Technical Manual For Roller, Motorized, Vibrating Tandem Steel Drums - 1

CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
FIELD MAINTENANCE
PREPARATION FOR STORAGE OR SHIPMENT
WARRANTY INFORMATION
Table 1. List of Abbreviations/Acronyms.
Table 1. - List of Abbreviations/Acronyms - Continued.
Table 1. - List of Abbreviations/Acronyms - Continued.
EQUIPMENT DESCRIPTION AND DATA
Figure 1. Location and Description of Major Components.
Table 1. Location and Description of Major Components - Continued.
Table 3. General.
Table 5. Refill Capacities.
Table 7. Vibratory System.
THEORY OF OPERATION
ENGINE SYSTEM
Figure 1. Engine System.
FUEL SYSTEM
Figure 2. Fuel System.
COOLING SYSTEM
Figure 3. Cooling System.
ELECTRICAL SYSTEM
Figure 4. Electrical System.
ELECTRICAL SYSTEM - Continued
ELECTRICAL SYSTEM - Continued
PROPEL SYSTEM
Figure 6. Propel System.
HYDRAULIC STEERING SYSTEM
Figure 7. Hydraulic Steering System.
VIBRATORY SYSTEM
Figure 8. Vibratory System.
WATER SPRAY SYSTEM
Figure 9. Water Spray System.
CHAPTER 2. TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INTRODUCTION
EXPLANATION OF TROUBLESHOOTING PROCEDURES
Figure 1. Electrical Schematic. (Page 1 of 6)
Figure 2. Electrical Schematic. (Page 2 of 6)
Figure 3. Electrical Schematic. (Page 3 of 6)
Figure 4. Electrical Schematic. (Page 4 of 6)
Figure 5. Electrical Schematic. (Page 5 of 6)
Figure 6. Electrical Schematic. (Page 6 of 6)
TROUBLESHOOTING SYMPTOM INDEX
TROUBLESHOOTING SYMPTOM INDEX - Continued
TROUBLESHOOTING SYMPTOM INDEX - Continued
COOLANT IN ENGINE OIL/ENGINE OIL IN COOLANT
TROUBLESHOOTING PROCEDURE
TROUBLESHOOTING PROCEDURE - Continued
ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START
ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START - Continued
Figure 1. Fuel Shutoff Valves.
ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START - Continued
Figure 2. Fuel Filter Drain Valve.
Figure 3. Fuel Lines.
Figure 4. Fuel Lift Pump.
ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START - Continued
Figure 5. Engine Cold Start Heater.
ENGINE CRANKS BUT WILL NOT START OR IS HARD TO START - Continued
Figure 6. Engine Cold Start Heater.
Figure 7. Engine Cold Start Heater.
Figure 8. Engine Cold Start Heater.
ENGINE EXHAUST SMOKES EXCESSIVELY (BLACK OR GRAY SMOKE)
ENGINE EXHAUST SMOKES EXCESSIVELY (BLACK OR GRAY SMOKE) - Continued
Figure 1. Engine Cold Start Heater.
Figure 2. Engine Cold Start Heater.
ENGINE EXHAUST SMOKES EXCESSIVELY (BLACK OR GRAY SMOKE) - Continued
ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE)
ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE) - Continued
Figure 2. Engine Cold Start Heater.
ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE) - Continued
Figure 3. Engine Cold Start Heater.
Figure 4. Engine Cold Start Heater.
ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE) - Continued
ENGINE IS SLUGGISH
ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE) - Continued
Figure 1. Fuel Filter Drain Valve.
ENGINE EXHAUST SMOKES EXCESSIVELY (WHITE OR BLUE SMOKE) - Continued
Figure 3. Throttle Cable.
Figure 4. Turbocharger.
ENGINE IS UNUSUALLY NOISY
Figure 1. Engine Fan Assembly.
Figure 2. Turbocharger.
ENGINE IS UNUSUALLY NOISY - Continued
Figure 3. Fuel Lines.
ENGINE IS USING MORE FUEL THAN USUAL
Figure 1. Engine Air Intake System.
Figure 2. Turbocharger
Figure 3. Turbocharger
ENGINE IS USING MORE OIL THAN USUAL
ENGINE MISFIRES OR IDLES ROUGH
ENGINE MISFIRES OR IDLES ROUGH - Continued
Figure 1. Fuel Filter Drain Valve.
Figure 2. Fuel Lines
ENGINE MISFIRES OR IDLES ROUGH - Continued
Figure 3. Fuel Lift Pump
ENGINE OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)
ENGINE OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON) - Continued
Figure 1. Engine Oil Level Check.
ENGINE OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON) - Continued
Figure 2. Oil Pressure Switch.
Figure 3. Engine Oil Level Check.
Figure 4. Fuel Lift Pump
ENGINE OPERATING TEMPERATURE IS TOO HIGH (WARNING LIGHT AND WARNING HORN ON)
ENGINE OPERATING TEMPERATURE IS TOO HIGH (WARNING LIGHT AND WARNING HORN ON) - Continued
Figure 1. Radiator Cap Assembly.
Figure 2. Radiator Cap Assembly.
Figure 3. Engine Fan Assembly.
Figure 4. Engine Fan Assembly.
Figure 5. Water Pump.
ENGINE OPERATING TEMPERATURE IS TOO HIGH (WARNING LIGHT AND WARNING HORN ON) - Continued
Figure 6. Engine Oil Cooler Lines.
ENGINE STARTS BUT WILL NOT KEEP RUNNING
Figure 1. Fuel Filter Drain Valve.
Figure 2. Fuel Lines
ENGINE STARTS BUT WILL NOT KEEP RUNNING - Continued
Figure 3. Fuel Lift Pump.
ENGINE SURGES (SPEED CHANGES)
ENGINE SURGES (SPEED CHANGES) - Continued
Figure 1. Fuel Lines.
ENGINE VIBRATES EXCESSIVELY
Figure 1. Engine Mounts.
Figure 2. Fuel Lines.
ENGINE WILL NOT STOP RUNNING
Figure 1. Engine Start Switch.
OIL LEAKING FROM EXHAUST
OIL LEAKING FROM EXHAUST - Continued
Figure 1. Turbocharger.
THROTTLE CONTROL WILL NOT CHANGE ENGINE SPEED (CB534B)
THROTTLE CONTROL WILL NOT CHANGE ENGINE SPEED (CB534B) - Continued
Figure 1. Throttle Control Cable.
ALTERNATOR INDICATOR IS ON
ALTERNATOR INDICATOR IS ON - Continued
Figure 1. Engine Fan Assembly.
Figure 2. Engine Fan Assembly.
Figure 3. Alternator Wiring.
Figure 4. Batteries and Battery Cables.
Figure 5. Batteries and Battery Cables.
Figure 6. Battery Disconnect Switch Wiring.
ALTERNATOR IS NOISY
ALTERNATOR IS NOISY - Continued
Figure 2. Engine Fan Assembly.
BACKUP ALARM DOES NOT WORK
BACKUP ALARM DOES NOT WORK - Continued
Figure 1. Backup Alarm Sending Unit Wiring.
Figure 2. Backup Alarm Wiring.
Figure 3. Backup Alarm Wiring.
FEET PER MINUTE (FPM) METER DOES NOT WORK (CB534C)
FEET PER MINUTE (FPM) METER DOES NOT WORK (CB534C) - Continued
Figure 1. Feet Per Minute (FPM) Meter Wiring.
FUEL GAUGE DOES NOT WORK
Figure 1. Fuel Level Sending Unit Wiring.
FUEL GAUGE DOES NOT WORK - Continued
FUEL GAUGE DOES NOT WORK - Continued
Figure 2. Fuel Gauge Wiring.
HORN DOES NOT WORK
HORN DOES NOT WORK - Continued
Figure 1. Horn Wiring.
Figure 2. Horn Switch Wiring.
Figure 3. Horn Switch Wiring.
NO POWER TO ACCESSORIES WITH THE ENGINE RUNNING
Figure 1. Main Relay Wiring.
Figure 2. Main Relay Wiring.
Figure 3. Main Relay Wiring.
Figure 4. Engine Start Switch Wiring.
Figure 5. Engine Start Switch Wiring.
ROLLER HAS NO ELECTRICAL POWER
ROLLER HAS NO ELECTRICAL POWER - Continued
Figure 1. Batteries.
Figure 2. Battery Cable Connections at Starter.
Figure 3. Battery Disconnect Switch Wiring.
Figure 4. Alternator Circuit Breaker Wiring.
Figure 5. Alternator Circuit Breaker Wiring.
Figure 6. Main Relay Wiring.
Figure 7. Main Relay Wiring.
Figure 8. Main Relay Wiring.
Figure 9. Engine Start Switch Wiring.
Figure 10. Engine Start Switch Wiring.
STARTER CONTINUES TO RUN AFTER ENGINE START SWITCH KEY IS RELEASED
STARTER CONTINUES TO RUN AFTER ENGINE START SWITCH KEY IS RELEASED - Continued
Figure 1. Starter Relay Wiring.
Figure 2. Starter Relay Wiring.
STARTER DOES NOT TURN OR TURNS SLOWLY
STARTER DOES NOT TURN OR TURNS SLOWLY - Continued
Figure 1. Battery Cable Connections at Starter.
Figure 2. Batteries and Battery Cables.
Figure 3. Battery Cable Connections at Starter.
STARTER DOES NOT TURN OR TURNS SLOWLY - Continued
Figure 4. Battery Cable Connections at Starter.
STARTER DOES NOT TURN OR TURNS SLOWLY - Continued
Figure 5. Starter Relay Wiring.
Figure 6. Starter Relay Wiring.
Figure 7. Starter Relay Wiring.
STARTER DOES NOT TURN OR TURNS SLOWLY - Continued
Figure 8. Neutral Start Relay No. 1 Wiring.
Figure 9. Starter Relay Wiring.
Figure 10. Neutral Start Relay No. 1 Wiring.
Figure 11. Neutral Start Relay No. 1 Wiring.
Figure 12. Engine Start Switch Wiring.
Figure 13. Engine Start Switch Wiring.
STARTER TURNS, BUT DOES NOT CRANK ENGINE
STARTING AID SWITCH DOES NOT WORK
TROUBLESHOOTING PROCEDURE
Figure 1. Starting Aid Switch Wiring.
Figure 2. Starting Aid Switch Wiring.
VIBRATIONS PER MINUTE (VPM) TACHOMETER DOES NOT WORK
Figure 1. Vibration Sensor Wiring.
Figure 2. Vibrator Sensor Wiring.
VIBRATIONS PER MINUTE (VPM) TACHOMETER DOES NOT WORK - Continued
Figure 3. Vibration Per Minute (VPM) Meter Wiring.
WARNING AND INDICATOR LIGHTS DO NOT OPERATE
WARNING AND INDICATOR LIGHTS DO NOT OPERATE - Continued
Figure 2. Functional Indicator and Warning Light Assemblies.
Table 2. Continuity Checks.
Figure 3. Functional Indicator and Warning Light Assemblies.
Figure 4. Functional Indicator and Warning Light Assembly Wiring.
Figure 5. Functional Light Relay Wiring.
Figure 6. Functional Light Relay Wiring.
Figure 7. Functional Light Relay Wiring.
Figure 8. Warning Light Relay Wiring.
Figure 9. Warning Light Relay Wiring.
Figure 10. Warning Light Relay Wiring.
Figure 11. Hourmeter Wiring.
Figure 12. Hourmeter Wiring.
Figure 13. Warning Alarm Diodes.
Figure 14. Warning Alarm Diodes.
WORK LIGHTS AND GAUGE LIGHTS DO NOT OPERATE
WORK LIGHTS AND GAUGE LIGHTS DO NOT OPERATE - Continued
Figure 1. Light Circuit Breaker Wiring.
Figure 2. Light Circuit Breaker Wiring.
Figure 3. Work Light Control Switch Wiring.
HYDRAULIC OIL PRESSURE IS LOW (WARNING LIGHT AND WARNING HORN ON)
Figure 1. Hydraulic Oil Filter Indicator.
HYDRAULIC OIL TEMPERATURE IS HIGH (WARNING LIGHT AND WARNING HORN ON)
Figure 1. Hydraulic Oil Filter Indicator.
Figure 2. Engine Fan Assembly.
POWER STEERING PUMP MAKES NOISE AND STEERING CYLINDER RODS DO NOT MOVE SMOOTHLY
Figure 1. Power Steering Pump.
ROLLER DOES NOT TURN WHEN STEERING WHEEL IS TURNED
Figure 1. Power Steering Pump.
ROLLER TURNS SLOWLY IN BOTH DIRECTIONS
Figure 1. Power Steering Pump.
TOO MUCH FORCE IS NEEDED TO TURN STEERING WHEEL
Figure 1. Power Steering Pump.
PARKING BRAKE DOES NOT DISENGAGE WHEN PARKING BRAKE SWITCH IS PULLED UP
PARKING BRAKE DOES NOT DISENGAGE WHEN PARKING BRAKE SWITCH IS PULLED UP - Continued
Figure 1. Parking Brake Solenoid Wiring.
Figure 2. Parking Brake Solenoid Wiring.
Figure 3. Parking Brake Switch Wiring.
Figure 4. Parking Brake Switch Wiring.
Figure 5. Brake Relay No. 1 Wiring.
Figure 6. Brake Relay 1 Wiring.
Figure 7. Brake Relay No. 1 Wiring.
PARKING BRAKE DOES NOT ENGAGE WHEN PARKING BRAKE SWITCH IS PUSHED DOWN
PARKING BRAKE DOES NOT ENGAGE WHEN PARKING BRAKE SWITCH IS PUSHED DOWN - Continued
Figure 1. Parking Brake Switch Wiring.
PROPEL MOTOR IS NOISY
PROPEL MOTOR LEAKS OIL
PROPEL SYSTEM DOES NOT CHANGE SPEEDS WHEN PROPEL SPEED SWITCH IS MOVED
PROPEL SYSTEM DOES NOT CHANGE SPEEDS WHEN PROPEL SPEED SWITCH IS MOVED - Continued
Figure 1. Shift Solenoid Wiring.
Figure 2. Shift Solenoid Wiring.
Figure 3. Propel Speed Switch Wiring.
Figure 4. Propel Speed Switch Wiring.
PROPEL SYSTEM ENGAGES VERY QUICKLY WHEN MAKING A SHIFT
Figure 1. Hydraulic Oil Filter Indicator.
PROPEL SYSTEM ENGAGES VERY SLOWLY WHEN MAKING A SHIFT
Figure 1. Hydraulic Oil Filter Indicator.
PROPEL SYSTEM OPERATES IN FORWARD SPEEDS ONLY
PROPEL SYSTEM OPERATES IN REVERSE SPEEDS ONLY
ROLLER WILL NOT MOVE WHEN PROPEL CONTROL LEVER IS OPERATED
Figure 1. Hydraulic Oil Filter Indicator.
NOISY VIBRATORY MOTOR
VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO HIGH PITCH
VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO HIGH PITCH - Continued
Figure 1. High Amplitude Solenoid Wiring.
Figure 2. Amplitude Select Switch Wiring.
Figure 3. Amplitude Select Switch Wiring.
VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO LOW PITCH
VIBRATION DOES NOT OCCUR WHILE AMPLITUDE SELECT SWITCH IS SET TO LOW PITCH - Continued
Figure 1. Low Amplitude Solenoid Wiring.
Figure 2. Amplitude Select Switch Wiring.
Figure 3. Amplitude Select Switch Wiring.
VIBRATION DOES NOT STOP WHEN TRAVEL STOPS
VIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVEL
VIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVEL - Continued
Figure 1. Rear Drum Solenoid Wiring.
Figure 2. Vibration Push Switch Wiring.
Figure 3. Vibration Push Switch Wiring.
Figure 4. Drum Select Switch Wiring.
VIBRATION DOES NOT WORK IN FORWARD OR REVERSE TRAVEL - Continued
Figure 5. Vibration Control Switch Wiring.
Figure 6. Vibration Control Switch Wiring.
Figure 7. Amplitude Select Switch Wiring.
Figure 8. Amplitude Select Switch Wiring.
VIBRATION FREQUENCY START-UP IS SLOW, TIME LAG AFTER TRAVEL STARTS IS EXCESSIVE
VIBRATION OCCURS IN ONLY ONE DRUM
VIBRATION OCCURS IN ONLY ONE DRUM - Continued
Figure 1. Drum Solenoid Wiring.
Figure 2. Drum Select Switch Wiring.
Figure 3. Drum Select Switch Wiring.
VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO AUTOMATIC MODE
VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO AUTOMATIC MODE - Continued
Figure 1. Vibration Control Switch Wiring.
Figure 2. Vibration Control Switch Wiring.
VIBRATION ONLY OCCURS WHILE VIBRATION CONTROL SWITCH IS SET TO MANUAL MODE
Figure 1. Vibration Control Switch Wiring.
Figure 2. Vibration Control Switch Wiring.
Figure 3. Amplitude Select Switch Wiring.
Figure 4. Amplitude Select Switch Wiring.
VIBRATION STOPS TOO SOON BEFORE TRAVEL STOPS
VIBRATORY SYSTEM ENGAGES HARSHLY
NO SPRAY AT EITHER DRUM WHEN WATER SPRAY SWITCH IS IN INTERMITTENT SPRAY POSITION
Figure 1. Water Spray Switch Wiring.
Figure 2. Water Spray Switch Wiring.
Figure 3. Intermittent Water Spray Timer Wiring.
Figure 4. Front And Rear Intermittent Relay Wiring.
Figure 5. Water Spray Pump Connector Wiring.
NOZZLE SPRAY PATTERN IS INCONSISTENT
SPRAY DOES NOT OCCUR IN EITHER DRUM WHEN WATER SPRAY SWITCH IS IN CONTINUOUS SPRAY POSITION
Figure 1. Water Spray Switch Wiring.
Figure 2. Water Spray Switch Wiring.
Figure 3. Water Spray Pump Connector Wiring.
WATER CONSUMPTION UNEQUAL BETWEEN TANKS
Figure 1. Water Spray System Water Lines.
Figure 2. Water Spray Pump Test.
WATER SPRAY OCCURS ON ONE DRUM ONLY
WATER SPRAY OCCURS ON ONE DRUM ONLY - Continued
Figure 1. Water Spray Pump Connector Wiring.
Figure 2. Water Spray System Waterlines.
WATER SPRAY PRESSURE IS LOW
Figure 1. Water Spray System Water Lines.
Figure 2. Water Spray Pump Test.
CHAPTER 3. PREVENTIVE MAINTENANCE INSTRUCTIONS
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES
LUBRICATION ORDER
LUBRICATION ORDER - Continued
Figure 1. Lubrication Chart.
LUBRICATION ORDER - Continued
LUBRICATION ORDER - Continued
LUBRICATION ORDER - Continued
LUBRICATION ORDER - Continued
LUBRICATION ORDER - Continued
LUBRICATION ORDER - Continued
LUBRICATION ORDER - Continued
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (QUARTERLY)
Table 1. Preventive Maintenance Checks and Services (PMCS) (Quarterly) for CB534 Roller.
Table 1. Preventive Maintenance Checks and Services (PMCS) (Quarterly) for CB534 Roller - Continued
Figure 1. Fan Belts.
Table 1. Preventive Maintenance Checks and Services (PMCS) (Quarterly) for CB534 Roller - Continued
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (ANNUAL)
Figure 1. Platform.
Table 1. Preventive Maintenance Checks and Services (PMCS) (Annual) for CB534 Roller - Continued.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (BIENNIAL)
PMCS Mandatory Replacement Parts List
CHAPTER 4. MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
INSPECTION INSTRUCTIONS - Continued
ENGINE, TURBO, DIESEL TESTS
CYLINDER COMPRESSION TEST - Continued
ENGINE OIL SERVICE
DRAIN/FILTER REMOVAL
Figure 1. Engine Oil Drain.
Figure 2. Engine Oil Filter Removal.
Figure 3. Engine Oil Filter Installation.
Figure 4. Engine Oil Fill
ENGINE ASSEMBLY REPLACEMENT
Figure 1. Engine Assembly Removal.
Figure 2. Engine Assembly Removal
Figure 3. Engine Assembly Removal.
Figure 4. Engine Assembly Removal
Figure 6. Engine Assembly Removal.
Figure 8. Engine Assembly Removal
Figure 10. Engine Assembly Removal.
Figure 12. Engine Assembly Removal.
Figure 13. Engine Assembly Removal.
Figure 14. Engine Assembly Removal.
Figure 16. Engine Assembly Removal.
Figure 17. Engine Assembly Removal.
Figure 19. Engine Assembly Removal.
Figure 20. Engine Assembly Removal.
Figure 22. Engine Assembly Removal.
Figure 23. Engine Assembly Removal.
Figure 24. Engine Assembly Installation.
Figure 25. Engine Assembly Installation.
Figure 27. Engine Assembly Installation.
Figure 28. Engine Assembly Installation.
Figure 29. Engine Assembly Installation.
Figure 31. Engine Assembly Installation.
Figure 33. Engine Assembly Installation.
Figure 34. Engine Assembly Installation.
Figure 36. Engine Assembly Installation.
Figure 38. Engine Assembly Installation.
Figure 40. Engine Assembly Installation.
Figure 42. Engine Assembly Installation.
Figure 44. Engine Assembly Installation.
Figure 45. Engine Assembly Installation.
FOLLOW-ON MAINTENANCE
ENGINE LIFTING PLATES REPLACEMENT
Figure 1. Engine Lifting Plates Removal.
Figure 2. Engine Lifting Plates Removal
Figure 3. Engine Lifting Plates Installation.
Figure 4. Engine Lifting Plates Installation.
FRONT ENGINE MOUNT REPLACEMENT
Figure 1. Front Engine Mount Removal.
Figure 2. Front Engine Mount Removal.
FRONT ENGINE MOUNT REPLACEMENT - Continued
Figure 3. Front Engine Mount Removal.
FRONT ENGINE MOUNT REPLACEMENT - Continued
Figure 4. Front Engine Mount Installation.
Figure 6. Front Engine Mount Installation.
REAR ENGINE MOUNT REPLACEMENT
Figure 1. Rear Engine Mount Removal.
Figure 2. Rear Engine Mount Removal
Figure 3. Rear Engine Mount Removal.
Figure 5. Rear Engine Mount Removal
Figure 6. Rear Engine Mount Installation.
Figure 7. Rear Engine Mount Installation.
Figure 9. Rear Engine Mount Installation.
REAR ENGINE MOUNT REPLACEMENT - Continued
CYLINDER HEAD REPLACEMENT
Figure 1. Cylinder Head Removal
Figure 2. Cylinder Head Removal
Figure 4. Cylinder Head Cleaning and Inspection
Figure 5. Cylinder Head Installation
Figure 7. Cylinder Head Installation
CYLINDER HEAD REPLACEMENT - Continued
CRANKSHAFT PULLEY REPLACEMENT
Figure 1. Crankshaft Pulley Removal.
Figure 2. Crankshaft Pulley Installation
CRANKSHAFT FRONT OIL SEAL REPLACEMENT
Figure 2. Crankshaft Front Oil Seal Installation.
CRANKSHAFT REAR OIL SEAL REPLACEMENT
Figure 1. Crankshaft Rear Oil Seal Removal.
Figure 2. Crankshaft Rear Oil Seal Installation
Figure 4. Crankshaft Rear Oil Seal Installation
FLYWHEEL ASSEMBLY REPLACEMENT
Figure 1. Flywheel Assembly Removal.
Figure 2. Flywheel Assembly Removal.
Figure 4. Flywheel Assembly Installation.
Figure 5. Flywheel Assembly Installation.
FLYWHEEL ASSEMBLY REPLACEMENT - Continued
FLYWHEEL HOUSING REPLACEMENT
Figure 1. Flywheel Housing Removal.
Figure 2. Flywheel Housing Removal
Figure 3. Flywheel Housing Installation.
Figure 4. Flywheel Housing Installation.
VALVE LASH (CLEARANCE) ADJUSTMENT
VALVE LASH (CLEARANCE) ADJUSTMENT - Continued
ROCKER SHAFT ASSEMBLY REPLACEMENT
Figure 1. Rocker Shaft Assembly Removal.
Figure 2. Rocker Shaft Assembly Installation.
ROCKER ARM ASSEMBLY REPAIR
Figure 1. Rocker Arm Disassembly.
Figure 2. Rocker Arm Assembly.
IDLER GEAR AND HUB REPLACEMENT
Figure 1. Idler Gear and Hub Removal.
Figure 3. Idler Gear and Hub Removal
Figure 4. Idler Gear and Hub Installation.
Figure 5. Idler Gear and Hub Installation.
Figure 6. Idler Gear and Hub Installation.
TIMING GEAR CASE COVER REPLACEMENT
Figure 2. Timing Gear Case Cover Installation.
Figure 4. Timing Gear Cover Installation.
OIL PAN REPLACEMENT
Figure 1. Oil Pan Removal.
Figure 2. Oil Pan Removal.
Figure 3. Oil Pan Installation
Figure 4. Oil Pan Installation
ENGINE OIL PUMP REPLACEMENT
Figure 1. Engine Oil Pump Removal.
Figure 2. Engine Oil Pump Installation.
ENGINE OIL COOLER REPLACEMENT
Figure 1. Engine Oil Cooler Removal.
Figure 1. Engine Oil Cooler Removal - Continued
Figure 2. Engine Oil Cooler Installation
ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534B)
Figure 2. Engine Oil Cooler Lines and Fittings Removal.
Figure 3. Engine Oil Cooler Lines and Fittings Removal.
Figure 4. Engine Oil Cooler Lines and Fittings Installation.
Figure 5. Engine Oil Cooler Lines and Fittings Installation.
Figure 7. Engine Oil Cooler Lines and Fittings Installation.
ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534B) - Continued
ENGINE OIL COOLER LINES AND FITTINGS REPLACEMENT (CB534C)
Figure 1. Engine Oil Cooler Lines and Fittings Removal.
Figure 2. Engine Oil Cooler Lines and Fittings Removal.
Figure 4. Engine Oil Cooler Lines and Fittings Removal.
Figure 6. Engine Oil Cooler Lines and Fittings Installation.
Figure 8. Engine Oil Cooler Lines and Fittings Installation.
ENGINE OIL SAMPLING VALVE AND FITTINGS REPLACEMENT
Figure 1. Engine Oil Sampling Valve and Fittings Removal
Figure 2. Engine Oil Sampling Valve and Fittings Removal.
Figure 4. Engine Oil Sampling Valve and Fittings Installation
GAUGE ROD (DIPSTICK) TUBE ASSEMBLY REPLACEMENT
Figure 1. Gauge Rod (Dipstick) Tube Assembly Removal.
Figure 2. Gauge Rod (Dipstick) Tube Assembly Installation.
ENGINE OIL FILLER REPLACEMENT
Figure 2. Engine Oil Filler Removal.
Figure 3. Engine Oil Filler Installation
ENGINE OIL FILLER REPLACEMENT - Continued
VALVE COVER AND BREATHER TUBE REPLACEMENT
Figure 1. Valve Cover and Breather Tube Removal.
Figure 2. Valve Cover and Breather Tube Removal.
Figure 3. Valve Cover and Breather Tube Removal.
Figure 4. Valve Cover and Breather Tube Installation.
Figure 5. Valve Cover and Breather Tube Installation.
Figure 6. Valve Cover and Breather Tube Installation.
OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534B)
Figure 1. Oil Filter Head Assembly Removal.
Figure 2. Oil Filter Head Assembly Installation
OIL FILTER HEAD ASSEMBLY REPLACEMENT (CB534C)
Figure 1. Oil Filter Head Assembly Removal.
Figure 2. Oil Filter Head Assembly Installation
OIL STRAINER AND SUCTION TUBE REPLACEMENT
Figure 2. Oil Strainer and Suction Tube Removal.
Figure 3. Oil Strainer and Suction Tube Installation.
OIL STRAINER AND SUCTION TUBE REPLACEMENT - Continued
INTAKE MANIFOLD REPLACEMENT
Figure 2. Intake Manifold Removal.
Figure 3. Intake Manifold Removal
Figure 4. Intake Manifold Installation.
Figure 5. Intake Manifold Installation
INTAKE MANIFOLD REPLACEMENT - Continued
EXHAUST MANIFOLD REPLACEMENT (CB534B)
Figure 2. Exhaust Manifold Installation.
EXHAUST MANIFOLD REPLACEMENT (CB534C)
Figure 2. Exhaust Manifold Installation.
FUEL INJECTOR AND NOZZLE TEST
Figure 1. Fuel Injector and Nozzle Test.
FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534B)
Figure 2. Fuel Injector and Nozzle Removal.
Figure 3. Fuel Injector and Nozzle Installation
FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534B) - Continued
FUEL INJECTOR AND NOZZLE REPLACEMENT (CB534C)
Figure 1. Fuel Injector and Nozzle Removal.
Figure 2. Fuel Injector and Nozzle Installation
Figure 3. Fuel Injector and Nozzle Installation.
FUEL INJECTION PUMP GEAR REPLACEMENT
Figure 1. Fuel Injection Pump Gear Removal.
Figure 2. Fuel Injection Pump Gear Installation
Figure 3. Fuel Injection Pump Gear Removal.
Figure 5. Fuel Injection Pump Gear Installation
FUEL INJECTION PUMP REPLACEMENT
Figure 1. Fuel Injection Pump Removal.
Figure 2. Fuel Injection Pump Installation
FUEL INJECTION PUMP TEST AND ADJUSTMENT (CB534B)
FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534B)
FUEL LINES AND FITTINGS REMOVAL
Figure 1. Fuel Lines and Fittings Removal.
FUEL LINES AND FITTINGS INSTALLATION
Figure 2. Fuel Lines and Fittings Installation
Figure 3. Fuel Injector Lines and Fittings Removal.
Figure 4. Fuel Injector Lines and Fittings Installation.
FUEL INJECTOR LINES AND FITTINGS REPLACEMENT (CB534C)
FUEL LINES AND FITTINGS REMOVAL
Figure 1. Fuel Lines and Fittings Removal.
FUEL LINES AND FITTINGS INSTALLATION
Figure 2. Fuel Lines and Fittings Installation
FUEL INJECTOR LINES AND FITTINGS REMOVAL
Figure 3. Fuel Injector Lines and Fittings Removal
Figure 4. Fuel Injector Lines and Fittings Installation.
FUEL INJECTOR LINES AND FITTINGS INSTALLATION - Continued
FUEL LIFT PUMP REPLACEMENT
Figure 1. Fuel Lift Pump Removal.
Figure 2. Fuel Lift Pump Removal
FUEL LIFT PUMP REPLACEMENT - Continued
Figure 3. Fuel Lift Pump Removal
FUEL LIFT PUMP REPLACEMENT - Continued
Figure 4. Fuel Lift Pump Installation
Figure 6. Fuel Lift Pump Installation.
AIR CLEANER CAP REPLACEMENT
Figure 1. Air Cleaner Removal.
Figure 2. Air Cleaner Installation
AIR CLEANER ELEMENTS AND AIR CLEANER ASSEMBLY REPLACEMENT
Figure 1. Air Cleaner Elements and Air Cleaner Assembly Removal
Figure 2. Air Cleaner Elements and Air Cleaner Assembly Removal.
Figure 4. Air Cleaner Elements and Air Cleaner Assembly Removal
Figure 5. Air Cleaner Elements and Air Cleaner Assembly Removal
Figure 6. Air Cleaner and Air Cleaner Assembly Installation
Figure 7. Air Cleaner Elements and Air Cleaner Assembly Installation
Figure 9. Air Cleaner Elements and Air Cleaner Assembly Installation
AIR CLEANER ELEMENTS AND AIR CLEANER ASSEMBLY REPLACEMENT - Continued
AIR CLEANER SUPPORT ASSEMBLY REPLACEMENT
Figure 2. Air Cleaner Support Assembly Removal.
Figure 3. Air Cleaner Support Assembly Removal.
Figure 5. Air Cleaner Support Assembly Removal.
Figure 7. Air Cleaner Support Assembly Installation.
Figure 9. Air Cleaner Support Assembly Installation.
Figure 10. Air Cleaner Support Assembly Installation
AIR CLEANER SERVICE INDICATOR REPLACEMENT
Figure 2. Air Cleaner Service Indicator Removal
Figure 4. Air Cleaner Service Indicator Installation.
TURBOCHARGER REPLACEMENT
Figure 1. Turbocharger Removal.
Figure 2. Turbocharger Removal
Figure 4. Turbocharger Removal.
Figure 5. Turbocharger Installation
Figure 6. Turbocharger Installation
Figure 7. Turbocharger Installation
TURBOCHARGER REPLACEMENT
TURBOCHARGER REPAIR
Figure 2. Turbocharger Disassembly.
Figure 3. Turbocharger Assembly
TURBOCHARGER REPAIR - Continued
TURBOCHARGER OIL LINES, HOSES, AND FITTINGS REPLACEMENT
Figure 1. Turbocharger Oil Lines, Hoses, and Fittings Removal
Figure 3. Turbocharger Oil Lines, Hoses, and Fittings Removal.
Figure 4. Turbocharger Oil Lines, Hoses, and Fittings Installation
Figure 5. Turbocharger Oil Lines, Hoses, and Fittings Installation
TURBOCHARGER OIL LINES, HOSES, AND FITTINGS REPLACEMENT - Continued
FUEL/HYDRAULIC OIL TANK DRAIN/FILL
Figure 1. Fuel Tank Drain.
Figure 2. Hydraulic Oil Tank Drain
Figure 3. Hydraulic Oil Tank Fill.
Figure 4. Fuel Tank Fill.
FUEL/HYDRAULIC OIL TANK AND DRAIN LINES REPLACEMENT
Figure 1. Drain Lines Removal.
Figure 2. Drain Lines Removal.
Figure 3. Drain Lines Removal.
Figure 4. Fuel/Hydraulic Oil Tank Removal.
Figure 6. Fuel/Hydraulic Oil Tank Removal.
Figure 8. Fuel/Hydraulic Oil Tank Removal.
Figure 9. Fuel/Hydraulic Oil Tank Removal.
Figure 11. Fuel/Hydraulic Oil Tank Removal
Figure 12. Fuel/Hydraulic Oil Tank Removal.
Figure 14. Fuel/Hydraulic Oil Tank Removal
Figure 16. Fuel/Hydraulic Oil Tank Removal.
Figure 17. Fuel/Hydraulic Oil Tank Removal
Figure 19. Fuel/Hydraulic Oil Tank Removal.
Figure 20. Fuel/Hydraulic Oil Tank Installation.
Figure 22. Fuel/Hydraulic Oil Tank Installation.
Figure 23. Fuel/Hydraulic Oil Tank Installation.
Figure 25. Fuel/Hydraulic Oil Tank Installation.
Figure 26. Fuel/Hydraulic Oil Tank Installation.
Figure 28. Fuel/Hydraulic Oil Tank Installation
Figure 29. Fuel/Hydraulic Oil Tank Installation.
Figure 30. Fuel/Hydraulic Oil Tank Installation.
Figure 31. Fuel/Hydraulic Oil Tank Installation.
Figure 33. Fuel/Hydraulic Oil Tank Installation.
Figure 35. Fuel/Hydraulic Oil Tank Installation.
Figure 36. Drain Lines Installation
Figure 37. Drain Lines Installation
AIR CLEANER SUPPORT ASSEMBLY REPLACEMENT - Continued
FUEL CAP ASSEMBLY REPAIR
Figure 1. Fuel Cap Assembly Removal.
Figure 2. Fuel Cap Disassembly.
FUEL CAP ASSEMBLY REPAIR - Continued
Figure 3. Fuel Cap Assembly.
Figure 4. Fuel Cap Assembly Installation.
FUEL FILTER ASSEMBLY REPLACEMENT
FUEL FILTER ELEMENT REMOVAL
Figure 1. Fuel Filter Assembly Removal.
Figure 2. Fuel Filter Assembly Installation.
Figure 3. Fuel Filter Assembly Installation.
FUEL FILTER ASSEMBLY REMOVAL
Figure 4. Fuel Filter Assembly Removal.
Figure 5. Fuel Filter Assembly Removal.
Figure 7. Fuel Filter Assembly Removal.
Figure 8. Fuel Filter Assembly Disassembly.
Figure 9. Fuel Filter Assembly Inspection
Figure 10. Fuel Filter Assembly Assembly.
Figure 11. Fuel Filter Assembly Installation
Figure 13. Fuel Filter Assembly Installation.
Figure 14. Fuel Filter Assembly Installation
FUEL FILTER ASSEMBLY INSTALLATION - Continued
PRIMING FUEL SYSTEM
PRIMING FUEL SYSTEM - Continued
Figure 1. Priming Fuel System.
Figure 2. Priming Fuel System.
Figure 3. Priming Fuel System.
PRIMING FUEL SYSTEM - Continued
FUEL/WATER SEPARATOR ASSEMBLY SERVICE
Figure 1. Fuel/Water Separator Element Removal.
Figure 2. Fuel/Water Separator Element Removal
Figure 3. Fuel/Water Separator Element Installation.
Figure 4. Fuel/Water Separator Element Installation.
Figure 5. Fuel/Water Separator Element Installation.
Figure 6. Fuel/Water Separator Assembly Removal
Figure 7. Fuel/Water Separator Assembly Removal
Figure 8. Fuel/Water Separator Assembly Removal
Figure 10. Fuel/Water Separator Disassembly.
Figure 11. Fuel/Water Separator Disassembly
Figure 12. Fuel/Water Separator Assembly
Figure 13. Fuel/Water Separator Assembly
Figure 14. Fuel/Water Separator Assembly
Figure 16. Fuel/Water Separator Assembly Installation.
FUEL/WATER SEPARATOR ASSEMBLY INSTALLATION - Continued
COLD START HEATER REPLACEMENT
Figure 1. Cold Start Heater Removal.
Figure 2. Cold Start Heater Removal
Figure 4. Cold Start Heater Installation.
THROTTLE CABLE REPLACEMENT/ADJUSTMENT (CB534B)
Figure 1. Throttle Cable Removal.
Figure 2. Throttle Cable Removal
Figure 4. Throttle Cable Removal.
Figure 6. Throttle Cable Removal
Figure 7. Throttle Cable Removal.
Figure 9. Throttle Cable Removal
Figure 10. Throttle Cable Installation.
Figure 11. Throttle Cable Installation
Figure 12. Throttle Cable Installation.
Figure 14. Throttle Cable Installation
Figure 15. Throttle Cable Installation.
Figure 17. Throttle Cable Installation
ADJUSTMENT
Figure 18. Throttle Cable Adjustment
Figure 20. Throttle Cable Adjustment.
LOW IDLE SPEED ADJUSTMENT
Figure 1. Low Idle Speed Adjustment.
Figure 2. Low Idle Speed Adjustment
LOW IDLE SPEED ADJUSTMENT - Continued
THROTTLE CONTROL REPLACEMENT (CB534C)
Figure 1. Throttle Control Removal.
Figure 2. Throttle Control Installation
Figure 3. Throttle Control Adjustment
THROTTLE CONTROL REPLACEMENT (CB534C) - Continued
MUFFLER AND TAILPIPE REPLACEMENT
Figure 1. Muffler and Tailpipe Removal.
Figure 2. Muffler and Tailpipe Removal.
Figure 4. Muffler and Tailpipe Removal.
Figure 6. Muffler and Tailpipe Installation
Figure 7. Muffler and Tailpipe Installation.
Figure 8. Muffler and Tailpipe Installation
COOLANT SYSTEM PRESSURE TEST
COOLANT SYSTEM PRESSURE TEST - Continued
Figure 1. Coolant System Pressure Test
RADIATOR ASSEMBLY REPLACEMENT
Figure 1. Radiator Assembly Removal.
Figure 2. Radiator Assembly Removal.
RADIATOR ASSEMBLY REPLACEMENT - Continued
Figure 3. Radiator Assembly Installation.
Figure 4. Radiator Assembly Installation.
RADIATOR ASSEMBLY REPLACEMENT - Continued
RADIATOR ASSEMBLY REPAIR
RADIATOR HOSES REPLACEMENT
Figure 1. Radiator Hoses Removal.
Figure 2. Radiator Hoses Installation
COOLANT SYSTEM SERVICE
COOLANT SYSTEM SERVICE - Continued
Figure 1. Coolant System Check
Figure 2. Coolant System Drain.
Figure 3. Coolant System Drain.
Figure 4. Coolant System Fill.
THERMOSTAT MAINTENANCE (CB534B)
Figure 1. Thermostat Removal.
Figure 2. Thermostat Installation
THERMOSTAT MAINTENANCE (CB534C)
Figure 1. Thermostat Removal.
Figure 2. Thermostat Installation.
THERMOSTAT MAINTENANCE (CB534C) - Continued
THERMOSTAT HOUSING REPLACEMENT (CB534B)
Figure 1. Thermostat Housing Removal.
Figure 2. Thermostat Housing Removal.
Figure 3. Thermostat Housing Removal.
Figure 4. Thermostat Housing Installation.
Figure 5. Thermostat Housing Installation.
Figure 6. Thermostat Housing Installation.
THERMOSTAT HOUSING REPLACEMENT (CB534C)
Figure 1. Thermostat Housing Removal.
Figure 2. Thermostat Housing Installation.
THERMOSTAT HOUSING REPLACEMENT (CB534C) - Continued
WATER PUMP REPLACEMENT
Figure 1. Water Pump Removal.
Figure 3. Water Pump Removal.
Figure 5. Water Pump Removal.
Figure 6. Water Pump Installation
Figure 7. Water Pump Installation.
Figure 9. Water Pump Installation
WATER PUMP REPLACEMENT - Continued
FAN DRIVE HOUSING ASSEMBLY REPLACEMENT
Figure 2. Fan Drive Housing Assembly Installation.
FAN ASSEMBLY AND GUARD REPLACEMENT
Figure 1. Fan Assembly and Guard Removal.
Figure 2. Fan Assembly and Guard Removal.
Figure 3. Fan Assembly and Guard Removal.
Figure 4. Fan Assembly and Guard Installation
Figure 6. Fan Assembly and Guard Installation
FAN V-BELTS MAINTENANCE
Figure 1. Fan V-Belts Removal
Figure 2. Fan V-Belts Installation
Figure 3. Fan V-Belts Adjustment.
FAN V-BELTS MAINTENANCE - Continued
ALTERNATOR REPLACEMENT
Figure 2. Alternator Removal
Figure 3. Alternator Removal
Figure 4. Alternator Installation
Figure 5. Alternator Installation
ALTERNATOR REPLACEMENT - Continued
ALTERNATOR TEST
ALTERNATOR TEST - Continued
ALTERNATOR BRACKET REPLACEMENT
Figure 2. Alternator Bracket Removal.
Figure 4. Alternator Bracket Installation.
ALTERNATOR CIRCUIT BREAKER REPLACEMENT
Figure 1. Alternator Circuit Breaker Removal.
Figure 2. Alternator Circuit Breaker Installation.
STARTER REPLACEMENT
Figure 1. Starter Removal.
Figure 2. Starter Removal.
Figure 3. Starter Removal.
Figure 4. Starter Removal.
Figure 5. Starter Installation
Figure 6. Starter Installation
Figure 7. Starter Installation
Figure 8. Starter Installation
STARTER RELAY SWITCH ASSEMBLY REPLACEMENT
Figure 1. Starter Relay Switch Removal.
Figure 3. Starter Relay Switch Installation.
Figure 4. Starter Relay Switch Installation.
MAIN RELAY REPLACEMENT
Figure 1. Main Relay Removal.
Figure 2. Main Relay Removal.
Figure 4. Main Relay Installation
RELAY REPLACEMENT
Figure 1. Relay Removal.
Table 1. Wire and Relay Connections (CB534B)
Figure 2. Relay Removal.
Table 2. Wire and Relay Connections (CB534C)
Figure 3. Relay Removal.
Figure 4. Relay Removal
Figure 5. Relay Installation.
Figure 6. Relay Installation.
PARKING BRAKE SWITCH REPLACEMENT
Figure 1. Parking Brake Switch Removal.
Figure 2. Parking Brake Switch Removal.
Figure 3. Parking Brake Switch Removal.
Figure 4. Parking Brake Switch Installation.
Figure 6. Parking Brake Switch Installation.
WATER SPRAY SWITCH REPLACEMENT
Figure 2. Water Spray Switch Removal.
Figure 3. Water Spray Switch Removal.
Figure 5. Water Spray Switch Installation.
Figure 6. Water Spray Switch Installation
DRUM SELECT SWITCH REPLACEMENT
Figure 2. Drum Select Switch Removal.
Figure 3. Drum Select Switch Removal
Figure 5. Drum Select Switch Installation.
Figure 6. Drum Select Switch Installation.
VIBRATION CONTROL SWITCH REPLACEMENT
Figure 1. Vibration Control Switch Removal
Figure 2. Vibration Control Switch Removal
Figure 4. Vibration Control Switch Installation.
Figure 6. Vibration Control Switch Installation
AMPLITUDE SELECT SWITCH REPLACEMENT
Figure 1. Amplitude Select Switch Removal.
Figure 2. Amplitude Select Switch Removal.
Figure 4. Amplitude Select Switch Installation.
Figure 6. Amplitude Select Switch Installation.
PROPEL SPEED RANGE SWITCH REPLACEMENT
Figure 1. Propel Speed Range Switch Removal.
Figure 2. Propel Speed Range Switch Removal
Figure 3. Propel Speed Range Switch Removal.
Figure 5. Propel Speed Range Switch Installation.
Figure 6. Propel Speed Range Switch Installation.
WORK LIGHT CONTROL SWITCH REPLACEMENT
Figure 2. Work Light Control Switch Removal.
Figure 3. Work Light Control Switch Installation.
Figure 4. Work Light Control Switch Installation.
INTERMITTENT WATER SPRAY TIMER REPLACEMENT
Figure 1. Intermittent Water Spray Timer Removal
Figure 2. Intermittent Water Spray Timer Removal
Figure 3. Intermittent Water Spray Timer Installation.
INTERMITTENT WATER SPRAY TIMER REPLACEMENT - Continued
FUSE AND FUSE HOLDER REPLACEMENT
Figure 2. Fuse and Fuse Holder Removal.
Figure 3. Fuse and Fuse Holder Removal.
Figure 5. Fuse and Fuse Holder Installation.
Figure 6. Fuse and Fuse Holder Installation.
STARTING AID SWITCH REPLACEMENT
Figure 1. Starting Aid Switch Removal.
Figure 2. Starting Aid Switch Removal.
Figure 3. Starting Aid Switch Installation.
Figure 4. Starting Aid Switch Installation.
ENGINE START SWITCH REPLACEMENT
Figure 1. Engine Start Switch Removal.
Figure 2. Engine Start Switch Removal.
Figure 4. Engine Start Switch Installation.
Figure 5. Engine Start Switch Installation.
ENGINE START SWITCH REPLACEMENT - Continued
VIBRATION PUSH SWITCH REPLACEMENT
Figure 1. Vibration Push Switch Removal.
Figure 2. Vibration Push Switch Removal.
Figure 3. Vibration Push Switch Installation.
Figure 4. Vibration Push Switch Installation.
FUEL LEVEL GAUGE REPLACEMENT
Figure 1. Fuel Level Gauge Removal.
Figure 2. Fuel Level Gauge Removal
Figure 4. Fuel Level Gauge Removal.
Figure 5. Fuel Level Gauge Removal
Figure 7. Fuel Level Gauge Installation.
Figure 9. Fuel Level Gauge Installation.
Figure 10. Fuel Level Gauge Installation
SERVICE METER REPLACEMENT
Figure 1. Service Meter Removal.
Figure 2. Service Meter Removal
Figure 4. Service Meter Installation.
Figure 6. Service Meter Installation.
VIBRATIONS PER MINUTE (VPM) TACHOMETER AND FEET PER MINUTE (FPM) METER REPLACEMENT
Figure 1. VPM Tachometer and FPM Meter Removal
Figure 2. VPM Tachometer and FPM Meter Removal
Figure 4. VPM Tachometer and FPM Meter Removal
Figure 5. VPM Tachometer and FPM Meter Removal
Figure 6. VPM Tachometer and FPM Meter Removal
Figure 7. VPM Tachometer and FPM Meter Installation.
Figure 8. VPM Tachometer and FPM Meter Installation.
Figure 9. VPM Tachometer and FPM Meter Installation.
Figure 11. VPM Tachometer and FPM Meter Installation.
HOURMETER PRESSURE SWITCH REPLACEMENT
Figure 1. Hourmeter Pressure Switch Removal.
Figure 2. Hourmeter Pressure Switch Installation.
ENGINE OIL PRESSURE SWITCH REPLACEMENT
Figure 1. Oil Pressure Switch Removal.
Figure 2. Oil Pressure Switch Installation.
LIGHTS CIRCUIT BREAKER REPLACEMENT
Figure 2. Lights Circuit Breaker Removal.
Figure 3. Lights Circuit Breaker Installation.
LIGHTS CIRCUIT BREAKER REPLACEMENT - Continued
STARTING AID RESISTOR REPLACEMENT
Figure 2. Starting Aid Resistor Removal.
Figure 3. Starting Aid Resistor Installation.
STARTING AID RESISTOR REPLACEMENT - Continued
FUEL SOLENOID RESISTOR REPLACEMENT
Figure 2. Fuel Solenoid Resistor Removal.
Figure 3. Fuel Solenoid Resistor Installation
FUEL SOLENOID RESISTOR REPLACEMENT - Continued
ALTERNATOR LIGHT REPLACEMENT
Figure 2. Alternator Light Removal.
Figure 3. Alternator Light Removal
Figure 5. Alternator Light Installation.
Figure 6. Alternator Light Installation
Figure 8. Alternator Light Installation.
FUNCTIONAL INDICATOR LIGHT ASSEMBLY REPLACEMENT
Figure 1. Functional Indicator Light Removal
Figure 2. Functional Indicator Light Removal
Figure 4. Functional Indicator Light Installation.
Figure 5. Functional Indicator Light Installation
Figure 6. Functional Indicator Light Installation.
WORK LIGHT ASSEMBLY MAINTENANCE
Figure 2. Work Light Removal.
Figure 3. Work Light Removal.
Figure 5. Work Light Installation
Figure 6. Work Light Installation
Figure 8. Work Light Adjustment
WORK LIGHT BULB REPLACEMENT
Figure 2. Work Light Bulb Removal.
Figure 3. Work Light Bulb Installation
WORK LIGHT BULB REPLACEMENT - Continued
WARNING LIGHTS ASSEMBLY REPLACEMENT
Figure 1. Warning Light Removal.
Figure 2. Warning Light Removal
Figure 4. Warning Light Installation.
Figure 5. Warning Light Installation
Figure 6. Warning Light Installation.
BACKUP ALARM SENDING UNIT REPLACEMENT
Figure 2. Backup Alarm Sending Unit Removal.
Figure 4. Backup Alarm Sending Unit Installation.
WATER TEMPERATURE SENDING UNIT REPLACEMENT
Figure 1. Water Temperature Sending Unit Removal
Figure 2. Water Temperature Sending Unit Installation.
FUEL LEVEL SENDING UNIT REPLACEMENT
Figure 1. Fuel Level Sending Unit Removal.
Figure 2. Fuel Level Sending Unit Installation.
VIBRATION SENSOR MAINTENANCE
Figure 1. Vibration Sensor Removal.
Figure 2. Vibration Sensor Installation.
Figure 3. Vibration Sensor Adjustment
HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT
Figure 1. Temperature Sensor Removal
Figure 2. Temperature Sensor Installation
WARNING HORN ASSEMBLY REPLACEMENT
Figure 2. Warning Horn Removal.
Figure 3. Warning Horn Installation
BACKUP ALARM REPLACEMENT
Figure 1. Backup Alarm Removal
Figure 2. Backup Alarm Removal
Figure 3. Backup Alarm Installation.
Figure 4. Backup Alarm Installation
HORN SWITCH REPLACEMENT
Figure 2. Horn Switch Removal.
Figure 3. Horn Switch Installation
HORN SWITCH REPLACEMENT - Continued
HORN ASSEMBLY REPLACEMENT
Figure 1. Horn Removal.
Figure 2. Horn Removal
Figure 3. Horn Installation.
Figure 4. Horn Installation.
BATTERY MAINTENANCE
BATTERY MAINTENANCE - Continued
Figure 1. Battery Inspection.
Figure 2. Battery Removal.
Figure 3. Battery Removal
Figure 4. Battery Installation.
Figure 5. Battery Installation.
BATTERY DISCONNECT SWITCH REPLACEMENT
Figure 1. Battery Disconnect Switch Removal.
Figure 2. Battery Disconnect Switch Removal
Figure 3. Battery Disconnect Switch Installation
Figure 4. Battery Disconnect Switch Installation.
BATTERY CABLE REPLACEMENT
BATTERY CABLE REPLACEMENT - Continued
Figure 1. Battery Cable Removal
Figure 3. Battery Cable Removal.
Figure 4. Battery Cable Removal
Figure 5. Battery Cable Removal.
Figure 6. Battery Cable Removal
Figure 7. Battery Cable Installation.
Figure 9. Battery Cable Installation
Figure 10. Battery Cable Installation
Figure 11. Battery Cable Installation
Figure 12. Battery Cable Installation
Figure 13. Battery Cable Installation
BATTERY CABLE REPLACEMENT - Continued
NATO CONNECTOR REPLACEMENT
NATO CONNECTOR REPLACEMENT - Continued
Figure 1. NATO Connector Removal
Figure 2. NATO Connector Removal.
Figure 3. NATO Connector Installation
Figure 4. NATO Connector Installation.
GROUND CABLE REPLACEMENT
Figure 1. Ground Cable Removal
GROUND CABLE REPLACEMENT - Continued
Figure 2. Ground Cable Installation.
GENERAL WIRING REPAIR
Figure 1. Solderless Terminal Replacement.
Figure 2. Wire Splicing Using Butt Connectors.
WIRE SPLICING USING SOLDER METHOD
Figure 3. Wire Splicing Using Solder Method.
Figure 4. Wire Splicing Using Solder Method.
Figure 5. Male Cable Connector Replacement
Figure 6. Female Cable Connector Replacement.
Figure 7. Wiring Repair.
Figure 9. Wiring Repair
Figure 10. Wiring Repair
GROUP II TERMINAL DISASSEMBLY
GROUP II TERMINAL DISASSEMBLY - Continued
GROUP II TERMINAL ASSEMBLY
GROUP II TERMINAL ASSEMBLY - Continued
GENERAL WIRING REPAIR - Continued
ENGINE WIRING HARNESS REPLACEMENT
ENGINE WIRING HARNESS REPLACEMENT - Continued
Figure 1. Engine Wiring Harness Removal
Figure 2. Engine Wiring Harness Removal.
Figure 4. Engine Wiring Harness Removal
Figure 6. Engine Wiring Harness Removal.
Figure 8. Engine Wiring Harness Removal
Figure 10. Engine Wiring Harness Removal.
Figure 12. Engine Wiring Harness Removal.
Figure 14. Engine Wiring Harness Removal.
Figure 16. Engine Wiring Harness Removal.
Figure 18. Engine Wiring Harness Installation.
Figure 20. Engine Wiring Harness Installation.
Figure 23. Engine Wiring Harness Installation.
Figure 25. Engine Wiring Harness Installation.
Figure 27. Engine Wiring Harness Installation.
Figure 29. Engine Wiring Harness Installation.
Figure 31. Engine Wiring Harness Installation.
Figure 33. Engine Wiring Harness Installation.
Figure 34. Engine Wiring Harness Installation.
ENGINE WIRING HARNESS REPLACEMENT - Continued
FRONT WIRING HARNESS REPLACEMENT
Figure 1. Front Wiring Harness Removal
Figure 2. Front Wiring Harness Removal.
Figure 4. Front Wiring Harness Removal
Figure 6. Front Wiring Harness Removal.
Figure 8. Front Wiring Harness Removal
Figure 10. Front Wiring Harness Removal.
Figure 11. Front Wiring Harness Removal.
Figure 12. Front Wiring Harness Installation
Figure 14. Front Wiring Harness Installation.
Figure 16. Front Wiring Harness Installation
Figure 18. Front Wiring Harness Installation.
Figure 20. Front Wiring Harness Installation
Figure 22. Front Wiring Harness Installation.
REAR WIRING HARNESS REPLACEMENT
Figure 1. Rear Wiring Harness Removal.
Figure 2. Rear Wiring Harness Removal.
Figure 4. Rear Wiring Harness Removal.
Figure 6. Rear Wiring Harness Removal.
Figure 7. Rear Wiring Harness Removal.
Figure 8. Rear Wiring Harness Removal.
Figure 10. Rear Wiring Harness Removal.
Figure 11. Rear Wiring Harness Removal
Figure 12. Rear Wiring Harness Installation.
Figure 13. Rear Wiring Harness Installation.
Figure 15. Rear Wiring Harness Installation.
Figure 16. Rear Wiring Harness Installation.
Figure 18. Rear Wiring Harness Installation.
Figure 20. Rear Wiring Harness Installation.
Figure 22. Rear Wiring Harness Installation.
INSTRUMENT WIRING HARNESS REPLACEMENT
Figure 1. Instrument Wiring Harness Removal.
Figure 2. Instrument Wiring Harness Removal
Figure 3. Instrument Wiring Harness Removal.
Figure 4. Instrument Wiring Harness Removal
Figure 6. Instrument Wiring Harness Removal.
Figure 8. Instrument Wiring Harness Removal
Figure 10. Instrument Wiring Harness Removal.
Figure 12. Instrument Wiring Harness Removal.
Figure 13. Instrument Wiring Harness Removal.
Figure 14. Instrument Wiring Harness Installation
Figure 15. Instrument Wiring Harness Installation.
Figure 17. Instrument Wiring Harness Installation
Figure 19. Instrument Wiring Harness Installation.
Figure 21. Instrument Wiring Harness Installation
Figure 23. Instrument Wiring Harness Installation.
Figure 24. Instrument Wiring Harness Installation
Figure 26. Instrument Wiring Harness Installation.
MAIN WIRING HARNESS REPLACEMENT (CB534B)
MAIN WIRING HARNESS REPLACEMENT (CB534B) - Continued
MAIN WIRING HARNESS REPLACEMENT (CB534B) - Continued
MAIN WIRING HARNESS REPLACEMENT (CB534B) - Continued
MAIN WIRING HARNESS REPLACEMENT (CB534C)
MAIN WIRING HARNESS REPLACEMENT (CB534C) - Continued
MAIN WIRING HARNESS REPLACEMENT (CB534C) - Continued
MAIN WIRING HARNESS REPLACEMENT (CB534C) - Continued
MAIN WIRING HARNESS REPLACEMENT (CB534C) - Continued
SEPARATE AND CONNECT VIBRATORY AND PROPEL PUMPS
Figure 1. Vibratory and Propel Pumps Separate
Figure 2. Vibratory and Propel Pumps Separate
Figure 4. Vibratory and Propel Pumps Connect.
VIBRATORY AND PROPEL PUMPS REPLACEMENT
VIBRATORY AND PROPEL PUMPS REPLACEMENT - Continued
Figure 1. Vibratory and Propel Pumps Removal
VIBRATORY AND PROPEL PUMPS REPLACEMENT - Continued
Figure 2. Vibratory and Propel Pumps Installation.
REAR PROPEL MOTOR REPLACEMENT
REAR PROPEL MOTOR REPLACEMENT - Continued
Figure 1. Rear Propel Motor Removal.
Figure 2. Rear Propel Motor Installation.
PROPEL MOTOR AND TORQUE HUB REPLACEMENT
Figure 1. Propel Motor and Torque Hub Removal.
Figure 2. Propel Motor and Torque Hub Removal.
Figure 3. Propel Motor and Torque Hub Removal.
Figure 4. Propel Motor and Torque Hub Installation.
Figure 5. Propel Motor and Torque Hub Installation.
Figure 6. Propel Motor and Torque Hub Installation.
PROPEL CONTROL LEVER ASSEMBLY MAINTENANCE
Figure 1. Propel Control Lever Removal
Figure 2. Propel Control Lever Removal
PROPEL CONTROL LEVER ASSEMBLY MAINTENANCE - Continued
Figure 3. Propel Control Lever Disassembly.
PROPEL CONTROL LEVER ASSEMBLY MAINTENANCE - Continued
Figure 4. Propel Control Lever Assembly.
Figure 5. Propel Control Lever Installation.
Figure 6. Propel Control Lever Installation
PROPEL CONTROL LEVER VIBRATORY SYSTEM ENGAGEMENT STOPS ADJUSTMENT
Figure 1. Engagement Stops Adjustment.
Figure 2. Engagement Stops Adjustment.
Figure 3. Engagement Stops Adjustment.
PROPEL CONTROL LEVER TENSION ADJUSTMENT
PROPEL CONTROL LEVER TENSION ADJUSTMENT - Continued
PROPEL AND VIBRATORY VALVE TESTS AND ADJUSTMENTS
Figure 1. Valve Tests and Adjustments.
Figure 2. Valve Tests and Adjustments.
REVERSE MAIN RELIEF VALVE PRESSURE TEST - Continued
Figure 3. Valve Tests and Adjustments.
Figure 4. Valve Tests and Adjustments.
Figure 5. Valve Tests and Adjustments.
FORWARD MAIN RELIEF VALVE PRESSURE TEST - Continued
Figure 7. Valve Tests and Adjustments.
Figure 8. Valve Tests and Adjustments.
Figure 9. Valve Tests and Adjustments.
Figure 10. Valve Tests and Adjustments.
Figure 12. Valve Tests and Adjustments.
Figure 13. Valve Tests and Adjustments.
Figure 14. Valve Tests and Adjustments.
Figure 15. Valve Tests and Adjustments.
Figure 17. Valve Tests and Adjustments.
Figure 18. Valve Tests and Adjustments.
DAMPED CONTROL HEAD ADJUSTMENT - Continued
Figure 1. Pressure Override Relief Valve Pressure Test.
Figure 2. Pressure Override Relief Valve Pressure Test.
PROPEL AND SPEED CONTROL VALVE REPAIR
Figure 1. Propel and Speed Control Valve Disassembly.
Figure 2. Propel and Speed Control Valve Assembly
HYDRAULIC PUMP DRIVE REPLACEMENT
Figure 1. Hydraulic Pump Drive Removal.
Figure 2. Hydraulic Pump Drive Installation.
FRONT AND REAR PROPEL GEARBOX SERVICE
Figure 1. Propel Gearbox Service.
Figure 2. Propel Gear Service.
Figure 3. Propel Gearbox Service.
FRONT AND REAR PROPEL GEARBOX SERVICE - Continued
SEPARATE AND CONNECT PROPEL MOTOR AND TORQUE HUB
Figure 2. Propel Motor and Torque Hub Separate.
Figure 3. Propel Motor and Start Hub Connect.
Figure 4. Propel Motor and Start Hub Connect.
UNIVERSAL JOINT AND SHAFT MAINTENANCE
UNIVERSAL JOINT AND SHAFT MAINTENANCE - Continued
Figure 1. Universal Joint and Shaft Disassembly.
UNIVERSAL JOINT AND SHAFT MAINTENANCE - Continued
Figure 2. Universal Joint and Shaft Assembly
BRAKE CONTROL VALVE REPLACEMENT
Figure 1. Brake Control Valve Removal.
Figure 2. Brake Control Valve Removal.
Figure 4. Brake Control Valve Removal.
Figure 6. Brake Control Valve Removal.
Figure 8. Brake Control Valve Removal.
Figure 9. Brake Control Valve Installation.
Figure 11. Brake Control Valve Installation.
Figure 13. Brake Control Valve Installation.
Figure 15. Brake Control Valve Installation.
BRAKE CONTROL VALVE REPLACEMENT - Continued
BRAKE CONTROL VALVE REPAIR
Figure 1. Brake Control Valve Disassembly.
Figure 2. Brake Control Valve Assembly.
BRAKE CONTROL VALVE REPAIR - Continued
BRAKE HOSES, LINES, AND FITTINGS REPLACEMENT
Figure 1. Brake Hoses, Lines, and Fittings Inspection.
Figure 2. Brake Hoses, Lines, and Fittings Replacement.
Figure 3. Brake Hoses, Lines, and Fittings Replacement.
Figure 5. Brake Hoses, Lines, and Fittings Replacement.
Figure 7. Brake Hoses, Lines, and Fittings Replacement.
Figure 8. Brake Hoses, Lines, and Fittings Replacement.
Figure 9. Brake Hoses, Lines, and Fittings Replacement.
Figure 11. Brake Hoses, Lines, and Fittings Replacement.
Figure 13. Brake Hoses, Lines, and Fittings Replacement.
Figure 15. Brake Hoses, Lines, and Fittings Replacement.
Figure 17. Brake Hoses, Lines, and Fittings Replacement.
Figure 19. Brake Hoses, Lines, and Fittings Replacement.
Figure 21. Brake Hoses, Lines, and Fittings Replacement.
Figure 22. Brake Hoses, Lines, and Fittings Replacement.
Figure 23. Brake Hoses, Lines, and Fittings Replacement.
Figure 24. Brake Hoses, Lines, and Fittings Replacement.
Figure 25. Brake Hoses, Lines, and Fittings Replacement.
Figure 26. Brake Hoses, Lines, and Fittings Replacement.
Figure 27. Brake Hoses, Lines, and Fittings Replacement.
Figure 29. Brake Hoses, Lines, and Fittings Replacement.
Figure 31. Brake Hoses, Lines, and Fittings Replacement.
Figure 32. Brake Hoses, Lines, and Fittings Replacement.
Figure 34. Brake Hoses, Lines, and Fittings Replacement.
Figure 35. Brake Hoses, Lines, and Fittings Replacement.
Figure 36. Brake Hoses, Lines, and Fittings Replacement.
Figure 38. Brake Hoses, Lines, and Fittings Replacement.
Figure 40. Brake Hoses, Lines, and Fittings Replacement.
Figure 42. Brake Hoses, Lines, and Fittings Replacement.
Figure 43. Brake Hoses, Lines, and Fittings Replacement.
Figure 44. Brake Hoses, Lines, and Fittings Replacement.
Figure 45. Brake Hoses, Lines, and Fittings Replacement.
Figure 47. Brake Hoses, Lines, and Fittings Replacement.
Figure 48. Brake Hoses, Lines, and Fittings Replacement.
Figure 49. Brake Hoses, Lines, and Fittings Replacement.
Figure 51. Brake Hoses, Lines, and Replacement.
Figure 53. Brake Hoses, Lines, and Fittings Replacement.
Figure 55. Brake Hoses, Lines, and Fittings Replacement.
Figure 57. Brake Hoses, Lines, and Fittings Replacement.
Figure 59. Brake Hoses, Lines, and Fittings Replacement.
Figure 60. Brake Hoses, Lines, and Fittings Replacement.
MANUAL BRAKE RELEASE PUMP MAINTENANCE
Figure 1. Manual Brake Release Pump Removal.
Figure 2. Manual Brake Release Pump Removal
Figure 4. Manual Brake Release Pump Removal.
Figure 5. Manual Brake Release Pump Disassembly.
CLEANING AND INSPECTION
Figure 6. Manual Brake Release Pump Assembly
Figure 7. Manual Brake Release Pump Installation.
Figure 8. Manual Brake Release Pump Installation.
Figure 9. Manual Brake Release Pump Installation.
MANUAL BRAKE RELEASE PUMP MAINTENANCE - Continued
BRAKE CONTROL VALVE COIL REPLACEMENT
Figure 1. Brake Control Valve Coil Removal.
Figure 2. Brake Control Valve Coil Installation.
STEERING WHEEL AND COLUMN REPLACEMENT
Figure 1. Steering Wheel and Column Removal.
Figure 2. Steering Wheel and Column Removal
Figure 3. Steering Wheel and Column Installation.
Figure 4. Steering Wheel and Column Installation.

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