OPERATOR AND SERVICE MANUAL
FIGURE 1-2 OPERATIONS CONTROLS AND INDICATORS.
FIGURE 2-1. COMPACTOR DIMENSIONS.
TABLE 2-1. COMPACTOR DIMENSIONS AND WEIGHT SPECIFICATIONS (See figure 2-1).
TABLE 2-2. PERFORMANCE SPECIFICATIONS.
TABLE 2-3B. ENGINE SPECIFICATIONS - DETROIT DIESEL.
TABLE 2-4B. FUEL SYSTEM SPECIFICATIONS - DETROIT DIESEL.
TABLE 2-5. ELECTRICAL SPECIFICATIONS.
TABLE 2-6. TRANSMISSION AND TORQUE CONVERTER SPECIFICATIONS.
TABLE 2-7. FINAL DRIVE AND TRANSFER CASE SPECIFICATIONS.
TABLE 2-7. FINAL DRIVE AND TRANSFER CASE SPECIFICATIONS (CONT.).
TABLE 2-8C. STEERING SPECIFICATIONS - DETROIT DIESEL.
TABLE 2-11. TIRE INFLATION SYSTEM SPECIFICATIONS.
TABLE 2-11. TIRE INFLATION SYSTEM SPECIFICATIONS (CONT.)
TABLE 2-11. TIRE INFLATION SYSTEM SPECIFICATIONS (CONT.)
TABLE 2-12. TORQUE SPECIFICATIONS FOR STANDARD HARDWARE.
TABLE 3-1. OPERATING CONTROLS AND INDICATORS.
TABLE 3-1. OPERATING CONTROLS AND INDICATORS (CONT.).
TABLE 3-1. OPERATING CONTROLS AND INDICATORS (CONT.).
FIGURE 3-2. OPERATING CONTROLS AND INDICATORS.
OPERATING THE UNIT
TIRE INFLATION SYSTEM OPERATION.
FIGURE 3-5. BALLASTING INSTRUCTIONS.
FIGURE 4-1. MAINTENANCE CHART.
TABLE 4-1. HYSTER-CARE MAINTENANCE SCHEDULE.
TABLE 4-1. HYSTER-CARE MAINTENANCE SCHEDULE (CONT.).
TABLE 4-1. HYSTER-CARE MAINTENANCE SCHEDULE (CONT.).
SECTION 4. MAINTENANCE
FIGURE 4-3. BATTERY LOCATION.
FIGURE 4-4. DRIVE BELTS.
FIGURE 4-5C. ELECTRICAL SCHEMATIC-DETROIT DIESEL.
FIGURE 4-6. STEERING HYDRAULIC OIL.
FIGURE 4-9. WATER SYSTEM STRAINER.
FIGURE 4-10. REAR CENTER WHEEL SPRING ADJUSTMENT
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE.
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-2. TROUBLE ANALYSIS FOR DETROIT DIESEL FUEL SYSTEM.
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM.
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM (CONT.).
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM (CONT.).
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM (CONT.).
TABLE 5-4. TROUBLE ANALYSIS FOR TRANSMISSION & TORQUE CONVERTER.
TABLE 5-4. TROUBLE ANALYSIS FOR TRANSMISSION & TORQUE CONVERTER (CONT.).
TABLE 5-4. TROUBLE ANALYSIS FOR TRANSMISSION & TORQUE CONVERTER (CONT.).
TABLE 5-5. TROUBLE ANALYSIS FOR FINAL DRIVE & TRANSFER CASE (CONT.).
TABLE 5-6. TROUBLE ANALYSIS FOR STEERING SYSTEM.
TABLE 5-6. TROUBLE ANALYSIS FOR STEERING SYSTEM (CONT.).
TABLE 5-6. TROUBLE ANALYSIS FOR STEERING SYSTEM (CONT.).
TABLE 5-7. TROUBLE ANALYSIS FOR BRAKE ASSEMBLY SYSTEM.
TABLE 5-9. TROUBLE ANALYSIS FOR TIRE INFLATION SYSTEM.
TABLE 5-9. TROUBLE ANALYSIS FOR TIRE INFLATION SYSTEM (CONT.).
TABLE 5-9. TROUBLE ANALYSIS FOR TIRE INFLATION SYSTEM (CONT.).
SECTION 6. ELECTRICAL
FIGURE 6-4. ELECTRICAL SCHEMATIC DETROIT DIESEL
FIGURE 6-8. INSTRUMENT PANEL DETROIT DIESEL.
FIGURE 6-6. ELECTRICAL ROUTING DETROIT DIESEL.
SECTION 7. TRANSMISSION
REASSEMBLY OF TORQUE CONVERTER
INSTALLATION OF TORQUE CONVERTER
FIGURE 7-8.
REMOVAL OF TRANSMISSION.
CLUSTER GEAR REMOVAL.
FORWARD CLUTCH CYLINDER DISASSEMBLY
REASSEMBLY OF FORWARD-REVERSE TRANSMISSION
REASSEMBLY OF REVERSE CLUTCH- SHAFT AND PACK.
REASSEMBLY OF FORWARD CLUTCH-SHAFT AND PACK.
INSTALLATION OF IDLER GEAR SHAFT.
INSTALLATION OF CONTROL VALVE.
DISASSEMBLY OF CONTROL VALVE.
INSPECTION AND CLEANING.
PRESSURE CHECKS.
3-SPEED RANGE TRANSMISSION
DISASSEMBLY OF 3-SPEED RANGE TRANSMISSION
CLEANING AND INSPECTION.
REASSEMBLY OF 3-SPEED RANGE TRANSMISSION
REASSEMBLY OF 3-SPEED RANGE TRANSMISSION - Continued
INSTALLATION OF 3-SPEED RANGE TRANSMISSION
DISASSEMBLY OF TRANSFER CASE.
DISASSEMBLY OF TRANSFER CASE - Continued
DISASSEMBLY OF PINION SHAFT.
REASSEMBLY OF TRANSFER BOX.
REASSEMBLY OF PINION SHAFT.
REASSEMBLY OF OUTPUT SHAFT.
FINAL DRIVE
PINION REMOVAL.
DISASSEMBLY OF DIFFERENTIAL.
INSPECTION
REASSEMBLY OF DIFFERENTIAL.
INSTALLATION
DIFFERENTIAL ADJUSTMENT.
WHEEL HUB INSTALLATION.
RIM INSTALLATION.
CHECKING GEAR TEETH CONTACT PATTERN
POWER OPERATION.
MANUAL OPERATION.
DISASSEMBLY OF STEERING CONTROL UNIT
DISASSEMBLY OF STEERING CONTROL UNIT - Continued
DISASSEMBLY OF STEERING CONTROL UNIT - Continued
CLEANING AND INSPECTION.
REASSEMBLY OF STEERING CONTROL UNIT
REASSEMBLY OF STEERING CONTROL UNIT - Continued
REASSEMBLY OF STEERING CONTROL UNIT - Continued
STEERING CYLINDERS
DISASSEMBLY
INSTALLATION
REMOVAL
INSTALLATION
STEERING PUMP
DISASSEMBLY
REASSEMBLY
FLOW DIVIDER
REASSEMBLY AND INSTALLATION
SERVICE BRAKE SYSTEM
MASTER CYLINDER.
OUTSIDE REAR WHEELS
CLEANING AND INSPECTION
DISASSEMBLY OF WHEEL BRAKES
REAR WHEEL HUB INSTALLATION
WHEEL BRAKE CYLINDERS
CLEANING AND INSPECTION
INSTALLATION
CLEANING AND INSPECTION
ADJUSTMENT
PRESSURE SPRAY SYSTEM
FIGURE 11-2. PRESSURE WATER SPRAY SYSTEM.
DISASSEMBLY
FIGURE 12-1.
INTAKE AND COMPRESSION (Loaded)
LUBRICATION
DISASSEMBLY OF CYLINDER HEAD
FIGURE 12-8.
INSPECTION
SECTION 12. TIRE INFLATION SYSTEM
REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK.
REASSEMBLY AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.
CHECKS AND ADJUSTMENTS
PRESSURE REGULATING VALVE
QUICK RELEASE VALVE
PART II. SUPPLEMENTAL OPERATING MAINTENANCE AND REPAIR PARTS INSTRUCTIONS
TABLE OF CONTENTS
TABLE OF CONTENTS (Continued)
GENERAL
Personnel and Training.
Reporting
SECTION II. MAINTENANCE
Equipment Serviceability Criteria (ESC).
Towing The Roller.
SECTION III. REPAIR PARTS SUPPLY
Requisitioning Repair Parts
PUBLICATIONS
APPENDIX B. WARRANTY GUIDELINE
APPENDIX B. WARRANTY GUIDELINE - Continued
APPENDIX C. MAINTENANCE ALLOCATION CHART
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 III - TOOL. AND TEST EQUIPMENT REQUIREMENTS
SECTION III - TOOL. AND TEST EQUIPMENT REQUIREMENTS - Continued
CCE MANUFACTURER FIELD CAMPAIGNS AND MODIFICATION PROCEDURES
BASIC ISSUE ITEMS LIST
INITIAL RECOMMENDATION - PRESCRIBED LOAD LIST (PLL) - AUTHORIZED STOCKAGE LIST (ASL)
ADDITIONAL REPAIR PARTS
ADDITIONAL REPAIR PARTS - Continued
SAMPLE FORMAT - DA FORM 2765 PART NUMBER REQUEST
SAMPLE FORMAT - MILSTRIP REQUISITION FOR (NSN)
SAMPLE FORMAT - MILSTRIP REQUISITION FOR (NON-NSN)
SAMPLE FORMAT - MILSTRIP REQUISITION FOR (NON-NSN) - Continued
SAMPLE FORMAT- MILSTRIP REQUISITION FOR CCE (NON-NSN) (MANUAL)
INSTRUCTIONS
MAINTENANCE AND OPERATING SUPPLY LIST
MAINTENANCE AND OPERATING SUPPLY LIST
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
PART III. PARTS MANUAL
INDEX
UNIT IDENTIFICATION
Section A. INTRODUCTION
How To Use The Illustrated Parts Manual
When The Part Number Is Known
OPERATION AND MAINTENANCE TIPS
Section B. COWLING AND FLOOR PLATE
COWLING AND FLOOR PLATES
HITCH
Section C. POWER UNIT
COOLING SYSTEM
ENGINE MOUNTS AND OIL DRAIN LINE
EXHAUST SYSTEM
Section D. FUEL SYSTEM
AIR FILTER
FUEL SYSTEM
Section E. ELECTRICAL EQUIPMENT
ELECTRICAL SYSTEM
Section G. POWER TRAIN TRANSMISSION
TRANSMISSION
TRANSMISSION CONTROL VALVE
CLUTCH PACK
TRANSMISSION CASE AND REGULATORS
TRANSMISSION OIL FILTER
TRANSFER DRIVE
FORWARD AND REVERSE CONTROL
REAR WHEELS
FINAL DRIVE
TRANSFER DRIVE SHAFT
DRIVE PLATE AND TORQUE CONVERTER HOUSING
Section H. BRAKES AND LINKAGE
BRAKE SYSTEM
BRAKES
MASTER CYLINDER
PARKING BRAKE
PARKING BRAKE LEVER
Section K. STEERING AND LINKAGE
STEERING CONTROL
STEERING CYLINDER
STEERING PUMP
STEERING SYSTEM
Section P. OPTIONAL EQUIPMENT
WATER SPRAY SYSTEM
WATER SPRAY SYSTEM - Continued
TIRE AND WHEEL CHART
TIRE INFLATION SYSTEM
TIRE INFLATION SYSTEM - Continued
AIR COMPRESSOR
ROTATING UNION
LIGHTING-SYSTEM
AIR REGULATOR
Section Q. NUMERICAL INDEX
NUMERICAL INDEX
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
PART IV. DIESEL ENGINE OPERATOR S MANUAL
TABLE OF CONTENTS
PRINCIPLES OF OPERATION
GENERAL DESCRIPTION
Fig. 2 - In-Line Engine Model Description, Rotation and Accessory Arrangement
Fig. 3 - 6V Engine Model Description, Rotation and Accessory Arrangement
GENERAL SPECIFICATIONS
ENGINE MODEL AND SERIAL NUMBER DESIGNATION
Cross Section Views of a Typical In-Line Engine
Cross Section Views of a Typical 6V-53 Engine
ENGINE SYSTEMS
Fig. 3 - Removing Injector from Cylinder Head
Fig. 4 - Typical Fuel Strainer and Filter Mounting
Fig. 5 - Typical Spin-On Type Fuel Strainer and Fuel Filter Mounting
Fig. 7 - Air Intake System Through Blower and Engine (6V-53 Engine)
Fig. 8 - Light-Duty Oil Bath Air Cleaner
Fig. 11 - Air Cleaner Tray (Clean)
Fig. 12 - United Specialties Dry Type Air Cleaner
Crankcase Ventilation
Fig. 15 - Typical V-Type Engine Oil Filter Mounting
Fig. 16 - Schematic Diagram of Typical In-Line Engine Lubricating System
Fig. 17 - Schematic Diagram of Typical 6V Engine Lubricating System
Fig. 18 - Typical Cooling System for In-Line Engines
Fig. 19 - Typical Cooling System for V-Type Engine
ENGINE COOLING SYSTEM MAINTENANCE
Flushing
Fig. 20 - Raw Water Pump Used on In-Line Engine
Raw Water Pump
SECTION 4. ENGINE EQUIPMENT INSTRUMENT PANEL, INSTRUMENTS AND CONTROLS
Throttle Control
ENGINE PROTECTIVE SYSTEMS
AUTOMATIC ELECTRICAL SHUT-DOWN SYSTEM
Fig. 4 - Automatic Electrical Shut-Down System Incorporating Hot Wire Relay
Fig. 5 - Alarm System Wiring Diagram
STARTING SYSTEMS
Fig. 6 - Schematic Diagram of Hydrostarter System Showing Oil Flow
Fig. 7: Hydrostarter Remote Control System
LUBRICATION AND PREVENTIVE MAINTENANCE
Marine Application
Fig. 8 - Typical Fluid Starting Aid
Fig. 9 - Quick-Start Assembly
POWER TAKE-OFF ASSEMBLIES
Fig. 11 - Checking Clutch Adjustment with a Torque Wrench and Adaptor
WARNER MARINE GEAR
SECTION 5. OPERATING INSTRUCTIONS
Lubrication Fittings
Engine Temperature
STOPPING
Fig. 1 - Location of Controls on Power Generator Set
PREPARING GENERATOR FOR LOAD
PARALLELING
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE
LUBRICATION AND PREVENTIVE MAINTENANCE
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
FUEL OIL SPECIFICATIONS
LUBRICATING OIL SPECIFICATIONS
NEW ENGINE OIL CLASSlFICATION SYSTEM
SERVICE AND INSPECTION INTERVALS
ENGINE COOLANT
Fig. 2 - Heat Transfer Capacity
Fuel, Oil and Coolant Specifications
Fig. 4 - Coolant Freezing and Boiling Temperatures vs. Antifreeze Concentration (Sea Level)
GENERAL RECOMMENDATIONS
SECTION 7. ENGINE TUNE-UP PROCEDURES
EXHAUST VALVE CLEARANCE ADJUSTMENT
FOUR VALVE CYLINDER HEADS
TIMING FUEL INJECTOR
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
Position Injector Rack Control Levers
Fig. 6 - Governor Spring Assemblies
Adjust Maximum No-load Engine Speed
Fig. 8 - Adjusting Buffer Screw
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
Position Injector Rack Control Lovers
Fig. 5 - Checking Injector Control Rack "Spring"
Adjust Maximum No-load Engine Speed
Adjust Buffer Screw
VARIABLE SPEED MECHANICAL GOVERNOR (OPEN LINKAGE) AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 4 Adjusting Fuel Rod Length
Fig. 6 - Adjusting Idle Speed
Fig. 7 - Adjusting Buffer Screw
VARIABLE SPEED MECHANICAL GOVERNOR (ENCLOSED LINKAGE) AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 4 - Checking Injector Control Rack "Sprint"
Fig. 5 - Locating of Shims and Stops
Fig. 6 Adjusting Idle Speed
Fig. 8 - Adjusting Booster Spring
VARIABLE SPEED MECHANICAL GOVERNOR AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 4 - Checking Rotating Movement of Injector Control Rack
Adjust Maximum No-load Speed
Fig. 7 - Adjusting Idle Speed
Fig. 9 Adjusting Booster Spring
SUPPLEMENTARY GOVERNING DEVICE ADJUSTMENT
Fig. 3 - Throttle Delay Yield Lever (In-Line Engine)
Fig. 5 - Adjusting Throttle Delay Cylinder
ADJUSTMENT OF MECHANICAL GOVERNOR SHUTDOWN SOLENOID
Fig. 7 - Typical Limiting Speed Governor Lever Position
Fig. 1 - Hydraulic Governor Mounted on Engine
Fig. 4 - Adjusting Droop Bracket
Fig. 5 - Adjusting Maximum Engine Speed
Fig. 2 Hydraulic Governor Controls
SECTION 8. TROUBLE SHOOTING
Engine Out of Fuel
Exhaust Back Pressure
Air Box Pressure
PROPER USE OF MANOMETER
SECTION 9. STORAGE
POWER TARE-OFF
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
POWER TAKE-OFF
Built-In Parts Book
Built-In Parts Book - Continued
Built-In Parts Book - Continued
GROUP NOMENCLATURE
STANDARD AND STANDARD OPTION EQUIPMENT
Built-In Parts Book - Continued
Cylinder Head
Connectin Rod, Piston and Liner
Accessory Drive for Belt Driven Accessory (Drive Hub Type)
Valve Operating Mechanism (4 Vave)
Injectors and Controls
Air Shut-Down Housing
Blower Assembly And Drive (4 Cylinder)
Blower Assembly And Drive (6 Cylinder)
Oil Pump and Regulator
Oil Filter
Oil Cooler (6V-53)
Fresh Water Pump
Fan Mount (6V-53)
Fan Mount
hear Exchanger (6V-53)
Tachometer Drive Covers and Adaptors
Air Compressor And Drive
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
PART V. DIESEL ENGINE SERVICE MANUAL
TABLE OF CONTENTS
IMPORTANT SAFETY NOTICE
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
SCOPE AND USE OF THE MANUAL
PRINCIPLES OF OPERATION
GENERAL DESCRIPTION
Fig. 2 In-line Engine Model Description, Rotation, and Accessory Arrangements
Fig. 3-6 and 8V Engine Model Description, Rotation and Accessory Arrangement
Fig. 4 - Cylinder Designation and Firing Order
Fig. 5 Typical Model and Serial Numbers as Stamped on Cylinder Block (In-Line Engine)
INJECTOR HIGH PRESSURE TEST
Fig. 14 - Injector Needle Valve Test with Auxiliary Tester J 22640
Fig. 18 - Setting Comparator Stroke Counter
Fig. 20 - Position of Calibrator Fuel flow Pipes
GENERAL PROCEDURES
Rust Preventive
WORK SAFELY
Cross Section of a Typical In-Line Engine
SECTION 1. ENGINE (less major assemblies)
Fig. 1 - Cylinder Block (Four Cylinder Block Shown)
Fig. 3 - Air and Water Passages in In-Line Cylinder Block
Remove and Disassemble Engine
Fig. 7 - Location of the Four 3/8-16 Bolt Holes in Rear of Cylinder Block
Fig. 9 - Engine Mounted on Overhaul Stand
Fig. 11 - Location of Block Bore Seal Ring Groove
Fig. 14 - Typical Cylinder Block Markings
Inspect Cylinder Block
Assemble and Install Engine
CYLINDER BLOCK END PLATE
CYLINDER BLOCK END PLATE - Continued
AIR BOX DRAINS
Inspection
CYLINDER HEAD
Cylinder Head Maintenance
Fig. 2 - Lifting Cylinder Head Assembly Off Cylinder Block with Tool J 22062-01
Fig. 3 - Checking Bottom Face of Cylinder Head for Warpage
Fig. 5 - Correct Installation of Water Nozzles in Four-Valve Cylinder Head
Fig. 6 - Sequence for Tightening Cylinder Head Bolts
Install Cylinder Mood
VALVE AND INJECTOR OPERATING MECHANISM
Fig. 4 - Testing Push Rod Spring
Fig. 6 - Former and Current Cam Followers
Fig. 7 - Removing or lnstalling Cam Follower Roller and Pin with Tool J 5840
Fig. 10 - Adjusting Cam Follower Guide
Remove and Install Cam Follower Roller and Pin
Fig. 12 - Relationship Between Exhaust Valve Bridge and Valve Stems
Install Rocker Arms and Rocker Arm Shaft
EXHAUST VALVES
Fig. 4 - Cleaning Valve Guide
Inspection
Fig. 6 - Installing Valve Guide
Fig. 8 - Installing Valve Seat Insert
Fig. 9 - Refacing Exhaust Valve
Fig. 12 - Relationship Between Exhaust Valve, Insert and Cylinder Head (Four Valve Head)
Fig. 15 - Former and Current Design Exhaust Valves (Four Valve Head)
Fig. 16 - Checking Valve Opening Pressure with Gage WRE-500-60
Fig. 1 - Typical Valve Rocker Cover Assembly
CRANKSHAFT
Fig. 3 Removing or Installing Crankshaft
Fig. 4 - Typical Ridging of Crankshaft
Inspection for Cracks
Fig. 9 . Crankshaft Journal Fillets
Crankshaft Grinding
Fig. 11 . Checking Crankshaft End Play
Install Crankshaft
CRANKSHAFT OIL SEALS
Fig. 5 . Use of Front Oil Seal Sleeve on Grooved Crankshaft (In-line Engines)
Install Crankshaft Rear Oil Seal
Install Crankshaft Rear Oil Seal - Continued
CRANKSHAFT MAIN BEARINGS
Fig. 5 Removing Upper Rear Main Bearing Shell
Fig. 6 Comparison of Main Bearing Shells
Fig. 7 Main Bearing Measurements
Fig. 9- Crankshaft Thrust Washers in Place
Install Main gearing Shells ( Crankshaft in Place)
ENGINE FRONT COVER (Lower)
Fig. 3 -Installing Lower Engine Front Cover In-Line Engine
CRANKSHAFT PULLEY
Fig. 3 Cone Mounted Pulley
Fig. 1 - Removing Flywheel
Install Flywheel
FLYWHEEL HOUSING
Fig. 3 - Flywheel Housing Bolt Sizes and Tightening Sequence (Operation 1).-ln.Line Engine
Fig. 6 - Flywheel Housing Bolt Tightening Sequence (Operation 2).InLine Engine
fig. 9- Checking Flywheel Housing Concentrtcity
Install Flywheel Housing
PISTON AND PISTON RINGS
Disassemble Piston and Connecting Rod
Fig. 4 Comparison of Pistons
Fig. 6 Location of Joint in Piston Pin Bushings
Fig. 8 - Measuring Piston-to-liner Clearance
Fitting Piston Rings
Install Piston Rings
CONNECTING ROD
Fig. 3 Magnetic Particle Inspection Limits for Connecting Rod
Fig. 4 - Removing or Installing Bushings
Fig. 9 - Installing Piston Pin Retainer
Assemble Connecting Rod to Piston
CONNECTING ROD BEARINGS
Install Connecting Rod Bearing Shells
Fig. 2 Removing Cylinder Liner
Fig. 4 - Checking Bore of Cylinder Liner
Fig. 6 - Cylinder Liner Ridge Due to Wear
Fig. 7 Checking Distance of Liner Flange Below Top Face of Block
Fig. 9 - Cylinder Liner Seal Ring Location in Cylinder Block Bore
Install Cylinder liner, Piston and Connecting Rod Assembly
ENGINE BALANCE AND BALANCE WEIGHTS
Install Front Balance Weights
GEAR TRAIN AND ENGINE TIMING
IN-LINE ENGINE
IN-LINE ENGINE - Continued
ENGINE TIMING
Chock Engine liming
CAMSHAFT, BALANCE SHAFT AND BEARINGS
Fig. 3 Removing End Bearing
Fig. 4 Installing Intermediate Camshaft Bearing
Fig. 6. Location of Notch in Relation to Shaft Bore Centerline
Install Intermediate and/or Center Camshaft Bearings
Fig. 7 Removing and Replacing Camshaft or Balance Shaft Bearings
Fig. 8 Camshaft and Balance Shaft Details and Relative Location of Parts
CAMSHAFT AND BALANCE SHAFT GEARS
Fig. 2 Installing Camshaft Gear
IDLER GEAR AND BEARING ASSEMBLY
Fig, 3 Idler Gear Details and Relative Location of Parts
CRANKSHAFT TIMING GEAR
Install Crankshaft liming Gear
Fig. 1 - Accessory Drive Locations (In-Line Engines)
Fig. 3 Air Compressor Drive
Fig. 5 Components of Accessory Drive for Belt Driven Accessory (Drive Hub Type)
Fig. 8 Location of Oil Seal Spacer
Install Accessory Drive
ENGINE FRONT COVER (Upper)
Install Cover
Fig. 1 Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance
CAMSHAFT CUP PLUG INSTALLATION
TROUBLE SHOOTING
SPECIFICATIONS
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
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
SECTION 2. FUEL SYSTEM AND GOVERNORS CONTENTS
Fig. 1 Typical Fuel System for In-Lime Engines
FUEL INJECTOR (NEEDLE VALVE)
Fig. 3. Fuel Metering from No-Load to Full. Loead
Fig. 7- Removing Injector from Cylinder Head
Fig. 8 Checking Rack and Plunger for Free Movement
Fig. 11. Removing Injector Follower Stop Pin
INJECTOR CONTROL RACK AND PLUNGER MOVEMENT TEST
INJECTOR HIGH PRESSURE TEST
Fig. 14 lnjector Needle Valve Test with Auxiliary Tester J 22640
NEEDLE VALVE TESTS
Fig. 20 Position of Calibrator Fuel Flow Pipes
Fig. 22 - Setting Calibrator Stroke Counter
Fig. 25 - Removing Injector Nut
Fig 28 - Cleaning Spray Tip Orifices
Fig. 30 - Cleaning Injector Nut Spray Tip Seat
Fig. 34 - Location of Filter In lnjector Body
Fig. 35 - Details of Injector Filters and Caps and Their Relative Location
Fig. 38 - Comparison of Former and New Design Injector Parts
Lapping Injector Parts
Fig. 42 - Checking Injector Spray Tip Concentricity
Fig. 43 - Relationship Between Exhaust Valve Bridge and Valve Stems
Test Reconditioned Injector
FUEL INJECTOR TUBE
Fig. 3 Upsetting Infector Tube
Fig. 5 - Reaming Injector Tube for Injector Nut
Fig. 1 Typical Fuel Pump Assembly
Fig. 2 Fuel Pump Valving and Rotation (Right Hand Pump Shown)
Fig. 4 - Removing Oil Seals
Fig. 5 - Fuel Pump Details and Relative Location of Parts (Right Hand Pump Shown)
Fig. 7 - Installing Outer Oil Seal
FUEL PUMP DRIVE
MECHANICAL GOVERNORS
LIMITING SPEED MECHANICAL GOVERNOR
Remove Governor from Engine
Disassemble Governor Weight Housing
Assemble Governor Cover
Fig. 5 - Governor Housings and Relative. Location of Parts
Install Governor
Install Governor - Continued
SHOP NOTES-TROUBLE SHOOTING-SPECIFICATIONS-SERVICE TOOLS
INJECTOR TIMING
INJECTOR COMPARATOR AND CALIBRATOR READINGS
REPLACING INJECTOR FOLLOWER SPRING
LOCATING AIR LEAKS IN FUEL LINES
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
Trouble Shooting (Needle Valve Injectors)
Trouble Shooting (Needle Valve Injectors) - Continued
FUEL PUMP MAINTENANCE
SPECIFICATIONS
SERVICE TOOLS
SECTION 3. AIR INTAKE SYSTEM
Fig. 1 - Air Silencer Mounted on In-Line Engine
AIR SHUT-DOWN HOUSING
Fig. 2 - Installing Air Shut-Off Valve Spring and Valve
Install Air Shut-Down Housing (In-Line Engines)
BLOWER
Fig. 5 - Removing Blower Rotor Gears
Disassemble Blower
Fig. 7 - Typical Blower Details and Relative Location of Parts (3.53 Engine Blower)
Fig. 11 - Installing Blower Housing Over Rotors
Fig. 12 - Installing Rear End Plate
Fig. 15 - Minimum Blower Rotor Clearance
Fig. 16 - Measuring Rotor Lobe to End Plate Clearance
Fig. 17 Inserting Cam in Blower Drive Support
ENGINE BLOWER
SHOP NOTES - TROUBLE SHOOTING - SPECIFICATIONS - SERVICE TOOLS - SHOP NOTES
Fig. 4 - End Plate Oil Drain Back Counterbore
SPECIFICATIONS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SECTION 4. LUBRICATION SYSTEM
Fig. 1 - Schematic Diagram of Typical In-Line Engine Lubrication System
IN-LINE ENGINES
IN-LINE ENGINES - Continued
LUBRICATING OIL PUMP
Fig. 3 - Measuring Rotor Clearance
Fig. 5 - Lubricating Oil Pump Details and Relative Location of Parts (Current)
Fig. 8 - Installing Oil Pump Drive Gear
Install Oil Pump
LUBRICATING OIL PRESSURE REGULATOR
LUBRICATING OIL COOLER
Fig. 3 - oil Cooler Details and Relative Location of Parts (In-Line Engine)
Clean Oil Cooler Core
Install Oil Cooler Core
Fig. 1 - Typical oil Dipstick Mounting
Fig. 1 - Typical oil Pan
Fig. 1 - Typical Crankcase Breather Mounting (In-line Engine)
Service
SPECIFICATIONS - SERVICE TOOLS
SPECIFICATIONS
SECTION 5. COOLING SYSTEM
WATER P U M P
Fig. 4 - Removing Shaft from Impeller with Tools J 8329 and ,J 358-1
Fig. 6 Fresh Water Pump Details and Relative Location of Parts
Fig. 7- Comparison of Water Pumps
THERMOSTAT
Install Thermostat
Fig. 5 Bleed Hole in Thermostat Housing
ENGINE COOLING FAN
Fig. 3 - Removing Fan Hub (Pulley)
Fig. 5 Current Fan Hub Assembly (In-Line Engine)
Fig. 8 - Typical Fan Hub and Adjusting Bracket Details and Relative Location of Parts (In-Line Engine)
IN-LINE ENGINES (CURRENT)
IN-LINE ENGINES (CURRENT) - Continued
WATER FILTER AND CONDITIONER
Service
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SECTION 6. EXHAUST SYSTEM
EXHAUST MANIFOLD (AIR COOLED)
Install Exhaust Manifold
SECTION 7. ELECTRICAL EQUIPMENT, INSTRUMENTS AND PROTECTIVE SYSTEMS
BATTERY - CHARGING GENERATOR (D.C. and A.C.)
Fig. 2 - 30 DN Type 100 A.C. Self-Rectifying Generator (Alternator)
Install Generator
Fig. 4-20. DN Type 250 AC Self-Rectifying Generator (Alternator)
BATTERY-CHARGING GENERATOR REGULATOR
TRANSISTORIZED AND TRANSISTOR REGULATORS
TRANSISTOR REGULATOR
Fig. 5 - Transistor Regulator with Plug-ln Connecttons
STARTING MOTOR
Fig. 2 Cross-Section of Motor with Intermediate-Duty Clutch
Flywheel Ring Gears
TROUBLESHOOTING - SPECIFICATIONS - SERVICE TOOLS
CHECKING ENGINE ELECTRICAL GENERATING SYSTEM
SERVICE TOOLS
SECTION 13. OPERATING INSTRUCTIONS
ENGINE OPERATING INSTRUCTIONS
Lubrication Fittings
Warm-Up
Avoid Unnecessary Engine Idling
ENGINE OPERATING CONDITIONS
3-ENGINE (4-Valve Cylinder Head)
3-ENGINE (4-Valve Cylinder Head) - Continued
ENGINE RUN-IN INSTRUCTIONS
Instrumentation
BASIC RUN-IN INSPECTION
ENGINE TEST REPORT
INSPECTION AFTER FINAL RUN-IN
DETROIT DIESEL FUEL OIL SPECIFICATIONS
DETROIT DIESEL LUBRICATING OIL SPECIFICATIONS
ENGINE COOLANT
Fuel, Oil and Coolant Specifications
COOLANT INHIBITOR CHART
ANTIFREEZE
COOLANT RECOMMENDATIONS
SECTION 14. ENGINE TUNE-UP
Tune-Up Sequence for Mechanical Governor
EXHAUST VALVE CLEARANCE ADJUSTMENT
ENGINES WITH FOUR VALVE CYLINDER HEADS
FUEL INJECTOR TIMING
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 2 - Positioning the Rear Injector Rack Control Lever
Fig. 4 - Governor Spring Assemblies
Fig. 5 - Adjusting Engine Idle Speed
SECTION 15. PREVENTIVE MAINTENANCE - TROUBLE SHOOTING - STORAGE
LUBRICATION AND PREVENTIVE MAINTENANCE
LUBRICATION AND PREVENTIVE MAINTENANCE CHART
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
TROUBLE S H O O T I N G
Fuel Flow Test
Exhaust Back Pressure
Fig. 2 - Comparison of Column Height for Mercury and Water Manometers
Trouble Shooting (Engine)
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
STORAGE
EXTENDED STORAGE (30 days or more)
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
PART VI. DIESEL ENGINE PARTS MANUAL
GENERAL INFORMATION
INDEX
INDEX - Continued
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
GROUP NOMENCLATURE
MODEL DESCRIPTION CHART IN-LINE ENGINES
FIG. 1B INLINE 53 CYLINDER BLOCK (with end plate)
FIG. 2A. CYLIDER HEAD
FIGURE 3A. CRANKSHAFT (3-53)
FIG. 4D. LOWER FRONT COVER AND OIL PUMP
FIG. 5A FLYWHEEL AND FLYWHEEL HOUSING (In-Line Models)
FIG. 6A CONNECTING ROD, PISTON AND LINER
FIG. 7A. CRANKSHAFT
FIG. 7F. IDLER GEAR
FIG. 8A ACCESSORY DRIVE (Double Belt)
FIG. 9C. VALVE AND ROCKER BRIDGE
ROCKER COVER
TYPICAL 4 CYLINDER FAN TO FLYWHEEL INDUSTRIAL UNIT
BLOCK ASSY., CYLINDER
BLOCK CYLINDER
HEAD ASSY. CYLINDER
TUBE, INJECTOR HOLE
HEAD ASSEMBLY, CYLINDER
CRANKSHAFT ASSY.
SHELL, CRANKSHAFT MAIN BEARING
COVER, ENGINE FRONT-LOWER
FLYWHEEL
HOUSING, FLYWHEEL
CONNECTING ROD ASSY.
PISTON ASSY.
CYLINDER KIT
CAMSHAFT ASSY.
WEIGHT, REAR BALANCER
ADAPTOR, ACCESSORY DRIVE
ARM ASSY. EXHAUST VALVE
BRACKET, ROCKER SHAFT
VALVE, EXHAUST
GASKET, ROCKER COVER
GROUP NOMENCLATURE
FIG. 1B FUEL INJECTOR
FIG 2A. FUEL PUMP
FIGURE 3B. FUEL FILTER (CANISTER TYPE ELEMENT)
FIG. 4A TYPICAL FUEL SYSTEM (In-line Engine)
FIG. 5D MECHANICAL GOVERNOR HOUSING WEIGHTS AND LEVER (Closed Linkage)
FIG. 5G LIMITING SPEED GOVERNOR SPRING AND HOUSING
FIG. 5H MECHANICAL GOVERNOR COVER (Double Lever)
FIG. 5L GOVERNOR WEIGHT SHAFT AND CARRIER
FIG. 7A INJECTOR CONTROL TUBE (Inline Engine)
INJECTOR ASSY.
SPRING, INJECTOR PLUNGER
RETAINER, INJECTOR GEAR
PUMP ASSY., FUEL
SEAL, FUEL PUMP OIL
GASKET, FUEL PUMP TO ENGINE
SPRING, FUEL PUMP VALVE RETAINING
STRAINER ASSY., FUEL
PLUG, FUEL STRAINER COVER
GASKET, FUEL FILTER COVER TO SHELL
PIPE, FUEL
TUBE, STRAINER TO FUEL PUMP
GOVERNOR ASSY.
LEVER, GOVERNOR COVER THROTTLE SHAFT
LEVER, GOV. OPERATING SHAFT
SPRING, GOVERNOR LOW SPEED
SCREW ASSY., GOV. BUFFER
SEAL, GOVERNOR
RETAINER, GOVERNOR SHUTDOWN SHAFT PACKING
SUPPORT, GOVERNOR WEIGHT SHAFT BEARING
BRACKET, INJECTOR CONTROL TUBE
CLIP, GOVERNOR CONTROL WIRE TUBE
GROUP NOMENCLATURE
FIG. 3B. BLOWER AND AIR INLET HOUSING
FIG. 4A. 3-53. BLOWER
HOUSING ASST., AIR INLET
WIRE, AIR INLET HOUSING SHUTDOWN
BLOWER ASSY.
SCREEN, BLOWER
SEAL, BLOWER HOUSING END PLATE
GROUP NOMENCLATURE
FIG. 1A. OIL PUMP AND PRESSURE REGULATOR (INLINE ENGINE)
FIG. 2A. OIL DISTRIBUTION SYSTEM
FIG. 3A. OIL FILTER
FIG. 4C. OIL COOLER
FIG. 6A. DIPSTICK
FIG. 7B OIL PAN (STAMPED)
FIG. 8A BREATHER AND OIL FILLER
PUMP ASSY., OIL
VALVE, OIL PRESSURE REGULATOR
FILTER ASSY., OIL
GASKET, OIL FILTER COVER NUT
GASKET, OIL FILTER TUBE ADAPTOR
CORE ASSY., OIL COOLER
CAP, OIL FILLER TUBE
DIPSTICK
PAN, OIL
PIPE, BREATHER
GROUP NOMENCLATURE
FIG. 1A TYPICAL COOLING SYSTEM (Inline Engines)
FIG. 2A FRESH WATER PUMP
PUMP ASSY., FRESH WATER
GASKET, FRESH WATER PUMP BODY COVER
ELBOW, WATER OUTLET
HOSE, WATER BY-PASS TUBE
ELBOW, OIL COOLER WATER OUTLET
BLADE, FAN
SEAL, FAN SHAFT
GROUP NOMENCLATURE
FIG. 1A EXHAUST MANIFOLD (Center Outlet)
MANIFOLD, EXHAUST
FLANGE, EXHAUST
GROUP NOMENCLATURE
FIG. 1A BATTERY CHARGING GENERATOR
GENERATOR ASSY.
B-PACKET, GENERATOR MOUNTING
MOTOR ASSY. STARTING
FIGURE 1-2 OPERATIONS CONTROLS AND INDICATORS.
FIGURE 2-1. COMPACTOR DIMENSIONS.
TABLE 2-1. COMPACTOR DIMENSIONS AND WEIGHT SPECIFICATIONS (See figure 2-1).
TABLE 2-2. PERFORMANCE SPECIFICATIONS.
TABLE 2-3B. ENGINE SPECIFICATIONS - DETROIT DIESEL.
TABLE 2-4B. FUEL SYSTEM SPECIFICATIONS - DETROIT DIESEL.
TABLE 2-5. ELECTRICAL SPECIFICATIONS.
TABLE 2-6. TRANSMISSION AND TORQUE CONVERTER SPECIFICATIONS.
TABLE 2-7. FINAL DRIVE AND TRANSFER CASE SPECIFICATIONS.
TABLE 2-7. FINAL DRIVE AND TRANSFER CASE SPECIFICATIONS (CONT.).
TABLE 2-8C. STEERING SPECIFICATIONS - DETROIT DIESEL.
TABLE 2-11. TIRE INFLATION SYSTEM SPECIFICATIONS.
TABLE 2-11. TIRE INFLATION SYSTEM SPECIFICATIONS (CONT.)
TABLE 2-11. TIRE INFLATION SYSTEM SPECIFICATIONS (CONT.)
TABLE 2-12. TORQUE SPECIFICATIONS FOR STANDARD HARDWARE.
TABLE 3-1. OPERATING CONTROLS AND INDICATORS.
TABLE 3-1. OPERATING CONTROLS AND INDICATORS (CONT.).
TABLE 3-1. OPERATING CONTROLS AND INDICATORS (CONT.).
FIGURE 3-2. OPERATING CONTROLS AND INDICATORS.
OPERATING THE UNIT
TIRE INFLATION SYSTEM OPERATION.
FIGURE 3-5. BALLASTING INSTRUCTIONS.
FIGURE 4-1. MAINTENANCE CHART.
TABLE 4-1. HYSTER-CARE MAINTENANCE SCHEDULE.
TABLE 4-1. HYSTER-CARE MAINTENANCE SCHEDULE (CONT.).
TABLE 4-1. HYSTER-CARE MAINTENANCE SCHEDULE (CONT.).
SECTION 4. MAINTENANCE
FIGURE 4-3. BATTERY LOCATION.
FIGURE 4-4. DRIVE BELTS.
FIGURE 4-5C. ELECTRICAL SCHEMATIC-DETROIT DIESEL.
FIGURE 4-6. STEERING HYDRAULIC OIL.
FIGURE 4-9. WATER SYSTEM STRAINER.
FIGURE 4-10. REAR CENTER WHEEL SPRING ADJUSTMENT
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE.
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-1 TROUBLE ANALYSIS FOR DETROIT DIESEL ENGINE. - Continued
TABLE 5-2. TROUBLE ANALYSIS FOR DETROIT DIESEL FUEL SYSTEM.
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM.
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM (CONT.).
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM (CONT.).
TABLE 5-3. TROUBLE ANALYSIS FOR ELECTRICAL SYSTEM (CONT.).
TABLE 5-4. TROUBLE ANALYSIS FOR TRANSMISSION & TORQUE CONVERTER.
TABLE 5-4. TROUBLE ANALYSIS FOR TRANSMISSION & TORQUE CONVERTER (CONT.).
TABLE 5-4. TROUBLE ANALYSIS FOR TRANSMISSION & TORQUE CONVERTER (CONT.).
TABLE 5-5. TROUBLE ANALYSIS FOR FINAL DRIVE & TRANSFER CASE (CONT.).
TABLE 5-6. TROUBLE ANALYSIS FOR STEERING SYSTEM.
TABLE 5-6. TROUBLE ANALYSIS FOR STEERING SYSTEM (CONT.).
TABLE 5-6. TROUBLE ANALYSIS FOR STEERING SYSTEM (CONT.).
TABLE 5-7. TROUBLE ANALYSIS FOR BRAKE ASSEMBLY SYSTEM.
TABLE 5-9. TROUBLE ANALYSIS FOR TIRE INFLATION SYSTEM.
TABLE 5-9. TROUBLE ANALYSIS FOR TIRE INFLATION SYSTEM (CONT.).
TABLE 5-9. TROUBLE ANALYSIS FOR TIRE INFLATION SYSTEM (CONT.).
SECTION 6. ELECTRICAL
FIGURE 6-4. ELECTRICAL SCHEMATIC DETROIT DIESEL
FIGURE 6-8. INSTRUMENT PANEL DETROIT DIESEL.
FIGURE 6-6. ELECTRICAL ROUTING DETROIT DIESEL.
SECTION 7. TRANSMISSION
REASSEMBLY OF TORQUE CONVERTER
INSTALLATION OF TORQUE CONVERTER
FIGURE 7-8.
REMOVAL OF TRANSMISSION.
CLUSTER GEAR REMOVAL.
FORWARD CLUTCH CYLINDER DISASSEMBLY
REASSEMBLY OF FORWARD-REVERSE TRANSMISSION
REASSEMBLY OF REVERSE CLUTCH- SHAFT AND PACK.
REASSEMBLY OF FORWARD CLUTCH-SHAFT AND PACK.
INSTALLATION OF IDLER GEAR SHAFT.
INSTALLATION OF CONTROL VALVE.
DISASSEMBLY OF CONTROL VALVE.
INSPECTION AND CLEANING.
PRESSURE CHECKS.
3-SPEED RANGE TRANSMISSION
DISASSEMBLY OF 3-SPEED RANGE TRANSMISSION
CLEANING AND INSPECTION.
REASSEMBLY OF 3-SPEED RANGE TRANSMISSION
REASSEMBLY OF 3-SPEED RANGE TRANSMISSION - Continued
INSTALLATION OF 3-SPEED RANGE TRANSMISSION
DISASSEMBLY OF TRANSFER CASE.
DISASSEMBLY OF TRANSFER CASE - Continued
DISASSEMBLY OF PINION SHAFT.
REASSEMBLY OF TRANSFER BOX.
REASSEMBLY OF PINION SHAFT.
REASSEMBLY OF OUTPUT SHAFT.
FINAL DRIVE
PINION REMOVAL.
DISASSEMBLY OF DIFFERENTIAL.
INSPECTION
REASSEMBLY OF DIFFERENTIAL.
INSTALLATION
DIFFERENTIAL ADJUSTMENT.
WHEEL HUB INSTALLATION.
RIM INSTALLATION.
CHECKING GEAR TEETH CONTACT PATTERN
POWER OPERATION.
MANUAL OPERATION.
DISASSEMBLY OF STEERING CONTROL UNIT
DISASSEMBLY OF STEERING CONTROL UNIT - Continued
DISASSEMBLY OF STEERING CONTROL UNIT - Continued
CLEANING AND INSPECTION.
REASSEMBLY OF STEERING CONTROL UNIT
REASSEMBLY OF STEERING CONTROL UNIT - Continued
REASSEMBLY OF STEERING CONTROL UNIT - Continued
STEERING CYLINDERS
DISASSEMBLY
INSTALLATION
REMOVAL
INSTALLATION
STEERING PUMP
DISASSEMBLY
REASSEMBLY
FLOW DIVIDER
REASSEMBLY AND INSTALLATION
SERVICE BRAKE SYSTEM
MASTER CYLINDER.
OUTSIDE REAR WHEELS
CLEANING AND INSPECTION
DISASSEMBLY OF WHEEL BRAKES
REAR WHEEL HUB INSTALLATION
WHEEL BRAKE CYLINDERS
CLEANING AND INSPECTION
INSTALLATION
CLEANING AND INSPECTION
ADJUSTMENT
PRESSURE SPRAY SYSTEM
FIGURE 11-2. PRESSURE WATER SPRAY SYSTEM.
DISASSEMBLY
FIGURE 12-1.
INTAKE AND COMPRESSION (Loaded)
LUBRICATION
DISASSEMBLY OF CYLINDER HEAD
FIGURE 12-8.
INSPECTION
SECTION 12. TIRE INFLATION SYSTEM
REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK.
REASSEMBLY AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.
CHECKS AND ADJUSTMENTS
PRESSURE REGULATING VALVE
QUICK RELEASE VALVE
PART II. SUPPLEMENTAL OPERATING MAINTENANCE AND REPAIR PARTS INSTRUCTIONS
TABLE OF CONTENTS
TABLE OF CONTENTS (Continued)
GENERAL
Personnel and Training.
Reporting
SECTION II. MAINTENANCE
Equipment Serviceability Criteria (ESC).
Towing The Roller.
SECTION III. REPAIR PARTS SUPPLY
Requisitioning Repair Parts
PUBLICATIONS
APPENDIX B. WARRANTY GUIDELINE
APPENDIX B. WARRANTY GUIDELINE - Continued
APPENDIX C. MAINTENANCE ALLOCATION CHART
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 III - TOOL. AND TEST EQUIPMENT REQUIREMENTS
SECTION III - TOOL. AND TEST EQUIPMENT REQUIREMENTS - Continued
CCE MANUFACTURER FIELD CAMPAIGNS AND MODIFICATION PROCEDURES
BASIC ISSUE ITEMS LIST
INITIAL RECOMMENDATION - PRESCRIBED LOAD LIST (PLL) - AUTHORIZED STOCKAGE LIST (ASL)
ADDITIONAL REPAIR PARTS
ADDITIONAL REPAIR PARTS - Continued
SAMPLE FORMAT - DA FORM 2765 PART NUMBER REQUEST
SAMPLE FORMAT - MILSTRIP REQUISITION FOR (NSN)
SAMPLE FORMAT - MILSTRIP REQUISITION FOR (NON-NSN)
SAMPLE FORMAT - MILSTRIP REQUISITION FOR (NON-NSN) - Continued
SAMPLE FORMAT- MILSTRIP REQUISITION FOR CCE (NON-NSN) (MANUAL)
INSTRUCTIONS
MAINTENANCE AND OPERATING SUPPLY LIST
MAINTENANCE AND OPERATING SUPPLY LIST
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
PART III. PARTS MANUAL
INDEX
UNIT IDENTIFICATION
Section A. INTRODUCTION
How To Use The Illustrated Parts Manual
When The Part Number Is Known
OPERATION AND MAINTENANCE TIPS
Section B. COWLING AND FLOOR PLATE
COWLING AND FLOOR PLATES
HITCH
Section C. POWER UNIT
COOLING SYSTEM
ENGINE MOUNTS AND OIL DRAIN LINE
EXHAUST SYSTEM
Section D. FUEL SYSTEM
AIR FILTER
FUEL SYSTEM
Section E. ELECTRICAL EQUIPMENT
ELECTRICAL SYSTEM
Section G. POWER TRAIN TRANSMISSION
TRANSMISSION
TRANSMISSION CONTROL VALVE
CLUTCH PACK
TRANSMISSION CASE AND REGULATORS
TRANSMISSION OIL FILTER
TRANSFER DRIVE
FORWARD AND REVERSE CONTROL
REAR WHEELS
FINAL DRIVE
TRANSFER DRIVE SHAFT
DRIVE PLATE AND TORQUE CONVERTER HOUSING
Section H. BRAKES AND LINKAGE
BRAKE SYSTEM
BRAKES
MASTER CYLINDER
PARKING BRAKE
PARKING BRAKE LEVER
Section K. STEERING AND LINKAGE
STEERING CONTROL
STEERING CYLINDER
STEERING PUMP
STEERING SYSTEM
Section P. OPTIONAL EQUIPMENT
WATER SPRAY SYSTEM
WATER SPRAY SYSTEM - Continued
TIRE AND WHEEL CHART
TIRE INFLATION SYSTEM
TIRE INFLATION SYSTEM - Continued
AIR COMPRESSOR
ROTATING UNION
LIGHTING-SYSTEM
AIR REGULATOR
Section Q. NUMERICAL INDEX
NUMERICAL INDEX
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
NUMERICAL INDEX - Continued
PART IV. DIESEL ENGINE OPERATOR S MANUAL
TABLE OF CONTENTS
PRINCIPLES OF OPERATION
GENERAL DESCRIPTION
Fig. 2 - In-Line Engine Model Description, Rotation and Accessory Arrangement
Fig. 3 - 6V Engine Model Description, Rotation and Accessory Arrangement
GENERAL SPECIFICATIONS
ENGINE MODEL AND SERIAL NUMBER DESIGNATION
Cross Section Views of a Typical In-Line Engine
Cross Section Views of a Typical 6V-53 Engine
ENGINE SYSTEMS
Fig. 3 - Removing Injector from Cylinder Head
Fig. 4 - Typical Fuel Strainer and Filter Mounting
Fig. 5 - Typical Spin-On Type Fuel Strainer and Fuel Filter Mounting
Fig. 7 - Air Intake System Through Blower and Engine (6V-53 Engine)
Fig. 8 - Light-Duty Oil Bath Air Cleaner
Fig. 11 - Air Cleaner Tray (Clean)
Fig. 12 - United Specialties Dry Type Air Cleaner
Crankcase Ventilation
Fig. 15 - Typical V-Type Engine Oil Filter Mounting
Fig. 16 - Schematic Diagram of Typical In-Line Engine Lubricating System
Fig. 17 - Schematic Diagram of Typical 6V Engine Lubricating System
Fig. 18 - Typical Cooling System for In-Line Engines
Fig. 19 - Typical Cooling System for V-Type Engine
ENGINE COOLING SYSTEM MAINTENANCE
Flushing
Fig. 20 - Raw Water Pump Used on In-Line Engine
Raw Water Pump
SECTION 4. ENGINE EQUIPMENT INSTRUMENT PANEL, INSTRUMENTS AND CONTROLS
Throttle Control
ENGINE PROTECTIVE SYSTEMS
AUTOMATIC ELECTRICAL SHUT-DOWN SYSTEM
Fig. 4 - Automatic Electrical Shut-Down System Incorporating Hot Wire Relay
Fig. 5 - Alarm System Wiring Diagram
STARTING SYSTEMS
Fig. 6 - Schematic Diagram of Hydrostarter System Showing Oil Flow
Fig. 7: Hydrostarter Remote Control System
LUBRICATION AND PREVENTIVE MAINTENANCE
Marine Application
Fig. 8 - Typical Fluid Starting Aid
Fig. 9 - Quick-Start Assembly
POWER TAKE-OFF ASSEMBLIES
Fig. 11 - Checking Clutch Adjustment with a Torque Wrench and Adaptor
WARNER MARINE GEAR
SECTION 5. OPERATING INSTRUCTIONS
Lubrication Fittings
Engine Temperature
STOPPING
Fig. 1 - Location of Controls on Power Generator Set
PREPARING GENERATOR FOR LOAD
PARALLELING
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE
LUBRICATION AND PREVENTIVE MAINTENANCE
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
SECTION 6. LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
FUEL OIL SPECIFICATIONS
LUBRICATING OIL SPECIFICATIONS
NEW ENGINE OIL CLASSlFICATION SYSTEM
SERVICE AND INSPECTION INTERVALS
ENGINE COOLANT
Fig. 2 - Heat Transfer Capacity
Fuel, Oil and Coolant Specifications
Fig. 4 - Coolant Freezing and Boiling Temperatures vs. Antifreeze Concentration (Sea Level)
GENERAL RECOMMENDATIONS
SECTION 7. ENGINE TUNE-UP PROCEDURES
EXHAUST VALVE CLEARANCE ADJUSTMENT
FOUR VALVE CYLINDER HEADS
TIMING FUEL INJECTOR
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
Position Injector Rack Control Levers
Fig. 6 - Governor Spring Assemblies
Adjust Maximum No-load Engine Speed
Fig. 8 - Adjusting Buffer Screw
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
Position Injector Rack Control Lovers
Fig. 5 - Checking Injector Control Rack "Spring"
Adjust Maximum No-load Engine Speed
Adjust Buffer Screw
VARIABLE SPEED MECHANICAL GOVERNOR (OPEN LINKAGE) AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 4 Adjusting Fuel Rod Length
Fig. 6 - Adjusting Idle Speed
Fig. 7 - Adjusting Buffer Screw
VARIABLE SPEED MECHANICAL GOVERNOR (ENCLOSED LINKAGE) AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 4 - Checking Injector Control Rack "Sprint"
Fig. 5 - Locating of Shims and Stops
Fig. 6 Adjusting Idle Speed
Fig. 8 - Adjusting Booster Spring
VARIABLE SPEED MECHANICAL GOVERNOR AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 4 - Checking Rotating Movement of Injector Control Rack
Adjust Maximum No-load Speed
Fig. 7 - Adjusting Idle Speed
Fig. 9 Adjusting Booster Spring
SUPPLEMENTARY GOVERNING DEVICE ADJUSTMENT
Fig. 3 - Throttle Delay Yield Lever (In-Line Engine)
Fig. 5 - Adjusting Throttle Delay Cylinder
ADJUSTMENT OF MECHANICAL GOVERNOR SHUTDOWN SOLENOID
Fig. 7 - Typical Limiting Speed Governor Lever Position
Fig. 1 - Hydraulic Governor Mounted on Engine
Fig. 4 - Adjusting Droop Bracket
Fig. 5 - Adjusting Maximum Engine Speed
Fig. 2 Hydraulic Governor Controls
SECTION 8. TROUBLE SHOOTING
Engine Out of Fuel
Exhaust Back Pressure
Air Box Pressure
PROPER USE OF MANOMETER
SECTION 9. STORAGE
POWER TARE-OFF
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
POWER TAKE-OFF
Built-In Parts Book
Built-In Parts Book - Continued
Built-In Parts Book - Continued
GROUP NOMENCLATURE
STANDARD AND STANDARD OPTION EQUIPMENT
Built-In Parts Book - Continued
Cylinder Head
Connectin Rod, Piston and Liner
Accessory Drive for Belt Driven Accessory (Drive Hub Type)
Valve Operating Mechanism (4 Vave)
Injectors and Controls
Air Shut-Down Housing
Blower Assembly And Drive (4 Cylinder)
Blower Assembly And Drive (6 Cylinder)
Oil Pump and Regulator
Oil Filter
Oil Cooler (6V-53)
Fresh Water Pump
Fan Mount (6V-53)
Fan Mount
hear Exchanger (6V-53)
Tachometer Drive Covers and Adaptors
Air Compressor And Drive
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
PART V. DIESEL ENGINE SERVICE MANUAL
TABLE OF CONTENTS
IMPORTANT SAFETY NOTICE
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
SCOPE AND USE OF THE MANUAL
PRINCIPLES OF OPERATION
GENERAL DESCRIPTION
Fig. 2 In-line Engine Model Description, Rotation, and Accessory Arrangements
Fig. 3-6 and 8V Engine Model Description, Rotation and Accessory Arrangement
Fig. 4 - Cylinder Designation and Firing Order
Fig. 5 Typical Model and Serial Numbers as Stamped on Cylinder Block (In-Line Engine)
INJECTOR HIGH PRESSURE TEST
Fig. 14 - Injector Needle Valve Test with Auxiliary Tester J 22640
Fig. 18 - Setting Comparator Stroke Counter
Fig. 20 - Position of Calibrator Fuel flow Pipes
GENERAL PROCEDURES
Rust Preventive
WORK SAFELY
Cross Section of a Typical In-Line Engine
SECTION 1. ENGINE (less major assemblies)
Fig. 1 - Cylinder Block (Four Cylinder Block Shown)
Fig. 3 - Air and Water Passages in In-Line Cylinder Block
Remove and Disassemble Engine
Fig. 7 - Location of the Four 3/8-16 Bolt Holes in Rear of Cylinder Block
Fig. 9 - Engine Mounted on Overhaul Stand
Fig. 11 - Location of Block Bore Seal Ring Groove
Fig. 14 - Typical Cylinder Block Markings
Inspect Cylinder Block
Assemble and Install Engine
CYLINDER BLOCK END PLATE
CYLINDER BLOCK END PLATE - Continued
AIR BOX DRAINS
Inspection
CYLINDER HEAD
Cylinder Head Maintenance
Fig. 2 - Lifting Cylinder Head Assembly Off Cylinder Block with Tool J 22062-01
Fig. 3 - Checking Bottom Face of Cylinder Head for Warpage
Fig. 5 - Correct Installation of Water Nozzles in Four-Valve Cylinder Head
Fig. 6 - Sequence for Tightening Cylinder Head Bolts
Install Cylinder Mood
VALVE AND INJECTOR OPERATING MECHANISM
Fig. 4 - Testing Push Rod Spring
Fig. 6 - Former and Current Cam Followers
Fig. 7 - Removing or lnstalling Cam Follower Roller and Pin with Tool J 5840
Fig. 10 - Adjusting Cam Follower Guide
Remove and Install Cam Follower Roller and Pin
Fig. 12 - Relationship Between Exhaust Valve Bridge and Valve Stems
Install Rocker Arms and Rocker Arm Shaft
EXHAUST VALVES
Fig. 4 - Cleaning Valve Guide
Inspection
Fig. 6 - Installing Valve Guide
Fig. 8 - Installing Valve Seat Insert
Fig. 9 - Refacing Exhaust Valve
Fig. 12 - Relationship Between Exhaust Valve, Insert and Cylinder Head (Four Valve Head)
Fig. 15 - Former and Current Design Exhaust Valves (Four Valve Head)
Fig. 16 - Checking Valve Opening Pressure with Gage WRE-500-60
Fig. 1 - Typical Valve Rocker Cover Assembly
CRANKSHAFT
Fig. 3 Removing or Installing Crankshaft
Fig. 4 - Typical Ridging of Crankshaft
Inspection for Cracks
Fig. 9 . Crankshaft Journal Fillets
Crankshaft Grinding
Fig. 11 . Checking Crankshaft End Play
Install Crankshaft
CRANKSHAFT OIL SEALS
Fig. 5 . Use of Front Oil Seal Sleeve on Grooved Crankshaft (In-line Engines)
Install Crankshaft Rear Oil Seal
Install Crankshaft Rear Oil Seal - Continued
CRANKSHAFT MAIN BEARINGS
Fig. 5 Removing Upper Rear Main Bearing Shell
Fig. 6 Comparison of Main Bearing Shells
Fig. 7 Main Bearing Measurements
Fig. 9- Crankshaft Thrust Washers in Place
Install Main gearing Shells ( Crankshaft in Place)
ENGINE FRONT COVER (Lower)
Fig. 3 -Installing Lower Engine Front Cover In-Line Engine
CRANKSHAFT PULLEY
Fig. 3 Cone Mounted Pulley
Fig. 1 - Removing Flywheel
Install Flywheel
FLYWHEEL HOUSING
Fig. 3 - Flywheel Housing Bolt Sizes and Tightening Sequence (Operation 1).-ln.Line Engine
Fig. 6 - Flywheel Housing Bolt Tightening Sequence (Operation 2).InLine Engine
fig. 9- Checking Flywheel Housing Concentrtcity
Install Flywheel Housing
PISTON AND PISTON RINGS
Disassemble Piston and Connecting Rod
Fig. 4 Comparison of Pistons
Fig. 6 Location of Joint in Piston Pin Bushings
Fig. 8 - Measuring Piston-to-liner Clearance
Fitting Piston Rings
Install Piston Rings
CONNECTING ROD
Fig. 3 Magnetic Particle Inspection Limits for Connecting Rod
Fig. 4 - Removing or Installing Bushings
Fig. 9 - Installing Piston Pin Retainer
Assemble Connecting Rod to Piston
CONNECTING ROD BEARINGS
Install Connecting Rod Bearing Shells
Fig. 2 Removing Cylinder Liner
Fig. 4 - Checking Bore of Cylinder Liner
Fig. 6 - Cylinder Liner Ridge Due to Wear
Fig. 7 Checking Distance of Liner Flange Below Top Face of Block
Fig. 9 - Cylinder Liner Seal Ring Location in Cylinder Block Bore
Install Cylinder liner, Piston and Connecting Rod Assembly
ENGINE BALANCE AND BALANCE WEIGHTS
Install Front Balance Weights
GEAR TRAIN AND ENGINE TIMING
IN-LINE ENGINE
IN-LINE ENGINE - Continued
ENGINE TIMING
Chock Engine liming
CAMSHAFT, BALANCE SHAFT AND BEARINGS
Fig. 3 Removing End Bearing
Fig. 4 Installing Intermediate Camshaft Bearing
Fig. 6. Location of Notch in Relation to Shaft Bore Centerline
Install Intermediate and/or Center Camshaft Bearings
Fig. 7 Removing and Replacing Camshaft or Balance Shaft Bearings
Fig. 8 Camshaft and Balance Shaft Details and Relative Location of Parts
CAMSHAFT AND BALANCE SHAFT GEARS
Fig. 2 Installing Camshaft Gear
IDLER GEAR AND BEARING ASSEMBLY
Fig, 3 Idler Gear Details and Relative Location of Parts
CRANKSHAFT TIMING GEAR
Install Crankshaft liming Gear
Fig. 1 - Accessory Drive Locations (In-Line Engines)
Fig. 3 Air Compressor Drive
Fig. 5 Components of Accessory Drive for Belt Driven Accessory (Drive Hub Type)
Fig. 8 Location of Oil Seal Spacer
Install Accessory Drive
ENGINE FRONT COVER (Upper)
Install Cover
Fig. 1 Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance
CAMSHAFT CUP PLUG INSTALLATION
TROUBLE SHOOTING
SPECIFICATIONS
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
EXCEPTIONS TO STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
STANDARD PIPE PLUG TORQUE SPECIFICATIONS
SERVICE TOOLS
SERVICE TOOLS - Continued
SECTION 2. FUEL SYSTEM AND GOVERNORS CONTENTS
Fig. 1 Typical Fuel System for In-Lime Engines
FUEL INJECTOR (NEEDLE VALVE)
Fig. 3. Fuel Metering from No-Load to Full. Loead
Fig. 7- Removing Injector from Cylinder Head
Fig. 8 Checking Rack and Plunger for Free Movement
Fig. 11. Removing Injector Follower Stop Pin
INJECTOR CONTROL RACK AND PLUNGER MOVEMENT TEST
INJECTOR HIGH PRESSURE TEST
Fig. 14 lnjector Needle Valve Test with Auxiliary Tester J 22640
NEEDLE VALVE TESTS
Fig. 20 Position of Calibrator Fuel Flow Pipes
Fig. 22 - Setting Calibrator Stroke Counter
Fig. 25 - Removing Injector Nut
Fig 28 - Cleaning Spray Tip Orifices
Fig. 30 - Cleaning Injector Nut Spray Tip Seat
Fig. 34 - Location of Filter In lnjector Body
Fig. 35 - Details of Injector Filters and Caps and Their Relative Location
Fig. 38 - Comparison of Former and New Design Injector Parts
Lapping Injector Parts
Fig. 42 - Checking Injector Spray Tip Concentricity
Fig. 43 - Relationship Between Exhaust Valve Bridge and Valve Stems
Test Reconditioned Injector
FUEL INJECTOR TUBE
Fig. 3 Upsetting Infector Tube
Fig. 5 - Reaming Injector Tube for Injector Nut
Fig. 1 Typical Fuel Pump Assembly
Fig. 2 Fuel Pump Valving and Rotation (Right Hand Pump Shown)
Fig. 4 - Removing Oil Seals
Fig. 5 - Fuel Pump Details and Relative Location of Parts (Right Hand Pump Shown)
Fig. 7 - Installing Outer Oil Seal
FUEL PUMP DRIVE
MECHANICAL GOVERNORS
LIMITING SPEED MECHANICAL GOVERNOR
Remove Governor from Engine
Disassemble Governor Weight Housing
Assemble Governor Cover
Fig. 5 - Governor Housings and Relative. Location of Parts
Install Governor
Install Governor - Continued
SHOP NOTES-TROUBLE SHOOTING-SPECIFICATIONS-SERVICE TOOLS
INJECTOR TIMING
INJECTOR COMPARATOR AND CALIBRATOR READINGS
REPLACING INJECTOR FOLLOWER SPRING
LOCATING AIR LEAKS IN FUEL LINES
TROUBLE SHOOTING CHARTS (Needle Valve Injectors)
Trouble Shooting (Needle Valve Injectors)
Trouble Shooting (Needle Valve Injectors) - Continued
FUEL PUMP MAINTENANCE
SPECIFICATIONS
SERVICE TOOLS
SECTION 3. AIR INTAKE SYSTEM
Fig. 1 - Air Silencer Mounted on In-Line Engine
AIR SHUT-DOWN HOUSING
Fig. 2 - Installing Air Shut-Off Valve Spring and Valve
Install Air Shut-Down Housing (In-Line Engines)
BLOWER
Fig. 5 - Removing Blower Rotor Gears
Disassemble Blower
Fig. 7 - Typical Blower Details and Relative Location of Parts (3.53 Engine Blower)
Fig. 11 - Installing Blower Housing Over Rotors
Fig. 12 - Installing Rear End Plate
Fig. 15 - Minimum Blower Rotor Clearance
Fig. 16 - Measuring Rotor Lobe to End Plate Clearance
Fig. 17 Inserting Cam in Blower Drive Support
ENGINE BLOWER
SHOP NOTES - TROUBLE SHOOTING - SPECIFICATIONS - SERVICE TOOLS - SHOP NOTES
Fig. 4 - End Plate Oil Drain Back Counterbore
SPECIFICATIONS
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SERVICE TOOLS
SECTION 4. LUBRICATION SYSTEM
Fig. 1 - Schematic Diagram of Typical In-Line Engine Lubrication System
IN-LINE ENGINES
IN-LINE ENGINES - Continued
LUBRICATING OIL PUMP
Fig. 3 - Measuring Rotor Clearance
Fig. 5 - Lubricating Oil Pump Details and Relative Location of Parts (Current)
Fig. 8 - Installing Oil Pump Drive Gear
Install Oil Pump
LUBRICATING OIL PRESSURE REGULATOR
LUBRICATING OIL COOLER
Fig. 3 - oil Cooler Details and Relative Location of Parts (In-Line Engine)
Clean Oil Cooler Core
Install Oil Cooler Core
Fig. 1 - Typical oil Dipstick Mounting
Fig. 1 - Typical oil Pan
Fig. 1 - Typical Crankcase Breather Mounting (In-line Engine)
Service
SPECIFICATIONS - SERVICE TOOLS
SPECIFICATIONS
SECTION 5. COOLING SYSTEM
WATER P U M P
Fig. 4 - Removing Shaft from Impeller with Tools J 8329 and ,J 358-1
Fig. 6 Fresh Water Pump Details and Relative Location of Parts
Fig. 7- Comparison of Water Pumps
THERMOSTAT
Install Thermostat
Fig. 5 Bleed Hole in Thermostat Housing
ENGINE COOLING FAN
Fig. 3 - Removing Fan Hub (Pulley)
Fig. 5 Current Fan Hub Assembly (In-Line Engine)
Fig. 8 - Typical Fan Hub and Adjusting Bracket Details and Relative Location of Parts (In-Line Engine)
IN-LINE ENGINES (CURRENT)
IN-LINE ENGINES (CURRENT) - Continued
WATER FILTER AND CONDITIONER
Service
STANDARD BOLT AND NUT TORQUE SPECIFICATIONS
SECTION 6. EXHAUST SYSTEM
EXHAUST MANIFOLD (AIR COOLED)
Install Exhaust Manifold
SECTION 7. ELECTRICAL EQUIPMENT, INSTRUMENTS AND PROTECTIVE SYSTEMS
BATTERY - CHARGING GENERATOR (D.C. and A.C.)
Fig. 2 - 30 DN Type 100 A.C. Self-Rectifying Generator (Alternator)
Install Generator
Fig. 4-20. DN Type 250 AC Self-Rectifying Generator (Alternator)
BATTERY-CHARGING GENERATOR REGULATOR
TRANSISTORIZED AND TRANSISTOR REGULATORS
TRANSISTOR REGULATOR
Fig. 5 - Transistor Regulator with Plug-ln Connecttons
STARTING MOTOR
Fig. 2 Cross-Section of Motor with Intermediate-Duty Clutch
Flywheel Ring Gears
TROUBLESHOOTING - SPECIFICATIONS - SERVICE TOOLS
CHECKING ENGINE ELECTRICAL GENERATING SYSTEM
SERVICE TOOLS
SECTION 13. OPERATING INSTRUCTIONS
ENGINE OPERATING INSTRUCTIONS
Lubrication Fittings
Warm-Up
Avoid Unnecessary Engine Idling
ENGINE OPERATING CONDITIONS
3-ENGINE (4-Valve Cylinder Head)
3-ENGINE (4-Valve Cylinder Head) - Continued
ENGINE RUN-IN INSTRUCTIONS
Instrumentation
BASIC RUN-IN INSPECTION
ENGINE TEST REPORT
INSPECTION AFTER FINAL RUN-IN
DETROIT DIESEL FUEL OIL SPECIFICATIONS
DETROIT DIESEL LUBRICATING OIL SPECIFICATIONS
ENGINE COOLANT
Fuel, Oil and Coolant Specifications
COOLANT INHIBITOR CHART
ANTIFREEZE
COOLANT RECOMMENDATIONS
SECTION 14. ENGINE TUNE-UP
Tune-Up Sequence for Mechanical Governor
EXHAUST VALVE CLEARANCE ADJUSTMENT
ENGINES WITH FOUR VALVE CYLINDER HEADS
FUEL INJECTOR TIMING
LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK CONTROL ADJUSTMENT
Fig. 2 - Positioning the Rear Injector Rack Control Lever
Fig. 4 - Governor Spring Assemblies
Fig. 5 - Adjusting Engine Idle Speed
SECTION 15. PREVENTIVE MAINTENANCE - TROUBLE SHOOTING - STORAGE
LUBRICATION AND PREVENTIVE MAINTENANCE
LUBRICATION AND PREVENTIVE MAINTENANCE CHART
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
LUBRICATION AND PREVENTIVE MAINTENANCE - Continued
TROUBLE S H O O T I N G
Fuel Flow Test
Exhaust Back Pressure
Fig. 2 - Comparison of Column Height for Mercury and Water Manometers
Trouble Shooting (Engine)
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
Trouble Shooting (Engine) - Continued
STORAGE
EXTENDED STORAGE (30 days or more)
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE
PART VI. DIESEL ENGINE PARTS MANUAL
GENERAL INFORMATION
INDEX
INDEX - Continued
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
ALPHABETICAL INDEX - Continued
GROUP NOMENCLATURE
MODEL DESCRIPTION CHART IN-LINE ENGINES
FIG. 1B INLINE 53 CYLINDER BLOCK (with end plate)
FIG. 2A. CYLIDER HEAD
FIGURE 3A. CRANKSHAFT (3-53)
FIG. 4D. LOWER FRONT COVER AND OIL PUMP
FIG. 5A FLYWHEEL AND FLYWHEEL HOUSING (In-Line Models)
FIG. 6A CONNECTING ROD, PISTON AND LINER
FIG. 7A. CRANKSHAFT
FIG. 7F. IDLER GEAR
FIG. 8A ACCESSORY DRIVE (Double Belt)
FIG. 9C. VALVE AND ROCKER BRIDGE
ROCKER COVER
TYPICAL 4 CYLINDER FAN TO FLYWHEEL INDUSTRIAL UNIT
BLOCK ASSY., CYLINDER
BLOCK CYLINDER
HEAD ASSY. CYLINDER
TUBE, INJECTOR HOLE
HEAD ASSEMBLY, CYLINDER
CRANKSHAFT ASSY.
SHELL, CRANKSHAFT MAIN BEARING
COVER, ENGINE FRONT-LOWER
FLYWHEEL
HOUSING, FLYWHEEL
CONNECTING ROD ASSY.
PISTON ASSY.
CYLINDER KIT
CAMSHAFT ASSY.
WEIGHT, REAR BALANCER
ADAPTOR, ACCESSORY DRIVE
ARM ASSY. EXHAUST VALVE
BRACKET, ROCKER SHAFT
VALVE, EXHAUST
GASKET, ROCKER COVER
GROUP NOMENCLATURE
FIG. 1B FUEL INJECTOR
FIG 2A. FUEL PUMP
FIGURE 3B. FUEL FILTER (CANISTER TYPE ELEMENT)
FIG. 4A TYPICAL FUEL SYSTEM (In-line Engine)
FIG. 5D MECHANICAL GOVERNOR HOUSING WEIGHTS AND LEVER (Closed Linkage)
FIG. 5G LIMITING SPEED GOVERNOR SPRING AND HOUSING
FIG. 5H MECHANICAL GOVERNOR COVER (Double Lever)
FIG. 5L GOVERNOR WEIGHT SHAFT AND CARRIER
FIG. 7A INJECTOR CONTROL TUBE (Inline Engine)
INJECTOR ASSY.
SPRING, INJECTOR PLUNGER
RETAINER, INJECTOR GEAR
PUMP ASSY., FUEL
SEAL, FUEL PUMP OIL
GASKET, FUEL PUMP TO ENGINE
SPRING, FUEL PUMP VALVE RETAINING
STRAINER ASSY., FUEL
PLUG, FUEL STRAINER COVER
GASKET, FUEL FILTER COVER TO SHELL
PIPE, FUEL
TUBE, STRAINER TO FUEL PUMP
GOVERNOR ASSY.
LEVER, GOVERNOR COVER THROTTLE SHAFT
LEVER, GOV. OPERATING SHAFT
SPRING, GOVERNOR LOW SPEED
SCREW ASSY., GOV. BUFFER
SEAL, GOVERNOR
RETAINER, GOVERNOR SHUTDOWN SHAFT PACKING
SUPPORT, GOVERNOR WEIGHT SHAFT BEARING
BRACKET, INJECTOR CONTROL TUBE
CLIP, GOVERNOR CONTROL WIRE TUBE
GROUP NOMENCLATURE
FIG. 3B. BLOWER AND AIR INLET HOUSING
FIG. 4A. 3-53. BLOWER
HOUSING ASST., AIR INLET
WIRE, AIR INLET HOUSING SHUTDOWN
BLOWER ASSY.
SCREEN, BLOWER
SEAL, BLOWER HOUSING END PLATE
GROUP NOMENCLATURE
FIG. 1A. OIL PUMP AND PRESSURE REGULATOR (INLINE ENGINE)
FIG. 2A. OIL DISTRIBUTION SYSTEM
FIG. 3A. OIL FILTER
FIG. 4C. OIL COOLER
FIG. 6A. DIPSTICK
FIG. 7B OIL PAN (STAMPED)
FIG. 8A BREATHER AND OIL FILLER
PUMP ASSY., OIL
VALVE, OIL PRESSURE REGULATOR
FILTER ASSY., OIL
GASKET, OIL FILTER COVER NUT
GASKET, OIL FILTER TUBE ADAPTOR
CORE ASSY., OIL COOLER
CAP, OIL FILLER TUBE
DIPSTICK
PAN, OIL
PIPE, BREATHER
GROUP NOMENCLATURE
FIG. 1A TYPICAL COOLING SYSTEM (Inline Engines)
FIG. 2A FRESH WATER PUMP
PUMP ASSY., FRESH WATER
GASKET, FRESH WATER PUMP BODY COVER
ELBOW, WATER OUTLET
HOSE, WATER BY-PASS TUBE
ELBOW, OIL COOLER WATER OUTLET
BLADE, FAN
SEAL, FAN SHAFT
GROUP NOMENCLATURE
FIG. 1A EXHAUST MANIFOLD (Center Outlet)
MANIFOLD, EXHAUST
FLANGE, EXHAUST
GROUP NOMENCLATURE
FIG. 1A BATTERY CHARGING GENERATOR
GENERATOR ASSY.
B-PACKET, GENERATOR MOUNTING
MOTOR ASSY. STARTING