FRONT AXLE
CASTER ANGLE
Fig. 4 Toe-In Measurement
TURNING ANGLE
Fig. 5 Inner Wheel Turns in a Smaller Circle Than Outside Wheel
TROUBLE SHOOTING
TROUBLE SHOOTING - Continued
FRONT AXLE - I-BEAM TYPE
SPECIFICATIONS
STEERING KNUCKLE BUSHINGS
Steering Knuckle Removal
Steering knuckle Bushings (Nylon and Teflon)
Steering Knuckle Bushing Installation (Bronze)
KNUCKLE PIN INSTALLATION
TIE ROD ENDS
DRAG LINK
TORQUE CHART
REAR AXLE
SPECIFICATIONS
STD and STDD SERIES
INTER-AXLE DIFFERNTIAL
DOUBLE REDUCTION DRIVE UNIT DESCRIPTION
REMOVE AND DISASSEMBLE DRIVE UNIT
REMOVE DRIVE UNIT FROM HOUSING
DISASSEMBLE INTERAXLE (3rd) DIFFERENTIAL ASSEMBLY
REMOVE AND DISASSEMBLE HYPOID PINION AND QUILL, BEARING AND HOUSING ASSEMBLY
REMOVE AND DISASSEMBLE HYPOID PINION AND QUILL, BEARING AND HOUSING ASSEMBLY - Continued
REMOVE AND DISASSEMBLE THRUSHAFT ASSEMBLY
REMOVE AND DISASSEMBLE THRUSHAFT ASSEMBLY - Continued
REMOVE AND DISASSEMBLE THRUSHAFT ASSEMBLY - Continued
CORROSION PREVENTION
REASSEMBLE AND INSTALL DRIVE UNIT
REASSEMBLE CROSS SHAFT ASSEMBLY
REASSEMBLE CROSS SHAFT ASSEMBLY - Continued
REASSEMBLE AND INSTALL HYPOID PINION AND QUILL, BEARING AND HOUSING ASSEMBLY
ASSEMBLE AND INSTALL THRU-SHAFT ASSEMBLY
ASSEMBLE INTERAXLE DIFFERENTIAL
SHIFT SHAFT ADJUSTMENT
CORRECT TOOTH CONTACT ASSURES LONGER GEAR LIFE
ASSEMBLE AND INSTALL AXLE DIFFERENTIAL
INSTALLATION OF BEARING CUPS IN CARRIER LEG BORES
COMPLETE DRIVE UNIT ASSEMBLY
HOW TO MATCH TANDEM TIRES
TABULATION OF TORQUE LIMITS
LOCKING TYPE DIFFERENTIAL
Fig. 1 Internal Spring Design Differential Locking Unit (Exploded View
Fig. 3 Typical installation of No Spin, unit (Cross Sectional View)
Fig. 4 Straight Forward Driving
Fig. 8 Forward Left Hand Turn (Cross Sectional View)
Fig. 10 Inserting Assembly Retaining Bolt
IMPORTANT PRECAUTION
Fig . 12 Cutaway View of Tandem Lock NoSPIN Inter-Axle Differential
FAILURE ANALYSIS
FAILURE ANALYSIS - Continued
Fig . 1-Scored and Scuffed Gear Teeth .
Fig . 2-Scuffed Gear Teeth--Coast Sides Only .
Fig . 3-Fractured Gear Teeth
Fig. 4-Pitted Bevel Pinion Teeth
Fig . 5-Fatigue Fracture-Bevel Drive Pinion
Fig . 6-Overheated Gear Set .
Fig . 7-Pitted Planetary Gear Teeth .
Fig. 8-Shock Fracture.
Fig. 9-Worn High Speed Clutch Plate and Differential Bearing Adjuster
Fig. 10-Worn Support Case Hub.
Fig. 11-Scoring and Seizure of Spider and Pinions
Fig. 12-Fatigue Fracture-Differential Side Gears
Fig. 13-Fatigue Fracture-Misalignment.
Fig. 14-Shock Fracture
Fig. 15-Fatigue-At Axle Shaft Flange
Fig. 16-Twisted Shaft
Fig. 17-Bent Housing
Fig. 18-Wear--Inner Bearing Bore.
Fig. 19-Roller Bearing End Wear.
Fig. 20 - Ball Inner Race Damaged From Circulation of Abrasive Material.
Fig. 22 - Ball Bearing Inner Race Marked From False Brinelling.
Fig. 24-Bearing Shield Damaged From Removal With Punch.
Fig. 26 - Failure of Ball Separator As Result of Misalignment
BODIES AND CABS CONVENTIONAL RIVETED CAB INDEX
Fig. 1. Instrument Panel Gauges and Controls
Fig. 2. Cab Assembly (Exploded View)
Fig. 2. Cab Assembly (Exploded View) - Continued
Fig. 3. Cab Door Window and Vent Assembly (Exploded View)
BODIES AND CABS
WINDOW REGULATOR
VENT WINDOW
CAB DOOR LOCK AND REMOTE CONTROL
SUN VISOR
SUN VISOR - Continued
CAB REAR WINDOW GLASS
CAB REAR WINDOW GLASS INSTALLATION
WINDSHIELD WIPER MOTOR
Fig. 41 Cab Mounting (Exploded View)
Legend for Fig. 42
Fig. 42. Cab Structure Sections
Fig. 43 Cab Floor Substructure
BODY MOUNTINGS
LUBRICATION
Fig . 48. Exploded View of Front End Sheet Metal Leg
Radiator Sheet Metal Shell
PROCEDURES AND INSTRUCTIONS FOR WELDING ALUMINUM CABS, BODIES AND STRUCTURES
Fig. 2. Diagram Showing Details of Shorting Arc Process and the Inert Gas Shielding
TYPICAL SHORTING ARC WELDING CONDITIONS
Fig. 3. Chipping Along Length of Crack. Chipping is not necessary on Sheet Aluminum.
Crack Repair
Fig. 6. Showing method of applying short run of weld.
PREPARATION OF ALUMINUM FOR PAINTING
Fig. 10. Details of the plug weld.
PROPERTIES OF ALUMINUM
WELDING TERMS
WELDING TERMS - Continued
WELDING TERMS - Continued
FIBERGLASS REPAIR INSTRUCTIONS
Fig. 1. Fiberglass Repair Kit
REPAIRING FIBERGLASS
Small Scratches or Chipped Area
Fig . 1. "Air Viking" Suspension Seat
AIR SUSPENSION SYSTEM
Fig. 7. Air Suspension System
Fig. 9. Shock Absorber Removal
Fig. 10. Exploded View of Air Suspension Seat
BENDIX WESTINGHOUSE
SPECIFICATIONS
Fig . 1 Exterior View of TuFlo 400 and 5 Compressor
Fig. 4 Compression of Air
Removing and Disassembling Cylinder Head
INSPECTION OF PARTS
Fig. 7 Measuring Piston Diameter
Fig . 9 Sectional View of Block and Crankcase
Fig. 10 Installing Wrist Pin Lock Wire
Fig. 13 Exploded View of Air Strainer
TROUBLE SHOOTING
AIR BRAKE COMPONENTS
AIR BRAKE COMPONENTS - Continued
Fig. 1 - Leak Detector Tester (SE2326)
Fig . 2 Sectional View of type d-2 Governor
Leakage Tests
ASSEMBLY, ADJUST AND TEST
CHAPTER II. RESERVOIR DRAIN COCK SAFETY VALVE PRESSURE GAUGE - LOW PRESSURE INDICATOR - STOP LIGHT SWITCH
SERVICE CHECKS
Fig 5. Cross Sectional View of Low Pressure Indicator
Fig 6. Stop Light Switch
AUTOMATIC RESERVOIR DRAIN VALVE
SERVICE CHECKS
Fig. 13 Sectional View of Automatic Reservoir Drain Value
ASSEMBLY
Fig. 1 Cross Sectional View of One-Way Check Valve
BRAKE VALVE
Inspection and Cleaning
Fig. 1. Quick Release Valve
Fig. 2. Sectional View of Quick Release valve
Fig. 3 Limiting and Quick Release Valve Combination
SERVICE CHECKS
RELAY VALVE
CLEANING AND INSPECTION
SPRING BRAKE AND TWO-WAY CONTROL VALVE
TWO-WAY CONTROL VALVE
Fig. 4. Sectional View of Type PB Two-Way Control Valve
SERVICE CHECKS
CLEANING AND INSPECTION
FLEXIBLE HOSE, NYLON TUBING, RIGID PIPING AND FITTINGS
Hose Assembly Special Instructions
Fig. 6. Nylon Tubing assembly with Long nut
SERVICE CHECKS
ALCOHOL EVAPORATOR
Fig. 3. Cutaway View of AE-1 Alcohol Evaporator
TESTING FOR SERVICEABILITY
TROUBLE SHOOTING GUIDE
TROUBLE SHOOTING GUIDE - Continued
Fig. 1. AD-1 Air Dryer
Fig. 5. AD-2 Operational Charge Cycle
Fig. 6. Operational Purge Cycle
REMOVAL OF DESICCANT CARTRIDGE AD-1 & AD-2
Fig. 8. Installing O-Rings
Fig. 10 Installing Felt Cloth in Cartridge
Fig 14 Installing Second Perforated Plate
REBUILDING AD-1 END COVER ASSEMBLY
Fig. 19 Purge Valve Assembly Disassembled
OUTLET PORT CHECK VALVE ON AD-2
FOUNDATION BRAKE - AIR CAM-ACTUATED TYPE
Fig. 1 Foundation Brake Assembly
Fig. 2 Exploded View of Front Brake Group
Fig. 4 Exploded View of Rear Brake Group
Fig. 7 Brake Chamber and Slack Adjuster
Fig. 10 Scored Brake Drum
Fig. 13 Lining Selected Too Thick
Fig. 15 Sequence in Securing Brake Block Lining to Shoe
Fig. 19 Typical "Spring Brake" Air Chamber
SLACK ADJUSTERS
Fig. 20 Sectional View of Slack Adjuster
LUBRICATION
WEDGE ACTUATED TYPE - STOPMASTER
INDEX
STOPMASTER BRAKES
STOPMASTER ACTUATING SYSTEM
BRAKE ADJUSTMENT
POWER UNIT ADJUSTMENT
SERVICE RECOMMENDATIONS
TROUBLE SHOOTING GUIDE
RDA Bolted on Spider Mounted Integral Plunger Housings
SERVICING POWER UNITS
REMOVING POWER UNIT FROM BRAKE ASSEMBLY.
AIR CHAMBERS
INSTALLING POWER UNIT ONTO BRAKE ASSEMBLY
INSTALLING BOTTOMING TYPE POWER UNIT
SERVICING BRAKE SHOES
ASSEMBLE SEALS ONTO PLUNGERS
INSTALL PLUNGERS INTO PLUNGER HOUSING
AUTOMATIC ADJUSTING PLUNGERS
AUTOMATIC ADJUSTING PLUNGERS - Continued
Stopmater Brakes - Problem Analysis Guide
Maintenance Guide
RDA STOPMASTER
STOPMASTER II WEDGE BRAKE DESIGN IMPROVEMENTS
ADJUSTING PAWL ASSEMBLY
GROOVED BRAKE LINING
TROUBLE SHOOTING GUIDE
REMOVE POWER UNIT FROM BRAKE ASSEMBLY
REASSEMBLE AIR CHAMBER
REMOVE AND DISASSEMBLE AUTOMATIC ADJUSTING ASSEMBLY
PREPARE FOR REASSEMBLY
TRUCK SERVICE MANUAL
SPRING ACTUATED-TANDEM TYPE 30 INCH CHAMBERS
Fig. 3 Type 30 Chamber.
Fig. 4 Parking Brake and Service Brake in Released Position (Air Pressure Applied to Parking Brake Spring).
Fig. 8 Backing Off Release Bolt.
Fig. 9 Removing Clamp Ring.
Fig. 13 Removing Head, Spring and Piston Assembly
Fig. 17 Piston, Spring and Head Assembly.
Fig. 19 Aligning Piston with Head Bore.
Fig. 20 Early Model Parking Spring Brake Unit Having Mounting Plate and Rubber Pad
COOLING SYSTEM
ANTIFREEZE - PERMANENT TYPE
Fig. 1 Radiator Cap (Pressure Type)
Fig. 3 Installing Core Plug Using SE1725 Installer Tool with SE1581B Handle.
Transmission Oil Cooler or Heat Exchanger
Pressure Flushing
Test Equipment
TROUBLE SHOOTING
AUTOMATIC RADIATOR SHUTTER
Fig. 1 Radiator Shutter Control.
Fig. 2 Radiator Control Assembly (Exploded View).
Fig. 4 Shutter Control Thermostat Unit Adjustment.
TROUBLE SHOOTING
TROUBLE SHOOTING (Continued)
ALTERNATOR MODEL 27SI TYPE 200 80 AMP
DESCRIPTION
Undercharged Battery
Overcharged Battery
Rotor Field Winding Checks
Rectifier Bridge Check
Bearing Replacement and Lubrication
Fig. 12 Connections for Bench Check of Alternator
TRUCK SERVICE MANUAL
ELECTRICAL
Fig. 1 Six-Volt Storage Battery (Cutaway)
Fig. 6 Typical Multiple Battery Installation
Fig. 7 Battery Maintenance Checks
Fig. 9 Proper Jumper Cable Connection
Fig. 11 High Rate Discharge Tester
Putting Dry Charged Batteries into Service
Fig. 14 Using Terminal Puller
Fig. 17 Spreading Cable Clamp with Terminal Spreader
PROPERTIES OF ELECTROLYTE
BATTERY STOCK MAINTENANCE
CIRCUIT DIAGRAM AND CIRCUIT COMPONENTS
CIRCUIT DIAGRAM AND CIRCUIT COMPONENTS - Continued
FUSE AND CIRCUIT BREAKER PANELS
FUSE PANEL AND CIRCUIT BREAKER PANEL LOCATIONS
HEADLIGHTS SINGLE
HEADLIGHTS SINGLE - ELECTRICAL
HEADLIGHTS SINGLE - ELECTRICAL - Continued
HEADLIGHT AIMING
STARTING MOTOR ENCLOSED SHIFT LEVER TYPE
Fig. 1 Heavy Duty Starting Motor with Enclosed Shift Lever.
Fig. 3 Sectional View of Staring Motor with Heavy Duty Sprag Clutch
Fig. 5 Cranking Voltage Test
Fig. 7 Cranking Circuit Test
Fig. 8 Control Circuit Test
INSPECTION AND REPAIR
Fig. 12 Testing Armature for Grounds
PINION CLEARANCE
Fig. 15 Pinion Drive Clearance Check Hookup
MODEL NTC 290 CUBIC INCH DISPLACEMENT 855
Fig. 2-1 Checking lubricating oil filler tube cap
Maintenance Schedule
Check Oil Bath Cleaner Oil Level
Fig. 2-4, (N10098) Lubricating oil filter (center bolt)
Fig. 2-22, (N20311) Crankcase breather combination Type
Fig. 2-27, (Ni1977) Checking belt tension
Fig. 2-29, (N11974) Water pump -with idler
Fig. 2-50, (Nl14230) Accessory drive pulley markings
Fig. 2-52, (N114220) Valve set timing marks
Table 2-14: Injector Adjustment (Oil Temperature)
Fig. 2-63, (N10146) Vibration damper alignment marks
Change Aneroid Oil And Replace Breather
Replace Bellows And Calibrate Aneroid
SEASONAL CHECKS
Fig. 2-70, (N11953) Tightening turbocharger mounting nuts
Table 2-18: Thermal Control Settings
Table 3-3: Arctic Oil Recommendations
Table 3-4: Spin-On Type DCA Water Filter
Trouble Shooting
Trouble Shooting - Continued
Trouble Shooting - Continued
Operating Principles
Fig 5-1, (FWC-13) Fuel flow diagram - PT (type G) pump- inline engine
Fig. 5-7, (F5244). Aneroid cutaway
Fig. 5-11, (FWC 29),. Fuel injection cycle PT (type D) injector 5/16 inch diameter plunger.
Cooling System
INDEX
855 CUBIC INCH DISPLACEMENT
855 CUBIC INCH DISPLACEMENT - Continued
Introduction
TRUCK SERVICE MANUAL - ENGINE
Engine Disassembly Group 0
Fig. 0-4, (N100120). Removing fan hub assembly (FFC Series)
Fig . 09, (N 10093) .Removing vibration damper - Viscous type
Connecting Rod And Piston Assemblies
Steam Cleaning
Fig . 10 . Cylinder block, exploded view
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0)
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0) (Cont.)
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0) (Cont.)
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0) (Cont.)
CYLINDER BLOCK
Fig. 1-1 (N 10103). Cylinder liner counterbore dimension location
Fig. 1-2 (N10181) Cylinder block height check location.
Cylinder Head Capscrew Threads
CLEAN DRILLINGS IN CRANKSHAFT
Fig . 143 (V50138) Identification of rod and main journal size
Fig. 1-6 (V40114). Connecting rod specifications.
Fig. 1-8 (N10194) . Connecting rod wear limits
Fig. 1-10. (N10158) Installing piston pin bushing in rod.
Chamber Piston Pin Bore
Fig. 1-11 (N20171) Piston check points.
Fig. 1-12. (N10145). Gear case cover and trunion bushing.
Fig. 1-13, (V40156). ST-1059 Counterbore Tool
INSTALLATION AND OPERATION
MACHINING THE BLOCK
Fig. 1-15, (V40172). ST-1168 Boring Tool.
Fig. 1-16, (ST-1177). Exploded view of ST-1177 Boring Tool
ASSEMBLING MICROMETER TOOL BIT SETTING GAUGE AND TOOL BIT
USE OF THE BRIDGES
Fig . 2-1 (N10295) . Cylinder head - exploded view
Table 2-1: Specifications - Inch [mm] (Reference Fig . 2-1)
Table 2-1: Specifications - Inch [mm] (Reference Fig. 2-1) (Cont.)
Fig. 2-2 (N10278) ST-1179 Injector sleeve holding tool
Fig. 2-4 (N10228) Valve seat insert-cross section
Valve Crosshead Guides And Crossheads
Fig. 2-7 (N10231) Minimum valve head rim thickness
Resurface Cylinder Head
Sleeve Installation
Grind Valves
INSTRUCTIONS FOR USE OF SERVICE TOOLS
ST-1010 Water Hole Counterboring Tool
Fig. 3-1. (N1039). Rocker levers, shaft and housing
Fig. 3-2, (N 10318). Breather hole location
Fig. 3-4, (N10326). Rocker lever assembly
ROCKER HOUSING COVER
Fig. 4-1, (N10419). Cam followers and push tubes
Fig. 4-2 (N10412) Cam follower exploded view
PUSH TUBES
Fuel System
Fig. 7-0 Lubricating oil pump, exploded view
Table 7-5: Lubricating Oil Pump Specifications - Inch [mm) (Reference Fig. 7-0)
Table 7-5: Lubricating Oil Pump Specifications - Inch [mm) (Reference Fig. 7-0) (Cont)
LUBRICATING OIL DIPSTICK
Fig. 7-1. (V40726) Dipstick markings
Fig. 7-3 (V50709) By-pass filter installation
Fig. 7-8 (N10705) Aligning oil cooler index marks
Fig. 7-9 (N10741) Lubricating oil cooler exploded view
REPAIR (HEADER LEAKS)
ASSEMBLY
Fig. 8-1, (N10843). Water pump exploded view (855 C.I.D Series)
WATER PUMP/I D LER (FFC SERIES-ECCENTRIC)
THERMOSTAT AND HOUSING
Fig. 8-4, (N 10839). Fan hub assembly with tapered roller bearing and spacer
Table 9-1: Drive Unit Specifications - Inch [mm]
Fig. 9-1, (N10903). Fuel pump or compressor drive
Fig. 9-2, (N10906). Fuel pump, hydraulic governor and hourmeter drive
DRIVE PULLEYS INSPECTION AND REPAIR
Fig. 10-1, (N21019). Glow plug preheater adapter spray nozzle
Fig. 10-2, (CGS-20). Air cleaner restriction indicator
TURBOCHARGERS
Fig. 14-1, (N 1142356). Engine exploded view
Crankshaft Flange Capscrew Torque Specifications - ft-lb. [kg m]
Crankshaft And Main Bearings
Cylinder Liners
Fig. 14-4, (N11424). Checking gear backlash
Fig. 146, (N114236). Cam follower torquing sequence
Fig. 148, (Ni1432). injection timing procedure
Fig. 14-9, (N11463). Rocker lever housing torquing sequence
Fig. 14-11, (N114129). Checking lubricating oil pump gear backlash
Fig. 14-12, (N114134). Checking gear case cover to block alignment
Fig. 14-15, (N11448). Indicating flywheel housing face
Fig. 14-16, (N114136). Checking oil pan to block alignment
Fig. 14-21, (N114140). Checking vibration damper run-out
Fan Hub And Pulley
Water Manifold And Thermostat Housing
Fig. 14-24, (N11471). Checking belt tension manually
Fig. 14-25, (N114220). Valve set timing mark
Fig. 14-28 (N114237), Bottoming Injector plunger in cup
Fig. 14-30, (N1 1466). Adjusting injector plunger
Fig. 14-31, (N114215). Adjusting valves
Fig. 1433, (N11963). Lubricating system priming point
Cold Start With Preheater
CHECKS DURING RUNING TEST
Table 1415: Normal Lubricating Oil Pressure
ANEROID CONTROL ADJUSTMENT
Temporary Storage
Inspection
WATER TEMPERATURE GAUGE
Fig. 15-1 (VI1306). Wiring diagram
Fig. 16-1A (V11306A). Wiring diagram (cont'd.)
Fig. 15-18 (V11306B). Wiring diagram (cont'd.)
Specifications and Wear Limits Group 18
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
CAPSCREW MARKINGS AND TORQUE VALUES
Table 18-1: Oil Recommendations
Table 18-2: Operating Temperatures Vs Viscosity
Recommended Fuel Oil Properties
Table 18-5: Package or Canister D C A Water Filter
Fig. 20-2. (N12045 J). Clearance area between lever and crosshead
Fig. 20-5. (N12032 J). Wiring diagram
Index
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
GENERAL
REPAIR AND REINFORCEMENTS
Fig. 5 Suggested Types of Reinforcing Plates and Method of Attaching to Frame Rail.
REPAIR AND REINFORCEMENTS
REPAIR AND REINFORCEMENTS - Continued
Frame Straightening
AIR CLEANER INDEX
Fig. 1 Dry Type Air Cleaner
Fig. 2 Heavy Duty Dry Type Air Cleaner
Injectors PT type
Fig. 6-1-5, FWC27. Cylindrical PT (D) injector cross-section
Fig. 6-1-9, F60197. Loosening cup retainer
Fig. 6-1-17, F60105. New injector cup tip
Fig. 6-1-20, F60108. Seat pattern of plunger In cup
Fig. 6-1-32, F60194. Installing cup on barrel
Fig. 6-1-38, F60198. Checking plunger to cup binding
Fig. 6-1-40, F60200. Size location on Injector adapter
Fig. 6-1-44, F60167. ST990 injector leakage tester
Fig. 6-1-46, F60169. Bubble check or bowl oil level
Fig. -1-56, F6234. Inserting injector into ST-1058 pot
Fig. 6-1-62, F60176. Rotating plunger coupling and spacer
Fig. 6-1-36, F60207. PT (type D) Injector in ST668
Table 6-1-14: ST-668 Cup Seat Spacer
Fig. 6-1-70, F60124. Clamping cylinder and seat
Fig. 6-1-75, F60129. Measuring fuel in vial
Fig, 6-1-77A, F60160. Clutch arm removal and clutch adjustment
Fig. 6-1-79, F60182. Filling gauge to remove air bubbles
Fig. 6-1-81, F60131. ST789 load cell
Fig. 6-1-85, F60135. Position assembly
Fig. 6-1-88, F60138. Start counter at zero
Fig. 6-1-92, F60142. Installing restrictor orifice
Fig. 6-1-109, F60203. Center injector inlet in ST1058 inlet hole
Fig. 6-1-111, F60213. Check leakage at inlet port
Fig. 6-1-114, F60216. Knob spacing
Fig. 6-1-94, F60143. Orifice size gauge
Trouble Shooting The ST790
Complaints And Corrections
Fig. 6-1-121, Test stand hydraulic system
CHECK 4 FUEL GAUGE
Fig. 6-1-123, F60159. Hydraulic loading cylinder
Check 11 - Plunger Actuating Link
Check 14 - Solenoid Valve
Check 2 - Test Oil Temperature
Check 3 - Check Ball Travel
Check 1 - Filter Installation
Check 2 - Defective Barrel To Adapter Seal
Check 6 - Excessive Link Wear
FUEL PUMP - PT REBUILDING
Fig. 1, F5295. PT (type G) AFC fuel pump
Fig. 5.1, FWC-33. Fuel flow in PT fuel system
Gear Pump And Pulsation Damper
Front Drive Cover And Governor Plunger
FUEL PUMP FILTER SCREEN
Fig. 5-17, F514. Reaming drive shaft bushing with ST-490
Fig, 5-23, F5139. Removing torque spring
Fig. 5-24, F5301. Removing AFC side cover plate
Fig. 5-27, F5304. Removing AFC barrel retaining ring.
Fig. 5-30, F5140. Tachometer and matching drive gears
Fig. 5-33, F524. Locating notches for right hand pump.
Fig. 5-36, F5132. Pulsation damper - exploded view
Fig. 5-38, F528. Inspecting plate type valve
Fig. 5-44, F5232. High pressure fuel shut-down valve Assembly
Fig. 5-48, F539. Removing snap ring from groove
Fig. 5-53, F541. Pressing drive bearing on shaft
Fig. 5-57, F544. Securing snap ring in groove
Fig. 5-68, F5148. Standard governor - exploded view
Fig. 5-94, F556. Installing tachometer drive
Fig. 5-97, F558. Installing washer over idle screw
Fig. 5-103, F564. Installing throttle restriction plunger
Fig. 5-109, F562. Torquing gear pump capscrews
Fig. 5-126, F-5187.ST-1162 fuel pump throttle adjustment template
INDEX
FUEL PUMP PT (TYPE G) CALIBRATION INSTRUCTIONS
FUEL PUMP PT (TYPE G) CALIBRATION INSTRUCTIONS - Continued
Fig. 5-1-1, F5100. Cummins ST-848 Fuel pump test stand
Chemical And Physical Requirements
Fig. 5-1-3, F5164. Cummins ST-445 Fuel pump test strand
Fig. 5-1-5, F5169. Mounting fuel pump with spline drive
Fig. 5-1-11, F5104. Shim throttle restriction plunger
Fig. 5-1-13, FWC-31. PT Type G) Fuel pump cross-section and flow
Fig. 5-1-18, F5240. Comparison of fuel pump springs
Fig. 5-1-20, F5112. Adjust throttle leakage rate
Fig, 5-1-24, F5239, Setting throttle travel with protractor
Fig, F-1-27, F5117. Check weight assist effect
Fig. 5127B, F5272. Spring pack cover plug removed, pump at 600 RPM.
Throttle Leakage
Housing Porosity Check
Table 5-1-9: Gear Pump Flow
Complaint and Corrections
Complaint and Corrections - Continued
Complaint and Corrections - Continued
Complaint and Corrections - Continued
Complaint and Corrections - Continued
Fig 52 1, N 11026 Aneroid mounted on engine
Fig. 5-2-3, F5287. Adjusting aneroid fuel screw
Table 5-2-3: Starting Check Valve Spring Specifications
Air Actuation Pressure Setting Of Turbocharger Engines
Fig. 5-2-7, F5249. Aneroid exploded view
Maintenance, Trouble Shooting And Repair Maintenance
Adjustment On Engine
Checking and Adjusting Fuel Manifold Pressure
Fig. 531, F5178. Checking fuel manifold pressure
Engine Power
Fig. 535 F5181. Sealing fuel pump
Fig. 5 3 6. F5241. Drilling spring pack housing with ST1175
TURBOCHARGER
VT-50 Turbochargers
Operation and Maintenance
Fig. 104, TA2. Checking air inlet restriction
Major Cleaning Operation
Trouble Shooting
Trouble Shooting - Continued
Trouble Shooting - Continued
Fig. 10-8, T-516. Pulling impeller from rotor shaft
Fig. 10.9, T-418. Removing oil seal diffuser plate
Fig. 10-15, T-31 1. Inspecting turbine casing
Fig. 10-18, T-431. Checking rotor thrust surface
Fig. 10-20, T-316. Measuring floating bearing O.D.
Fig. 10-28, T-536. Installing "O" ring on bearing housing
Fig. 10-24, T-433. Installing sealing ring
Fig. 10-36, T-421. Torquing "V" clamp bolts and nuts
Fig. 10-38, T-545. Checking rotor end clearance
Fig. 10-40, T-333. Turbocharger mounting
VT-50 Specifications
INSTRUMENT GROUP
Fig. 1. Electrical Instrument Gauge Printed Circuit Board
SPEEDOMETER
Fig. 17. Semi-Rigid Speedometer Cable.
AC MANUFACTURED INSTRUMENT GAUGES
Fig. 21. Battery-Generating System Indicator Gauge
Fig. 22. Fuel Gauge Circuit
Fig. 24. Checking Fuel Level Gauge System Components
Fig. 25. Checking Fuel Level Gauge System Components
Fig. 27. Oil Temperature Gauge Circuit
Oil Temperature Gauge
LUBRICATION FOR LUBRICATION INTERVALS REFER TO OPERATORS MANUAL
AXLE - REAR
BRAKES (Continued)
ELECTRICAL
ENGINE
ENGINE (Continued)
POWER TAKE OFF
STEERING
TRANSMISSION
WHEEL BEARINGS
PROPELLER SHAFT
Fig. 1 Typical Propeller Shaft Installation
Fig. 3. "Broken Back" Type Drive Line
Fig. 4. Universal Joint Speed Fluctuations
Fig. 6. Slip Joint Alignment Arrows
Fig. 7. Balancing Parking Brake Drum
Fig. 9. Drive Line Horizontal and Vertical Alignment
Fig. 11. Measuring Mounted Engine Angle
Fig. 12. Checking Main Transmission Companion Flange Vertical Alignment
Fig. 14. Main and Auxiliary Transmission Center Lines Not Parallel
Fig. 16 Rear Axle Pinion Shaft and Engine Crankshaft Horizontal Center Lines Parallel
Fig. 18 Checking Yokes for Distortion
Fig. 19 Checking Yoke Run-Out
TROUBLESHOOTING
UNIVERSAL JOINTS
DISASSEMBLY - SOLID CROSS TYPE
REASSEMBLY SOLID CROSS TYPE
SPRINGS
Fig. 7 Lubricated Spring Shackle (Driven-in type spring pin).
Cleaning, Inspection and Repair
TROUBLESHOOTING
EQUALIZING BEAM SUSPENSION
SUSPENSION SYSTEM TORQUE CHART (NEWTON METERS)
Fig. 1. Tandem Axle with Equalizing Beam Suspension
LUBRICATION
REPLACING EQUALIZER BEAM BUSHINGS
Fig. 9 Installing Equalizer Beam End Bushing
Fig. 11 Installing Center Sleeve and Bushing
Fig. 13 Exploded View of Leaf Spring Type Suspension
Installing Equalizer Beams and Cross Tube
Installing Axle Assemblies
ADAPTER CHART
POWER STEERING PUMP
SPECIFICATIONS
Identification of Numbers and Letters
Fig. 1. Cutaway of Pump.
DISASSEMBLY
Fig. 5 Exploded View of Pump.
DISASSEMBLY - Continued
DISASSEMBLY - Continued
REASSEMBLY
TROUBLESHOOTING PROCEDURE
Fig. 19 Pressure Gauge Installed in System
PRESSURE CHECKING THE POWER STEERING PUMP SYSTEM
STEERING GEAR WITH INTEGRAL POWER
SPECIFICATIONS
Fig. 1 External View
Fig. 5 Pitman Arm Puller
DISASSEMBLY
DISASSEMBLY - Continued
DISASSEMBLY - Continued
DISASSEMBLY - Continued
CLEANING, INSPECTION AND REPAIR
CLEANING, INSPECTION AND REPAIR - Continued
CLEANING, INSPECTION AND REPAIR - Continued
Bleeding Air from System
ADJUSTING RELIEF VALVE PLUNGERS
Schematic of Dual Integral Power Steering Gear System
Secondary Gear
Fig . 42 Exploded View of Steering Gear (Dual System)
TROUBLE SHOOTING CHART
TROUBLE SHOOTING CHART - Continued
TROUBLE SHOOTING CHART - Continued
TORQUE CHART
STEERING COLUMN ASSEMBLY
Figure 1.
Fig . 2 Plastic Horn Button Removal
Fig . 3 Steering Wheel Removal Using Puller SE-1821
Fig . 7 Remove Steering Jacket Tube Bearings Using Puller SE-1746
Fig. 9 Bearing Removal, Yoke in Vise
Fig . 13 Snap Ring Installation
Fig . 15 Steering Gear Alignment
TORQUE CHART
TORQUE CHART - Continued
IMPORTANT SAFETY NOTICE
TABLE OF CONTENTS
Section 3. PREVENT MAINTENANCE
Section 4. GENERAL OVERHAUL INFORMATION
Section 6. REBUILD OF SUBASSEMBLIES
Section 7. ASSEMBLY OF TRANSMISSION FROM SUBASSEMBLIES
Section 8. WEAR LIMITS AND SPRING DATA
FOLDOUTS
Section 1. GENERAL INFORMATION
Fig. 1-4. Model HT 750 transmission-right-front view
Fig. 1-7 Transmission name plate
SPECIFICATIONS AND DATA
SPECIFICATIONS AND DATA CHART
SPECIFICATIONS AND DATA CHART - Continued
GENERAL INFORMATION
Section 2. DESCRIPTION AND OPERATION
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
HT 700D SERIES TRANSMISSIONS
Clutch Circuit, Drive Ranges
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
Fig. 2-8. Neutral torque path
Fig. 2-9. First-gear
Fig. 2-10. Second-gear torque path
Fig. 2-11. Third-gear torque path
Fig. 2-12. Fourth-gear torque path
Fig. 2-13. Fifth-gear torque path
Fig. 2-14. Reverse-gear torque path
Section 3. PREVENTIVE MAINTENANCE
HT 700D SERIES TRANSMI SSIONS
PREVENTIVE MAINTENANCE
HT 700D SERIES TRANSMISSIONS
PREVENTIVE MAINTENANCE
EXTERNAL LINES AND OIL COOLER
SHIFT POINT CHECK
PRESERVATION AND STORAGE
Storage, 1 Year-Without Oil
CHECKING OIL PRESSURES
Fig. 3-1. Transmission check points, external connections (c,/o retarder)
Fig. 3-2 Oil pressure check points (with retarder)
TROUBLESHOOTING CHART
TROUBLESHOOTING CHART - Continued
TROUBLESHOOTING CHART - Continued
TROUBLESHOOTING CHART - Continued
Section 4. GENERAL OVERHAUL INFORMATION
Fig., -1. Work table
SPECIAL TOOLS TABLE (fig. 4-2, 4-3, 4-4)
Fig. 4-3 Special tools (24 through 55)
Fig. 4-4 Special (56 through 60)
CLEANING, INSPECTION
Inspecting Bearings
Fig. 1-5 Method of measuring clutch plate cone
TORQUE SPECIFICATIONS
Fig. 5-1. Installing transmission overhaul stand
Fig. 5-3. Removing modulator actuator rod
Fig. 5-7. Removing oil pan screws
Fig. 5-11. Removing oil filter
Fig. 5-16 Control valve body bolt locations
Fig. 5-19 Removing torque converter pump
Fig. 5-26 Removing torque converter housing
Fig. 5-31 Removing forward clutch assembly
Fig. 5-37 Removing second-clutch snapring
Fig. 5-41 Removing rear cover
Fig. 5.44. Removing first clutch plates .
DISASSEMBLY
Section 6. INSPECTION AND REBUILD OF SUBASSEMBLIES
Fig. 6-5. Components of control valve assembly
Fig. 6-6. Ball locations for control valve.
Fig. 6-7. Control valve assembly - with components installed.
LEGEND FOR FIGURE 6-7.
HT 700D SERIES TRANSMISSIONS
INSPECTION AND REBUILD
Fig. 6-8 Tightening selector valve stop bolt .
Fig. 6-9. Installing stator freewheel roller
Fig. 6.12. Torque converter pump components.
Fig. 6.14. Supporting oil pump during removal.
Fig. 6-15. Oil pump and torque converter housing .
Fig. 6-17. Tool for installing front support needle bearing
Fig. 6-20 Checking oil pump drive gear end clearance
Fig. 6-29 Forward clutch components
Fig. 6-31 Removing PTO gear from forward clutch
Fig. 6-35 Forward clutch assembly cross section
Fig. 6-36 Installing forward clutch piston
Fig. 6-39 Removing (or installing) fourth clutch rear bearing race
Fig. 6-12 Installing fourth clutch piston
Fig. 6-4. Checking fourth clutch running clearance
Fig. 6-17 Installing orifice plug into main shaft
Fig. 6-50 Removing output shaft rear oil seal
Fig. 6-52. Removing (or Installing) output shaft
Fig. 6-54. Removing speedometer driven gear bushing
Fig. 6-57. Installing piston into rear cover
Fig. 6-59. Installing output shaft bushing
Fig. 6-62. Installing manual shaft oil seal
Fig. 6-63. Components of low planetary carrier assembly
Fig. 6.65. Removing retainer rings from first clutch
Fig. 6-66. Components of gear unit and main shaft assembly (HT750CRD)
FLEX DISK ASSEMBLY
Fig. 6-68. Components of front planetary carrier assembly
CENTER PLANETARY CARRIER ASSEMBLY
Fig. 6.69 Components of center planetary carrier assembly
Fig. 6-72. Components of rear planetary carrier assembly
Fig. 6.74. Torque requirements for threaded fasteners
Fig. 7-4. Installing second clutch snapring
Fig. 7-6. Checking selective snapring clearance
Fig. 7-9. Installing rear cover assembly
Fig. 7-11. Checking first clutch clearance
Fig. 7-12. Installing first clutch plates
Fig. 7-15. Installing second clutch plate
Fig. 7-17. Installing center support
Fig. 7-19. Low planetary carrier, ring gear and clutch
Fig. 7-24. Installing center support
INSTALLING FOURTH, THIRD, FORWARD CLUTCHES
Fig. 7.33. Installing third clutch snapring
Fig. 7-35. Installing forward clutch assembly
Fig. 7-38 insulating pilot tube screw
Fig. 7-47 Installing snapring onto the converter ground sleeve
Fig. 7.53 Installing control valve body
Fig. 7-56 Valve body assemblies (HT750)
Fig. 7-58 Installing flywheel and turbine
Fig. 7-61 Installing modulator actuator rod
Fig. 7-63 Removing transmission from overhaul stand
POWER TAKEOFF COMPONENTS
Section 8. WEAR LIMITS AND SPRING DATA
WEAR LIMITS AND SPRING DATA
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
Foldout 2. Model HT 750CRD Transmission - Cross Section View
LEGEND FOR B, FOLD OUT 7.
B, foldout 7. Lockup clutch and torque converter-exploded view
A, foldout 7. Flex disc and flywheel assemblies-exploded view
B, foldout 10. Front support and valve assembly-exploded view
A, foldout 11. Forward clutch assembly-exploded view
B, foldout 11. Fourth-clutch assembly-exploded view
LEGEND A FOLDOUT 12
A, foldout 12. Third-clutch, center support, and second clutch-exploded view
LEGEND FOR A, FOLDOUT 13
A, foldout 13. Gear unit and main shaft assembly exploded view
LEGEND A, FOLDOUT 14
A, foldout 14. Transmission housing, oil filter and oil pan-exploded view
B, foldout 14. First clutch--exploded view
A, foldout 15. Adapter housing, low-clutch plates and low carrier
LEGEND A, FOR FOLDOUT 16
A, foldout 16. First and low piston, rear cover, output shaft and governor-exploded view
LEGEND B, FOR FOLDOUT 16
B, foldout 16. Control valve assembly-exploded view
A, foldout 17. Lockup cutoff, low shift and low trimnmer valve body assemblies-exploded view
INDEX
SHIFT ROD ARRANGEMENTS
SPICER TRANSMISSION LUBRICATION
AUXILIARY TRANSMISSION ASSEMBLY
SHIFTER HOUSING FRONT CONTROL
Figure 1
INSTALLATION OF SHIFTER HOUSING ON CASE
GEARS AND CASE
MAINSHAFT REMOVAL & DISASSEMBLY
Figure 5
COUNTERSHAFT REASSEMBLY IMPORTANT
MAINSHAFT ASSEMBLY AND INSTALLATION PARTIAL INSTALLATION OF MAIN DRIVE GEAR
MAINSHAFT ASSEMBLY
INSTALLATION OF MAINSHAFT
INSTALLATION OF MAINSHAFT - Continued
INSTALLATION OF MAINSHAFT - Continued
IMPORTANT PROCEDURE
Driver Training
Walking or Jumping Out of Gear
Jumping Out of Gear
Interchangeability
WHEELS, DRUMS, RIMS AND TIRES
WHEELS, DRUMS, RIMS AND TIRES - Continued
WHEEL BEARING ADJUSTMENT
Fig. 3 Heavy Duty
Fig. 4. Medium Duty
UNITIZED OIL SEAL (AXLE RING NOT REQUIRED)
Unitized Seal Installation
INITIAL LUBRICATION OF WHEEL BEARINGS
BRAKE DRUMS
BRAKE DRUMS - Continued
Fig. 2 Drop Center Type Disc Wheel (Tubeless)
Wheel Studs and Mounting Nuts
RIM TIGHTENING AND ALIGNMENT
WHEEL AND TIRE BALANCING
Fig. 11 Chart Showing Effects of Bleeding
Fig. 13 Speed vs. Mileage
The next three steps apply only to the hot patch method.
MOUNTING AND DISMOUNTING TIRES
MOUNTING NUTS (Disc Wheels)
ONE PIECE DROP CENTER HEAVY DUTY TUBELESS TIRES (7.00-20 and Up)
Mounting Instructions
Mounting Instructions - Continued
THREE-PIECE FLAT BASE
Mounting
LOAD AND INFLATION CHART
TORQUE CHART
CONTENTS
SINGLE SPEED - TWO
MODEL NUMBER CONSTRUCTION 26DD SERIES EXTRA HEAVY DUTY P.T.O.
Fig. 1. PTO Lubrication Adaptation
'Unknown' by LOGSA - Page 881 of 894
P.T.O COMMON PARTS LIST FOR 26DD Series
Governor Drive
SERVICE INSTRUCTIONS FOR THE C10000 SERIES TELESCOPIC CYLINDERS
SERVICE INSTRUCTIONS FOR THE C10000 SERIES TELESCOPIC CYLINDERS - Continued
DIRECTIONAL CONTROL VALVE
PUMP SERVICE REMOVAL
Marvel "12-IN-1" Hydraulic Filters for Suction, Return, and Low Pressure Lines
Simplified Ordering
DUMP BODY COMPONENTS
CASTER ANGLE
Fig. 4 Toe-In Measurement
TURNING ANGLE
Fig. 5 Inner Wheel Turns in a Smaller Circle Than Outside Wheel
TROUBLE SHOOTING
TROUBLE SHOOTING - Continued
FRONT AXLE - I-BEAM TYPE
SPECIFICATIONS
STEERING KNUCKLE BUSHINGS
Steering Knuckle Removal
Steering knuckle Bushings (Nylon and Teflon)
Steering Knuckle Bushing Installation (Bronze)
KNUCKLE PIN INSTALLATION
TIE ROD ENDS
DRAG LINK
TORQUE CHART
REAR AXLE
SPECIFICATIONS
STD and STDD SERIES
INTER-AXLE DIFFERNTIAL
DOUBLE REDUCTION DRIVE UNIT DESCRIPTION
REMOVE AND DISASSEMBLE DRIVE UNIT
REMOVE DRIVE UNIT FROM HOUSING
DISASSEMBLE INTERAXLE (3rd) DIFFERENTIAL ASSEMBLY
REMOVE AND DISASSEMBLE HYPOID PINION AND QUILL, BEARING AND HOUSING ASSEMBLY
REMOVE AND DISASSEMBLE HYPOID PINION AND QUILL, BEARING AND HOUSING ASSEMBLY - Continued
REMOVE AND DISASSEMBLE THRUSHAFT ASSEMBLY
REMOVE AND DISASSEMBLE THRUSHAFT ASSEMBLY - Continued
REMOVE AND DISASSEMBLE THRUSHAFT ASSEMBLY - Continued
CORROSION PREVENTION
REASSEMBLE AND INSTALL DRIVE UNIT
REASSEMBLE CROSS SHAFT ASSEMBLY
REASSEMBLE CROSS SHAFT ASSEMBLY - Continued
REASSEMBLE AND INSTALL HYPOID PINION AND QUILL, BEARING AND HOUSING ASSEMBLY
ASSEMBLE AND INSTALL THRU-SHAFT ASSEMBLY
ASSEMBLE INTERAXLE DIFFERENTIAL
SHIFT SHAFT ADJUSTMENT
CORRECT TOOTH CONTACT ASSURES LONGER GEAR LIFE
ASSEMBLE AND INSTALL AXLE DIFFERENTIAL
INSTALLATION OF BEARING CUPS IN CARRIER LEG BORES
COMPLETE DRIVE UNIT ASSEMBLY
HOW TO MATCH TANDEM TIRES
TABULATION OF TORQUE LIMITS
LOCKING TYPE DIFFERENTIAL
Fig. 1 Internal Spring Design Differential Locking Unit (Exploded View
Fig. 3 Typical installation of No Spin, unit (Cross Sectional View)
Fig. 4 Straight Forward Driving
Fig. 8 Forward Left Hand Turn (Cross Sectional View)
Fig. 10 Inserting Assembly Retaining Bolt
IMPORTANT PRECAUTION
Fig . 12 Cutaway View of Tandem Lock NoSPIN Inter-Axle Differential
FAILURE ANALYSIS
FAILURE ANALYSIS - Continued
Fig . 1-Scored and Scuffed Gear Teeth .
Fig . 2-Scuffed Gear Teeth--Coast Sides Only .
Fig . 3-Fractured Gear Teeth
Fig. 4-Pitted Bevel Pinion Teeth
Fig . 5-Fatigue Fracture-Bevel Drive Pinion
Fig . 6-Overheated Gear Set .
Fig . 7-Pitted Planetary Gear Teeth .
Fig. 8-Shock Fracture.
Fig. 9-Worn High Speed Clutch Plate and Differential Bearing Adjuster
Fig. 10-Worn Support Case Hub.
Fig. 11-Scoring and Seizure of Spider and Pinions
Fig. 12-Fatigue Fracture-Differential Side Gears
Fig. 13-Fatigue Fracture-Misalignment.
Fig. 14-Shock Fracture
Fig. 15-Fatigue-At Axle Shaft Flange
Fig. 16-Twisted Shaft
Fig. 17-Bent Housing
Fig. 18-Wear--Inner Bearing Bore.
Fig. 19-Roller Bearing End Wear.
Fig. 20 - Ball Inner Race Damaged From Circulation of Abrasive Material.
Fig. 22 - Ball Bearing Inner Race Marked From False Brinelling.
Fig. 24-Bearing Shield Damaged From Removal With Punch.
Fig. 26 - Failure of Ball Separator As Result of Misalignment
BODIES AND CABS CONVENTIONAL RIVETED CAB INDEX
Fig. 1. Instrument Panel Gauges and Controls
Fig. 2. Cab Assembly (Exploded View)
Fig. 2. Cab Assembly (Exploded View) - Continued
Fig. 3. Cab Door Window and Vent Assembly (Exploded View)
BODIES AND CABS
WINDOW REGULATOR
VENT WINDOW
CAB DOOR LOCK AND REMOTE CONTROL
SUN VISOR
SUN VISOR - Continued
CAB REAR WINDOW GLASS
CAB REAR WINDOW GLASS INSTALLATION
WINDSHIELD WIPER MOTOR
Fig. 41 Cab Mounting (Exploded View)
Legend for Fig. 42
Fig. 42. Cab Structure Sections
Fig. 43 Cab Floor Substructure
BODY MOUNTINGS
LUBRICATION
Fig . 48. Exploded View of Front End Sheet Metal Leg
Radiator Sheet Metal Shell
PROCEDURES AND INSTRUCTIONS FOR WELDING ALUMINUM CABS, BODIES AND STRUCTURES
Fig. 2. Diagram Showing Details of Shorting Arc Process and the Inert Gas Shielding
TYPICAL SHORTING ARC WELDING CONDITIONS
Fig. 3. Chipping Along Length of Crack. Chipping is not necessary on Sheet Aluminum.
Crack Repair
Fig. 6. Showing method of applying short run of weld.
PREPARATION OF ALUMINUM FOR PAINTING
Fig. 10. Details of the plug weld.
PROPERTIES OF ALUMINUM
WELDING TERMS
WELDING TERMS - Continued
WELDING TERMS - Continued
FIBERGLASS REPAIR INSTRUCTIONS
Fig. 1. Fiberglass Repair Kit
REPAIRING FIBERGLASS
Small Scratches or Chipped Area
Fig . 1. "Air Viking" Suspension Seat
AIR SUSPENSION SYSTEM
Fig. 7. Air Suspension System
Fig. 9. Shock Absorber Removal
Fig. 10. Exploded View of Air Suspension Seat
BENDIX WESTINGHOUSE
SPECIFICATIONS
Fig . 1 Exterior View of TuFlo 400 and 5 Compressor
Fig. 4 Compression of Air
Removing and Disassembling Cylinder Head
INSPECTION OF PARTS
Fig. 7 Measuring Piston Diameter
Fig . 9 Sectional View of Block and Crankcase
Fig. 10 Installing Wrist Pin Lock Wire
Fig. 13 Exploded View of Air Strainer
TROUBLE SHOOTING
AIR BRAKE COMPONENTS
AIR BRAKE COMPONENTS - Continued
Fig. 1 - Leak Detector Tester (SE2326)
Fig . 2 Sectional View of type d-2 Governor
Leakage Tests
ASSEMBLY, ADJUST AND TEST
CHAPTER II. RESERVOIR DRAIN COCK SAFETY VALVE PRESSURE GAUGE - LOW PRESSURE INDICATOR - STOP LIGHT SWITCH
SERVICE CHECKS
Fig 5. Cross Sectional View of Low Pressure Indicator
Fig 6. Stop Light Switch
AUTOMATIC RESERVOIR DRAIN VALVE
SERVICE CHECKS
Fig. 13 Sectional View of Automatic Reservoir Drain Value
ASSEMBLY
Fig. 1 Cross Sectional View of One-Way Check Valve
BRAKE VALVE
Inspection and Cleaning
Fig. 1. Quick Release Valve
Fig. 2. Sectional View of Quick Release valve
Fig. 3 Limiting and Quick Release Valve Combination
SERVICE CHECKS
RELAY VALVE
CLEANING AND INSPECTION
SPRING BRAKE AND TWO-WAY CONTROL VALVE
TWO-WAY CONTROL VALVE
Fig. 4. Sectional View of Type PB Two-Way Control Valve
SERVICE CHECKS
CLEANING AND INSPECTION
FLEXIBLE HOSE, NYLON TUBING, RIGID PIPING AND FITTINGS
Hose Assembly Special Instructions
Fig. 6. Nylon Tubing assembly with Long nut
SERVICE CHECKS
ALCOHOL EVAPORATOR
Fig. 3. Cutaway View of AE-1 Alcohol Evaporator
TESTING FOR SERVICEABILITY
TROUBLE SHOOTING GUIDE
TROUBLE SHOOTING GUIDE - Continued
Fig. 1. AD-1 Air Dryer
Fig. 5. AD-2 Operational Charge Cycle
Fig. 6. Operational Purge Cycle
REMOVAL OF DESICCANT CARTRIDGE AD-1 & AD-2
Fig. 8. Installing O-Rings
Fig. 10 Installing Felt Cloth in Cartridge
Fig 14 Installing Second Perforated Plate
REBUILDING AD-1 END COVER ASSEMBLY
Fig. 19 Purge Valve Assembly Disassembled
OUTLET PORT CHECK VALVE ON AD-2
FOUNDATION BRAKE - AIR CAM-ACTUATED TYPE
Fig. 1 Foundation Brake Assembly
Fig. 2 Exploded View of Front Brake Group
Fig. 4 Exploded View of Rear Brake Group
Fig. 7 Brake Chamber and Slack Adjuster
Fig. 10 Scored Brake Drum
Fig. 13 Lining Selected Too Thick
Fig. 15 Sequence in Securing Brake Block Lining to Shoe
Fig. 19 Typical "Spring Brake" Air Chamber
SLACK ADJUSTERS
Fig. 20 Sectional View of Slack Adjuster
LUBRICATION
WEDGE ACTUATED TYPE - STOPMASTER
INDEX
STOPMASTER BRAKES
STOPMASTER ACTUATING SYSTEM
BRAKE ADJUSTMENT
POWER UNIT ADJUSTMENT
SERVICE RECOMMENDATIONS
TROUBLE SHOOTING GUIDE
RDA Bolted on Spider Mounted Integral Plunger Housings
SERVICING POWER UNITS
REMOVING POWER UNIT FROM BRAKE ASSEMBLY.
AIR CHAMBERS
INSTALLING POWER UNIT ONTO BRAKE ASSEMBLY
INSTALLING BOTTOMING TYPE POWER UNIT
SERVICING BRAKE SHOES
ASSEMBLE SEALS ONTO PLUNGERS
INSTALL PLUNGERS INTO PLUNGER HOUSING
AUTOMATIC ADJUSTING PLUNGERS
AUTOMATIC ADJUSTING PLUNGERS - Continued
Stopmater Brakes - Problem Analysis Guide
Maintenance Guide
RDA STOPMASTER
STOPMASTER II WEDGE BRAKE DESIGN IMPROVEMENTS
ADJUSTING PAWL ASSEMBLY
GROOVED BRAKE LINING
TROUBLE SHOOTING GUIDE
REMOVE POWER UNIT FROM BRAKE ASSEMBLY
REASSEMBLE AIR CHAMBER
REMOVE AND DISASSEMBLE AUTOMATIC ADJUSTING ASSEMBLY
PREPARE FOR REASSEMBLY
TRUCK SERVICE MANUAL
SPRING ACTUATED-TANDEM TYPE 30 INCH CHAMBERS
Fig. 3 Type 30 Chamber.
Fig. 4 Parking Brake and Service Brake in Released Position (Air Pressure Applied to Parking Brake Spring).
Fig. 8 Backing Off Release Bolt.
Fig. 9 Removing Clamp Ring.
Fig. 13 Removing Head, Spring and Piston Assembly
Fig. 17 Piston, Spring and Head Assembly.
Fig. 19 Aligning Piston with Head Bore.
Fig. 20 Early Model Parking Spring Brake Unit Having Mounting Plate and Rubber Pad
COOLING SYSTEM
ANTIFREEZE - PERMANENT TYPE
Fig. 1 Radiator Cap (Pressure Type)
Fig. 3 Installing Core Plug Using SE1725 Installer Tool with SE1581B Handle.
Transmission Oil Cooler or Heat Exchanger
Pressure Flushing
Test Equipment
TROUBLE SHOOTING
AUTOMATIC RADIATOR SHUTTER
Fig. 1 Radiator Shutter Control.
Fig. 2 Radiator Control Assembly (Exploded View).
Fig. 4 Shutter Control Thermostat Unit Adjustment.
TROUBLE SHOOTING
TROUBLE SHOOTING (Continued)
ALTERNATOR MODEL 27SI TYPE 200 80 AMP
DESCRIPTION
Undercharged Battery
Overcharged Battery
Rotor Field Winding Checks
Rectifier Bridge Check
Bearing Replacement and Lubrication
Fig. 12 Connections for Bench Check of Alternator
TRUCK SERVICE MANUAL
ELECTRICAL
Fig. 1 Six-Volt Storage Battery (Cutaway)
Fig. 6 Typical Multiple Battery Installation
Fig. 7 Battery Maintenance Checks
Fig. 9 Proper Jumper Cable Connection
Fig. 11 High Rate Discharge Tester
Putting Dry Charged Batteries into Service
Fig. 14 Using Terminal Puller
Fig. 17 Spreading Cable Clamp with Terminal Spreader
PROPERTIES OF ELECTROLYTE
BATTERY STOCK MAINTENANCE
CIRCUIT DIAGRAM AND CIRCUIT COMPONENTS
CIRCUIT DIAGRAM AND CIRCUIT COMPONENTS - Continued
FUSE AND CIRCUIT BREAKER PANELS
FUSE PANEL AND CIRCUIT BREAKER PANEL LOCATIONS
HEADLIGHTS SINGLE
HEADLIGHTS SINGLE - ELECTRICAL
HEADLIGHTS SINGLE - ELECTRICAL - Continued
HEADLIGHT AIMING
STARTING MOTOR ENCLOSED SHIFT LEVER TYPE
Fig. 1 Heavy Duty Starting Motor with Enclosed Shift Lever.
Fig. 3 Sectional View of Staring Motor with Heavy Duty Sprag Clutch
Fig. 5 Cranking Voltage Test
Fig. 7 Cranking Circuit Test
Fig. 8 Control Circuit Test
INSPECTION AND REPAIR
Fig. 12 Testing Armature for Grounds
PINION CLEARANCE
Fig. 15 Pinion Drive Clearance Check Hookup
MODEL NTC 290 CUBIC INCH DISPLACEMENT 855
Fig. 2-1 Checking lubricating oil filler tube cap
Maintenance Schedule
Check Oil Bath Cleaner Oil Level
Fig. 2-4, (N10098) Lubricating oil filter (center bolt)
Fig. 2-22, (N20311) Crankcase breather combination Type
Fig. 2-27, (Ni1977) Checking belt tension
Fig. 2-29, (N11974) Water pump -with idler
Fig. 2-50, (Nl14230) Accessory drive pulley markings
Fig. 2-52, (N114220) Valve set timing marks
Table 2-14: Injector Adjustment (Oil Temperature)
Fig. 2-63, (N10146) Vibration damper alignment marks
Change Aneroid Oil And Replace Breather
Replace Bellows And Calibrate Aneroid
SEASONAL CHECKS
Fig. 2-70, (N11953) Tightening turbocharger mounting nuts
Table 2-18: Thermal Control Settings
Table 3-3: Arctic Oil Recommendations
Table 3-4: Spin-On Type DCA Water Filter
Trouble Shooting
Trouble Shooting - Continued
Trouble Shooting - Continued
Operating Principles
Fig 5-1, (FWC-13) Fuel flow diagram - PT (type G) pump- inline engine
Fig. 5-7, (F5244). Aneroid cutaway
Fig. 5-11, (FWC 29),. Fuel injection cycle PT (type D) injector 5/16 inch diameter plunger.
Cooling System
INDEX
855 CUBIC INCH DISPLACEMENT
855 CUBIC INCH DISPLACEMENT - Continued
Introduction
TRUCK SERVICE MANUAL - ENGINE
Engine Disassembly Group 0
Fig. 0-4, (N100120). Removing fan hub assembly (FFC Series)
Fig . 09, (N 10093) .Removing vibration damper - Viscous type
Connecting Rod And Piston Assemblies
Steam Cleaning
Fig . 10 . Cylinder block, exploded view
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0)
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0) (Cont.)
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0) (Cont.)
Table 1-1: Cylinder Block Specifications - Inch [mm] (Reference Fig. 1-0) (Cont.)
CYLINDER BLOCK
Fig. 1-1 (N 10103). Cylinder liner counterbore dimension location
Fig. 1-2 (N10181) Cylinder block height check location.
Cylinder Head Capscrew Threads
CLEAN DRILLINGS IN CRANKSHAFT
Fig . 143 (V50138) Identification of rod and main journal size
Fig. 1-6 (V40114). Connecting rod specifications.
Fig. 1-8 (N10194) . Connecting rod wear limits
Fig. 1-10. (N10158) Installing piston pin bushing in rod.
Chamber Piston Pin Bore
Fig. 1-11 (N20171) Piston check points.
Fig. 1-12. (N10145). Gear case cover and trunion bushing.
Fig. 1-13, (V40156). ST-1059 Counterbore Tool
INSTALLATION AND OPERATION
MACHINING THE BLOCK
Fig. 1-15, (V40172). ST-1168 Boring Tool.
Fig. 1-16, (ST-1177). Exploded view of ST-1177 Boring Tool
ASSEMBLING MICROMETER TOOL BIT SETTING GAUGE AND TOOL BIT
USE OF THE BRIDGES
Fig . 2-1 (N10295) . Cylinder head - exploded view
Table 2-1: Specifications - Inch [mm] (Reference Fig . 2-1)
Table 2-1: Specifications - Inch [mm] (Reference Fig. 2-1) (Cont.)
Fig. 2-2 (N10278) ST-1179 Injector sleeve holding tool
Fig. 2-4 (N10228) Valve seat insert-cross section
Valve Crosshead Guides And Crossheads
Fig. 2-7 (N10231) Minimum valve head rim thickness
Resurface Cylinder Head
Sleeve Installation
Grind Valves
INSTRUCTIONS FOR USE OF SERVICE TOOLS
ST-1010 Water Hole Counterboring Tool
Fig. 3-1. (N1039). Rocker levers, shaft and housing
Fig. 3-2, (N 10318). Breather hole location
Fig. 3-4, (N10326). Rocker lever assembly
ROCKER HOUSING COVER
Fig. 4-1, (N10419). Cam followers and push tubes
Fig. 4-2 (N10412) Cam follower exploded view
PUSH TUBES
Fuel System
Fig. 7-0 Lubricating oil pump, exploded view
Table 7-5: Lubricating Oil Pump Specifications - Inch [mm) (Reference Fig. 7-0)
Table 7-5: Lubricating Oil Pump Specifications - Inch [mm) (Reference Fig. 7-0) (Cont)
LUBRICATING OIL DIPSTICK
Fig. 7-1. (V40726) Dipstick markings
Fig. 7-3 (V50709) By-pass filter installation
Fig. 7-8 (N10705) Aligning oil cooler index marks
Fig. 7-9 (N10741) Lubricating oil cooler exploded view
REPAIR (HEADER LEAKS)
ASSEMBLY
Fig. 8-1, (N10843). Water pump exploded view (855 C.I.D Series)
WATER PUMP/I D LER (FFC SERIES-ECCENTRIC)
THERMOSTAT AND HOUSING
Fig. 8-4, (N 10839). Fan hub assembly with tapered roller bearing and spacer
Table 9-1: Drive Unit Specifications - Inch [mm]
Fig. 9-1, (N10903). Fuel pump or compressor drive
Fig. 9-2, (N10906). Fuel pump, hydraulic governor and hourmeter drive
DRIVE PULLEYS INSPECTION AND REPAIR
Fig. 10-1, (N21019). Glow plug preheater adapter spray nozzle
Fig. 10-2, (CGS-20). Air cleaner restriction indicator
TURBOCHARGERS
Fig. 14-1, (N 1142356). Engine exploded view
Crankshaft Flange Capscrew Torque Specifications - ft-lb. [kg m]
Crankshaft And Main Bearings
Cylinder Liners
Fig. 14-4, (N11424). Checking gear backlash
Fig. 146, (N114236). Cam follower torquing sequence
Fig. 148, (Ni1432). injection timing procedure
Fig. 14-9, (N11463). Rocker lever housing torquing sequence
Fig. 14-11, (N114129). Checking lubricating oil pump gear backlash
Fig. 14-12, (N114134). Checking gear case cover to block alignment
Fig. 14-15, (N11448). Indicating flywheel housing face
Fig. 14-16, (N114136). Checking oil pan to block alignment
Fig. 14-21, (N114140). Checking vibration damper run-out
Fan Hub And Pulley
Water Manifold And Thermostat Housing
Fig. 14-24, (N11471). Checking belt tension manually
Fig. 14-25, (N114220). Valve set timing mark
Fig. 14-28 (N114237), Bottoming Injector plunger in cup
Fig. 14-30, (N1 1466). Adjusting injector plunger
Fig. 14-31, (N114215). Adjusting valves
Fig. 1433, (N11963). Lubricating system priming point
Cold Start With Preheater
CHECKS DURING RUNING TEST
Table 1415: Normal Lubricating Oil Pressure
ANEROID CONTROL ADJUSTMENT
Temporary Storage
Inspection
WATER TEMPERATURE GAUGE
Fig. 15-1 (VI1306). Wiring diagram
Fig. 16-1A (V11306A). Wiring diagram (cont'd.)
Fig. 15-18 (V11306B). Wiring diagram (cont'd.)
Specifications and Wear Limits Group 18
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
Specifications and Wear Limits Group 18 - Continued
CAPSCREW MARKINGS AND TORQUE VALUES
Table 18-1: Oil Recommendations
Table 18-2: Operating Temperatures Vs Viscosity
Recommended Fuel Oil Properties
Table 18-5: Package or Canister D C A Water Filter
Fig. 20-2. (N12045 J). Clearance area between lever and crosshead
Fig. 20-5. (N12032 J). Wiring diagram
Index
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
GENERAL
REPAIR AND REINFORCEMENTS
Fig. 5 Suggested Types of Reinforcing Plates and Method of Attaching to Frame Rail.
REPAIR AND REINFORCEMENTS
REPAIR AND REINFORCEMENTS - Continued
Frame Straightening
AIR CLEANER INDEX
Fig. 1 Dry Type Air Cleaner
Fig. 2 Heavy Duty Dry Type Air Cleaner
Injectors PT type
Fig. 6-1-5, FWC27. Cylindrical PT (D) injector cross-section
Fig. 6-1-9, F60197. Loosening cup retainer
Fig. 6-1-17, F60105. New injector cup tip
Fig. 6-1-20, F60108. Seat pattern of plunger In cup
Fig. 6-1-32, F60194. Installing cup on barrel
Fig. 6-1-38, F60198. Checking plunger to cup binding
Fig. 6-1-40, F60200. Size location on Injector adapter
Fig. 6-1-44, F60167. ST990 injector leakage tester
Fig. 6-1-46, F60169. Bubble check or bowl oil level
Fig. -1-56, F6234. Inserting injector into ST-1058 pot
Fig. 6-1-62, F60176. Rotating plunger coupling and spacer
Fig. 6-1-36, F60207. PT (type D) Injector in ST668
Table 6-1-14: ST-668 Cup Seat Spacer
Fig. 6-1-70, F60124. Clamping cylinder and seat
Fig. 6-1-75, F60129. Measuring fuel in vial
Fig, 6-1-77A, F60160. Clutch arm removal and clutch adjustment
Fig. 6-1-79, F60182. Filling gauge to remove air bubbles
Fig. 6-1-81, F60131. ST789 load cell
Fig. 6-1-85, F60135. Position assembly
Fig. 6-1-88, F60138. Start counter at zero
Fig. 6-1-92, F60142. Installing restrictor orifice
Fig. 6-1-109, F60203. Center injector inlet in ST1058 inlet hole
Fig. 6-1-111, F60213. Check leakage at inlet port
Fig. 6-1-114, F60216. Knob spacing
Fig. 6-1-94, F60143. Orifice size gauge
Trouble Shooting The ST790
Complaints And Corrections
Fig. 6-1-121, Test stand hydraulic system
CHECK 4 FUEL GAUGE
Fig. 6-1-123, F60159. Hydraulic loading cylinder
Check 11 - Plunger Actuating Link
Check 14 - Solenoid Valve
Check 2 - Test Oil Temperature
Check 3 - Check Ball Travel
Check 1 - Filter Installation
Check 2 - Defective Barrel To Adapter Seal
Check 6 - Excessive Link Wear
FUEL PUMP - PT REBUILDING
Fig. 1, F5295. PT (type G) AFC fuel pump
Fig. 5.1, FWC-33. Fuel flow in PT fuel system
Gear Pump And Pulsation Damper
Front Drive Cover And Governor Plunger
FUEL PUMP FILTER SCREEN
Fig. 5-17, F514. Reaming drive shaft bushing with ST-490
Fig, 5-23, F5139. Removing torque spring
Fig. 5-24, F5301. Removing AFC side cover plate
Fig. 5-27, F5304. Removing AFC barrel retaining ring.
Fig. 5-30, F5140. Tachometer and matching drive gears
Fig. 5-33, F524. Locating notches for right hand pump.
Fig. 5-36, F5132. Pulsation damper - exploded view
Fig. 5-38, F528. Inspecting plate type valve
Fig. 5-44, F5232. High pressure fuel shut-down valve Assembly
Fig. 5-48, F539. Removing snap ring from groove
Fig. 5-53, F541. Pressing drive bearing on shaft
Fig. 5-57, F544. Securing snap ring in groove
Fig. 5-68, F5148. Standard governor - exploded view
Fig. 5-94, F556. Installing tachometer drive
Fig. 5-97, F558. Installing washer over idle screw
Fig. 5-103, F564. Installing throttle restriction plunger
Fig. 5-109, F562. Torquing gear pump capscrews
Fig. 5-126, F-5187.ST-1162 fuel pump throttle adjustment template
INDEX
FUEL PUMP PT (TYPE G) CALIBRATION INSTRUCTIONS
FUEL PUMP PT (TYPE G) CALIBRATION INSTRUCTIONS - Continued
Fig. 5-1-1, F5100. Cummins ST-848 Fuel pump test stand
Chemical And Physical Requirements
Fig. 5-1-3, F5164. Cummins ST-445 Fuel pump test strand
Fig. 5-1-5, F5169. Mounting fuel pump with spline drive
Fig. 5-1-11, F5104. Shim throttle restriction plunger
Fig. 5-1-13, FWC-31. PT Type G) Fuel pump cross-section and flow
Fig. 5-1-18, F5240. Comparison of fuel pump springs
Fig. 5-1-20, F5112. Adjust throttle leakage rate
Fig, 5-1-24, F5239, Setting throttle travel with protractor
Fig, F-1-27, F5117. Check weight assist effect
Fig. 5127B, F5272. Spring pack cover plug removed, pump at 600 RPM.
Throttle Leakage
Housing Porosity Check
Table 5-1-9: Gear Pump Flow
Complaint and Corrections
Complaint and Corrections - Continued
Complaint and Corrections - Continued
Complaint and Corrections - Continued
Complaint and Corrections - Continued
Fig 52 1, N 11026 Aneroid mounted on engine
Fig. 5-2-3, F5287. Adjusting aneroid fuel screw
Table 5-2-3: Starting Check Valve Spring Specifications
Air Actuation Pressure Setting Of Turbocharger Engines
Fig. 5-2-7, F5249. Aneroid exploded view
Maintenance, Trouble Shooting And Repair Maintenance
Adjustment On Engine
Checking and Adjusting Fuel Manifold Pressure
Fig. 531, F5178. Checking fuel manifold pressure
Engine Power
Fig. 535 F5181. Sealing fuel pump
Fig. 5 3 6. F5241. Drilling spring pack housing with ST1175
TURBOCHARGER
VT-50 Turbochargers
Operation and Maintenance
Fig. 104, TA2. Checking air inlet restriction
Major Cleaning Operation
Trouble Shooting
Trouble Shooting - Continued
Trouble Shooting - Continued
Fig. 10-8, T-516. Pulling impeller from rotor shaft
Fig. 10.9, T-418. Removing oil seal diffuser plate
Fig. 10-15, T-31 1. Inspecting turbine casing
Fig. 10-18, T-431. Checking rotor thrust surface
Fig. 10-20, T-316. Measuring floating bearing O.D.
Fig. 10-28, T-536. Installing "O" ring on bearing housing
Fig. 10-24, T-433. Installing sealing ring
Fig. 10-36, T-421. Torquing "V" clamp bolts and nuts
Fig. 10-38, T-545. Checking rotor end clearance
Fig. 10-40, T-333. Turbocharger mounting
VT-50 Specifications
INSTRUMENT GROUP
Fig. 1. Electrical Instrument Gauge Printed Circuit Board
SPEEDOMETER
Fig. 17. Semi-Rigid Speedometer Cable.
AC MANUFACTURED INSTRUMENT GAUGES
Fig. 21. Battery-Generating System Indicator Gauge
Fig. 22. Fuel Gauge Circuit
Fig. 24. Checking Fuel Level Gauge System Components
Fig. 25. Checking Fuel Level Gauge System Components
Fig. 27. Oil Temperature Gauge Circuit
Oil Temperature Gauge
LUBRICATION FOR LUBRICATION INTERVALS REFER TO OPERATORS MANUAL
AXLE - REAR
BRAKES (Continued)
ELECTRICAL
ENGINE
ENGINE (Continued)
POWER TAKE OFF
STEERING
TRANSMISSION
WHEEL BEARINGS
PROPELLER SHAFT
Fig. 1 Typical Propeller Shaft Installation
Fig. 3. "Broken Back" Type Drive Line
Fig. 4. Universal Joint Speed Fluctuations
Fig. 6. Slip Joint Alignment Arrows
Fig. 7. Balancing Parking Brake Drum
Fig. 9. Drive Line Horizontal and Vertical Alignment
Fig. 11. Measuring Mounted Engine Angle
Fig. 12. Checking Main Transmission Companion Flange Vertical Alignment
Fig. 14. Main and Auxiliary Transmission Center Lines Not Parallel
Fig. 16 Rear Axle Pinion Shaft and Engine Crankshaft Horizontal Center Lines Parallel
Fig. 18 Checking Yokes for Distortion
Fig. 19 Checking Yoke Run-Out
TROUBLESHOOTING
UNIVERSAL JOINTS
DISASSEMBLY - SOLID CROSS TYPE
REASSEMBLY SOLID CROSS TYPE
SPRINGS
Fig. 7 Lubricated Spring Shackle (Driven-in type spring pin).
Cleaning, Inspection and Repair
TROUBLESHOOTING
EQUALIZING BEAM SUSPENSION
SUSPENSION SYSTEM TORQUE CHART (NEWTON METERS)
Fig. 1. Tandem Axle with Equalizing Beam Suspension
LUBRICATION
REPLACING EQUALIZER BEAM BUSHINGS
Fig. 9 Installing Equalizer Beam End Bushing
Fig. 11 Installing Center Sleeve and Bushing
Fig. 13 Exploded View of Leaf Spring Type Suspension
Installing Equalizer Beams and Cross Tube
Installing Axle Assemblies
ADAPTER CHART
POWER STEERING PUMP
SPECIFICATIONS
Identification of Numbers and Letters
Fig. 1. Cutaway of Pump.
DISASSEMBLY
Fig. 5 Exploded View of Pump.
DISASSEMBLY - Continued
DISASSEMBLY - Continued
REASSEMBLY
TROUBLESHOOTING PROCEDURE
Fig. 19 Pressure Gauge Installed in System
PRESSURE CHECKING THE POWER STEERING PUMP SYSTEM
STEERING GEAR WITH INTEGRAL POWER
SPECIFICATIONS
Fig. 1 External View
Fig. 5 Pitman Arm Puller
DISASSEMBLY
DISASSEMBLY - Continued
DISASSEMBLY - Continued
DISASSEMBLY - Continued
CLEANING, INSPECTION AND REPAIR
CLEANING, INSPECTION AND REPAIR - Continued
CLEANING, INSPECTION AND REPAIR - Continued
Bleeding Air from System
ADJUSTING RELIEF VALVE PLUNGERS
Schematic of Dual Integral Power Steering Gear System
Secondary Gear
Fig . 42 Exploded View of Steering Gear (Dual System)
TROUBLE SHOOTING CHART
TROUBLE SHOOTING CHART - Continued
TROUBLE SHOOTING CHART - Continued
TORQUE CHART
STEERING COLUMN ASSEMBLY
Figure 1.
Fig . 2 Plastic Horn Button Removal
Fig . 3 Steering Wheel Removal Using Puller SE-1821
Fig . 7 Remove Steering Jacket Tube Bearings Using Puller SE-1746
Fig. 9 Bearing Removal, Yoke in Vise
Fig . 13 Snap Ring Installation
Fig . 15 Steering Gear Alignment
TORQUE CHART
TORQUE CHART - Continued
IMPORTANT SAFETY NOTICE
TABLE OF CONTENTS
Section 3. PREVENT MAINTENANCE
Section 4. GENERAL OVERHAUL INFORMATION
Section 6. REBUILD OF SUBASSEMBLIES
Section 7. ASSEMBLY OF TRANSMISSION FROM SUBASSEMBLIES
Section 8. WEAR LIMITS AND SPRING DATA
FOLDOUTS
Section 1. GENERAL INFORMATION
Fig. 1-4. Model HT 750 transmission-right-front view
Fig. 1-7 Transmission name plate
SPECIFICATIONS AND DATA
SPECIFICATIONS AND DATA CHART
SPECIFICATIONS AND DATA CHART - Continued
GENERAL INFORMATION
Section 2. DESCRIPTION AND OPERATION
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
HT 700D SERIES TRANSMISSIONS
HT 700D SERIES TRANSMISSIONS
Clutch Circuit, Drive Ranges
HT 700D SERIES TRANSMISSIONS
DESCRIPTION AND OPERATION
Fig. 2-8. Neutral torque path
Fig. 2-9. First-gear
Fig. 2-10. Second-gear torque path
Fig. 2-11. Third-gear torque path
Fig. 2-12. Fourth-gear torque path
Fig. 2-13. Fifth-gear torque path
Fig. 2-14. Reverse-gear torque path
Section 3. PREVENTIVE MAINTENANCE
HT 700D SERIES TRANSMI SSIONS
PREVENTIVE MAINTENANCE
HT 700D SERIES TRANSMISSIONS
PREVENTIVE MAINTENANCE
EXTERNAL LINES AND OIL COOLER
SHIFT POINT CHECK
PRESERVATION AND STORAGE
Storage, 1 Year-Without Oil
CHECKING OIL PRESSURES
Fig. 3-1. Transmission check points, external connections (c,/o retarder)
Fig. 3-2 Oil pressure check points (with retarder)
TROUBLESHOOTING CHART
TROUBLESHOOTING CHART - Continued
TROUBLESHOOTING CHART - Continued
TROUBLESHOOTING CHART - Continued
Section 4. GENERAL OVERHAUL INFORMATION
Fig., -1. Work table
SPECIAL TOOLS TABLE (fig. 4-2, 4-3, 4-4)
Fig. 4-3 Special tools (24 through 55)
Fig. 4-4 Special (56 through 60)
CLEANING, INSPECTION
Inspecting Bearings
Fig. 1-5 Method of measuring clutch plate cone
TORQUE SPECIFICATIONS
Fig. 5-1. Installing transmission overhaul stand
Fig. 5-3. Removing modulator actuator rod
Fig. 5-7. Removing oil pan screws
Fig. 5-11. Removing oil filter
Fig. 5-16 Control valve body bolt locations
Fig. 5-19 Removing torque converter pump
Fig. 5-26 Removing torque converter housing
Fig. 5-31 Removing forward clutch assembly
Fig. 5-37 Removing second-clutch snapring
Fig. 5-41 Removing rear cover
Fig. 5.44. Removing first clutch plates .
DISASSEMBLY
Section 6. INSPECTION AND REBUILD OF SUBASSEMBLIES
Fig. 6-5. Components of control valve assembly
Fig. 6-6. Ball locations for control valve.
Fig. 6-7. Control valve assembly - with components installed.
LEGEND FOR FIGURE 6-7.
HT 700D SERIES TRANSMISSIONS
INSPECTION AND REBUILD
Fig. 6-8 Tightening selector valve stop bolt .
Fig. 6-9. Installing stator freewheel roller
Fig. 6.12. Torque converter pump components.
Fig. 6.14. Supporting oil pump during removal.
Fig. 6-15. Oil pump and torque converter housing .
Fig. 6-17. Tool for installing front support needle bearing
Fig. 6-20 Checking oil pump drive gear end clearance
Fig. 6-29 Forward clutch components
Fig. 6-31 Removing PTO gear from forward clutch
Fig. 6-35 Forward clutch assembly cross section
Fig. 6-36 Installing forward clutch piston
Fig. 6-39 Removing (or installing) fourth clutch rear bearing race
Fig. 6-12 Installing fourth clutch piston
Fig. 6-4. Checking fourth clutch running clearance
Fig. 6-17 Installing orifice plug into main shaft
Fig. 6-50 Removing output shaft rear oil seal
Fig. 6-52. Removing (or Installing) output shaft
Fig. 6-54. Removing speedometer driven gear bushing
Fig. 6-57. Installing piston into rear cover
Fig. 6-59. Installing output shaft bushing
Fig. 6-62. Installing manual shaft oil seal
Fig. 6-63. Components of low planetary carrier assembly
Fig. 6.65. Removing retainer rings from first clutch
Fig. 6-66. Components of gear unit and main shaft assembly (HT750CRD)
FLEX DISK ASSEMBLY
Fig. 6-68. Components of front planetary carrier assembly
CENTER PLANETARY CARRIER ASSEMBLY
Fig. 6.69 Components of center planetary carrier assembly
Fig. 6-72. Components of rear planetary carrier assembly
Fig. 6.74. Torque requirements for threaded fasteners
Fig. 7-4. Installing second clutch snapring
Fig. 7-6. Checking selective snapring clearance
Fig. 7-9. Installing rear cover assembly
Fig. 7-11. Checking first clutch clearance
Fig. 7-12. Installing first clutch plates
Fig. 7-15. Installing second clutch plate
Fig. 7-17. Installing center support
Fig. 7-19. Low planetary carrier, ring gear and clutch
Fig. 7-24. Installing center support
INSTALLING FOURTH, THIRD, FORWARD CLUTCHES
Fig. 7.33. Installing third clutch snapring
Fig. 7-35. Installing forward clutch assembly
Fig. 7-38 insulating pilot tube screw
Fig. 7-47 Installing snapring onto the converter ground sleeve
Fig. 7.53 Installing control valve body
Fig. 7-56 Valve body assemblies (HT750)
Fig. 7-58 Installing flywheel and turbine
Fig. 7-61 Installing modulator actuator rod
Fig. 7-63 Removing transmission from overhaul stand
POWER TAKEOFF COMPONENTS
Section 8. WEAR LIMITS AND SPRING DATA
WEAR LIMITS AND SPRING DATA
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
WEAR LIMITS AND SPRING DATA - Continued
Foldout 2. Model HT 750CRD Transmission - Cross Section View
LEGEND FOR B, FOLD OUT 7.
B, foldout 7. Lockup clutch and torque converter-exploded view
A, foldout 7. Flex disc and flywheel assemblies-exploded view
B, foldout 10. Front support and valve assembly-exploded view
A, foldout 11. Forward clutch assembly-exploded view
B, foldout 11. Fourth-clutch assembly-exploded view
LEGEND A FOLDOUT 12
A, foldout 12. Third-clutch, center support, and second clutch-exploded view
LEGEND FOR A, FOLDOUT 13
A, foldout 13. Gear unit and main shaft assembly exploded view
LEGEND A, FOLDOUT 14
A, foldout 14. Transmission housing, oil filter and oil pan-exploded view
B, foldout 14. First clutch--exploded view
A, foldout 15. Adapter housing, low-clutch plates and low carrier
LEGEND A, FOR FOLDOUT 16
A, foldout 16. First and low piston, rear cover, output shaft and governor-exploded view
LEGEND B, FOR FOLDOUT 16
B, foldout 16. Control valve assembly-exploded view
A, foldout 17. Lockup cutoff, low shift and low trimnmer valve body assemblies-exploded view
INDEX
SHIFT ROD ARRANGEMENTS
SPICER TRANSMISSION LUBRICATION
AUXILIARY TRANSMISSION ASSEMBLY
SHIFTER HOUSING FRONT CONTROL
Figure 1
INSTALLATION OF SHIFTER HOUSING ON CASE
GEARS AND CASE
MAINSHAFT REMOVAL & DISASSEMBLY
Figure 5
COUNTERSHAFT REASSEMBLY IMPORTANT
MAINSHAFT ASSEMBLY AND INSTALLATION PARTIAL INSTALLATION OF MAIN DRIVE GEAR
MAINSHAFT ASSEMBLY
INSTALLATION OF MAINSHAFT
INSTALLATION OF MAINSHAFT - Continued
INSTALLATION OF MAINSHAFT - Continued
IMPORTANT PROCEDURE
Driver Training
Walking or Jumping Out of Gear
Jumping Out of Gear
Interchangeability
WHEELS, DRUMS, RIMS AND TIRES
WHEELS, DRUMS, RIMS AND TIRES - Continued
WHEEL BEARING ADJUSTMENT
Fig. 3 Heavy Duty
Fig. 4. Medium Duty
UNITIZED OIL SEAL (AXLE RING NOT REQUIRED)
Unitized Seal Installation
INITIAL LUBRICATION OF WHEEL BEARINGS
BRAKE DRUMS
BRAKE DRUMS - Continued
Fig. 2 Drop Center Type Disc Wheel (Tubeless)
Wheel Studs and Mounting Nuts
RIM TIGHTENING AND ALIGNMENT
WHEEL AND TIRE BALANCING
Fig. 11 Chart Showing Effects of Bleeding
Fig. 13 Speed vs. Mileage
The next three steps apply only to the hot patch method.
MOUNTING AND DISMOUNTING TIRES
MOUNTING NUTS (Disc Wheels)
ONE PIECE DROP CENTER HEAVY DUTY TUBELESS TIRES (7.00-20 and Up)
Mounting Instructions
Mounting Instructions - Continued
THREE-PIECE FLAT BASE
Mounting
LOAD AND INFLATION CHART
TORQUE CHART
CONTENTS
SINGLE SPEED - TWO
MODEL NUMBER CONSTRUCTION 26DD SERIES EXTRA HEAVY DUTY P.T.O.
Fig. 1. PTO Lubrication Adaptation
'Unknown' by LOGSA - Page 881 of 894
P.T.O COMMON PARTS LIST FOR 26DD Series
Governor Drive
SERVICE INSTRUCTIONS FOR THE C10000 SERIES TELESCOPIC CYLINDERS
SERVICE INSTRUCTIONS FOR THE C10000 SERIES TELESCOPIC CYLINDERS - Continued
DIRECTIONAL CONTROL VALVE
PUMP SERVICE REMOVAL
Marvel "12-IN-1" Hydraulic Filters for Suction, Return, and Low Pressure Lines
Simplified Ordering
DUMP BODY COMPONENTS
