 REX PART NO. 102-8404-1
FIG. 37. FIFTH WHEEL - TACH DRIVE
FIFTH WHEEL -- GEARCASE - GENERATOR VISUAL PERFORIMANCE INDICATOR
FIFTH WHEEL -- GEARCASE - GENERATOR VISUAL PERFORIMANCE INDICATOR - Continued
FIG. 38. EXPLODED VIEW OF ENGINE
FIG. 39. MANIFOLD AND CRANKCASE GROUP
MANIFOLD AND CRANKCASE GROUP
FIG. 40. CRANKSHAFT, PISTON AND CONNECTING ROD GROUP
CRANKSHAFT, PISTON AND CONNECTING ROD GROUP
FIG. 41. CAMSHAFT AND FUEL PUMP MOUNTING GROUP
FIG. 42. OIL FILTER AND OIL FILLER MOUNTING GROUP
FIG. 43. AIR SHROUDING
FIG. 44. CYLINDER BLOCK ASSEMBLY
FIG. 45. MAGNETO AND GEAR COVER GROUP
FIG. 46. K 95 L Oil Pump Assembly
FIG. 47. T 89K-S1, GOVERNOR ASSEMBLY
FIG. 48. TT-45-L AND TT-45L-1 GOVERNOR CONTROL ASSEMBLIES
FIG. 50. Q12J GASKET SET
FIG. 50. STARTING MOTOR ASSEMBLY WITH FOLO-THRU BENDIX
FIG. 51. STARTER MOUNTING
Fig. 52. YC66D-S1 HIGH TEMP. SAFETY SWITCH KIT.
Fig. 53. WALBRO CARBURETOR MODEL LUB.
WALBRO CARBURETOR
Fig. 54. LO-64 SIDE MOUNT AIR CLEANER ASSEMBLY.
Fig. 55. MAGNETO - Fairbanks-Morse No. FM-XZE4B7-4, Wisconsin Motor No. Y-98-C-S2 per MIL-E-11275-C Specifications
Fig. 55. MAGNETO (Cont.)
Fig. 55. MAGNETO (Cont.)
FIG. 56. FRONT AXLE ASSEMBLY.
FRONT AXLE - FRONT AXLE KIT 102-9438-1 - ROCKWELL STANDARD #FC-901
FIG. 57. CONTROLS.
FIG. 57. CONTROLS. - Continued
FIG. 57. CONTROLS. - Continued
FIG. 57. CONTROLS. - Continued
FIG. 58. MAIN FRAME, ENGINE HOUSE, FLOORBOARD AND FENDERS.
MAIN FRAME - ENGINE HOUSE - FLOORBOARD- FENDERS
MAIN FRAME - ENGINE HOUSE - FLOORBOARD- FENDERS - Continued
FUEL TANK - SUCTION & RETURN FUEL LINES OPERATOR'S SEAT - TOOL BOX
DECALS AND LABELS REX SELF PROPELLED PULVI MIXER
WIRING SCHEMATIC - LIGHTING
INDEX
INDEX - Continued
TABLE OF CONTENTS
Table of Contents (Continued)
SUBSECTION I - GENERAL
Load Classification
SUBSECTION II. MAINTENANCE
Shipment and Storage
SUBSECTION III. REPAIR PARTS SUPPLY
Requisitioning Repair Parts
APPENDIX A. EQUIPMENT PUBLICATIONS
APPENDIX B. WARRANTY GUIDELINES
APPENDIX B. WARRANTY GUIDELINES - Continued
APPENDIX C. MAINTENANCE ALLOCATION CHART
APPENDIX C. MAINTENANCE ALLOCATION CHART - Continued
APPENDIX C. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
SECTION III - TOOL AND TEST EQUIPMENT REQUIREMENTS
SECTION III - TOOL AND TEST EQUIPMENT REQUIREMENTS - Continued
Section IV Remarks
CCE MANUFACTURER FIELD CAMPAIGNS AND MODIFICA-ION PROCEDURES
BASIC ISSUE ITEMS LIST
APPENDIX G. INITIAL RECOMMENDATION - PRESCRIBED LOAD LIST (PLL) - AUTHORIZED STOCKAGE LIST (ASL)
APPENDIX G. INITIAL RECOMMENDATION - PRESCRIBED LOAD LIST (PLL) - AUTHORIZED STOCKAGE LIST (ASL) - Continued
MAINTENANCE AND OPERATING SUPPLY LIST
MAINTENANCE AND OPERATING SUPPLY LIST - Continued
REQUISITION PROCESSING GENERAL INSTRUCTIONS
Requisition Format
NON-NSN REQUISITION FORMAT
PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES.
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES. - Continued
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
Figure 1-2. Number Plate
Figure 1-3. Two-Stroke Cycle Operation
GENERAL SPECIFICATIONS
Figure 1-4. Model Number Coding
Figure 1-5. Typical Engine Serial Number and Model Number as Stamped on Cylinder Block Option Plate
Lubrication System
CROSS SECTION OF ENGINE MODEL VH4D
Shipping and Lifting
Service Classification of Oil
Figure 1-8. Operating Controls
Water Temperature Gage
Starter Switch
TABLE 1-1. Oil Pressures For Various Engine
Cooling System
Figure 1-9. Hood and Rotor Assembly Nomenclature
Figure 1-10. Rotor Operation
Figure 1-11. Instant Depth Check
V.P.I. Fluid Handling System
Table 1-3. Pulvi-Mixer Reference Application Chart
Warm-Up Period
Figure 1-13. Spray bar Nozzle Assembly
Figure 1-15. Wash Down System
Figure 1-17. Standard Rotor
DIESEL ENGINE AND RELATED COMPONENTS
MAIN VEHICLE WIRING DIAGRAM
Tailboard Wearplate
ROTOR TINE REPLACEMENT
ROTOR AND JACK AXLE REMOVAL
SHEAR COUPLING REPAIR
SUBSECTION 2 EMULSION PUMP AND WASH DOWN PUMP
Troubleshooting
SUBSECTION 2 EMULSION PUMP AND WASH DOWN PUMP
HYDRAULIC BRAKE LAYOUT
DISASSEMBLY
BRAKE MASTER CYLINDER
Figure 7. Wheel Cylinder Exploded View
Figure 1. Sectional View of Type DPB Single Plate Clutch
GENERAL DESCRIPTION
Figure 2. Checking Dimension `A'
COMMON SERVICE PROBLEMS
COMMON SERVICE PROBLEMS (Cont.)
CHECKING FOR MISALIGNMENT
Figure 5. Knocking Out Drive Gear Assembly
Figure 8. Sectional and Exploded View of Rotor Drive transmission
FIGURE 9. Removing Drive Gear Bearing
FIGURE 12. Pressing on Countershaft Rear Bearing
TWO SPEED ROTOR DRIVE TRANSMISSION
DISASSEMBLE DRIVE UNIT
EXPLOSION VIEW OF UNIT HOUSING DRIVE AXLE
DISASSEMBLE PINION AND CAGE ASSEMBLY
COMPLETE ASSEMBLIES
REASSEMBLE PINION AND CAGE ASSEMBLY
REASSEMBLE PINION AND CAGE ASSEMBLY - Continued
ASSEMBLE DIFFERENTIAL AND BEVEL GEAR
ADJUST DIFFERENTIAL BEARING PRE-LOAD
TORQUE SPECIFICATIONS
SUBSECTION 5 REAR AXLE ASSEMBLY AND FINAL DRIVE
DISASSEMBLE PLANETARY SPIDER ASSEMBLY
REMOVE THE FLOATING RING GEAR ASSEMBLY
DISASSEMBLE BRAKE SHOE AND LINER ASSEMBLY
WHEEL BEARING ADJUSTMENT
REASSEMBLE PLANETARY SPIDER ASSEMBLY
INSTALL PLANETARY SPIDER ASSEMBLY
TWO SPEED NOSE BOX TRANSMISSION
TWO SPEED NOSE BOX TRANSMISSION
ASSEMBLY
TRACTION DRIVE AXLE
DISASSEMBLE DRIVE UNIT
PREPARE FOR REASSEMBLY
COMPLETE ASSEMBLIES
REASSEMBLE AXLE
REASSEMBLE PINION AND CAGE ASSEMBLY
ASSEMBLE DIFFERENTIAL AND BEVEL GEAR
ADJUST DIFFERENTIAL BEARING PRE-LOAD
TORQUE SPECIFICATIONS
SUBSECTION 6 HYDROSTATIC PUMP AND MOTOR
SCHEMATIC HYDROSTATIC DRIVE
HYDROSTATIC TRACTION DRIVE AND GEARING ARRANGEMENT DIAGRAM
Manual Displacement Control
Start Up Procedure
HYDROSTATIC PUMP AND MOTOR
HYDRAULIC SUPPORT SYSTEM
System Relief Valves
MOTOR REPLACEMENT
TROUBLESHOOTING GAUGE ISTALLATION AND INFORMATION
SYSTEM OPERATING HOT
SYSTEM RESPONSE IS SLUGGISH
Inspect Manual Displacement Control
Inspect Charge Check Valves
CONTROL ADJUSTMENTS
Centering Spring
MINOR REPAIRS
Shaft Seal
System Relief Valve
Motor Manifold
Installation
Control
FIXED DISPLACEMENT MOTOR
Special Tools
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
Special Tools - Continued
VARIABLE DISPLACEMENT PUMP
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
VARIABLE DISPLACEMENT PUMP - Continued
INSTALLATION TORQUE VALUES
SUBSECTION 7 HYDRAULIC PUMP
FIGURE 4 Marking of the Gears for Location
PUMP ASSEMBLY
FIGURE 12 Use of India Stone on Gears
FIGURE 17 Drive Shaft, Inner Wear Plate and Seal Assembly being Installed in Adapter
BREAK-IN OF REPAIRED PUMPS
FIGURE 1 Valve Section
REPLACING SPOOL SEALS IN CONTROL VALVE
REPLACING SPOOL SEALS IN CONTROL VALVE - Continued
FIGURE 4 Model V20 Directional Control Valve, Typical Main Assembly
TAILBOARD HYDRAULIC CYLINDER
SPRAY BAR HYDRAULIC CYLINDER
SPRAY BAR HYDRAULIC CYLINDER - Continued
SUBSECTION 10 - DIESEL ENGINE
SCOPE AND USE OF THE MANUAL
GENERAL PROCEDURES
GENERAL PROCEDURES - Continued
WORK SAFELY
CONTENTS
CYLINDER BLOCK
Fig. 2 - Cutaway View of Cylinder Block Showing Air and Water Passages
Fig. 5 - Engine Mounted on Overhaul Stand
Fig. 7 - Cleaning Cylinder Block
Fig. 9 - Cylinder Block Prepared for Pressure Test
Fig. 10 - Honing Bore of Cylinder Block
Fig. 12. Checking Bore of Cylinder Block
Fig. 14. Block Bore Measurement Record Form
Fig. 16. Checking Top Face of Cylinder Block
Fig. 18. Checking Depth of Counterbore for Cylinder Liner with Tool J 22273
Assemble and Install Engine
Assemble and Install Engine - Continued
CYLINDER BLOCK END PLATES
CYLINDER BLOCK END PLATES - Continued
Fig. 1. Air Box Drain Tubes
CYLINDER HEAD
Fig. 3. Typical Mounting of Cylinder Head
Cylinder Head Maintenance
Fig. 5. Removing or Installing Injector Control Tube
Fig. 7. Cylinder Head Prepared for Pressure Test using Tool J 28454
Non-Fluorescent Penetrant Method
Fig. 9- Minimum Distance Between Top and Bottom Faces of Cylinder Head
Assemble Cylinder Head
Fig. 11 Cylinder Head Seals and Gaskets
Fig. 13 Cylinder Head Bolt Tightening Sequence
Pre-lnstallation Inspection
VALVE AND INJECTOR OPERATING MECHANISM
Remove Rocker Arms and Shaft
Fig. 4. Cam Followers and Guide
Fig. 5. Cam Roller Clearances
Fig. 7. Testing Cam Follower Spring using Tool J 22738-02
Fig. 8. Removing or Installing Cam Follower Roller using Tool J 5840-01
Fig. 11. Checking Cam Follower to Guide
Fig. 12. Adjusting Cam Follower Guide
Fig. 2. Assembly of Exhaust Valves and Guides
Remove Exhaust Valve Spring (Cylinder Head Installed)
Fig. 4. Testing Exhaust Valve Spring using Tool J 22738-02
Fig. 6. Removing Exhaust Valve Guide
Fig. 9. Removing Valve Seat Insert
Fig. 11. Refacing Exhaust Valve
Fig. 14 - Relationship Between New Exhaust Valve, Insert and Cylinder Head
Fig. 16. Checking Pressure Required to Open the Exhaust Valve in Cylinder Head
Install Engine Lifter Bracket
Fig. 1. Typical Valve Rocker Cover Assembly (Current)
Remove and Install Valve Rocker Cover
Fig. 1. Typical Six Cylinder Crankshaft (Former)
Fig. 2. Typical Crankshaft, Timing Gear and Oil Pump Drive Gear Assembly-Four Cylinder Engine
Crankshaft Measurements
Fig. 4. Critical Crankshaft Loading Zones
Fig. 6. Dimensions of Crankshaft Journals
Fig. 8. New or Morco Remanufactured Crankshaft
Fig. 10. Checking Crankshaft End Play
Install Crankshaft
Fig. 1. Crankshaft Front Oil Seal
Fig. 4. Crankshaft Rear Oil Seal Mounting
Install Crankshaft Front Oil Seal
Fig. 1. Main Bearing Shells, Bearing Caps and Crankshaft Thrust Washers
Fig. 4. Removing Upper Rear Main Bearing Shell
Fig. 5. Comparison of Main Bearing Shells Minimum
Fig. 8. Crankshaft Thrust Washers in Place
Fig. 9 - Main Bearing Cap Marking
Fig. 1. Crankshaft Front Cover Mounting (Vibration Damper Removed)
Install Crankshaft Front Cover
CRANKSHAFT VIBRATION DAMPER
Fig. 3. Vibration Damper and Crankshaft Pulley Assembly Mounting
Install Vibration Damper on Crankshaft
Fig. 1. Removing Rubber Mounted Pulley from Crankshaft using Tool J 5356
Install Crankshaft Pulley
Remove Flywheel (Transmission Removed)
Remove Ring Gear
Fig. 4. Torque - Turn Limits
CLUTCH PILOT BEARING
Fig. 1. Typical Flywheel Housing Mounting
Fig. 3. Flywheel Housing Bolt Tightening Sequence (Operation 1)
Fig. 4. Flywheel Housing Bolt Tightening Sequence (Operation 2)
Fig. 1. Cross-Head Piston and Connecting Rod Assembly
Inspect Piston Rings
Fig. 5. Checking Fire Ring Groove in Piston Crown using Tool J 24599
Fig. 7. Installing Piston Pin
Fig. 9. Installing Piston Pin Retainer using Tool J 23762
Fig. 11 - Measuring Piston-to-Liner Clearance using Tool J 5438-01
Fig. 14 - Measuring Piston Ring Gap
Fig. 16. Piston Ring Installation Instructions.
CONNECTING ROD
Fig. 2. Magnetic Particle Inspection Limits for Connecting Rod.
Fig. 3 - Dimensional Inspection of Cross-Head Piston Connecting Rods
Assemble Connecting Rod to Piston
Fig. 1 - Connecting Rod and Bearing Shells
Install Connecting Rod Bearing Shells
Fig. 1. Typical Cylinder Liner.
Fig. 2 -Cylinder Liner
Fig. 6. Cylinder Liner Ridge Due to Wear.
Fig. 8 - Checking Bore of Cylinder Line Using Tool J 5347-01
NEW CYLINDER LINER TO NEW CYLINDER BLOCK BORE FITS
Fig. 9. Cylinder Liner Classification
Fig. 11. Checking Distance of Liner Flange Below Top Face of Block
Fig. 13. Typical Connecting Rod Markings
Install Cylinder Liner, Piston and Connecting Rod Assembly
Fig. 2. Loosening Nut on Camshaft or Balance
Install Front Balance Weights
Fig. 1. Gear Train and Timing Marks-Right-Hand Rotation Engine (Standard Timing Shown)
Fig. 2. Pointer Installation for Marking Top-Dead-Center
Fig. 3. Checking Engine Timing By Measuring Injector Depression
Fig. 1. Camshaft and Balance Shaft Assemblies
Fig. 2. Woodruff Keys for Current Camshafts
Fig. 5. Removing or Installing Shaft Bearing Retainer Bolts
Fig. 7. Removing Gear (Camshaft or Balance Shaft Gear Puller J 1902-01)
Fig. 9. Camshaft and Balance Shaft Journal Fillets
Fig. 10. Typical Camshaft and Balance Shaft Details and Relative Location of Parts
Fig. 11. Comparison of End Bearings and Thrust Washers
Fig. 12. Camshaft Plug Installation
Fig. 13. Camshaft Intermediate Bearing Lock Screws
Fig. 2. Removing Gear (Camshaft or Balance Shaft)
Fig. 3. Replacing Gear (Camshaft Shown)
Fig. 1. Idler Gear Mounting Typical
ig. 2. Pressing Hub Out of Bearing
Fig. 4. Idler Gear Details and Relative Location of Parts
Fig. 6. Fixture for Testing Bearing Pre-Load
Fig. 8. Checking Pre-Load of Idler Gear Bearing
Install Idler Gear, Hub and Bearing Assembly
Fig. 1. Removing Crankshaft Timing Gear
Fig. 1. Typical Blower Drive Gear and Support Assembly
Fig. 4. Bower Drive Shaft Mounting
Fig. 5. Typical Blower Drive Gear Details and Relative Location of Parts
Fig. 6. Inserting Blower Drive Cam
Fig. 1. Typical Components of Accessory Drive For Direct-Driven Accessories
ACCESSORY DRIVE
Fig. 1. Balance Weight Cover Mounting
CHECKING BEARING CLEARANCES
TROUBLE SHOOTING
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
uEXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
SPECIAL PLUG TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
Fig. 1. Schematic Diagram of Typical Fuel System
Fig. 2. Cutaway View of Fuel Injector
Fig. 3 Fuel Metering from No-Load to Full-Load
Fig. 6 Fuel Injector Mounting
Fig. 9. Removing Injector Follower Stop Pin
Fig. 11. Injector Tester J 23010 Clamping Heads
Fig. 12. Injector Installed in Tester J 23010 with clamping Head
Visual Inspection of Plunger
Fig. 15. Adaptor and Tube Assembly on Injector Tester J 23010
Unclamping the Injector
Fig. 16. Checking Needle Valve Lift
Fig. 17 - Injector Needle Valve Tester J 23010 with Auxiliary Tester J 22640
Fig. 20 - Position of Calibrator Fuel Flow Pipes
Fig. 22 Setting Calibrator Stroke Counter
Fig. 27. Cleaning injector Spray Tip
Fig. 31. Sealing Surfaces which may Require Lapping
Fig. 34. Location of Filter in Injector Body
Fig. 36. Injector Rack, Gear, Spray Tip and Valve Assembly Details and Relative Location of Parts
Fig. 37. Injector Plunger, Follower and Relative Location of Parts
Fig. 39. Spray Tip Sealing Surface Identification
Fig. 42. Installing Injector Follower Stop Pin
Fig. 43. Checking Injector Spray Tip Concentricity using Tool J 29584
Check Spray Tip Concentricity
Install Injector
Install Injector Tube
Fig. 3 - Upsetting Injector Tube
Fig. 5 - Reaming Injector Tube for Injector Nut
Ream Injector Tube
Fig. 1 - Typical Fuel Pump Assembly
Fig. 2 - Typical Fuel Pump Mounting and Drive
Fig. 3 - Fuel Pump Valving and Rotation (Right-Hand Pump)
Fig. 5 - Removing Pump Cover
Fig. 7 - Fuel Pump Details and Relative Location of Parts
Fig. 9 - Installing Outer Oil Seal
Fig. 10 Installing Drive Shaft and Gear Assembly
Fig. 1 - Typical Spin-On Filter Mounting
Fig. 1 - Cylinder Head with Integral Fuel Manifolds
MECHANICAL GOVERNOR
Remove Governor
Fig. 1 - Variable Speed Mechanical Governor
Fig. 2 - Variable Speed Governor Mounting
Fig. 5 Governor Control Housing Details and Relative Location of Parts
Fig. 7. Removing Operating Shaft from Operating Fork
Fig. 9. Governor Weight Housing Details and Relative Location of Parts
Fig. 11 Installing Needle Bearing in Governor Cover using Tool J 21068
Fig. 12. Cross Section of Governor Variable Speed Spring Housing
Fig. 13. Variable Speed Spring Housing and Shaft Details and Relative Location of Parts
Fig. 15. Governor Weight Housing
Install Governor
FUEL INJECTOR CONTROL TUBE
Install Injector Control Tube
Fig. 1. Checking Fuel Output
REFINISH LAPPING BLOCKS
EFFECT OF PRE-IGNITION ON FUEL INJECTOR
REFINISHING INJECTOR FOLLOWER FACE
PRESSURIZE FUEL SYSTEM CHECK FOR LEAKS
CHECKING FUEL FLOW
CHECKING FUEL FLOW - Continued
SHOOTING CHARTS (Needle Valve Injectors)
SHOOTING CHARTS (Needle Valve Injectors) - Continued
SHOOTING CHARTS (Needle Valve Injectors) - Continued
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
Fig. 1 - Air Flow Through Blower and Engine
Air Cleaner Mounting
Fig. 1 - Dry Type Air Cleaner (Heavy Duty)
Service
AIR SHUTDOWN HOUSING
Fig. 2 - Air Shutdown Housing Mounting and Bolt Location
BLOWER
Fig. 1 - Blower and Drive Assembly and Accessories including Mechanical Governor Attached to blower
Fig. 2 Typical Blower Mounting (71 Engine)
Fig. 4 Removing Blower Rotor Gears from Blower Rotor Shafts with Tool Set J 6270-F
Fig 5 - Removing Blower End Plate using Tool Set J 6270-F
Fig. 7 - Typical Details and Relative Location of Parts
Fig. 8 - Installing Oil Seal in Blower End Plate using Tool J 6270-3.
Fig. 10 - Position of Blower Front End Plate on Housing
Fig. 13 - Installing Roller Bearing on Rotor Shaft and in Front End Plate using Tool J 6270-4.
Fig. 14 - Installing Ball Bearing on Rotor Shaft and in Rear End Plate using Tool J 6270-7.
Fig. 16 - Measuring "CC" and "C" Clearances Between Blower Rotor Lobes.
Fig. 17 - Chart of Minimum Clearances for Blowers.
Fig. 18 - Diagram Showing Proper Location of Shims for Correct Rotor Lobe Clearances.
Attach Accessories to Blower
Fig. 1 - Removing Rotor Stub Shaft.
Install Service Rotor Front Stub Shaft
TABLE OF SPECIFICATIONS, NEW CLEARANCES AND WEAR LIMITS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
LUBRICATION SYSTEM
Fig. 1 - Schematic Diagram of Typical Lubrication System.
Fig. 2 - Blower Lubrication.
Fig. 1 - Oil Pump Assembly.
Fig. 2 - Typical Oil Pump Mounting.
Fig. 3 - Oil Pump Details and Relative Location of Parts.
Fig. 5 - Removing Oil Pump Drive Gear form Shaft.
Fig. 6 - Diameter and Location of Bushing in Oil Pump.
Fig. 8 - Removing Oil Pump Driving Gear from Crankshaft
Fig. 9 - Installing Oil Pump Driving Gear on Crankshaft
Install Oil Pump Driving Gear on Crankshaft
Fig. 1 - Lubricating Oil Pressure Regulator Details and Relative Location of Parts.
Assemble Oil Pressure Regulator
Fig. 1 - Typical Oil Filter Mounting.
Fig. 3- Bypass Valve
Figure 1. Typical Lubricating Oil Cooler Mounting-Radiator Cooled Engine
Fig. 2 Oil Cooler Core Prepared for Pressure Check
Install Lubricating Oil Cooler
LUBRICATING OIL COOLER BYPASS VALVE
Figure 1. Typical Dipstick Mounting
Figure 1. Typical Deep Sump Type Oil Pan
Figure 1. Breather Mounted on Cylinder Block
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
RADIATOR AND COOLING FAN
Fig. 1 - Typical Cooling System with Radiator and Fan
Cooling System Capacity
Miscellaneous Cooling System
LUBRICATION SYSTEM
Fig. 1 - Water Pump With Ceramic Insert in Impeller
Fig. 4 Pressing Pump Shaft from Impeller
Fig. 6 - Water Pump Details and Relative Location of Parts
Fig. 7 - Installing Pump Impeller
Fig. 1 - Typical Water Manifold Mounting Industrial Unit
Fig. 1 - Typical thermostat Housing Mounting (Radiator Cooling System)
Fig. 2 - Method of Checking Thermostat Operation
Cleaning Radiator
Fig. 1 Removing Radiator, Shell and Shroud with Lifting Hook (Typical)
COOLANT PRESSURE CONTROL CAP
Fig. 1 . Typical Fan and Fan Hub Assembly
Fig. 2 - Shaft Type Fan Hub Assembly Details for Compact Front End Engine.
Fig. 3 - Shaft Type Fan Hub Assembly.
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXHAUST SYSTEM
Fig. 1 - Typical Air-Cooled Exhaust Manifold Mounting.
Remove Exhaust Manifold
ELECTRICAL SYSTEM
Fig.1 - Hinge-Mounted Alternator.
Fig. 4 - Terminal Connections.
Fig. 6 - Charging Circuit.
ABNORMAL CHARGING SYSTEM OPERATION
Fig. 10 - Testing Diode Trio.
Fig. 11 - Testing Rectifier Bridge.
Fig. 13 - Drive End Bearing Assembly.
Fig. 16 - Tighten Alternator Pulley Retaining Nut
Fig. 17 - Battery Connecting Diagram.
Battery Safety Precautions
Fig. 2 - Cross-section of Starting Motor with Sprag Heavy-Duty Clutch Drive.
TROUBLESHOOTING
Interpreting Results of Tests
Fig. 5 - Checking Solenoid Hold-In Winding.
Fig. 6 - Checking Solenoid Pull-In Winding.
Fig. 8 - Measuring Pinion Clearance.
Fig. 1 - Typical Instrument Panel.
Fig. 3 - Tachometer Mounting.
Fig. 5 - Tachometer Head.
MANUAL SHUTDOWN SYSTEM
COLD WEATHER STARTING
ALIGNMENT TOOLS FOR TACHOMETER DRIVE COVERS AND ADAPTORS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
ENGINE OPERATING CONDITIONS
DYNAMOMETER TEST AND RUN-IN PROCEDURES
Dynamometer
ENGINE TEST REPORT
BASIC RUN-IN INSPECTION
INSPECTION AFTER FINAL RUN-IN
FUEL OILS FOR DETROIT DIESEL ENGINES
DIESEL FUEL LINE DE-ICER
LUBRICATING OILS FOR DETROIT DIESEL ENGINES
USED LUBE OIL ANALYSIS PROGRAM
LUBE OIL FILTER CHANGE INTERVAL
STATEMENT OF POLICY ON FUEL AND LUBRICANT ADDITIVES
COOLANT REQUIREMENTS
Fig. 1 - Heat Transfer Capacity
Fig. 2 Coolant Freezing and Boiling Temperatures vs. Antifreeze Concentration (Sea Level)
GENERAL RECOMMENDATIONS
GENERAL RECOMMENDATIONS - Continued
ENGINE TUNE-UP PROCEDURES
Fig. 1 - Adjusting Valve Clearance (Two Valve Head)
Fig. 1 - Timing Fuel Injector
Fig. 1 - Adjusting Governor Cap
Fig. 3 - Buffer and Idle Speed Adjusting Screw
Fig. 6 - Location of Stops and Shims
Adjust Booster Spring
PREVENTIVE MAINTENANCE TROUBLE SHOOTING - STORAGE - PLUGGING CHARTS
ENGINE OIL CHANGE INTERVALS
Diesel Fuel Contamination
Throttle and Clutch Controls
Exhaust System
Engine and Transmission Mounts
Crankcase Breather
Fig. 1 - Locating a Misfiring Cylinder
Fig. 2 - Checking Compression Pressure
Fig. 3 - Inspecting Piston Rings
PROPER USE OF MANOMETER
PRESSURE CONVERSION CHART
EXHAUST SMOKE ANALYSIS
EXHAUST SMOKE ANALYSIS - Continued
HARD STARTING
HARD STARTING - Continued
ABNORMAL ENGINE OPERATION
ABNORMAL ENGINE OPERATION - Continued
NO FUEL OR INSUFFICIENT FUEL
NO FUEL OR INSUFFICIENT FUEL - Continued
ABNORMAL ENGINE COOLANT OPERATING TEMPERATURE
EXCESSIVE CRANKCASE PRESSURE
LOW OIL PRESSURE
LOW OIL PRESSURE- CONTINUED
HIGH LUBRICATING OIL CONSUMPTION
HIGH LUBRICATING OIL CONSUMPTION - CONTINUED
PREPARING ENGINE FOR STORAGE
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
PLUGGING CHARTS - LC and RC ENGINES
PLUGGING CHARTS - LC and RC ENGINES - Continued
SUBSECTION 11 FRONT AXLE AND STEERING
INSTALLATION AND OPERATION
HYDRAULIC FLUID RECOMMENDATIONS
TABLE II - TROUBLE SHOOTING CHART
TABLE II. - TROUBLE SHOOTING CHART (CONTINUED)
Control Valve Sub-Assembly
STEERING GEAR REPLACEMENT
FRONT AXLE REPAIR
SUBSECTION 12 STEERING CYLINDER
POWER STEERING VALVE UNIT ON STEERING COLUMN
SUBSECTION 13 V.P.I. FLUID HANDLING SYSTEM
CALIBRATING THE V.P.I. SYSTEM-METER RECORDING UNIT
CALIBRATING THE V.P.I. SYSTEM-METER RECORDING UNIT - Continued
TRAVEL SPEED UNIT
PROPORTIONING SYSTEM UNIT
SUGGESTED EXTERNAL POWER SOURCE CIRCUITRY
V.P.I. TROUBLE SHOOTING
SUBSECTION 14 GASOLINE PUMP ENGINE
MAGNETO BREAKER POINT ADJUSTMENT
FIGURE 6. MAGNETO TIMING DIAGRAM
FIGURE 7. WIRING DIAGRAM
TROUBLES CAUSES AND REMEDIES
ENGINE SURGES OR GALLOPS
TESTING REBUILT ENGINE
CARBURETOR AND MANIFOLD
IDLER GEAR AND SHAFT
PISTONS and CONNECTING RODS
CYLINDER BLOCKS
VALVE TAPPETS
GOVERNOR ADJUSTMENT
WALBRO CARBURETOR
FIGURE 30. FLOAT SETTING
FIGURE 31. EXPLODED VIEW Instructions and Service Parts Illustration
LUBRICATION CHART 1 - GENERAL
LUBRICATION CHART 1 - GENERAL (Continued)
LUBRICATION CHART 2 - EMULSION HANDLING SYSTEM
FIG. 1. ROTOR HOOD, TAILBOARD, LIFT ARMS, HOOD ARMS, JACK AXLE ARMR AND SKIS
ROTOR HOOD-CRANE-TAILBOARD-LIFT ARMS - HOOD ARMS-JACK AXLE ARMS & SKIS - REX SELF-PROPELLED PULVI MIXERS
ROTOR ASSEMBLY WITH SOLID TUBE AND BEYEL EDGE TINES REX ASSEMBLY NO. 602.2720, COMPLETE
FIG. 3. ROTOR DRIVE CHAIN CASE (LEFT AND RIGHT REQUIRED)
ROTOR DRIVE CHAIN CASE
FIG. 4. ROTOR DRIVE LINE
ROTOR DRIVELINES
FIG. 5. EMULSION PUMP ASSEMBLY PEABODY - BARNES MODELS: 30CCG, 30CCG-1, 30CCG-2
EMULSION PUMP ASSEMBLY
FIG. 6. PUMP FOR WASH-DOWN SYSTEM
FIG. 7. EMULSION HANDLING UNIT PIPING, CONTROLS HYDRAULIC LINES AND FITTINGS
EMULSION HANDLING UNIT PIPING - CONTROLS - HYDRAULIC LINES & FITTINGS
EMULSION HANDLING UNIT PIPING - CONTROLS - HYDRAULIC LINES & FITTINGS - Continued
EMULSION HANDLING UNIT PIPING - CONTROLS - HYDRAULIC LINES & FITTINGS - Continued
FIG. 8. FLOW METER
FLOW METER AND TACHOMETER GENERATOR ASSY. 4' MODEL 4MLFT- SGH
FLOW METER AND TACHOMETER GENERATOR ASSY. 4' MODEL 4MLFT- SGH
FIG. 9. WATER AND ASPHALT SPRAY BARS AND ROTOR HOOD COVERS
WATER AND ASPHALT SPRAY BARS AND ROTOR HOOD COVERS REX SELF PROPELLED PULVI MIXERS
FIG. 10. TRACTION DRIVE WHEEL ENDS AND BRAKES
TRACTION DRIVE WHEEL ENDS INCLUDED IN AXLE ASSEMBLY 102-6168-1 ROCKWELL MODEL TA-279-HXI EFFECTIVE HK-381
TRACTION DRIVE WHEEL ENDS INCLUDED IN AXLE ASSEMBLY 102-6168-1 ROCKWELL MODEL TA-279-HXI EFFECTIVE HK-381 - Continued
FIG. 11. TWO SPEED TRANSMISSION - ROTOR DRIVE
ROTOR DRIVE TWO-SPEED TRANSMISSION REX PART NO. 602-10224-2 ROTOR DRIVE CLUTCH ASSEMBLY
ROTOR DRIVE TWO-SPEED TRANSMISSION REX PART NO. 602-10224-2 ROTOR DRIVE CLUTCH ASSEMBLY - Continued
FIG. 12. TRACTION DRIVE TRANSMISSION (2 SPEED)
TRACTION DRIVE TWO-SPEED TRANSMISSION INCLUDED IN AXLE ASSEMBLY 102-11053-1
FIG. 13. TRACTION DRIVE AXLE
DIFFERENTIAL, CASE AND HOUSING INCLUDED IN AXLE ASSEMBLY 102-11053-1
FIG. 14. ROTOR DRIVE AXLE
ROTOR DRIVE AXLE ROCKWELL STANDARD MODEL JH-150-X-48 DWG. 35-1019
ROTOR DRIVE AXLE ROCKWELL STANDARD MODEL JH-150-X-48 DWG. 35-1019
ROTOR DRIVE AXLE ROCKWELL STANDARD MODEL JH-150-X-48 DWG. 35-1019
LEFT HAND ROTATION TRACTION DRIVE HYDROSTATIC PUMP
HYDROSTATIC PUMP - TRACTION DRIVE UNIVERSAL JOINT & CONNECTIONS TO PUMP AND ENGINE PUSH PULL UNIT - FORWARD - REVERSE NEUTRAL START SWITCH
FIG. 17. TRACTION DRIVE MOTOR
FIG. 18. TRACTION DRIVE HYDRAULIC LINES
HYDRAULIC LINES & FITTINGS - TRACTION DRIVE WHEELS & TIRES REX HYDROSTATIC DRIVE PULVI MIXER
HYDRAULIC LINES & FITTINGS - TRACTION DRIVE WHEELS & TIRES REX HYDROSTATIC DRIVE PULVI MIXER - Continued
FIG. 19. HYDRAULIC PUMP FOR TAILBOARD - SPRAY BAR AND CRANE RAMS
FIG. 20. HYDRAULIC CONTROL VALVE FOR TAILBOARD AND ROTOR LIFT RAMS
HYDRAULIC CONTROL VALVE FOR ROTOR HOIST RAM AND TAILBOARD CONTROL RAM (GRESEN MFG. CO. "CP4" - 2 SPOOL)
FIG. 21. MODEL V20 DIRECTIONAL CONTROL VALVE TYPICAL MAIN ASSEMBLY
FIG. 22. 4-WAY, 3-POSITION VALVE SECTION
FIG. 23. STANDARD SPOOL POSITIONER
FIG. 25. OPTIONAL VERTICAL HANDLE AND BRACKET ASSEMBLY
FIG. 26. LOAD CHECK PLUG ASSEMBLY
FIG. 27. MODEL RDSON MAIN RELIEF VALVE (NON-ADJUSTABLE)
Standard Buna-N Seals and O-Rings
FIG. 28. HYDRAULIC LINES - VALVE TO SPRAY BAR
FIG. 29. HYDRAULIC LINES SCHEMATIC FOR ROTOR AND TAILBOARD
HYDRAULIC LINES SCHEMATIC ROTOR & TAILBOARD LIFT FOR G.M. DIESEL POWER ONLY REX DWG. NO. 602-2750
FIG. 30. HYDRAULIC CYLINDER FOR SPRAY BAR AND FIFTH WHEEL
FIG. 31. HYDRAULIC CYLINDER RAM FOR ROTOR LIFT
FIG. 32. HYDRAULIC CYLINDER FOR SPRAY BAR AND FIFTH WHEEL
FIG. 33. HYDRAULIC CYLINDER FOR TAILBOARD
FIG. 34. GENERAL MOTORS DIESEL POWER UNIT
GENERAL MOTORS DIESEL POWER UNIT - CONTINUED
GENERAL MOTORS DIESEL POWER UNIT - CONTINUED
GENERAL MOTORS DIESEL POWER UNIT - CONTINUED
FIG. 35. POWER STEERING PUMP
FIG. 36. POWER STEERING CYLINDER
POWER STEERING CYLINDER ASSEMBLY ROSS GEAR DIVISION PART NO. C36531-A4-50 REX PART NO. 102-8404-1
FIG. 37. FIFTH WHEEL - TACH DRIVE
FIFTH WHEEL -- GEARCASE - GENERATOR VISUAL PERFORIMANCE INDICATOR
FIFTH WHEEL -- GEARCASE - GENERATOR VISUAL PERFORIMANCE INDICATOR - Continued
FIG. 38. EXPLODED VIEW OF ENGINE
FIG. 39. MANIFOLD AND CRANKCASE GROUP
MANIFOLD AND CRANKCASE GROUP
FIG. 40. CRANKSHAFT, PISTON AND CONNECTING ROD GROUP
CRANKSHAFT, PISTON AND CONNECTING ROD GROUP
FIG. 41. CAMSHAFT AND FUEL PUMP MOUNTING GROUP
FIG. 42. OIL FILTER AND OIL FILLER MOUNTING GROUP
FIG. 43. AIR SHROUDING
FIG. 44. CYLINDER BLOCK ASSEMBLY
FIG. 45. MAGNETO AND GEAR COVER GROUP
FIG. 46. K 95 L Oil Pump Assembly
FIG. 47. T 89K-S1, GOVERNOR ASSEMBLY
FIG. 48. TT-45-L AND TT-45L-1 GOVERNOR CONTROL ASSEMBLIES
FIG. 50. Q12J GASKET SET
FIG. 50. STARTING MOTOR ASSEMBLY WITH FOLO-THRU BENDIX
FIG. 51. STARTER MOUNTING
Fig. 52. YC66D-S1 HIGH TEMP. SAFETY SWITCH KIT.
Fig. 53. WALBRO CARBURETOR MODEL LUB.
WALBRO CARBURETOR
Fig. 54. LO-64 SIDE MOUNT AIR CLEANER ASSEMBLY.
Fig. 55. MAGNETO - Fairbanks-Morse No. FM-XZE4B7-4, Wisconsin Motor No. Y-98-C-S2 per MIL-E-11275-C Specifications
Fig. 55. MAGNETO (Cont.)
Fig. 55. MAGNETO (Cont.)
FIG. 56. FRONT AXLE ASSEMBLY.
FRONT AXLE - FRONT AXLE KIT 102-9438-1 - ROCKWELL STANDARD #FC-901
FIG. 57. CONTROLS.
FIG. 57. CONTROLS. - Continued
FIG. 57. CONTROLS. - Continued
FIG. 57. CONTROLS. - Continued
FIG. 58. MAIN FRAME, ENGINE HOUSE, FLOORBOARD AND FENDERS.
MAIN FRAME - ENGINE HOUSE - FLOORBOARD- FENDERS
MAIN FRAME - ENGINE HOUSE - FLOORBOARD- FENDERS - Continued
FUEL TANK - SUCTION & RETURN FUEL LINES OPERATOR'S SEAT - TOOL BOX
DECALS AND LABELS REX SELF PROPELLED PULVI MIXER
WIRING SCHEMATIC - LIGHTING
INDEX
INDEX - Continued
TABLE OF CONTENTS
Table of Contents (Continued)
SUBSECTION I - GENERAL
Load Classification
SUBSECTION II. MAINTENANCE
Shipment and Storage
SUBSECTION III. REPAIR PARTS SUPPLY
Requisitioning Repair Parts
APPENDIX A. EQUIPMENT PUBLICATIONS
APPENDIX B. WARRANTY GUIDELINES
APPENDIX B. WARRANTY GUIDELINES - Continued
APPENDIX C. MAINTENANCE ALLOCATION CHART
APPENDIX C. MAINTENANCE ALLOCATION CHART - Continued
APPENDIX C. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
Section II. MAINTENANCE ALLOCATION CHART - Continued
SECTION III - TOOL AND TEST EQUIPMENT REQUIREMENTS
SECTION III - TOOL AND TEST EQUIPMENT REQUIREMENTS - Continued
Section IV Remarks
CCE MANUFACTURER FIELD CAMPAIGNS AND MODIFICA-ION PROCEDURES
BASIC ISSUE ITEMS LIST
APPENDIX G. INITIAL RECOMMENDATION - PRESCRIBED LOAD LIST (PLL) - AUTHORIZED STOCKAGE LIST (ASL)
APPENDIX G. INITIAL RECOMMENDATION - PRESCRIBED LOAD LIST (PLL) - AUTHORIZED STOCKAGE LIST (ASL) - Continued
MAINTENANCE AND OPERATING SUPPLY LIST
MAINTENANCE AND OPERATING SUPPLY LIST - Continued
REQUISITION PROCESSING GENERAL INSTRUCTIONS
Requisition Format
NON-NSN REQUISITION FORMAT
PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES.
OPERATOR/CREW AND ORGANIZATIONAL MAINTENANCE CHECKS AND SERVICES. - Continued
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
OPERATOR /CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
