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TM 5-4210-227-24&P-5

1. DISASSEMBLY Remove wheels and brake drums Remove clip spring over U spring with suit able tool Unhook and remove U spring Hold from turning the hold down nail outer spring cup with one hand depress spring until pliers can grip the nail Turn nail 1 4 turn and remove cup spring and hold down nail Remove brake shoes On FSH brakes incorporating the mechanical hand brake remove the cotter key on lever and remove spacer clip and hand brake assembly BRAKES F M M NO 4 G complete disassembly disconnect hydraulic line remove wheel cylinder attaching screw cap screw and wheel cylinder ASSEMBLY A Install wheel cylinder and tighten screw and cap screw securely Connect hydraulic line B Install on units employing the mechanical hand brake the hand brake lever assembly and insert clip spacer and cotter key C Insert push rod end of shoe in wheel cylinder and position brake shoe D Assemble hold down nails cups and springs E Assemble U spring Place hook in one shoe and stretch spring opposite hook into the other shoe F _ Assemble bottom clip spring into shoes over U spring G To position adjusting pawl on brakes with automat ic adjustment tap shoe in with lead hammer until brake assembly will go into drum ADJUSTMENT A FSH adjustable type brake has two eccentric cams that may be adjusted by use
2. 10s a dai Sun Ce Cero Co EE Bushing Sizing 9 REAMING 999 8 4 REAMING 5 Grease Seal Thrust Bearing Seal Knuckle to Axle Center Thrust Bearings with Seals 99 Installation of King Pin Caps Welsh Plugs and Greasing Installation of Steering and Tie Rod Tie Rod Assembly and nn sna rna nns General Wheel Bearing nennen Steering Stop Non Driving Front Axle Camber 5 01 27 eomm SERVICE NOTE For safety purposes and to maintain the mechanical integrity of components being serviced it is of utmost importance to follow completely all the procedures including all caution and important items throughout this manual TAPERED KNUCKLE PIN DESIGN CAP CAP SCREW LOCK WASHER STEERING ARM BALL NUT C
3. 00 _ 10412 REMOVAL ccccccccccceessseeececeessseeececessseeeeeceessseeececensiseeeeeensnaeees DILA O IAE Cleaning amp 12 NN s s T 12 EEEE E 13 Installation 1416 1967 DANA CORPORATION LITHO IN U S A FUNCTION In examining the automotive drive line it would be well to start with a review of drive shaft operation A critical examination of why it is there and what it must do may be helpful in analyzing its effect on the entire drive line system A drive shaft s functions can be briefly described as follows 1 It must transmit torque from the transmission to the axle This requirement makes it necessary that the drive shaft be capable of transmitting the maximum low gear torque developed by the engine and transmission ratio and any shock loads which may develop It must also be capable of rotating at the maximum speed required for vehicle operation This speed is often engine speed increased by an overdrive ratio in the transmission 2 The drive shaft must operate through constantly changing relative angles between transmission drive shaft and axle 3 The length of the drive shaft must be capable of changing while transmitting torque Length changes are caused by necessary axle movement Sue o torque reaction road deflections braking loads etc FIGURE 1 CONSTRUCTION The basic f
4. 2 CHELSEA 220 SERIES PARTS LIST amp SPECIFICATIONS AIR SHIFT P410 220 Item Part No Description Quantit 328723X AIR SHIFT ASSEMBLY Inculdes item 68 79 1 68 34 P 60 COVER Shift 1 69 11 P 75 SHAFT Shift 1 70 32 P 129 FORK Shifter 1 71 3 8316 SNAP RING 2 72 3 8315 COVER PLUG 2 73 28 P 42 O RING 2 74 37 P 21 SHIFTER SPRING 1 75 28 P 41 O RING 1 76 3 8447 4 SCREW Socket Head 1 77 378285 1 SCREW Guide 1 78 378554 1 N S 500897 3 SHIPPING PLUG 1 79 3 8969 INDICATOR SWITCH 1 80 3 8430 8 SCREW Hex Head 5 8 18x3 4 4 328388 27X AIR SHIFT INSTALLATION KIT 1 220 SERIES CHELSEA P410 220 PARTS LIST amp SPECIFICATIONS 220 SERIES PARTS LIST CASE DIMENSIONS Case Part Number Dimension and Dimensions Symbol Description CA Face of Case to Center Line of Input Hole 0 9727 0 6677 0 752 0 500 CB Face of Case to Center Line of Output Shaft Hole 3 516 3 211 3 296 2 543 CD Center Distance Between Input Gear amp Output Shaft 3 087 3 087 3 087 3 087 CE Face of Case to End of Shift Lever PITE 8 000 7 687 7 781 8 000 CH Face of Case to extreme Horizontal Edge of Case d 6 281 5 984 6 062 6 190 CU Output Shaft BELOW Center Line of Input Gear 1 750 1 750 1 750 1 941 CV Top to Bottom of Case Clearance d 7 750 7 750 7 750 7 906 CW Center Line of Output Shaft to Bot
5. Lubri ant acc act acta UM PACING WMS NNNM TP P Temperature Indicators cL Traction Equalizer Recommended Lubricants Lube OW WAS COSTES MC e eee v ale Muli Grade eae IE EE Gear Lubricants for Low nennen nennen nnne nnne nnne rne Ee Em eee Lubricant Specifications and Change Intervals nennen nnne nnn rn 8 1 2 Front Dive SIGSHTO AUS 3 zia salo EN Em Oo oc 8 9 mere AWN AOS E e Grease 8 888888888 e 8888 Teese a a SIODMasier Wedge Cam Master Cam 8 8 e Dura Master Air Disc Brakes
6. Y OUTLET PORT Sectional SL 5 with a double check valve to perform the function of both It operates in conjunction with the brake valve and hand control valve by directing the flow of air from whichever delivers the higher pressure into a common delivery line and to the stop light switch closing the electrical circuit to the stop lamps The stop light switch can be used with either 12 or 24 volt systems The stop light switch is not a serviceable item and if found defective in either device the complete unit must be replaced The shuttle valve in the DS 2 is serviceable and may be replaced Both the SL 5 and DS 2 have been tested and meet the requirements of FMVSS 121 OPERATION The stop light switch mechanism is identical in the SL 5 and DS2 When a brake application is made air pressure from the brake valve enters the cavity below the diaphragm The air pressure below the diaphragm moves the piston until it contacts the leaf spring The leaf spring travels past a fulcrum at which point the leaf springs snaps a shorting bar which mates with the contact strips The stop light electrical circuit is completed lighting the stop lights before the brake application pressures reach 6 psi The snap action spring design minimizes arcing The Double Check Valve is activated by air being introduced through either of the two 2 inlet ports The greater pressure pushes the shuttle along its guides and
7. MSS 30 70 460 120 i i i 0 1000 2000 2000 4000 5000 7000 8000 Alternator RPM Leece Neville 7705 7706 165 Amps AT Fiqure 2 4D 1000 4000 Alternator RPM Alternator 7290 Delco Rem y 48951 4 4800 b IB Watts AT 120 Vales SX 2400 12 00 Anernator RPM Delco Remy 40SI 145 amps Fiaure 2 4E f AC 4 s e 4 6000 Motorola SA160 160 amp 1000 Figure 2 40 Inverter AMPERAGE Alternator Data Model Series 4 17 8 33 212 50 16 67 20 83 25 00 29 17 33 33 37 50 41 67 45 83 50 00 Amp Cont Intermit mus DNO 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 120 Amp Cap Delco Remy A40 4081 A30 A60 3900 3950 4050 4200 4400 4650 4900 5300 5750 6350 6900 7500 145 40 55 au Motorola 40 227 68 A30 A60 2900 3000 3200 3500 4000 4700 6500 _ __6 22 30 Motorola 1 40 i 84 A30 A60 3100 3250 3450 3700 4100 4500 5050 6350 84 30 Z 35 Motorola 40 85 30 60 2950 3100 3300 3500 4000 4250 4600 i 85 30 40 hos Motorola 1440 NE 120 A30 A60 3600 3750 3900 4100 4300 4550 4800 5150 5650 6500 7750 120 42 45 Motorola A40 AM UE 160 4250 4350 4500 4700
8. PISTON is located within the housing A rack on the piston engages the pinion gear on the output shaft Ports in the piston function for either pressure or exhaust depending upon direction of valve travel The piston centers itself over the Page 3 travels over shaft threaded area Two ports on valve outside diameter control oil flow through the pistion The valve has a linear motion permitting edges of the ports to seat against mating edges on the inside of the piston valve to provide steering action PINION AND OUTPUT SHAFT assembly located in the housing is turned by the piston rack This provides rotating action at the pitman arm connected to the steering linkage SHEPPARD POWER STEERING SERVICE MANUAL OPERATING PRINCIPLES The Sheppard Integral Power Steering Gear provides full time hydraulic steering which is light and responsive Only sufficient manual input effort to overcome the reversing springs and close the control valve to cause a pressure build up is required Full rated axle loads can be steered with ease The actuating shaft 1 is connected to the steering column and is threaded with an Acme type thread 2 The actuating valve 3 is threaded to accommodate the actuating shaft and is centered within the piston by reversing springs The valve moves in a linear motion within the piston permitting the edges of the valve to overlap mating edges on the inside of the piston This causes high pressure oil to
9. and should be equal 3VDC for the two leads If it is not the oscillator board should be replaced SCR CHECKOUT PROCEDURE Tools Required Ohm Meter or Continuity Tester 7 16 socket wrench with extender 3 4 socket wrench with extender A40 and A60 only screwdriver 1 Prior to checking out the SCRS be sure that the commutation fuses are good by following the commutation fuse checkout procedure 2 Open inverter by removing the front and top panel fasteners Carefully lay the front panel down on its face and remove the top panel 3 The engine and inverter are OFF for this test 4 SCR Silicon Controlled Rectifier is a semiconductor device which will not conduct electricity in either direction unless the GATE is impulsed to turn on the SCR When the GATE is impulsed turn the SCR ON the SCR will conduct from ANODE to CATHODE only The purpose of this test is to determine if the SCR will conduct 1 show low resistance without the GATE being turned on If so the SCR is shorted and should be replaced GATE LEAD NO CATHODE SCR OFF Direction on SCR will oon current NO 4 SCR ON DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 2824V O 4 8 9 SCR CHECKOUT PROCEDURE continued 5 Remove SCR cathode ground leads from ground These are RED 8 wires for A40 A60 and GREEN wires for an A30 which are attached to the bottom of the inve
10. 2 Discard the cover plate and cover plate gasket then clean the aperture pad using a putty knife or wire brush See Fig 2 NOTE Stuff a rag in the aperture opening to prevent dirt from entering the transmission while you are cleaning it 3 Using your hand rock the P T O driver gear in the transmission see Fig 3 and the driven gear in the P T O assembly see Fig 4 Rocking the gears provides two important factors a It shows you the amount of backlash that has been designed into each unit b It is helpful in establishing the proper backlash when installing the P T O 4 Install the proper studs in the P T O aperture pad using a stud driver See Fig 5 5 Where holes are tapped through the transmission case use Permatex or equivalent to prevent leaks NOTE Avoid contact of Permatex with automatic transmission fluid in automatics Always check to be sure that the studs do not interfere with transmission gears 8 P T O WI Fig 5 7 313 MOUNTING P T O TO TRANSMISSION continued 2 Tighten the studs securely and torque to 30 35 Ibs ft 4 14 4 84 kg meters for 6 bolt and 45 50 Ibs ft 6 22 6 91 kg meters for 8 bolt See Fig 6 Place the correct number of gaskets over studs See Fig 7 Do not use Permatex between gaskets because you may want to add or subtract gaskets to obtain proper backlash When mounting a P T O use gaskets between all mounting surfaces
11. TE rey vx mp 5 ni rys e gm nme ar Fretiage Also False Brineiling Wear Oxidation aladel Oxidation Pe eet Slip SIUE ae ian al y pups ey thal thet nro nera TAN etl FUN Gomer Probable Corrections 1 See Spicer Universal Joint Lube Specs 2 Replace Seals on New Kit Replace Compier Kit if Used 3 If Yoke Distorted Replace 4 Reduce U Joint Continuous Running Angles 5 Replace with Higher Capacity U Joint amp Driveshaft 6 Use Hi Temp Grease 7T Check U Joint Flex Effort If Sticks Binds or Grabs Replace U Joint Kit If Replacement Kit Sticks Binds or Grabs Check Yokes for Span Lug Squareness Cross Hole Alignment etc If Excessive Replace d E 2 LAXE SUHEUES Tun E sni al O D Wear at Extremities and 5 gip m aenn agaa nini j RN oat i meros Ez i as 4 2 DNE x ri ul E reb mul pend ku bou m Led per rg Lr TC ncm OEIL pee nz TE eee et GL M P onm me m rre vm rl Lig Tae e zw hir ues UT ee E ortam deu da e 2t Pupil ia Ly uet Lu 1 prs dro i ies Hee y un ats t LB icem Heater o a To ee d HT T 1 P n ERE Me na ae 8 Clean amp
12. RCCTIFIER 840665 H INTEGRAL CHARCING SYSTEM H Fig 5 13 OC DELCO REMY 405 REGULATOR BEFORE MODIFICATION DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 11 82 3 5 5 3 ALTERNATOR MODIFICATION INSTRUCTIONS FOR LEECE NEVILLE SERIES 2000JB The purpose of this modification is to provide a means to ground negative field brush permanently for use with positive switching regulators 22221 Remove four screws and carefully lift regulator free of housing Remove RED and BLACK leads from regulator noting their positions to facilitate assembly of new regulator Only the BLACK lead will be replaced The RED lead will not be used 2 2 2 Remove diode trio lead from diode trio terminal on outside of regulator housing 3 Loosen or remove inner nut which allows BLUE regulator lead or WHITE with BLUE tracer to be withdrawn from under head of diode trio terminal screw inside the regulator housing 4 Remove regulator ____ 5 Compress brush springs and hold them in place by passing pin through the retainer hold A suitable pin can be made from a piece of 1 32 rod or a paper clip ____ 6 Cut and tape securely the RED lead and tuck it into the bottom of the regulator housing Be sure that it does not interfere with brush and spring assemblies This lead will no longer be used 22 27 Take the 12 length of 16 AWG WHITE wire from the hardware kit and solder this wire to the negative brush
13. Use a spanner wrench to remove the piston plug from the piston Note The spanner wrench shown here can be fabricated using a piece of flat stock with two cap screws bolted in place with the proper spacing to fit the piston plug The seals on the piston plug can be removed and discarded if replacement is required Page 26 SHEPPARD POWER STEERING SERVICE MANUAL Mark the top adjustment nut and piston so that the nut can be reinstalled in its original position Caution Misadjustment of the top adjustment nut could cause erratic steering Use a 5 64 inch drill to drill out the adjusting nut lock pin A piece of stock material is used to turn the adjusting nut out of the piston Carefully slide the control valve and reversing springs out of the piston 5 44 The valve positioning pin now be removed from the piston Remove and discard the seal on the valve positioning pin Remove the remaining two reversing springs Page 27 SHEPPARD POWER STEERING SERVICE MANUAL 5 45 a A 0 S 46 5 47 3 16 inch allen wrench is used to remove the relief valve seats There is a slight spring tension on the relief ball valves Caution Handle carefully to avoid loss or personal injury The relief passage is drilled through the piston from end to end here is a ball valve and a valve seat at each end The ball valves are held against their seats by a spiral spr
14. understand recommended procedures Use only proper tools and observe all precautions pertaining to use of those tools Some components contain powerful springs and injury can result if not properly disassembled SD 06 7 1 81 Section VI ndi BRAKE SYSTEM Heavy Vehicle Systems Group Service Data SD 06 7 QR 1C DOUBLE CHECK AND QUICK RELEASE VALVE MOUNTING HOLES dme e T DELIVERY 12 DESCRIPTION The QR 1C is a dual function valve The valve s primary function is to serve the emergency side of a spring brake actuator as a quick release valve In addition it functions as an anti compound device The double check valve prevents a service and emergency brake application from occurring simultaneously The QR 1C Valve is generally mounted on the axle and serves two spring brake actuators The air connections to the QR 1C are as follows 1 QR 1 C delivery port 2 connected to emergency port of spring brake 2 QR 1C balance port 1 connected to delivery of brake valve or relay valve NOTE If relay valve is in stalled on vehicle it should be connected to the delivery side not service or signal side 3 QR 1C supply port 1 connected to delivery of park control valve OPERATION Spring Brakes Released When the spring brakes are released air from the park control valve flows through the QR 1C Valve causing the double check valve and quick release diaphragms to flex and seal the balance a
15. 4 BUSING EY Oe Em TROUGH Cal IMG 1 VOC TYDE ss spss te an se spe a age to sn se adn ap dn ase ceo ee ee eae Drive Units Differentials Drive Line Universal Joints Slip Yokes and Splines 220 00000 0 0 0 00 24 10 Steering Shaft Universal JOinls intuere eoru nana orna inen causas nain os Lubricant Capacities of Rockwell Components Single ARCS core 25 0 200000 000000 00 Planetary 28 Transfer Cases Lube and Interval Reference Chart 2 30 LUBRICATION INTRODUCTION The efficiency and life of mechanical equipment is as dependent upon proper lubrication as it is upon proper engineering design All mechanical components rely on lubricati
16. FOR FURTHER INFORMATION d REFER TO FIELD MAINTENANCE i AES RAE AS e Dre oe de Sey MANUALS COATED WITH AUST PREVENTATIVE L Gen se nde hay ne ENTIEIPATI Dc cuta cruris Py c mro dup aa MEA C NA TC error oFFHiGMWwAY AXLES FOR DRY PARTS INCREASE TORQUES 10 i CO AND WALL CHART FOR PARTS HEAVILY COATED WITH OIL a b DECREASE TORQUES 10 jj e TSME MAINTENANCE T T cun REV 8 79 Rockwell International Heavy Vehicles Components Operations Rockwell International Corporation 2135 West Maple Road Troy Michigan 48084 U S A OROCKWELL INTERNATIONAL PRINTED IN U S A heppard POWER Sue E b ae m Section IV STEERING SYSTEM SHEPPARD INC 101 PHILADELPHIA ST HANOVER PA 17331 SER CAT 0832 PHONE 717 637 3751 INTRODUCTION This Sheppard Power Steering Service Manual covers repair procedures for the steering gear assembly only The vehicle manufacturers service manuals should be used for removal and reinstallation instruction and hydraulic supply pump specifications All information illustrations and specifications referenced in this publication are the latest available at the time of printing The right is reserved to make changes at any time without notice Any reference made in this publication as to brand name special tools or item part numbers are made only as a guide An equivalent produc
17. FUEL SWITCH AE T Section VII ELECTRICAL SYSTEM WIPER SWITCH YELLOW HEA ORANGE RED HEATER BLOWER MOTOR SWITCH WASHER SWITCH WIPER SWITCH EMERGENCY STOP STEERING COLUMN JAKE BRAKE OPTION FUEL PUMP 1 M switch OP TION TM 9 OPTION 180 ui 1 HEADLIGHT foal 41 7 SV TCH START Tep mum D 2 gc l START O CP BUTTON 5 3 IGNITION SWITCH B3L start PANEL md COURTESY NIGHTS DOOR JAMB SW TCHES OPTION CUMNM NS y es Te T5 Ies N 9 9 75 BRAKE LIGHT SWITCH PARKING BRAKE PRESSURE SWITCH PRESSURE w l Get DUPLEX Electrical Circuit Schematic All Models m BRAKE OPTIONS ae WATER TEMP SENDER SWITCH SENDER REAR AIR LOW PRESSURE SWITCH JAKE OPT ON WASHER FUEL MOTOR 2 PRESSURESTAT l P4 TNO 3 RIGHT TURN AIR x SIGNAL DRYER _ ume NA 9 AUX PWR T 6 X BRAKE oc EN SWITCH ENGINE OIL PRESSURE 8 AMMETE SENDER SWITCH sHUNT _ ___ RR ql NEUTRAL START SWITC bed PRESSURE SENDER m I FRONT AIR fay BACK UP res LOW PRESSURE 2 ewi ES FRONT AXLE WHEFL SENSOA AUX GAUGE i 482 ENGINE ENCLOSURE 29
18. TYPICAL SINGLE COMPARTMENT RESERVOIR DESCRIPTION The reservoir is a storage tank its function is to provide a volume of compressed air for braking which will be adequate in relation to the volume used by the brake chambers and auxiliary devices and to provide a location in the system where the air heated by compression may be cooled and the water vapor condensed Bendix reservoirs are built in accordance with SAE Standard Air Brake Reservoir Test Code and Inspection Procedure SAE J 10 a They are made from steel sheet with stamped heads and rolled shells The seams are electrically welded and each reservoir is internally coated for corrosion resistance Each reservoir is tested at 300 PSI hydrostatic pressure Reservoirs are supplied in various pipe ferrule arrange ments and lengths and in diameters from 3 1 2 to 14 having various volumes from approximately 100 cubic inches to 7600 cubic inches for tractors and trailers All ferrules are tapped to SAE dryseal pipe thread standards Reservoirs are also supplied in double and triple compartment configuration and in some cases include an integral check valve between compartments in a double compartment reservoir Figure 1 illustrates a two compartment reservoir Two styles of check valves are shown in Figures 2 and 3 Figure 3 is the current design OPERATION The reservoirs in an air brake system primarily serve to store energy in the form of compressed air They also per
19. 0 or Serial Number on older chassis must be supplied when Ordering replacement parts 16 Item OR no co 11 12 13 14 15 16 17 Part No 7605 3333 7611 6833 7611 6834 7605 4103 7605 4110 7605 4109 7605 4106 7605 3376 7605 1893 7605 4101 7611 6881 7605 1893 7605 4100 7605 1754 7605 1755 7605 1752 7605 1753 7605 4104 7605 4107 7605 4113 Section VIII MISCELLANEOUS Description Cozy Wing Ventilator LH Cozy Wing Ventilator RH Rain Gutter Moulding Aluminum Window Moulding Door Glass Outside Door Handle Air Intake Cover Window Moulding amp Key Rubber Rear Side Glass Drip Moulding Window Moulding amp Key Rubber Windshield Rear Rider s Back Black Rear Rider s Back Red Rear Rider s Cushion Black Rear Rider s Cushion Red Fenderette Door Hinge OPTIONAL EQUIPMENT Not Shown Fender Liner Cab Exterior Qty 350 7605 1143 7605 1145 7604 7035 7605 1144 7605 0132 7605 3726 7605 4005 7605 4047 7605 4048 7605 4049 7605 4006 7605 1911 Section MISCELLANEOUS Description opotlights Optional Spotlight Bracket Optional Clearance Lights LH Spotlight Bracket Optional Arrow Turn Signal Headlight Bezel LG Headlight Assembly Mars 888 Ligh
20. 5 gt 4 8 42 C c o QD 9 55 Handle 4 7 8 Shank 3 Left ha 4 in 5 in 5 7s4 in 34 in in 1764 in 2 1352 in 4x1 in Hie in Weight depends on system used Consult factory M n 5 1 TU GU AS e 7 Tr a na snown right opposite dimenslons t 4 ae length of case width of case width of case with striker depthof case depth of case with striker mounting holes 4 on 3 x 358 HxV pattern oval mounting slots 2 on 3 centers on striker mounting faceof striker square hole for handle shank gt 4 056 A a E ERA ven 5 RET 2 ot 6 af re SY ERTI Um Y E S 70 as 412 49 v u Ue utt eet pathos d wre CANADIAN AND FOREIGN PATENT AL E a RS DF te wape s EVMIGSGELILANKIOUS i perdis 2506 i 1 gt cx Pe NE re general description This lock is intended primarily for passenger doors on vehicles Certified to meet the Federal Motor Vehicle Safety Standard No 206 and to comply with established OSHA safety standards this lock can be installed on doors as thin as He inches inner skin to inner skin or the inner surface of a door panel It can be use
21. CRANKING MOTORS Service Bulletin 1M 153 Assembly is the reverse of disassembly BRUSH ARMS Figure 22 Brush with offset hole assembled to brush arm Heavy Duty Sprag Clutch and DR 250 Drive An early type and a late type heavy duty sprag clutch are shown in Figures 14 and 15 and the DR 250 drive is shown in Figure 16 Remove the cupped pinion stop and split washer In removing the cupped pinion stop it will probably be damaged A new one will be required at time of reassembly Remove the other illustrated Do not lubricate the sprags on heavy duty clutches as they are lubricated for life with special oil at the factory Assembly is the disassembly parts as reverse of C Spline Drive and Positork Drive These types of drive assemblies are serviced by complete replacement only aac Figure 23Circuit for checking pinion clearance Types shown in Figures 1 2 and 3 SOLENOID CHECKS A basic solenoid circuit is shown in Figures 17 and 18 Solenoids may differ in appearance but can be checked electrically by connecting a battery of the specified voltage a switch and an ammeter to the two solenoid windings With all leads disconnected from the solenoid make test connections as shown to the solenoid switch S or Figure 25 Checking pinion clearance on SW terminal and to ground or to the second switch terminal G if present to check the hold in winding Fig 19 Use the
22. LUBE SPECS Lubricants For driveshaft applications involving shaft speeds over 500 RPM a high quality extreme pressure EP grease recommended by lubricant manufacturers for universal joints should be used Lithium soap base greases meeting NLGI Grade 1 and Grade 2 specifications are preferred The use of greases that tend to separate and cake should be avoided For driveshaft applications involving shaft speeds below 500 RPM a mineral oil in the SAE 140 to SAE 250 viscosity range should be used National Lubricating Grease Institute Relube Cycles Relubrication cycles for drive shaft universal joints and slip splines will vary with service requirements and operating conditions The following re lubrication schedule has been used successfully RE LUBE CYCLE OPERATING CONDITION Miles Hours Normal 6000 8000 150 200 Severe 2000 3000 50 75 For applications where conditions such as high speeds high ambient temperatures or high angles are present Sliding Spline Sections Lubricants Steel Splines Driveshaft steel splines should be lubricated with a good extreme pressure grease as recommended by lubricant manufacturers Extreme pressure grease satisfying NLGI Grade 1 has been adopted as the standard by our factories Glidecote TM Splines Any high grade multi purpose grease can be used Greases recommended lubricant manufacturers for universal joints have been found satisfactory for Glidecote splines PR
23. 1 Using chisel and hammer remove key from shaft 3 With 1 8 allen wrench remove allen screw Fig 1 Fig 1 22a Photo 1 18 from base of housing Photo 4 Photo 1 2 Remove four capscrews Fig 1 31 from shifter Photo 4 cover Fig 1 422 using 1 2 wrench and remove 4 Usi TERN passis TM shifter cover from P T O Discard gaskets Photos UU PDAS ame ee ped ee idler pin shaft Fig 1 7 through housing using 283 soft hammer or press Photos 5 amp 6 NOTE If P T O has pressure lube pin plug will have to be removed Photo 2 Photo 5 Photo 3 DISASSEMBLY 22 26 Series cont 6 oet P T O on its side output shaft up and unbolt four capscrews Fig 1 17 and remove open bearing cap Fig 1 9 Discard gaskets Photos 8 amp 9 Photo 8 Photo 6 5 Hemove gears Fig 1 5 and washers Fig 1 1113 from housing The bearings Fig 1 16 and spacer Fig 1 8 can also be removed from the input idler gear so they can be cleaned inspected and repacked with new bearing grease Photo 7 Photo 9 Photo 7 DISASSEMBLY 22 26 Series cont 7 Turn P T O over and proceed as in step 6 removing closed bearing cap Fig 1 10 Photos 10 amp 11 Photo 10 Photo 11 8 Using bearing pullers remove tapered bearing Fig 1 21 from input end of shaft For C4 and C6 assemblies shaft can be removed C3 or C5 follow step 9 Photos 12 amp 13 NOTE I
24. No 207U Same as No 206U cept with one remote control lever on back cover No 208U Same as No 206U ex cept with two remote control levers Same as 2070 ex cept remote control le ver is on front cover No 1 208U Same as No 208U except less locking feature EBER EAST PRODUCTS LIMITED TILLSONBURG ONT N4G 4H8 oL RHHUHES VE SECURITE SAFETY SLAM LOCKS DOFNART ACC S UN ESPACE POUVANT ETRE NESEY AARNE SUS OCCUPEE PR UN CU GES PASSECERS DOIT ETRE MUNIE CIUNE SEREURE CONFORME LA NORME DE SECLRITE No 206 25 32 INCH MAXIMUM 4 9 P p SUR LES VEHICULES ROUTIERS TOUTE S pnv 11 Les serrures Nos 52 ASL 5 ASL 60 ASL i LOCK THICKNESS et 206 lllusir es sur cette page et au verto sort corformes la 206 VERTICAL LOCKING AND UNLOCKING FROM INSIDE ON HIGHWAY VEHICLES ANY DOCR WITH ACCESS TO A SPACE OR COMPAPTHENT THAT MAY BE OCCLFIED BY ONE OR MORE PASSENCERS MUST BE EQUIPPED WITH DOCR LOCK IN COMPLIANCE WiTH SAFETY 72 STANDARD No 206 THUMB ROTARY LOCKING AND JNLOCKING es FROM INSIDE Locks No 52 ASL 56 ASL 60 ASL and 206 5 on this anc overleaf do comply 9T with safety standard 20 5 16 INCH SQUARE FOR INSIDE AND OUTSIDE HANDLES SECONDARY AND FULLY LATCHED PO INDEPENDENT DOUBLE LATCHING FOR SECURITY CB Ey ed 3 206 ED eR Check these additiona
25. SHORT SERIES STEERING GEAR 5 3 STEP BORE EEHING GEAH 3 2 382 5 7 SWIVEL MITEH INPUT S B T BOX MITER INPUT FOR 5 4 ANGLE DRIVE OR FIXED MITER GEAR INPUi DUAL STEERING CONTROLS Page 5 SHEPPARD POWER STEERING SERVICE MANUAL 5 number is cast into the steering gear housing and identifies the basic family to which the steering gear belongs 392 5 would indicate a 392 short series steering gear See series 4 and series 5 example below otamped letters and numbers on an exposed machined surface of the housing identifies the particular member of a family In the above example the complete identification is Model 392 SCU 4 392 5 cast number plus SCU 4 would refer to a short series 392 steering gear A serial number is also assigned to each steering gear and is interpreted below SERIAL NUMBER SYSTEM SYSTEM UP TO AND INCLUDING 1974 SYSTEM 1975 TO PRESENT AND FUTURE 4 PP 555 03 1856 MONTH YEAR BUILT SHEPPARD YEAR BUILT Par SHEPPARD 1974 1983 ei ONLY USED LAST USED LAST ETC NO ONLY TWO NO S REPRESENTS THIS SERIAL NO 83 D 1856 83 YEAR BUILT 19B3 0 MONTH APRIL 1856 REF ONLY DESCRIPTION OONDPAN BOLT LOCKWASHER GREASE FITTING SALT SEAL OIL SEAL PLUNGER O RING BEARING CAP SEAL RING LOCKING NUT PIN SEAL WASHER OIL SEAL ACTUATING SHAFT amp BRG ASS Y BEARING NUT PISTON amp VALVE ASS Y BOLT LOCKWASHER HOUSI
26. TEST OF REBUILT SLACK ADJUSTERS After lubricating rebuilt Slack Adjuster see Preventive Maintenance section all moving parts of the Slack Adjusters should rotate freely and not bind With Slack Adjuster installed In vehicle refer to Service Test section Check that rebuilt Slack Adjuster functions properly IMPORTANT PLEASE READ When working on or around air brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone 4 Never attempt to disassemble a component until you have read and understand recommended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools 50 051 6 81 Section VI BRAKE SYSTEM Heavy Vehicle S at Systems Group e r Formerly 50 66 SR
27. 1091 D31 D6F 1008468 D350 230 Detroit Diesel 8V 71 Turbo 8VA437868 Diesel Transmission Manufacturer Model Serial No Capacity Firefighting Water Pump Manufacturer Model Capacity Front Axle Manufacturer Model Capacity Serial No 1 Front Shock Absorbers Manufacturer Model 2 Front Springs Manufacturer Model Hear Axle Manufacturer Model Capacity Serial No 1 Rear Suspension Manufacturer Model Allison HT 740 2510087501 7 1 2 Gals Hale QSM FHD100 1000 GPM 150 psi Rockwell International FL 941 QX 70 20 000 Ibs N766718 Duplex 605 1258 Duplex 7804 6731 Rockwell International U 170 PX 99 31 000 Ibs NW8454892 Hendrickson Single Axle RS SA 340 h Alternator Manufacturer Model Amp i Batteries Manufacturer Model Voltage j Battery Isolator Manufacturer Model Hated Power Steering Gear Manufacturer Model I Power Steering Pum Manufacturer Model m Windshield Wipers Manufacturer Model Type n Radiator Manufacturer Model Air Cleaner Manufacturer Model Delco Remy 145 Harris 7605 0670 12 Sure Power 1602 3 09 BHP 9 2 100 rpm Sheppard 7605 5478 Vickers 7605 5256 American Bosch WWC 12L Electric Blackstone 7605 3750 FAAR 62891 3 q Driver s Seat Manufacturer Model Type Wheels Front Manufacturer Size Hear Manufacturer
28. 18 CARE AND MAINTENANCE CHECK TOOTH CONTACT Apply oiled red lead lightly to the hypoid gear teeth When the pinion is rotated the red lead is squeezed away by the contact of the teeth leaving bare areas the exact size shape and location of the contacts Sharper impressions may be obtained by applying a small amount of resistance to the gear with a flat steel bar and using a wrench to rotate the pinion When making adjustments check the drive side of the gear teeth Coast side should be automatically correct when drive side is correct As a rule coating about twelve teeth is sufficient for checking purposes After obtaining a satisfactory tooth contact especially in relation to the top and bottom of the tooth the backlash can be altered within the limits of 005 015 to obtain a better contact position relative to the length of the tooth A high backlash setting can be used to keep the contact from starting too close to the toe and a low backlash setting can be used to keep the contact from starting too far away from the toe After correct tooth contact has been established install adjusting nut locks and cap screws Tighten cap screws and lock wire to bearing cap cap screws For further detailed information refer to SAE Paper SP 228 Section 2 by W A Johnson and H F Cornish SINGLE REDUCTION DRIVE UNIT CORRECT TOOTH CONTACT ASSURES LONGER GEAR LIFE SATISFACTORY TOOTH CONTACT SATISFACTORY TOOTH CO
29. 2 Move horizontally to the intersection with the power curve 3 Read the alternator RPM on the horizontal axis below the intersect point 4 To convert alternator RPM to engine RPM divide alternator RPM by the pulley ratio 5 To determine the pulley ratio divide the crankshaft or drive pulley diameter by the alternator pulley diameter POWER OUTPUT It is important to vs DC note that the output 120 rating of a Dynamic Inverter is the com ioo bined 120VAC and 14 VDC output A graph i of the relationship of the 120VAC and LE 14VDC outputs of the Dynamic Inverters is shown in Figure 1 9 i 22 96 Oviput b Ampo et i 14 8 VDC SAO Waita at HM ae Figure 2 4A 7200 l I i I i 1 NEN 4800 r Watte At 120 Volts 1 3600 UN DUE NE 2400 1 1200 1000 2000 3000 4000 5000 8000 7000 8000 2000 3000 4000 6000 8000 7000 8000 Alternator RPM Alterneter RPM nn Leece Neville 8050 140 Amps Leece Nevile 4725 130 Amp Figure 2 4B Figure 2 4C DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 2 4 SELECTION OF ALTERNATOR AND INVERTER Continued ALTERNATOR PERFORMANCE DATA Continued At 120 Voits 7200 t t 6000 1 1 J 4800 R Lh aus Watts AC i i 3600 1200
30. 36 DASH DRILLING TEMPLATE For 6 amp 8 Bolt Air Shift for New Williams Valve 3 688 875 2 688 2 000 625 750 1 750 For Use with installation Sketches on Pages 32 33 and 34 38 1 312 1 750 2 Chelsea DANA CORPORATION DANA gt gt DRIVETRAIN SERVICE DIVISION BOX 3217TOLEDO OH 43691 Printed in U S A 6 81 Weatherly Index No 086 Section VIII P40DS MISCELLANEOUS P4304 DSD Date July 1979 Chelsea A22 amp 26 Series P T O Service Manual Side Mounted S A E Six Hole One Speed Two Gears EX e eod d Kan oM CONTENTS INTRODUCTION A22 amp 26 Series The 22 series is designed for low speed heavy duty single speed applications or for obtaining normal speed ratios on extra fast transmissions whereas the 26 series is designed for use on automatic transmissions operates at a high reduction making an ideal application for garbage packers and other hydraulic pump mount applications Both are rated for extra heavy duty operation and are standard with wire controls but feature such options as lever shift air shift pump flanges to fit most popular pumps and pressure lubrication to be used when the P T O is mounted on automatic transmissions Though the following instructions do not show the use of a press please note that if one is available we recommend that it be used for both disassembly and reassembly With the use of a press you are less
31. CTDC T L 80 1 iR STAR MODEL HRC No 680842 with anti rattle nub Our standard model Especially suited to fastening truck hoods and for heavy duty applications 23 184 Y MODEL HRC No 660638 with anti rattle nub Our largest model Long reach for extra stretch and aroundicorner fastening 3 8 oection VIII MISCELLANEOUS ow cost easy to inst Snug fit fastening with never a squeak Neat trim Special formula high impact resin handles and quality ru body are impervious to weather oils chemicals and dir HRC Rubber Hood Hooks have molded poly carbonate IBS handles Naval weapons spec OS 12531 temp range of mint 2 STAR MODEL HRC 680842 1101 without anti rattle nub MINI MODEL HRC No 67D794 wit anti rattle nub Our compact model Excel lent size for securely fastening battery box covers in limited space MIN MODEL HRC No 67D794 1101 without anti rattie nub 516 2 designed especially MISeEL FLA 005 for Huntington Rubber Hooks Precision made from high quality steel with a special hot zinc bright finish Attractive appear ance or easily painted in your shop if desired This heavy duty hardware accurately fits the Huntington Rubber Hood Hooks Also available chrome plated on special order 62 A 21 Dia HY 112 dL a E IN 5 11 33 Dia 1 T
32. Description T 328648X HOLLY GOVERNOR DRIVE KIT Contains items 46 50 328060X DRIVE SHAFT amp SPINNER ASS Y Contains items 46 amp 47 46 3 270 47 378178 SPINNER 48 378391 LOCKRING 49 28 P 53 50 328588 BEARING CAP with Bearing Cup 550221 TGovernor Drive Kit consists of parts shown plus gaskets 22 P 24 1 amp 22 P 24 2 Quantity h e 410 220 Suffix J M amp O K N P amp PUMP SHAFTS AND SPINNER ASS Y 220 SERIES PARTS LIST amp SPECIFICATIONS CHELSEA 328160X 328097X 328096X 328 43X 328724X 34 P 60 11 P 117 32 P 129 378447 4 28 P 142 500381 3 36 P 1 28 P 42 378315 3 8316 3 8285 1 3 8002 37 P 14 3 8554 500132 3 3 8969 3 8430 8 PUMP SHFT amp SPINNER ASS Y Includes Shaft 3 P 348 amp Spinner 378178 PUMP SHAFT amp SPINNER ASS Y Includes Shaft 3 311 amp Spinner 378178 PUMP SHAFT amp SPINNER ASS Y Includes Shaft 3 P 310 amp Spinner 378178 PUMP SHAFT amp SPINNER ASS Y Includes Shaft 3 P 702 amp Spinner 378178 LEVER CONTROL Description LEVER SHIFT COVER ASSY Y Contains items 51 66 COVER Shiffter SHAFT Shiffter FORK Shiffter SCREW Soc Head OIL SEAL JAM NUT Hex EYE BOLT O RING COVER PLUG SNAP RING SCREW Guide POPPET BALL POPPET SPRING CAP PLUG Pipe 1 8 27 INDICATOR SWITCH SCREW Hex Head 5 8 18 x 3 4 Quantity
33. GASKET CAPSCREW amp WASHER BUSHING amp SEAL SERA STEERING ARM DRAW KEY NUT BALL a COTTER aod STEERING SN SEAL STEERING i STEERING COTTER PIN ARM BALL COTTER PIN Y 3 CROSS TUBE PT us DRAW KEY ARM NUT 7 _ COTTER PIN TIE ROD END NUT STEERING KNUCKLE T SEAL IF REQ D KNUCKLEPIN BUSHING amp SEAL pt t STEERING I KEY dh G KNUCKLE ee TIE ROD ASSM CLAMP a LOCKNUT NUT CAPSCREW amp _ 4a_ STOP SCREW WASHER TTE tack nut TIE ROD END ASSM GREASE FITTING STEERING ARM NUT NON DRIVING FRONT AXLES CONVENTIONAL MODELS 900 901 AND 970 SEALED KNUCKLE PINS AND PERMANENTLY LUBRICAT ED CROSS TUBE MODELS 921 931 932 933 934 AND 971 EASY STEER MODELS 941 SERIES INCLUDES 941 942 943 944 ALUMINUM BEAM MODELS 931A SERIES INCLUDES 931 A AND 941 A TUBULAR BEAM MODELS 951 ALL FU SERIES AND FAE DISASSEMBLY FRONT AXLE CAUTION Heating of components to aid in disassembly is not allowed because it has a detrimental effect on axle components NOTE It is recommended that safety glasses be worn during disassembly and assembly REMOVE THE STEERING KNUCKLE A Jack up the front end of vehicle so that tires clear floor Block up securely at this position and remove jacks CAUTION prevent the vehicle from falling do not disassemble or perform knuckle repair with vehicle suppor
34. Size Tires Front Manufacturer Size Capacity Hear Manufacturer Size Capacity Muffler Manufacturer Model AC Inverter Manufacturer Model Siren PA Manufacturer Model Bostrom Four way Adjustable Standard Firestone 22 5 x 16 5 Firestone 20 x 8 5 Goodyear 16 5 R 22 5 18 P R 20 000 Ibs Michelin 12 00 R 20X 18 P H 31 000 Ibs Nelson 86130 21 Dynamote A40 120 Code 3 3100 CAPABILITIES Fire Truck Pump Ladder Turning Radius Inside 31 5 Outside 42 25 Rated Power 370 BHP 2 100 rpm Engine Governor Setting No Load 2 100 Top Speed 58 mph Acceleration 0 35 mph 14 Seconds Braking 20 to 0 mph 15 feet Angle of Departure Front 15 degrees Rear 15 degrees oingle Stage Centrifugal Midship Mounted Driven by the truck engine from the output shaft of transmission Min discharge 1000 gpm 2 150 psi Min discharge 100 gpm 2 200 psi Min discharge 500 250 psi From dry condition take suction and discharge water in 30 sec with a lift of 10 deg through 20 of 6 suction hose 12 VDC Priming Pump Water Tank 200 gals Basic Weight 11 560 Ibs Outrigger Operation Speed Lower Front 9 sec Rear 18 sec Raise Front 9 sec Rear 18 sec Complete extension elevation and 90 degrees rotation in 60 sec Hydraulic Tank 45 gals Imp Vil TRUCK FIRE FIGHTING LADDER 85 INDEX TO COMMERCIAL PUBLICATI
35. THERMOMETER The gauge set illustrated will indicate pressure PSI and flow GPM with a single connection in series with the high pressure line to the steering gear A shutoff valve is included S 14 Page 17 SHEPPARD POWER STEERING SERVICE MANUAL HYDRAULIC SUPPLY DIAGNOSIS PAGE 2 Using the equipment available to you proceed with your evaluation of the hydraulic supply system Refer to the diagnosis chart for further assistance 1 2 Make necessary gauge meter connections otart engine and check system oil level assuring that oil flow is in proper direction through the flow meter Place thermometer in reservoir Run the engine at correct idle speed and steer from lock to lock several times to allow system to warm up 140 to 160 degrees F Pump maximum pressure relief With the engine running at specified idle speed slowly turn the shutoff valve until closed and read the pressure at which the pressure relief valve opens Open the shutoff valve as quickly as possible to avoid heat build up or possible damage to the steering pump This pressure reading should equal the maximum pump pressure specified by the manufacturer of your chassis Check your specifications Caution A malfunctioning pressure relief valve may not relieve pump pressure and closing the shutoff valve may cause severe pump damages or high pressure hoses to rupture Constantly observe the pressure gauge while closing the shutoff valve If pressure
36. The chemicals and additives that give these lubricants increased load carrying capacity oxidize faster at temperatures above 200 F 104 C contributing to more rapid lubricant deterioration For this reason lubricants of this type that operate continuously at high temperatures must be changed more frequently to realize the inherent advantages they offer Refer to pages 6 and 7 for detailed information on recommended lubricants and temperature ranges DRAIIN PLUGS Any drive axle while it is working generates small metal wear particles at a fairly steady rate These wear particles are very fine but hard If these hard wear particles are allowed to circulate in the lubricant the internal components will wear at a much faster rate than normal Magnetic drain plugs perform the vital function of trapping these small metallic particles that circulate in the lubricant The magnet must be strong enough to firmly hold the particles under service conditions We recommend plugs having a minimum pickup capacity of 1 5 pounds 0 7 kg of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness if excessive material is allowed to collect on the element It is recommended that the plugs be changed or cleaned between lubrication intervals The plugs can be reused if they maintain the minimum pickup capacity Spare clean plugs should be kept on hand for replacement if required LUBRICATION NOTE F
37. m SOO 4906SC 01 49125 New Service Manual 5001 49245 5001 49325 DESCRIPTION This group of totally enclosed switches is designed for use in cranking motor circuits They are controlled by a hand snitch usually located in a position readily accessible to the operator The major parts of these switches are an operating coil a contactor shaft as sembly and a pair of heavy duty contacts When the operating coil is energized the contactor is forced against the main contacts and completes the circuit between the two contact terminal studs When the operating coil is de energized a spring returns the contactor to the open position INSTALLATION Mount the magnetic switch in a vertical position with the terminals at the bottom The leads from the battery and cranking motor should be kept as short as the installation permits Refer to the Wire Size Table for proper size of the connecting leads OPERATIONAL CHECK Should the switch fail to operate properly it should be removed from the vehicle and the following tests made 1 With a test lamp check each of the four terminals for grounds to the switch base Check to be certain there is no circuit between the two main contac4 terminals 2 Apply the rated battery voltage to the operating coil terminals to determine if contactor plunger is operating properly If the above tests indicate that the switch is operating properly and no grounds or shorts are present the other
38. os 0 76 C 0 76 8 30 000 miles Spring amp 100 000 miles 12 months e J9prng amp Fal Spring amp ra 1 12 months 12 months _ As Required 30 000 miles Spring amp Fale Monthl AsRequired of AsRequrd spnng amp Fall Spring amp Fa 1 Monthi DRIVE LINE UNIVERSAL JOINTS v X TRA LIFE 2022 y 16 000 miles 3sRequred UX TRA LIFE 50 000 miles As Required STEERING SHAFT UNIVERSAL JOINTS 0 617 A 30 000 miles Spring amp Fall e FRONT DRIVE STEERING AXLES Universal Joints Knuckles bearings andBushinp 0 _0 617 A 0 617 B 30 000 200005 0 Cross Tube End 55 5 PEN 9000m es 9ODhows 0 Drive Units Differential 0 76 0 76 0 76 B 30 000 miles ee 2000 hours e or Cr amp Fall ese Spring amp Fall ee PLANETARY AXLES Steering Universal Joints Cardan DEO LEA 001782 2082 1 200nows amp Constant Velocity 0 617 A 0 617 B 1500 hours or 1500 hours or 2122 22 2 3 Spnng amp Fale Sprng amp Fal KnuckleBearings amp Bushngs 0617A0617B 0 1 200hous 200hous Wheel Ends amp Drive Units Common Wheel End Housing _ Oil Level 0 7
39. 5 298X 9 70 38X 744 844 Ft Lb 2210 5 373X N S S 260 298 Lb Ft Kit No Bolts Lock Plates Bolt Torque 1610 5 279 5 73 109 98 741 17 24 Ft Lb 1710 5 280 6 73 109 230323 32 42 Ft Lb 1760 5 407 6 73 109 230323 32 42 Ft Lb 1810 5 281 6 73 109 230323 32 42 Ft Lb BEARING 1880 5 308X 7 73 115 231009 50 66 Ft Lb PLATE J 3 Probable Causes rao amp asses amp Pr 1 i E Beg EI gt obabie Correction Spicer Flange Bolt Information Part Numbers Diameter Thread Recommended and Length Under Head Torque 1000 1100 5 73 414 500357 10 231421 2 5 16 24x 7 8 22 26 Lb Ft 1350 1410 1550 5 73 2216 T T 24 x 1 1550 5 73 1125 Y 24 x 1 9 16 1280 1310 6 73 316 500357 11 231421 3 3 8 24 1 40 48 Lb Ft 1610 6 73 1219 24 1 3 16 i 1710 6 73 220 i i 24 x 1 1 4 1760 6 73 220 i 24 x 1 1 4 1610 6 73 325 m 24 x 1 9 16 1710 6 73 1227 i 24 x 1 11 16 1350 1410 7 73 219 500357 12 231421 4 7 16 20x 1 3 16 63 75 Lb Ft 1810 7 73 122 i n 20 x 1 3 8 1350 1410 7 73 126 i 20 x 1 5 8 1810 7 73 228 20 1 3 4 1480 1550 8 73 122 500357 13 231421 5 1 2 20x 1 3 8 97 116 Lb Ft 1650 8 73 123 Bearing Race Cap 20 x 1 7 16 i 1480 1550 8 73 228 500357 13 231421 5 20 x 1 3 4 1880 1910 10 73 131 500358 15 231421 7 5 8 18x 1 15 16 194 232 Lb Ft 1950 12 73 140 500358 17 231421 8 3 4 16x2 1 2 341 409 Lb Ft 2010 9 55 7
40. 5 8 18NF x 3 Lg PHOTO COPY AND USE FOR ORDER FORM CUSTOMER S ORDER NO OUR ORDER NO SOLD TO SHIPPED 181441 Ye 20 x 2 Lg Grade 5 Pitman Arm Installation Tool Set Page 67 SHEPPARD Inc HANOVER 17331 Phone Area Code 717 637 3751 Heavy Duty Power Steering TEST KIT This Tester is a self contained direct reading device to check system flow pressure both simultaneously Requiring no electrical connections it can detect worn components verify flow and pressure control settings or monitor overall system performance dd S 170 LOW COST EASY TO USE Only one hose connection is broken either at the pump output or at the pressure input to the power steering gear housing SHIPMENT FROM STOCK Installs between pump and steering gear INCLUDES SHEPPARD ia n SERVICE MANUAL ressure and flow can be read simultaneously 0 2000 P S I pressure gauge 1 10 G P M flow meter Complete with hoses amp standard swivel fitting PHOTO COPY AND USE FOR ORDER FORM CUSTOMER S ORDER NO DATE OUR ORDER NO SOLD TO SHIPPED TO QTY PART ORDERED NUMBER PART DESCRIPTION 2271 5517641 Pressure and Flow Test Kit Includes Sheppard service manual with operating instructions Page 68 Item Part No Description Qty 1 7605 7918 Hex Head Capscrew 4 2 7305 7919 1 3 7605 7920 Snap Ring 1 4 7605 79
41. 9 60 15 or 2 15 Legend Bubble type A protactor The most convenient way to determine 4 5 U joint angles in the side view is through use of a bubble type protracor Procedure is as follows Step Using a bubble protractor record inclination angles of drivetrain components Set protractor on machined surfaces of engine transmission axle or on machined lugs of transmission output and axle input yokes Note U joint angles can change significantly in a loaded situation Therefore check vehicle loaded and unloaded to achieve the accepted angle cancellation See Step IV Example 1 Eng Trans 4930 Down 2 Main Drive Shaft 7200 Down 3 Input ist Rear Axle 42900 Up Output 1st Rear Axle 4 00 Down 4 Inter axle 7 00 Down 5 Input 2nd Rear Axle 4 15 Ub Note If inclination of driveshaft is up and Eng Trans is down add to obtain the U joint angle Z a 2 1 7 00 4 30 2 30 Z b 2 3 7 00 4 00 3 00 Z c 4 7 00 4 00 3 00 Zd 4 5 7 00 4 15 2 45 Plan View This is the sum of the U joint angles in botn the plan view and side view compound angle The true U joint operating angle is calculated in the following manner Compound Angle C x Where x 2 15 as determined by measurement and calculation in Section 2 5 as det
42. DA FORM 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 JUL 79 z ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS SENT Linear Measure 1 centimeter 10 millimeters 39 inch 1 decimeter 10 centimeters 3 94 inches 1 meter 10 decimeters 39 37 inches 1 dekameter 10 meters 32 8 feet 1 hectometer 10 dekameters 328 08 feet 1 kilometer 10 hectometers 3 280 8 feet Weights 1 centigram 10 milligrams 15 grain 1 decigram 10 centigrams 1 54 grains 1 gram 10 decigram 035 ounce 1 decagram 10 grams 35 ounce 1 hectogram 10 decagrams 3 52 ounces 1 kilogram 10 hectograms 2 2 pounds 1 quintal 100 kilograms 220 46 pounds 1 metric ton 10 quintals 1 1 short tons To change inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons pound feet pound inches To centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters liters liters liters grams kilograms metric tons Newton meters Newton meters Fahrenheit temperature The Metric System and Equivalents Approximate Conversion Factors Liquid Measure 1 centiliter 10 milliters 34 fl ounce 1 deci
43. Do not stack more than 3 gaskets together Usually one thick gasket 020 50mm will be required Remember the lubricant in the transmission also lubricates the P T O Therefore at least one gasket must always be used on either side of filler blocks adapter assemblies or adapter plates More gaskets may be required when establishing proper backlash P T O to the transmission Copper gaskets are used as a guard against leaks under cap screw head See Fig 8 NOTE f holes in the P T O aperture are not drilled through discard the copper gaskets and replace them with lock washers The 220 Series must always have a copper washer under its one cap screw head that goes through inside of housing Fasten the P T O to the transmission torquing 6 bolt to 30 35 Ibs ft 4 14 4 84 kg meters and 3 bolt to 45 50 Ibs ft 6 22 6 91 kg meters See Fig 9 CHECKING BACKLASH To check for proper backlash on P T O s with shift cover m Remove the shift housing and or inspection plate 2 Mount the dial indicator so that it registers movement 3 of the input gear driven gear of the P T O See Fig 10 NOTE See Figure 11 for proper location of dial indicator contact point Two common type dial indicators shown Hold the P T O driver gear in transmission with a screwdriver or bar and rock the P T O input gear driven gear back and forth with your hand Note the total movement
44. H 170 H 172 L 100 with 3 545 thru 5 833 ratios except 4 875 ratios 7 562 192 08 mm with 6 166 thru 8 600 ratios including 4 875 ratio L 140 L 145 L 148 7 688 195 28 mm 7 625 193 68 mm L 155 with 3 545 thru 5 833 ratios except 4 875 ratios 7 562 192 08 mm with 6 166 thru 8 600 ratios 7 688 195 28 mm including 4 875 ratio L 172 7 625 193 68 mm Q 145 Q 146 Q 148 8 250 209 55 mm 100 110 8 750 222 25 mm R 114 R 115 R 120 R 140 141 143 R 155 R 158 R 160 R 162 R 164 R 170 R 171 R 173 10 000 254 00 mm R 180 U 140 8 750 222 25 mm U 170 10 000 254 00 mm U 180 10 SINGLE REDUCTION DRIVE UNIT BACKLASH SETTING CARRIER amp PITCH DIAMETER BACKLASH SETTING Single Reduction Carriers Less than 17 Pitch Dia 005 015 13 39 mm Single Reduction Carriers 17 Pitch Dia amp over 008 020 21 51 mm NOTE To determine approximate pitch diameter measure the ring gear outer diameter REASSEMBLE PINION AND CAGE ASSEMBLY D Install radial bearing lock ring and squeeze ring into pinion shaft groove with pliers A f new cups are to be installed press firmly against pinion bearing cage shoulders E Insert pinion and bearing assembly in pinion cage and position spacer or spacer combination B Lubricate bearings and cups with the over pinion shaft recommended axle lubricant F Press front bearing firmly against spacer G HRota
45. Heavy Vehicle Systems Group Section VI BRAKE SYSTEM Service Data Formerly SD 55 or RING BALL CAP NUT Aem Mi c mper m k SPRING BALL BODY SEAT GUIDE GASKET NUT 1 16 Figure 1 DESCRIPTION The In Line Single Check Valve is a device placed in an air line to allow air flow in one direction only and to prevent flow of air in the reverse direction The three types of In Line Single Check Valves used in service are T The ball type Figure 1 2 The disc type with integral seat Figure 2 3 The disc type with a replaceable seat Figure 3 the replaceable seat being made of either metal or rubber An arrow indicating the direction of air flow is cast into the of the valve OPERATION Air flow in the normal direction moves the check valve ball or disc from its seat and the flow is unobstructed Flow in the reverse direction is prevented by the seating of the ball or disc which is caused by a drop in up stream air pressure and assisted by the spring SPHING BODY DISCHARGE li EN 12 GROMMET VALVE STOP IN LINE SINGLE CHECK VALVES 1 2 SPRING 1 27 mei VALVE SCREW BUSHING WASHER SEAT CAP PREVENTIVE MAINTENANCE Every six months 1800 operating hours or every 50 000 miles disassemble clean and inspect all parts Replace any parts showing signs of wear or deterioration Reassemble and check for proper operation
46. Inspect all parts and replace any part showing signs of wear or deterioration REMOVAL 1 Block vehicle wheels and or hold vehicle by means other than air brakes 2 Drain all air brake system reservoirs 3 Identify and disconnect air lines from valve 4 Remove mounting bolts then valve DISASSEMBLY Mark the relationship of the body and cover before disassembly 1 Remove cap nut 2 Remove sealing ring from cap nut 3 Remove double check valve diaphragm 4 Remove four Phillips head screws 5 Separate the body and cover and remove the sealing ring and quick release diaphragm CLEANING AND INSPECTION Clean all metal parts in mineral spirits Wipe all rubber parts clean It is recommended that all rubber parts and any other part showing signs of wear or deterioration be replaced with genuine Bendix parts ASSEMBLY 1 Install sealing ring on cap nut 2 Install double check valve diaphragm in body 3 Install cap nut and torque to 150 400 inch pounds 4 Install sealing ring in valve body 5 Install the quick release diaphragm in the cover 6 Install the cover and diaphragm on body aligning the marks made during disassembly Secure together using the four Phillips head screws and torque to 30 60 inch pounds 7 Re install the QR 1C and before putting the vehicle in service perform the Operation and Leakage Tests OPERATING AND LEAKAGE TESTS Before performing these tests park the vehicle on a
47. Qo I 0 o O0 x I 0085 m s Oe o v C qt o amp gt Vs A remo 225 Z e c T 5 i Soe 2 lt lt lt 5 2 x c O c 2 3 25 5 505 lt 4225 YW 5 o 9 92 Cc e Liu 2 Ul pu 28 2 2o zy Sj gc z 2 r 0 f 2 4 v uo ieu 1 2 2 Oo o c bm cn ef Y J E mL a uum u BE a gt a oo 2 Uv o 5 5 5 Et S i vs e 9 e c O oO gt u T c WO 2 tris Qc ENE LO Z IBZ 4 BA SY CS RID 2 Ly 4 4 5 vo chos 54 c fts 514 CANADIAN AND FOREIGN PATENT We general description This lock is intended primarily for passenger doors on vehicles Certified to meet the Federal Motor Vehicle Safety Standard No 206 and to comply with established OSHA safety standards this lock be installed on doors as thin as 6 inches inner skin to inner skin or the inner surface of a door panel it can be used for direct operation remote operation or a combination of both The lock is designed so there is no concern about accidental lockouts because the inside thumb latch kicks out automatically when the door is slammed The split tumbler all
48. Reverse the order of disassembly to reassemble using new parts as required After reassembly of the complete miter housing to the bearing cap the backlash between the bevel gears must be checked With the gears free of grease turn the input shaft with the fingers to judge the clearance between the gears Add or remove proper shims to obtain zero clearance The miter housing should be filled with Fiske Multi Purpose Grease or an equivalent waterproof lubricant Page 64 SHEPPARD POWER STEERING SERVICE MANUAL 3 164 The Sheppard T box miter has two input shafts and is used where dual steering controls are desirable The box housing can be swiveled a full 360 degrees to place it in its optimum design position Note The miter housing in most cases will be indexed to the bearing cap with a roll pin which passes through the clamping bar and enters a drilled hole in the miter housing This ensures that the miter housing is placed in its optinum position The locating pin will also keep the housing from turning in service During reassembly make sure that the locating pin is properly installed The steering gear bearing cap and high pressure oil seal are serviced in the same manner as the fixed miter gear assembly Refer to the fixed miter section of this manual for complete details T BOX INPUT MITER DISASSEMBLY amp REPAIR Page 65 SHEPPARD POWER STEERING SERVICE MANUAL The two halves of the T box miter are se
49. START SWITCH TO MOTOR WINDINGS Figure 17 Basic solenoid circuit Types shown in Figures 1 2 and 3 CLEANING he drive armature and fields should not be cleaned in any degreasing tank or with grease dissolving solvents since these would dissolve the lubricant in the drive and damage the insulation in the armature and field coils All parts except the drive should be cleaned with mineral spirits and a brush The drive can be wiped with a clean cloth START SWITCH s HOLD IN WINDING Figure 1 Basic solenoid circuit Types shown in Figures 4 and 5 If the commutator is dirty it may be cleaned with No 00 sandpaper NEVER USE EMERY CLOTH TO CLEAN COMMUTATOR Brushes and Holders Inspect the brushes for wear If they are excessively when compared with a new brush they should be replaced Make sure the brush holders are clean and the brushes are not binding in the holders full brush surface should ride on the commutator to give proper performance Check by hand to insure that the brush spring are giving firm contact between the brushes and commutator If the springs are distorted or discolored they should be replaced ARMATURE SERVICING If the armature commutator is worn dirty out of round or has high insulation the armature should be put in a lathe so the commutator can be turned down The insulation should then be undercut 1 32 of an inch
50. This velocity change may upset steering performance When two universal joints are used it is in most instances possible to phase the two joints to match a high and low velocity in a manner that will provide equal velocity between the drive and driven shafts A third universal joint in the shaft arrangement can upset the phasing of the first two joints and it is important that this third joints operating angle is limited to a maximum of 20 25 degrees Phasing of the universal joints in the steering column can be checked quite easily Using an inch pound graduated dial reading type torque wrench read the variation in the torque reading while steering from lock to lock with a socket on the steering shaft nut under the horn button Variation of more than 15 indicates improper phasing This reading is taken with the vehicle stationary and the engine running Phasing can usually be accomplished by rotating the two piece intermediate shaft one spline at a time until the torque reading remains the same all the way around the 360 degree rotation of the steering wheel Page 14 Symptom Excessive backlash No attempt to return straight ahead from turns Possible cause Worn universal joint Worn pins and keys universal joint to actuating shaft and universal joint to steering shaft Low oil volume Pitman arm ball worn egg shaped Improperly adjusted drag link pitman arm to drag link and steering arm to drag link Loose bracke
51. cast brackets and some brake parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts are not ground or polished parts should remain in the tank long enough to be thoroughly cleaned and heated through This will aid the evaporation of the rinse water The parts should be thoroughly rinsed after cleaning to remove all traces of alkali CAUTION Exercise care to avoid skin rashes and inhalation of vapors when using alkali cleaners COMPLETE ASSEMBLIES Completely assembled axles torque dividers and transfer cases may be steam cleaned on the outside only to facilitate initial removal and disassembly providing all openings are closed Breathers vented shift units and all other openings should be tightly covered or closed to prevent the possibility of water entering the assembly DRYING Parts should be thoroughly dried immediately after SINGLE REDUCTION DRIVE UNIT cleaning Use soft clean lintless absorbent paper towels or wiping rags free of abrasive material such as lapping compound metal filings or contaminated Bearings should never be dried by spinning with compressed air CORROSION PREVENTION Parts that have been cleaned dried inspected and are to be immediately reassembled should be coated with light oil to prevent corrosion If these parts are to be stored for any length of time they should be treated with a good RUST PREVENTIVE and wrapped in special paper or other mat
52. driver Seal should be flush with bearing cap A Fit two gears Fig 1 3 amp 5 together when installed properly Photos 16 amp 17 Sliding gear Fig 1 3 should move freely on mating gear Fig 1 5 Photo 18 Photo 18 Photo 16 B Load gear Fig 1 5 in the following manner jm Place small amount of bearing grease in 1 0 Photo 19 Photo 19 Photo 17 12 REASSEMBLY 22 26 Series cont Place spacer Fig 1 8 in gear Photo 2 Put load pin in gear Photo 20 22 Photo 22 5 Load second row of 19 bearings Fig 1 Photo 20 is 16 around load pin Photo 23 3 Load first row of 19 bearings Fig 1 16 around nis Sin 24 d NOTE 26 series uses caged roller bearings thus it doesn t need a load or grease Photo 23 Photo 21 13 REASSEMBLY 22 26 Series cont C Start idler pin Fig 1 7 into housing from E Place loaded gear load pin still in place in set screw side and drive until pin breaks housing Load pin should fall through idler through inside wall Photo 24 pin hole if lined up properly Photos 26 amp 27 NOTE Idler pin groove has to line up with set screw hole Photo 26 Photo 24 D Place thrust washer Fig 1 13 in housing line up with idler pin hole tab in slot Photo 25 Photo 27 Photo 25 14 REASSEMBLY 22 26 Series cont F Insert thrust washer Fig 1 13 and drive idler pin through so it goes into gear Press
53. form the less obvious function of providing a means of cooling the air as delivered from the compressor and thereby condensing water vapor into a liquid as well as collecting oil passed by the compressor This water and oil collects as an emulsion the greatest amount in the reservoir nearest the compressor It should be drained either manually or by means of an automatic drain evice OPERATION OF INTEGRAL CHECK VALVE The integral check valve provides a one way passage of air from the upstream compartment to the downstream This check valve may serve to meet the legal requirement for a check valve to protect the service brake system in case of failure in the compressor discharge lines or first reservoir compartment PREVENTIVE MAINTENANCE reservoirs should be drained daily an automatic drain device is used it should be checked periodically for proper functioning lf an air dryer or aftercooler is used the reservoirs should be manually drained periodically to verify the proper function of the drying device Reservoirs which collected a considerable oily emulsion should be drained by opening a drain cock and allow to drain until all drainage Stops MAINTENANCE OF THE INTEGRAL CHECK VALVE Every six months 1800 operating hours or 50 000 miles the check valve on the two compartment reservoir should be tested for leakage as outlined below and parts inspected for damage or deterioration replaced if conside
54. forward and reverse thrust and a third bearing behind the pinion teeth to carry the radial load G in the housing bore rounded to prevent indenting the carrier flange Use a roller jack to safely remove carrier from using Hemove top nuts and washers and work carrier free A small pinch bar may be used to straighten the carrier However the end must be CARE AND MAINTENANCE DISASSEMBLE CARRIER Place carrier in suitable holding fixture as illustrated Prints of carrier repair stand are available upon request B Center punch one differential carrier leg and bearing cap to identify for properly reassembling C Cut lock wire if employed Remove capscrews and adjusting nut locks CARRIER IN REPAIR STAND NOTE If the initial inspection indicates that the drive gear D Remove bearing cap stud nuts or capscrews bearing is not going to be replaced we suggest the established caps and adjusting nuts backlash be measured and noted for reference and used at reassembly REMOVE DIFFERENTIAL AND GEAR ASSEMBLY g de E Lift out differential and gear assembly A Loosen jam nut and back off thrust block adjusting F Remove thrust block if used from inside of carrier screw housing SINGLE REDUCTION DRIVE UNIT DISASSEMBLE DIFFERENTIAL CASE AND GEAR ASSEMBLY gt If original identification marks are not clear mark differential case halves with a punch or chisel for correct alignment when
55. level surface and hold the vehicle by means other than the brakes 1 With the park control valve in the released position note that the spring brakes are released 2 Remove the air line connected to the QR 1C balance port and apply a soap solution to the exhaust and balance port A 1 bubble in 5 seconds is permissible at either location 3 Reconnect the QR 1C balance line and using the park control valve park the vehicle NOTE A prompt application of the spring brakes with an exhaust of air at the QR 1C exhaust port 4 Remove the air line connected to the supply port of the QR 1C With a service brake application hold applied apply a soap solution to the supply port and around the seam between the body and cover A 1 bubble in 5 seconds is permissible at the supply port No leakage is permitted between the body and cover 5 Reconnect the supply port air line If the valve does not function as described or if leakage is excessive it is recommended that it be replaced with a new or remanufactured unit or repaired with genuine Bendix parts INSTALLATION Mount valve with exhaust port pointing down securely tighten mounting bolts Reconnect air lines as identified during removal IMPORTANT PLEASE READ When working on or around air brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pre
56. lf the lamp lights at least one field coil is grounded which must be repaired or replaced This check cannot be made if the ground connection cannot be disconnected Opens Connect test lamp leads to ends of field coils If lamp does not light the field coils are open FIELD COIL REMOVAL Field coils can be removed from the field frame assembly by using a pole shoe screwdriver A pole shoe spreader should also be used to prevent distortion of the field frame Careful installation of the field coils is necessary to prevent shorting or grounding of the field coils as the pole shoes are tightened into place Where the pole shoe has a long lip on one side and a short lip on the other the long lip should be assembled in the direction of armature rotation so it becomes the trailing not leading edge of the pole shoe CLUTCH ASSEMBLY Disassembly procedures for the various types of clutches are outlined below A Intermediate Duty Sprag Clutch An early type clutch and late type clutch are shown in Figures 12 and 13 1 Remove the lock wire collar and jump spring from the sleeve assembly 2 Remove the spring stop washer and second lock wire from the early type clutch 3 Remove the retainer ring and large washers Do not remove the sleeve assembly or sprags from the shell assembly 4 Lubricate the sprags and saturate the felt washer with No 5W20 oil Heavier oil must not be used Page 9 9 B 4
57. maintenance and recognition of discrepancies may enable them to make necessary corrections to ward off a serious breakdown Drive Shaft Torque Twisted drive shaft tube Broken yoke shaft Broken journal cross Usually a result of torque overload How much torque can be generated in your application Here is how to figure L G T N E T x Trans L G R x 85 efficiency factor Wp x C O F x R R D L T to Slip Wheels 12x A R Axle ratio L G T Low gear torque C O F Coefficient of friction 7 N E T 2 Net engine torque D L T Drive line torque R R Tire loaded rolling radius L G R Low gear ratio Wer Weight on drive axle Relate the lesser of above to Spicer U joint ratings If your torque exceeds Spicer rating for U joint size in application switch to a size with a rating compatible to your calculation A primary source of problems contributing to Reduced life Vibrations Drive train component failures If suspected to be excessive CHECK Here is how ye Vehicle side rail or datum line A E 1 From side rail or convenient datum line measure offset dim c amp d 2 b d c 3 Measure dim a 4 With dim a amp b determined thru measurement calculate U joint angle by tan x 2 Example Where 40 0 45 6 0 Jeb d 6 0 4 5 1 5 dd b 1 5 tan 03750 a 40 tan 03750 2 9 or
58. sleeve engages the adjusting screw nut thus locking the adjusting screw in lace DO NOT ATTEMPT TO TURN THE ADJUSTING Sait WITHOUT FULLY DEPRESSING THE LOCK Using the Ball Indent Slack Adjuster Mechanism Figure 2 Before proceeding with adjustment measure distance from top of lock screw head to slack adjuster body To adjust back off lock screw counter clockwise and make necessary adjustment by turning the adjustin screw After adjustment is complete retighten loc screw making certain that lock ball is engaged on the lunger shaft Proper engage ment can be confirmed y checking the measurement from the top of the lock screw head to the slack adjuster body It should be the same before and after the adjustment PROCEDURE Vehicle brakes should normally be adjusted using the vehicle or brake manufacturers recommendations they are not available the following can be used 1 Bring the vehicle to rest on a level surface and chock the wheels 2 Mechanically release cage the spring brakes Preferred Adjustment Method Raise the vehicle wheel that is to be adjusted off the ground so that it turns freely Turn the slack adjuster adjusting mechanism until the brakes begin to drag is then locked off until the wheel turns reely This adjustment method will result in the shortest possible actuator stroke without the brakes dragging Alternate Adjustment Method 1 Determine the slack adjuster arm length Di
59. subtract its thickness 400 from the corrected pinion gauge dimension calculated in Step 4 Example Corrected Nominal Gauge Distance 4 809 005 4 804 Example Corrected Nominal Gauge Distance 4 809 005 4 804 Step Plate Thickness 400 Corrected Micrometer Distance Final measurement to be obtained 4 404 Initial Micrometer Reading Using original shim pack 4 384 Shim Pack Correction To be added 020 8 After making the necessary corrections to the shim pack and tightening the cap screws or nuts 14 CARE AND MAINTENANCE to the specified torque recheck the micrometer measurement again to be certain of the correct pinion adjustment C ADJUSTING THE PINION CAGE SHIM PACK THICKNESS WITHOUT A PINION SETTING GAUGE A second means of accurately installing a new pinion and cage assembly into the carrier is to mathematically calculate the proper pinion cage shim pack thickness The following are the procedures to use 1 Measure the thickness of the original shim pack used with the gear set being replaced Use a micrometer or vernier gauge Record this measurement for future use 2 Observe the PC or variation number on the original pinion being replaced If this number is a plus value subtract it from the original shim pack measurement taken in item 1 If the variation number is a minus value add it to the measurement from item 1 Make
60. 2 __ Special Brake Grease NLGI Grade No 1 0 617 A Chassis Grease 6 12 hydroxy lithium stearate grease NLGI Grade No 1 0 617 B Chassis Grease 8 12 hydroxy lithium stearate grease NLGI Grade No 2 Drive Unit Output 3 5 hydroxy lithium Bearing Pre Grease stearate grease NLGI Grade No 000 Approved Material Mobil Mobilux EP023 12 hydroxy lithium stearate grease with 7 to 9 polyethelene and molybdenum disulfate additives NLGI Grade No 2 cd Metallic based temperature resistant anti seizing compound Special Low Temperature Approved Material 40 F 40 C Brake Grease Mobil 28 These lubricants are never to be used in axles employing hypoid amboid spiral bevel or planetary gearing There is no upper limit on these outside temperatures for oils and greases Axle sump temperature must never exceed 250 F 121 C Grease recommendations are based on commercial products that have given satisfactory results in normal operation However there are many pro prietary grease products on the market which will perform satisfactorily and may be preferable because of supply problems common usage for other truck components etc Where such products are recommended by reputable suppliers for the specific lubrication of our components Rock well has no objections provided that these substitute products are equal or better than the Rockwell recommendations in lubrication properties wa ter resistance co
61. 260 381 410 420 431 and 812 Series Using New Williams Valve 378414 Pressure Protection Valve 378356 ni Valve Opens at Tube Nut Hex Nipple lt 379131 1 X P Bushing P Air m Supply Male Connector 3 Places ae Note Direction of Arrows Note Tube nut is reusable as long as nylon tubing is not removed from the tube nut Caution When installing nylon tubing avoid sharp angles exhaust and manifold systems Important When this installation is used on vehicles with automatic transmissions the P T O drive gear must be stopped before shifting Template for control plate on page 36 68 27 Name Plate Chelsea BE a i SENSA v RETUPE N 378464 Elbow 328863X Valve Assembly B IIBER 379130 Bracket 2 pe Wiel NIS 378415 7 EN q 415 H 378978 ATUDAR Indicator Light i E 4 ab 500376 6 Hex Nut 27 378969 500357 7 Lockwasher 4 Indicator Switch 2 ux 500448 9 Slotted Screw T 328388 27X Installation Kit To Shifter Cover Ass y Battery or ignition Warning Connect directly to air supply Do not use tubing between air supply and pressu otection valve 35 DASH DRILLING TEMPLATE For 6 amp 8 Bolt Air Shift for New Williams Valve 50 e For use with Installation sketch on Page 35
62. 29 13 5 65400 17 8 0 L 340 22 10 5 65456 17 8 0 L 350 24 11 5 65700 12 5 5 L 370 32 15 0 66700 20 9 5 L 600 35 16 5 67000 20 9 5 LT 200 31 14 5 68700 20 9 5 LT 300 29 13 5 72200 45 7 0 M 172 27 12 5 72300 21 10 0 QT 140 24 11 5 73300 8 4 0 QT 200 31 14 5 74400 9 4 5 QT 230 44 21 0 74878 12 5 5 QT 240 34 16 0 75300 20 9 5 QT 300 29 13 5 75357 20 9 5 3306 44 21 0 75400 20 9 5 QT 340 32 15 0 75700 24 11 55 Q 100 31 14 5 76400 18 8 5 Q 145 24 11 5 76700 26 12 0 Q 200 34 16 0 76784 26 12 0 Q 245 34 16 0 76790 28 13 0 Q 300 32 15 0 78000 20 9 5 345 32 15 0 79000 24 11 5 Q 350 34 16 0 79721 24 11 5 Q 370 34 16 0 93440 20 9 5 Q 380 36 17 0 94440 20 9 5 Q 390 36 17 0 96710 25 12 0 RL 170 48 22 5 98415 41 19 0 SINGLE AXLES t one pint 0 47 liters of lubricant to pinion cage when new or reconditioned drive unit is installed For correct lubricant specification see Pages 19 23 SHousing over 6 165 deep overall 26 LUBRICATION TANDEM AXLES t REFERENCE ONLY CAPACITY CAPACITY CAPACITY CAPACITY U S Pints Litres MODEL U S Pints Litres 50 353 24 11 5 SR 170 SD 454 26 12 0 forward 55 26 0 SD 472 28 13 0 rear 43 23 3 SD 473 28 13 0 SR 270 amp 280 SD 3000 19 9 0 forward 55 26 0 SD 3010 19 9 0 rear 55 26 0 SD 3020 31 14 5 SRD 22 10 5 eSDHD 116 17 0 SRDD 1200 110 0 SFD 75 16 7 0 SRHD SF
63. 3333 hours 934 951 and 971 Series 5 EET APPEAR 12 months ee SE Cross Tube End Assemblies 0 617 A 0 617 B 50 000 miles 12 months 50 000 miles or 3333 hours 12 months e 2000 hours 2000 hours DRIVEUNITS DIFFERENTIALS _ ___ With Traction Equilizer Additives BRAKES 0 76 0 76 A 0 76 B 2 100 C00 miles 12 montnse 30000mies iti Spring amp Fail 30 000 miles _Stopmaster Wedge 12096864 2222211 100 000 1 12 monthse 12monns Te months Cam Master Cam Manual Slacks and Camshaft 50 000 miles Spring amp Fall e Spring amp Fall 4 months 0 617 0 617 B Ancnor Pins 0 616 Automatic Slacks 0 616 A _ Manuai Slacks and Camshaft 0 617 A 0 617 B Ancnor Pins 0 616 Automatic Slacks 0 616 A P Series 12 months Q Series 1 2 months 12 months Dura Master Disc __Automatic Slack 0 616 A 26 000 miles 235000mis 1667 Actuating Components _ACaliperO 616 A 80 000 miles _ 50 000 miles __ __ 3334 0 Slide Pins Slide Pir Retainers At brake reline and caliper overhaul Powershaft and Stack Splines 0 637 WHEEL BEARINGS Grease Lubricated Oil Lubricated SPRING SEATS Bushing Metal Ny on amp Rolier Bearing Type
64. 7 13 5 13 1 8 125 21 P S I 7 8 RING 25 30 P S I 342 9mm 330 2mm 8 7 15 2 Kg cm 1 75 2 1 Kg cm2 r Nov 1974 T FITTING 378970 1 1 16 RING 25 30 P S I 1 75 2 1 Kg cm2 1 Converter driven P T O Drive Gear 26 CIRCUIT CHECK For Power Shift P T O s on Automatic Transmission 270 800 and 852 Series Perform the following and record the results when installing the P T O originally as a replacement or while trouble shooting 1 Install two 2 Pressure Gauges in the circuit as shown 300 400 PSI Gauges for Allisons Before 378965 Screen Adapter In Port of Solenoid Valve Between 378966 Screen Adapter and EE 5 pon 2 With Solenoid Valve Off record the pressures at inlet to Solenoid Valve for the transmission both cold ambient and at operating temperature for engine idle rpm and engine maximum rpm For Allisons should be 90 7 U FSI um MEE D Eee _ Cold Ambient At Operating Temperature Engine Idle 27 3 With the Solenoid Valve On record the corresponding pressures at the two 2 gauges with the transmission both cold ambient and at operating temperature for engine idle rpm and engine maximum rpm For Allisons should be 90 270 PSI Cold Ambient Operating Temperature Engine RPM Into Into Into Into Solenoid P T O Solenoid P T O Idle PSI PSI PSI PSI Maximum PSI PSI PSI PSI If at any time the above pressures are below 90 PSI
65. AND ACCESSORIES 2 6 1 Modification The following optional features are available on your inverter as factory modifications They can be ordered from the factory by designating on the order the inverter model number followed by the appropriate suffix designation a 2 6 2 240 Simultaneous output of 120 volts and 240 volts from the same inverter Maximum volt amperage output at 240 volts is 67 of maximum volt amperage at 120 volts MP The MP Marine option includes the Low Voltage Cutout feature which disconnects the AC load from the inverter when the AC output voltage drops below a safe level such as when the engine RPM falls below the minimum This feature is particularly applicable to boats 4 201 or 4 202 Remote Control is also included with the MP option 240 50Hz Export models available with 50 Hz 240 volt output Load DemandSiart Stop This feature senses load to start inverter and operate automatic throttle control When the load is removed inverter turns off and auto throttle returns to normal There is a 5 30 second delay before the Stop Mode The extent of this delay is subject to adjustment of Delay Control Knob on front panel Isolated Output ISO A means to ground one of the AC output leads for protection from electrical shock hazard when vehicle operates under conditions making shock a problem ISO is recommended for operation of electronic equipment Accessories The following convenience and safety accesso
66. Alternator 145 Amps 1 7605 0198 Alternator 160 Amp 1 10 7804 7736 Pulley 130 amp 160 Amp 1 7808 0471 Pulley 145 Amp 1 11 w alt 8 Woodruff Key 1 12 w alt Flat Washer 5 8 1 13 w alt Hex Nut 5 8 18 1 14 7604 2248 Alternator Belt 2 15 8855 1013 Lockwasher 1 2 3 16 8850 1008 Hex Nut 1 2 13 2 17 8820 1052 H H C S 7 16 14 x 1 1 2 2 18 8855 1012 Lockwasher 7 16 2 19 7604 6506 Alternator Mounting Bracket 1 20 7604 5145 Spacer 1 NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts Delco Remy CRANKING MOTORS 30 MT 35 MT 40 MT 50 MT Series Service Bulletin 1M 153 Section VII ELECTRICAL SYSTEM Dated 5 1 80 Supersedes Bulletin Dated 3 1 69 11 1 73 Reference 1B 115 1B 116 1M 186 1M 187 1M 188 1S 180 1S 186 1S 187 1M 188 Pages 12 Figure 1 Typical 50 MT Series heavy duty cranking motor The heavy duty cranking motors covered in this bulletin have a shift lever and solenoid plunger that are totally enclosed to protect them from exposure to dirt icing conditions and splash The nose housing can be rotated to obtain a number of different solenoid positions with respect to the mounting flange which is a feature that makes these motors universally adaptable to a wide variety of different mounting applications Positive lubrication is provided to the bronze bushings by an saturated wick that projects through t
67. Bolt 28 Ibs 270 27 6 45 05 300 30 6 Bolt 45 Ibs 321 Hel 320 6 Bolt 39 Ibs 322 Spur 5320 6 Bolt 39 Ibs 340 3AL 6 Boit 32 Ibs 350 935 36 amp 37 6 Bolt 37 Ibs 370 SR35 36 amp 37 6 Bolt 45 Ibs 381 5380 6 Bolt 23 Ibs OBS 6 1 80 416 6 Bolt 26 s 410 U 41D 6 Bolt 2 410 W 41K 6 Boit 26 105 410 X 41X 6 Bolt 26 165 42 6 Bolt 26 165 420 6 Bolt 26 165 430D 6 Bolt 30 165 431__U 6 Bolt 30 Ibs 430K 6 Bolt 30 165 431 6 Bolt 30 Ibs 450 S45 46 amp 47 6 Boit 37 ibs Same 510 Countershaft 18 Ibs Same 540 Countershaft 3 ibs Same 540 R Countershaft 38 37 ibs Same 540 5 Countershaft 28 3 Ibs 611 A 6 Bolt 13 53 Ibs 700 A26 Gear Box 11 39 Ibs 710 142627 Gear Single Speed Shaft 10 20 Two Speed amp Input Shaft 11 23 39 165 720 2615 Gear Box 13 26 49 165 730 2536 Gear Box 13 26 49 Ibs 740 2538 13 26 49 Ibs 800 810 8 Bolt 33 66 38 Ibs 812 811 8 Bolt 38 76 50 Ibs 8 821 8 Bolt 04 76 Ibs 832 831 8 Bolt 57 76 Ibs 822 841 8 Bolt 04 76 Ibs 852 851 8 Bolt 04 88 Ibs 862 861 8 Bolt 94 96 Ibs 900 4600 SplitShaftP T O 185165 910 4700 Split ShaftP T O 126 Ibs 930 5551 Split Shaft P T O 102 Ibs Front Mounted 492 491 Air Clutch 34 hs 2381 2740 Gear Box 6c 2642 Gear Box 69 sus 2420 Gear Box 69 Ibs This chart provides a guide to the many different models of P T O s which may be used in a given application From this group a model can be selected to meet the exact hors
68. C Variation Number must be used to modify the Nominal Pinion Gauging Dimension when using a pinion setting gauge or when calculating pinion cage shim pack thicknesses On the ring gear the number is usually found on the front face of the gear although sometimes it may be on the gear O D A gear and pinion which do not have the same matching numbers must not be run together The Pinion Cone Variation Number i 3 or P C 5 is normally found on the pinion head end however it may sometimes be located on a spline of a pinion with the larger parallel sided type splines or on the ring gear O D Therefore if either a pinion or a ring gear should require replacement both must be replaced in a matched set 4 Pinion Cone Variation Number NOTE The nominal pinion mounting distance and backlash setting is not marked on current gear sets Refer to the following charts for this information Each pinion has a Pinion Cone P C Variation Number which indicates variations in thousandths of an inch from the nominal mounting distance This Pinion Cone Variation Number is necessary NOMINAL PINION MOUNTING DISTANCE NOMINAL PINION AXLE MODELS MOUNTING DISTANCE 100 B 101 5 250 133 35 mm C 100 6 125 155 58 mm D 100 6 500 165 10 mm D 140 F 106 6 812 173 03 mm F 130 F 140 F 142 F 145 F 146 F 147 F 149 H 140 H 141 H 145 7 500 190 50 mm H 150 7 156 181 77 mm H 162 7 625 193 68 mm
69. CHECKOUT PROCEDURE continued With the START button depressed the voltage should read O Otherwise replace the K3 Relay COMMUTATION FUSE CHECKOUT PROCEDURE Tools Required Ohm Meter 1 Commutation fuses are in the larger fuseholders on the front panel of the inverter There are two commutation fuses on A30s and four commutation fuses on A40s and A60s 2 Remove the commutation fuses They must be checked with an Ohm Meter as they are solid fuses and visual inspection will not determine if they are good 3 Check the fuses with the Ohm Meter by placing a probe at each end If there is no resistance the fuse is good If there is high resistance the fuse is blown 4 If the fuses are blown be sure to replace them with the same value fuses 5 Recheck commutation fuses after new installation DYNAMIC INVERTER VOLTAGE REGULATOR PCB1 CHECKOUT PROCEDURE Tools Required Voltmeter with 0 15VDC scale 7 16 socket or open end wrench screwdriver 1 Open inverter by removing the front and top panel fasteners Carefully lay the front panel down on its face and remove the top panel 2 Locate the inverter voltage regulator CB1 on the left side of the inverter It is the forwardmost of the two circuit boards and there are five wires attached to the board or to a connector that is plugged into the board 3 The engine and ignition are OFF for this test 4 If the voltage regulator has a fuse mounted on the circuit board check the fuse f
70. F 1 E 318 8 4 55 LB FT T5 LB FT 58 16 60 6018 115 LB SB 18 55 8 LE FT 115 LB FT 34 18 90 120 LB FT ITELE FT PE 100 215 1B FT 300 CB FT 17 74 250 325 LB 450 LB FT 1 18 12 350 475 LB FT 650 LB FT STOP SCREW LOCKNUT 12 13 50 65 LB FT CROSS TUBE CLAMP NUT PLAIN NUT LOCRKNUT 518 24 85 115 LR N 75 100 LB IN HTEN 367 24 18 24 LB 15 29 LB FT mm T3520 35 5 LB FT 30 40 L8 FT 1 Torque to the initial range specified 12720 40 55 LB FT 35 50 LB FT 2 Advance the nul do not back off eign the cotter bale 50 65 LB FT MESS LB ET 3 Tha final stacked Sorge must nat exceed the Maximum Alter Assembh toque spacihied 4 the final torque exceeds Te maximum specified remove the nut and reinsiah correct specication 28 md STRAIGHT KING PIN MODELS STEERING ARM NUT DRAW KEY WEDGE ALUMINUM CENTER M3 1 5 30 40 LB FT DRAW KEY NUT STEEL CENTER PME ETE STEERING ARM BALL NUT nam LB FT ENEL pt 20 40 18 FT 79714 250 325 LB 450 LB sos PS ARTES 390525 LB FT 725 LB FT dd 550 740 LB FT 1025 LB FT 58 16 BOBO LS 11518 FT FT 1450 LB FT 58 18 60 80 LB FT 115 LR FT 1350 1825 LB FT 2525 LB FT 34 15 00 12018 FT TO LB FT 78 14 180 215 LB FT 300 LB FT CROSS TUBE ARM NUT INITIAL MAX AFTER RANGE ASSEMBLY 1 14 33529 LB T25 LB FT 1g te
71. FOR DELCO REMY 4051 SERIES TYPE 150 NOTE If you know you will be installing a Series A Dynamic Inverter on a Delco Remy 4051 alternator order alternator 1117152 This alternator is factory designed for use with Dynamic Inverters and REQUIRES NO FIELD MODIFICATION Remove jumper between trio terminal and F terminal and proceed to Section 3 5 1 The purpose of this modification is to provide a means to ground negative field brush permanently for use with positive switching regulators 1 Disconnect the battery grounding cable and remove the alternator from the engine mounting brackets alternator can be left on vehicle be sure to disconnect the battery grounding cable 2 Remove end plate of alternator from slip ring and frame 3 Hold shaft with hex wrench inserted into hex hole in end of shaft while removing shaft nut Remove washer pulley fan and slinger 4 Remove four thru bolts from drive end frame 5 Separate slip ring end frame and stator assembly from drive end frame and rotor assembly 6 Separate stator from end frame by removing three stator lead attaching nuts Fig 3 5 5 2B shows end frame with stator removed Copyright 1981 DYNAMOTE CORP Section X F2118B INSTALLATION INSTRUCTIONS 12 81 3 5 5 2 MODIFICATIONS FOR DELCO REMY 4051 SERIES continued 22 27 Remove the diode trio from the alternator and discard it It will not be used 8 Prepare 12 inch length of WHITE 16 AWG wire by putti
72. G Insert proper set screw Fig 1 18 in base of idler pin through until it is flush with the housing Photo 30 housing Photos 28 amp 29 Photo 30 4 Installation Of Shifter Cover A Place gasket Fig 1 14 on cover Fig 1 22 and put on P T O Photo 3 Photo 28 Photo 31 Photo 29 15 REASSEMBLY 22 26 Series cont B Using four capscrews Fig 1 31 boltcover to 5 P T O should now be checked to see that it shifts P T O Photo 32 properly and rolls freely Photo 32 16 TOOL KITS P T O Change Over Tool Kit T 7000 See Photo 34 Item Description Part No 1 oeal Slide T 7626 2 onap Ring Slide T 7627 3 Hammer 2 4 Bearing Driver T 7627 2 5 Bearing Puller Includes Jaws T 7625 amp Proto 4060A T 7624 1 6 Bearing Loading Pin 41 Series T 7625 7 Bearing Loading Pin 22 Series CT 8788 Photo 34 The No 3A Press shown mounted on a pedestal is a larger machine for heavier classes of work up to 5 tons The No 3A press comes equipped with a hand operated brake to hold the ram in position Photo 33 Required Tools For Servicing P T O s See Photo 33 P T O changeover tool kit ooft steel drift 5 long x 3 4 diameter Hydraulic or arbor press Socket set and torque wrench with 1 2 socket open or boxed end wrench would also be helpful Allen wrench set Cold chisel ooft hammer 2 or 3 Ib in tool kit Dial indicator Safety glasses DD It 62268
73. LHD OHD TDD UDD AND FDD models include separate cast housings to enclose their respective inter axle differential assemblies Baffles and dams are incorporated in these cast housings to maintain a reservoir of lubricant but may also trap wear particles and debris Therefore it is important to always purge the lubricant that is retained in these inter axle differential assemblies whenever the axle lubricant is changed initially at scheduled intervals or at overhauls For this purpose these types of carriers employ separate oil drain and fill holes located in either the inter axle differential cover or the inter axle differential housing Also change the oil filter of drive units employing a pump forced lubrication system Initially the filter should be changed at the same time as the oil or 1 000 3 000 miles 1 600 4 800 km Fill axles to bottom of level hole in carrier or housing with specified lubricant with the vehicle on level ground If the axle employs an inter axle differential of the type that can be directly filled through a top filler plug hole pour an additional 2 U S pints 0 946 liters of the same lubricant into the inter axle differential housing PROPER LUBRICANT LEVELS CARRIER HOUSING PLUG F ILL PLUG PINION ANGLE LESS THAN 7 FiLL TO CARRIER FILL PLUG HOLE PINION ANGLE THAN 7 FILL TO HOUSING FILL PLUG HOLE IMPORTANT The angle of the drive pinion as mounted under the veh
74. LUBRICATION TRANSFER CASEST REFERENCE ONLY The capacities of Transfer Cases are given in the vertical position Transfer Cases may be mounted at various approved angles by the vehicle manufacturer and normally should be filled to the top of the filler neck or bottom of the tapped hole Capacities will vary depending upon the angle of mounting and should be obtained from the vehicle manufacturer MODEL CAPACTY CAPACTY CAPACHY CAPACHY U S Pints Litres MODEL U S pints Litres 32 4 2 0 152 5 2 5 T 50 81 2 4 0 1 154 91 2 4 5 T 59 2 1 0 T 167 10 4 75 T 70 24 11 5 T 179 1 1 2 75 73 24 11 5 T 180 2 1 0 T 76 4 2 0 T 212 2 1 0 T 77 7 3 25 T 221 4 2 0 79 6 2 75 223 5 2 5 T 96 7 3 25 T 226 6 1 2 3 0 T 98 46 21 5 T 228 D 21 10 0 T 99 2 1 2 1 25 T 228 PD 24 11 5 T 136 14 6 5 T 236 22 10 5 T 138 14 6 5 T 282 19 9 0 t For correct lubricant specifications 14 29 LUBRICATION LUBE AND INTERVAL CHART MAXIMUM LUBRICATION CHANGE INTERVALS t STANDARD LUBES ON HIGHWAY ONLY HIGHWAY OFF ROAD FRONT AXLES NON DRIVE Knuckle Pins and Bushings Easy Steer 941 942 943 and 944 Series 0 617 0 617 B Lube lor Life 2n or 3333 hours months 22 Standard 900 901 903 and 970 Series 0 617 A 0 617 B 8000 miles 8000 mites 208 5 Sealed 921 930 931 932 933 0 617 A 0 617 B 50 000 miles 12 months 50 000 miles or
75. Lis 125 LB F1 114712 TT5 1090 1452 LB FT FOR ALL FASTENERS Al torques gren apply to parts light coated with rust preventative type oil For dry parts increase tongues 1055 e For parts heavily coaled wih od decrease Torgues 10 KNUCKLE CAP CAPSCREWS 5167 18 ee LB FT STOP SCREW LOCKNUT Tar 13 50 65 La FT 29 815 18 5815 5 15 34 15 18715 1 14 1 18 12 CROSS TUBE CLAMP NUT 5 1824 38 24 718 20 027 20 5187 18 CROSS TUBE END NUT INTIAL RANGE 40 5518 FT 60 80 EB FT 60 60 LB FT 160 215 LB FT 250 325 LB FT 350 173 LB FT MAX AFTER ASSEMBLY T51B 115 LB FT 115 LB FT I7TOLB FT 300 LB FT 450 LB FT BSOTB FT 0 Rockwell International Automotive Businesses Rockwell International Corporation 2135 West Maple Road Troy Michigan 48084 U S A FMM 2 10 84 Copyright Rockwell International 1984 Litho in USA 16579 Section Il FRONT AXLE Field Maintenance Manual No 1 Lubrication Rockwell Recommended Practices Specifications Lubricants e Capacities Change Intervals N Rockwell International science gets down to business LUBRICATION 1 552526 Recommended Lubrication Practices New and Reconditioned Axle Service Regular Axle
76. Lubricants chart for temperature limitations of each grade of oil SYNTHETIC LUBRICANTS synthetic lubricants may be used in drive axles provided they meet all of the requirements of Rockwell specifications 0 76 0 76 A 0 76 B 0 76 C 0 76 D 0 76 E 0 76 F 0 76 J or 0 76 K IMPORTANT Synthetic lubricants must be compatible with standard commercial seals used in the axle assembly drive unit and wheel ends otherwise special seals must be installed Contact your Rockwell representative for information on synthetic lubricants LUBRICATION LUBRICANT SPECIFICATIONS AND CHANGE INTERVALS NOTE The illustrations used in the following sections are typical examples and may not necessarily show all lubrication points for all models discussed 1 FRONT NON DRIVING AXLES SEALED KNUCKLE PIN CONVENTIONAL KNUCKLE PIN LUBRICANTS 0 617 A or 0 617 B All knuckle pins bushings cross tube end assemblies drag link ball sockets and wheel bearings Refer to Recommended Lubricants on pages 6 and 7 LUBE INTERVALS The following are minimum recommended intervals More frequent lubrication will prolong product life e Knuckle Pins and Bushings Conventional standard straight and tapered pin models FC FD FF FH FL and FQ 900 901 903 or 970 Series 16900 16930 16931 FAE 951 and 952 FU 910 930 and 935 Series 3 000 miles 4 800 km Sealed knuckle pin models FD FF FG and FL 921 930 931 932 933 934 951 and 971 Seri
77. M Lubricate pinion shaft oil seal and cover outer edge of seal body with a non hardening sealing I Press flange or yoke against forward bearing compound Press seal against cover shoulder and install washer and pinion shaft nut with seal driver N Install new gasket and bearing cover J Place pinion and cage assembly over carrier studs hold flange and tighten pinion shaft nut to the correct torque flange must be held O Press flange against forward bearing and install with a suitable tool or fixture to tighten nut washer and pinion shaft nut P Tighten nut to the correct torque value K Recheck pinion bearing preload torque If rotating torque is not within 5 to 15 pound inches repeat the foregoing procedure 12 ADJUSTING THE PINION CAGE SHIM PACK THICKNESS WITH A PINION SETTING GAUGE GAUGE DIMENSION STRADDLE MOUNTED PINION gt NOMINAL PINION MOUNTING DISTANCE i e 7 875 STAMPED ON NOSE OF PINION DIMENSION NOMINAL OVERHUNG PINION GAUGE DIMENSION HEAD PINION DIMENSION i e 3 066 CENTER LINE OF GEAR amp DIFF BEARING BORES NOMINAL GAUGE DIMENSION DIMENSION 4 809 i e 3 066 NOMINAL PINION MEASURED MOUNTING DISTANCE MINUS PINION HEAD i e 7 875 The correct use of a pinion setting gauge will simplify the accurate installation of the pinion and cage assembly into the carrier When using the pinion setting gauge never use the nominal pinion mounting dim
78. Output shaft bnnelled or dented Impact damages Broken or bent reversing spring Accident damaged 2 Air in system Note on scoring Minor scoring and scuffing of the piston and housing of the steering gear should not be cause for alarm During operation at relatively high pressures and flow rates this minor damage will not affect the safety or operation of the steering gear If scoring is severe leakage will affect steering reaction time and slow binding or uneven steering input will be noticeable In this case the damaged parts should be replaced Minor scoring should be polished with a fine hand stone or crocus cloth to allow free movement of mating parts The cylinder bore should not be honed or bored out as this will increase leakage Slow binding or uneven steering input can also be caused by problems with the hydraulic supply pump and it is important that the pump is operating properly See Hydraulic Supply Diagnosis section of this manual Page 25 SHEPPARD POWER STEERING SERVICE MANUAL REPAIR SHORT SERIES PISTONS To remove the control valve from the piston the piston plug must first be removed The plug is locked to the piston with a 1 8 inch soft pin Use a 5 64 inch drill to drill out the pin See variation on early production gears and 3 2 and 382 step bore steering gears S 37 Caution The bottom adjusting nut which is exposed should never be removed or the reference to the valve center is lost 5 38
79. Page 62 SHEPPARD POWER STEERING SERVICE MANUAL To remove the miter housing from the steering gear the clamping bars are both removed and the miter housing and gasket shim pack can be lifted off the bearing cap Note The miter housing to bearing cap position should be marked so that it can be reinstalled in its original location Some steering gear models will have a roll pin through the clamping bar and into the miter housing to index it to its design position In this case it is important that the clamping bar is reinstalled in the same position so that the roll pin can be reinstalled The miter housing can now be serviced Remove the lube fitting and the relief fitting on the opposite side of the housing 3 157 Turn the input shaft and line up the roll pin with the openings in the miter housing Use a drift punch and hammer to drive the roll pin out of the miter gear and input shaft The roll pin must be pushed through the hole in the opposite side of the housing The miter gear can now be pried off the input shaft and the shaft can be tapped out of the housing and bearing assembly Lever the oil seal out of the input shaft end of the miter housing Page 63 SHEPPARD POWER STEERING SERVICE MANUAL S 160 S 162 S 163 Use a spanner wrench to turn the bearing retainer out of the miter housing The double row bearing can now be drawn or tapped out of the housing for inspection or replacement
80. Propeller Shaft with or without Pump 10 End Yoke Input 10A Inter Axle End Yokes Tandem Axle Only Inter Axle Propeller Shaft Tandem Axle Only NOTE Due to the various propeller shaft combinations contact Duplex Truck Division for correct replacement parts NOTE Your chassis Vehicle Identification Number 1 or Seria Number on older chassis must be supplied when ordering replacement parts Section DRIVE LINES SPICER UNIVERSAL JOINTS AND DRIVESHAFTS 1330 THROUGH 1850 SERIES B MEDIUM AND HEAVY DUTY VEHICLES E egt Se ee a P Eme big A m ny T utere FOREWORD This manual is presented as a guide in solving problems associated with drive shafts made to discuss technical consideration of design or theory of vibrating systems No attempt has been In discussing installation of drive shafts no hard and fast rule or fine dividing line has been drawn between satisfactory and unsatisfactory operation The limits set forth in this manual correspond with our own standards Our long experience in the manufacture and installation of drive shafts has proven these standards to be accurate INDEX SNC Page FUNCTION RR So ciilleic 4 Nomenclature 00 00 5 6 Universal Joint Seals 8 9 Recommended 0 9 Service
81. REPAIRS Minor repairs to the reservoir consist of examining the reservoir mounting and the inspection of the outside for corrosion or damage The outside should be kept painted to prevent the possibility of corrosion causing a failure MAJOR REPAIRS Repairs involving welding should never be performed on reservoirs a reservoir has been damaged so as to be unfit for use it should be replaced with a new one In exceptional cases where the inside of a reservoir has become excessively coated with sludge which cannot be drained off it is sometimes advisable to remove it and clean with a solvent steam or water If a solvent is used to clean the reservoir the reservoir should be thoroughly aerated before reinstalling IMPORTANT PLEASE READ When working on or around brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended pressure and always wear safety glasses when working 4 Never attempt to disassemble a component until you have read understand recommended procedures Some components contain powerful springs and inj
82. STOP SCREW Figure 38 Maximum turn angle will then be determined by the arm or cylinder stop and not the axle stop This must be done for full left and full right turns HYDRAULIC RELIEF Hydraulic steering gears equipped with poppet valves should be adjusted while a 1 4 to 3 16 spacer is held between the axle stop pad and stop screws The poppet valves should be adjusted to allow pressure bypass at this position with spacer in place in full left and right turn positions During this setting the steering gear pressure should be at a minimum 600 psi or less Figure 39 KNUCKLE POSITIONS FOR POPPET VALVEf SETTINGS STOP SCREW Figure 39 TOE IN RECOMMENDATIONS The following recommendations are for all Rockwell front steering axles Rockwell concurs with the manufacturer s recommendation of 1 16 1 32 toe in for bias ply or radial ply tires with the weight of the empty unloaded vehicle on the axle For vehicles measured fully loaded the setting is 1 82 1 32 Do not measure toe in with the front axle jacked up The toe in should be measured with the weight of the vehicle on the axle MAKE SURE VEHICLE IS ON ALEVEL FLOOR A Jack up the front axle B Use paint or chalk and whiten the center area of both front tires around the entire circumference Position a scribe or pointed instrument against the whitened part of each tire and rotate the tires The scribe must be held firmly in place so that a si
83. Section 4 3 5 Checkout Vehicle Voltage Regulator PCB3 according to procedure in Section 4 3 12 Follow procedure to checkout K2 Relay Section 4 3 4 Checkout and replace 4 3 2 4 3 3 4 3 4 TROUBLE SHOOTING CHART continued MOST LIKELY FAILURES Based on our experience at DYNAMOTE the following in order of descending frequency are the most likely causes of inverter malfunction In each case there is a procedure to check it out 1 Relay 2 Blown Commutation Fuses 3 Shorted SCRs 4 Inverter Voltage Regulator Board no output 5 Inverter Oscillator Board K1 RELAY CHECKOUT PROCEDURE Tools Required Ohm Meter and Voltmeter with 0 15VDC scale 7 16 socket or open end wrench screwdriver 1 Open the inverter by removing the front top and back panel fasteners Carefully lay the front and back panels down and remove the top panel 2 Theengine and ignition should be OFF for the procedure 3 Locate the K1 Relay the larger cylindrical silver solenoid contactor on the right side of the inverter near the rear 4 Depress the START button and there should be an audible click if the relay is operating 5 With the Ohm Meter check the resistance across the two large terminals at the top of the relay WITHOUT depressing the START button the meter should read 100K Ohms to infinity gt WITH the START button depressed the meter should read less than 5 Ohms If the Relay does not pass all of th
84. Turn Signals 98 Circuit Breaker to Clearance amp Parking Light Relay amp Tail Light Relay 99 Circuit Breaker to Neutral Start Switch 100 Circuit Breaker to Jake Brake Option 101 Jake Brake Switch to Jake Brake Option 102 Jake Brake Switch to Jake Brake Option 102 Jake Brake Switch to Jake Brake Option 103 Jake Brake Switch to Jake Brake Option 104 Fast Idle Switch to Fast Idle Solenoid Option 104A Circuit Breaker to Fast Idle Switch Option 105 Auxilliary Gauge to Optional Accessory 106 Fuel Pump Switch to Fuel Pump Option 106A Fuel Pump Switch to Circuit Breaker 107 Circuit Breaker to Air Dryer 108 Circuit Breaker to Fuel Water Separator 109 Ignition Switch to Circuit Breaker 110 Ignition Switch to Tachometer Ignition Relay 1 amp Ignition Relay 2 126 Ammeter Positive to Ammeter Shunt 127 Ammeter Negative to Ammeter Shunt Note Your chassis Vehicle Identification Number or Serial Number on older chassis must be supplied when ordering replacement parts Alternator Section VII 8V 71TA ELECTRICAL SYSTEM 130 145 amp 160 Amp 6 15 16 617 18 Item Part No Description Qty 1 7808 0202 Adjusting Mounting Bracket 1 2 8820 1035 H H C S 3 8 16 x 1 1 3 8855 1011 Lockwasher 3 8 1 4 8850 1006 3 8 16 1 5 7810 1828 Adjusting Strap 1 6 8820 1068 H H C S 1 2 13 x 1 3 4 3 7 7602 7938 Hardened Washer 1 2 3 8 8852 1008 Crown Lock Nut 1 2 13 1 9 7604 5799 Alternator 130 Amp 1 7811 3243
85. a 4 Fi y f Fi PE P Ta Li F e dm Vt i n P j 1 X 3 4 mj EU gs ir GM l i exe 17 uM m 15 D 7 SUE 2 i it art erre ur i d x x Es n DLE ce iF Me e E P Te i ait in De 8 i ay UL E EEEE qmm M The DH Brake is a dual primary brake hydraulically actuated This brake commonly referred to as the Duplex Brake features identical shoe and liner assemblies and four identical return springs which simplify assembly and disassembly BRAKES F M M NO 4 DH BRAKE LAYOUT LINING ASSEMBLY SHOE GUIDE BOLT NUT SHOE GUIDE BOLT WASHER UNUS it MU MU i de i RONDA AET A ENE BRAKE SHOE AND BRAKE LEVER AND BRAKE LEVER AND WHEEL CYLINDER ASSEMBLY BRAKE LEVER ASSEMBLY WHEEL CYLINDER PUSHROD BRAKE ADJUSTING BOLT COTTER KEY BACKING PLATE AND BRAKE SHOE SPRING BRAKE SPIDER ASSEMBLY DISASSEMBLY F Unhook the return springs from the spider A Remove wheels and brake drums adjustment bolt and shoes Remove shoes B Remove cotter key from guide bolts C Install wheel cylinder clamp to prevent forcing si re ap pistons out of w
86. after removal Install covers and rivet securely 4 Install new welch plug in body 5 Lubricate as outlined in Preventive Maintenance section TYPE 35 WITH POSITIVE LOCK MECHANISM ASSEMBLY 1 Press worm shaft into worm Care should be exercised to be sure the worm shaft is pressed into the proper dimension 2 Install the worm shaft worm and gear in the Slack Adjuster body 3 Make certain that when pressing the worm shaft into the body that the height measurement between the top of the adjusting screw and slack adjuster body is the same before and after removal 4 Install worm lock guide pin in worm nut Screw the worm nut into Slack Adjuster body 6 Install worm lock and worm lock spring over worm shaft and adjusting screw nut 7 Depress worm lock and install lock nut pin in adjusting screw nut 8 Install set screw in worm nut 9 Assemble cover and cover nut to the body by installing the retaining ring 10 Lubricate Slack Adjuster as outlined in Preventive Maintenance section e TYPE 35 AND TYPE 55 WITHOUT RIVETED COVER AND BALL INDENT LOCK MECHANISM ASSEMBLY 1 Install plunger spring and plunger in body 2 Install Slack Adjuster gear in body 3 If worm was removed from shaft new worm should be pressed on shaft noting dimension as instructed in No 4 of disassembly procedure 4 Install worm and shaft Worm and shaft must be run in so that the worm fully engages slack adjuster worm gear Make
87. all parts in mineral spirits Replace all rubber parts and any part worn or damaged with genuine Bendix parts SERVICE CHECKS OPERATING CHECKS Block vehicle and hold by means other than vehicle brakes Charge air brake system to governor cut out pressure 1 Place parking control valve in the park position Observe that the spring brake actuators apply promptly the delivery port of the valve install a test gauge known to be accurate Place the parking control valve in the release position Observe that the spring brake actuators release fully 2 With the parking control valve in the release position note the gauge pressure reading Check the vehicle manual for the correct spring brake actuator hold off pres Piston 8 sure If the pressure reading is incorrect the valve must be repaired or replaced 3 Place the parking control valve in the park position the gauge reading should drop to zero promptly A slow release of pressure may indicate faulty operation of the single check valve within the Modulating Valve 4 Place the parking control valve in the release position Locate the number one service reservoir and drain it completely Apply the foot brake valve several times and note that the pressure reading on the gauge decreases each time the foot brake valve is applied After several applications pressure on the gauge will drop to the point where release of the spring brake actuators will no longer
88. any INSTALLING Block and hold vehicle by means other than air brakes Drain air system To avoid early fouling at the DV 2 thoroughly finish and clean the reservoir before installing the drain valve Aerate any tank thoroughly if any solvents have been used in the cleaning process IMPORTANT When installing a DV 2 drain valve equipped with a heater and thermostat first determine if the vehicle electrical system is 12 or 24 volt and that the Heater Thermostat Unit is of the same voltage The 14 gauge lead wire on the valve should be connected to the on position of the engine control or ignition switch Use an 8 amp fuse for one valve a 15 amp fuse for two valves and a 20 amp fuse for three valves All electrical connections must be waterproof CLEANING AND INSPECTION Cleaning solvent may be used on metal parts Rubber parts should be wiped clean Inspect all parts for wear or deterioration Discard filter screen if present Replace all parts not considered serviceable during these inspections Bendix Field Maintenance Kit 282134 contains all parts necessary for servicing all models of tire DV 2 ASSEMBLY Before assembling the valve apply a light film of grease on inlet valve seat DO NOT APPLY OIL TO THE INLET AND EXHAUST VALVE Place sealing ring in groove of cover Place valve guide over inlet and exhaust valve Place valve guide and inlet and exhaust assembly into cover wire will project through exhaus
89. as a package See Fig 15 3 Bench mount the adapter to the P T O using appropriate length studs See Fig 16 4 Proper backlash will determine the number of gaskets to be used between the adapter and the P T O See Fig 17 5 Remount the adapter assembly all gaskets and the P T O to the transmission their respective sequence See Fig 18 6 Secure all nuts and cap screws to proper torque Now run the P T O momentarily and check for noise CAUTION The transmission and P T O have no lubrication at this time so running time should be as short as possible e lf the P T O whines it may be mounted too tight too little backlash This indicates that gaskets should be added e lf the P T O clatters it may be mounted too loose too much backlash This indicates that gaskets should be removed General Rule A Chelsea 010 25mm gasket will change backlash approximately 006 15mm and a 020 50mm gasket changes backlash approximately 012 30mm 13 Figure 19 illustrates a typical input gear driven gear in a P T O that was mounted too deep insufficient backlash Extreme heat turned the gear blue resulted in gear and bearing failure LUBRICANT IN TRANSMISSION INSPECT INSTALLATION 1 Remove the filler plug from the transmission and add recommended transmission lubricant to the level prescribed by the transmission or truck manufacturer See Fig 20 NOTE f the P T O is mounte
90. as a pilot This tool is not required for Delrin bushings BUSHING REMOVAL AND INSTALLATION TOOL Figure 18 Figure 18 Dimension X is 0 010 less than the bushing bore Dimension Y is 0 010 less than the steering knuckle bore oee page 15 for dimensions A minimum press capacity of 5 tons is required to remove bronze and easy steer bushings IMPORTANT Fixture the knuckle firmly on the bed of the press to avoid knuckle slippage during bushing removal or Installation A The worn bushings are pressed out of the knuckle employing tool shown 12 B The new bushings will be installed with the same tool The pilot of this tool prevents collapse or distortion of bushing during installation BUSHING INSTALLATION STANDARD BRONZE BUSHINGS Before installation the bushings on some models must be properly oriented The grease hole in the bushing must line up with the grease hole in the knuckle The circumferential grease groove should be positioned toward the end of the king pin First press bushing into knuckle approximately 1 8 relieve press pressure and check alignment of tool and bushing The bushing can now be pressed in until it is flush with the top machined surface of the knuckle For those designs that have king pin seals the bushing can be pressed in until it is 135 to 165 from the inside machined surface of the knuckle This applies to both upper and lower bushings Do not install seals until aft
91. at 30 000 miles 48 000 km If yearly mileage is less than 30 000 miles 48 000 km change twice a year spring and fall AC 6W 6 ROD BRONZE BUSHING TYPE SPRING SEATS AND STEEL BUSHED TORQUE RODS i det LUBE LUBE STEEL BUSHED TORQUE RODS ONLY LUBRICANT Standard 0 617 A Refer to Recommended Lubricants pages 6 and 7 LUBE INTERVALS The spring seat assembly should be lubricated regularly with frequency depending upon the type of service and conditions under which the vehicle operates The suggested lubrication interval for units in continuous use is monthly However if unit is used in more extreme weather and road conditions shorter intervals may be necessary The lubrication interval for steel bushed torque rods if used would be the same as for the spring seat assembly at least once a month 8 DRIVE UNITS DIFFERENTIALS HYPOID AMBOID AND SPIRAL BEVEL GEARS SINGLE AND DOUBLE REDUCTION The design of these gear teeth which mesh with a sliding action enables them to withstand higher unit pressures Therefore the lubricant used must have extreme pressure properties Only lubricants with S A E designation API GL 5 meet these requirements and are recommended for hypoid amboid and spiral bevel gearing 19 LUBRICATION FRONT MOUNTED SINGLE REDUCTION Single Axles or Rear Rear Tandem Axles CARRIER HOUSING FILL PLUG FILL PLUG gi B hie ji D AN e
92. build up at one end of the piston This higher pressure on one end of the piston causes the piston to move in the bore of the gear housing The output shaft and pinion gear 4 are engaged to a rack gear 5 machined into one side of the piston As the piston moves the output shaft and pitman arm are rotated by the rack and pinion gear and steering operation is performed When rotation or input from the actuating shaft ceases pressure on or movement of the actuating valve stops and the reversing springs 6 at the ends of the valve center the valve in the piston relieving the high pressure and power to the steering ceases Movement of the actuating valve to control oil pressure is controlled by the deflection of the reversing spring at either end of the valve Total movement of the valve is approximately 040 of an inch Relief valve plungers 7 or adjustable stops are provided at the bearing cap and cylinder head When the plungers are adjusted properly they will automatically unload the hydraulic system if the wheels are turned to either extreme direction bus BUE o L Ti 4 When the engine is running there is constant oil flow through the steering gear at low pressure This constant oil flow provides for instant response and absorbs road shock to help eliminate steering wheel kick and protect the steering gear Pressure is equal throughout the steering gear and oil cooling and lubrication are assured Care should be u
93. carbon pile to decrease the battery voltage to the value specified in Service Bulletins 15 180 15 186 15 187 and 15 188 and com pare the ammeter reading with specifications high reading indicates shorted X hold in winding and a low reading excessive resistance To check the pull in winding connect from the solenoid switch terminal S to the solenoid motor or MOT terminal To check for grounds move battery lead from terminal to solenoid case and from M terminal to solenoid case Fig 19 not shown Ammeter should read zero for both windings If not solenoid is grounded NOTE If needed to reduce the voltage to the specified value connect the carbon pile between the battery and the M terminal as shown in dashed red instead of across the battery as shown in solid red lines If the carbon pile is not needed connect a jumper directly from the battery to the M terminal as shown by the dashed red line intermediate duty clutch motor Page 10 CRANKING MOTORS 1M 153 Service Bulletin BATTERY Figure 24 Circuit for checking pinion clearance Types shown in Figures 4 and 5 CAUTION To prevent overheating do not leave the pull in winding energized more than 15 seconds current draw will decrease as the winding temperature increases Figure 26 Checking pinion clearance on heavy duty motor A magnetic switch be checked in the same manner by connecting across it
94. closes the opposite inlet port The air is then directed out the common delivery line and to the stop light switch PREVENTIVE MAINTENANCE Every six months 1800 operating hours or 50 000 miles check the electrical connections and determine that stop lamps operate properly OPERATING AND LEAKAGE TEST Install an accurate air gauge in the service line or brake chamber Apply brake valve gradually Stop lamps should light at 6 psi or less and go out after the brake application is released This checks the electrical function of the stop light switch in either the SL 5 or DS 2 2 DS 2 only Apply the foot valve and coat the exhaust port of the hand valve or other alternate source Reverse the above applying the hand valve or other alternate source and coat the exhaust port of the foot valve In either mode a leakage of not more than a 1 bubble in 5 seconds is permissible 3 SL 5 or DS 2 When pressurized no leakage is permitted from the body of the valve or switch If the SL 5 or DS 2 does not function as described above or if leakage is excessive the valve or switch should be replaced with a new unit or in the case of the double check portion of the DS 2 repaired with genuine Bendix parts available at Bendix outlets REMOVING AND INSTALLING REMOVING 1 Block vehicle wheels or hold by means other than vehicle service brakes 2 Disconnect electrical connections from terminal SCrews 3 SL 5 Remove the switch usi
95. cylinder bore with opening for actuating shaft towards bearing cap end of housing Align timing mark on piston rack with center of pinion gear housing Grease housing bearing and quad ring and carefully slide output shaft through housing Align timing marks on pinion gear with timing mark on rack Caution If the rack is not properly timed to the pinion gear of the forged one piece shaft and gear assembly it is possible for the gears to disengage in service Install cylinder head with new gasket or seal Align reference marks and tighten bolts to specified torque Using a new gasket or seal on the bearing cap thread actuating shaft into the valve Line up punch marks on gear housing and bearing cap Turn shaft until cap comes into place on the end of cylinder Check plunger hole alignment with valve seat in the piston Tighten bolts to specified torque Note Variation oeveral steering gear models use square ring seals in place of gaskets on the cylinder head and bearing cap Page 44 3 105 REASSEMBLY SHEPPARD POWER STEERING SERVICE MANUAL 5 106 5 107 5 108 Position a new O ring seal on housing cover Install cover assembly may be necessary to use soft hammer to tap the cover in place Install the bolts and torque to proper specifications The relief valve plungers may now be installed using new O rings Turn them approximately six turns Final adjustment of the plungers are made when
96. diameters on spindles or in machined bores 6 Milling or machining of any component 7 Relocation of tie rod clamps CLEANING Parts having ground and polished surfaces such as knuckle pins knuckle pin sleeves bearings and spindles should be cleaned in a suitable solvent such as kerosene or diesel fuel CAUTION Exercise care to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners GASOLINE SHOULD NOT BE USED AS A SOLVENT DO NOT clean these parts in a hot solution tank or with water and alkaline solutions such as sodium hydroxide orthosilicates or phosphates ROUGH PARTS Rough parts such as cast brackets and some brake parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts are not ground or polished parts should remain in the tank long enough to be thoroughly cleaned and heated This will aid the evaporation of the rinse water The parts should be thoroughly rinsed after cleaning to remove all traces of alkali CAUTION Exercise care to avoid skin rashes and inhalation of vapors when using alkali cleaners DRYING Parts should be thoroughly dried immediately after cleaning Use soft clean lintless absorbent paper towels or wiping rags free of abrasive material such as lapping compound metal filings or contaminated oil Bearings should never be dried by spinning with compressed air CORROSION PREVENTION Parts that have been clean
97. drawkeys into position flat side toward king pin do not firmly seat them until after the end play measurement Install the lower drawkey from the front side and the upper drawkey from the rear Aluminum axles use a double drawkey arrangement with a through bolt Assemble so the wedged ends of the two keys contact the king pin and torque to restrict pin from moving while the end play is measured Measure end play per procedure 21 and adjust if necessary NOTE Never install both drawkeys from the same side Seating Keys After the specified end play is obtained seat the drawkeys firmly with a hammer and drift all except aluminum axle which does not require seating Figure 30 Figure 30 0 19 IMPORTANT Both the threaded and non threaded keys must be solidly seated in this manner The nut torque on the threaded design is only sufficient to hold the key in position and is not adequate to properly seat the key except aluminum axle Securing Threaded Drawkeys Steel Axles Install flanged locknut and torque to specification Refer to torque chart Securing Double Key With Through Bolt Aluminum Axles Torque to specification Securing Plain Drawkeys Plain drawkeys are secured by staking with a pointed punch and must therefore be only slightly below the forged surface of the axle center King pin kits are supplied with three different length upper shorter and lower longer drawkeys The seate
98. ends Use a buttonhook type of spring stretcher B Remove lever by dropping shoe assembly and rotating lever cam to pass through opening C Remove shoe and spring assembly and unhook springs from shoe ASSEMBLY A Lubricate housing abutment shoe cam pad and lever cam bearing area 22 Insert small hook of springs into shoe with opposite hook ends out Install lever and rotate cam so that shoe may be raised into actuating position Hook spring end hooks into housing ADJUSTMENT Pull lever forward to maximum cam travel and back off 3 8 Insert linkage connection pin Rockwell International Heavy Vehicles Components Operations Rockwell International Corporation 2135 West Maple Road Troy Michigan 48084 U S A REVB 79 1984 ROCKWELL INTERNATIONAL PRINTED IN U S A Wire No Circuit 1 otart Button 1 to Starter Solenoid 1A otart Button 2 to Starter Solenoid 2A Start Button 1 to Start Button 2 2B Ignition Relay 2 to Neutral Start Switch 2C Ignition Relay 2 to Start Button 3 Circuit Breaker to Front Spotlights 5A Tail Light Relay to License Plate Light 6 Circuit Breaker to Right and Left Turn Signals 7 Headlight Switch to Gauge and Indicator Lights 9 Headlight Switch to Clearance amp Parking and Tail Light Relays 9A Headlight Switch to Circuit Breaker 10 Fuel Gauge to Fuel Level Sender 11 Circuit Breaker to Positive Terminals of Gauges and Warning Lights 12 Circuit Breaker to Dash Engine
99. f If ampere output is within 10 per cent of rated output as stamped on generator frame Integral Charging System is not defective In this case an adjustment of the voltage setting may correct the undercharged condition Raise the setting by removing the voltage adjusting cap rotating in increments of 90 and then reinserting the cap in the connector body As illustrated in Figure 8 the cap is set for low voltage With position 2 aligned with the arrow the setting is increased to medium low position 3 is medium high and position HI is the highest regulator setting After adjusting the setting check for an improved battery condition after a service period of reasonable length such as one week IMPORTANT The voltage adjustment 1 in Figure 8 15 for purposes of illustration only The actual adjustment as shipped from the factory may be in some other position such as position 3 depending on the application requirement If readjusting the setting does not correct the undercharged condition proceed to Integral Charging System Repair If ampere output is not within 10 percent of rated output as stamped on Integral Charging oystem frame remove the Integral Charging System for repair as covered E section entitled GRAL CHARGING SYSTEM REPAIR OVERCHARGED BATTERY Check the battery per Delco Service Bulletin 1B 115 To repair the Integral Charging oystem observe the following procedure
100. faulty The alternator should removed and sent to an alternator repair shop 11 Red crease to 20 VDC Figure 3 6 1A INSTALLATION AND INVERTER CHECKOUT USING 4 2600 DYNAMIC INVERTER TEST MODULE SNOILONYLSNI NOILVTIVISNI X uOL329gq Read IMPORTANT NOTE above DO NOT MOVE SWITCH TO OR FROM POSITION 11 WHEN ENGINE IS ABOVE IDLE 8 3 6 1 3 6 2 CHECKOUT OF HARNESS INSTALLATION WITH DYNAMOTE 4 2600 DYNAMIC INVERTER TEST MODULE continued 5 If procedures on Switch Position 1 10 check out you may replace the covers on the inverter Your electrical system is ready for operation Any problems found during this test procedure can be discussed with the DYNAMOTE Service Department by calling our toll free number 1 800 426 2838 CHECKOUT OF HARNESS INSTALLATION AND ALTERNATOR OPERATION WITHOUT 4 2600 DYNAMIC INVERTER TEST MODULE NOTE FOR THIS TEST DO NOT PUSH OR RELEASE START SWITCH WHEN ENGINE IS RUNNING ABOVE IDLE Perform the checkout with a V 0 M capable of reading 15VDC 5OVDC and 100VDC Simpson 463 Fluke 8020A or equivalent Access to the terminal posts can be obtained either through the use of a Dynamic Test Strip plugged into the Test Receptacle on the inverter front panel or by removing the inverter panels carefully and exposing the terminals inside the back of the inverter TO CHECKOUT THE HARNESS FOLLOW THIS PROCEDURE Colors refer to wires attached to the indica
101. hydraulic lines J Bleed Hydraulic System after all brakes have been re assembled FSH SERIES BRAKES The FSH brake is a floating shoe hydraulic brake Actuation permits the shoes to center themselves in drum with equal effectiveness in either direction This brake is supplied either with or without a built in mechanical parking brake The FSH brake is also built with automatic adjustment for use on special applications On the FSH automatic type one actuation of the foot pedal sets the automatic adjustment No further adjustment of the brake is required during the full life of the brake lining CARE AND MAINTENANCE ADJUSTMENT The DH Brakes are adjusted from the backface of the backing plate at slotted holes Insert adjusting spoon through slotted hole to engage lugs on adjusting bolt Move handle up or down using slot end as a fulcrum To expand shoes move tool handle down when in the L H slot and move tool handle up when in the R H slot Shoe liners should be brought out tight against the brake drum Adjusting bolt should then be backed off until the drum can rotate freely Brake shoes should be adjusted individually FSH BRAKE LAYOUT ee RAND FAKE LIVER LEVER LFACHE wan CTL Pees ig Oe LVEF warp ur ipeni Lec ira oS DOW
102. is 010 greater than the new bushing dimension replace the bushings J Check axle center bore for condition and size Replace center if bore is 001 greater than specification 10 IMPORTANT Any indication of looseness in the total steering linkage arrangement under normal steering loads is sufficient cause to immediately check all pivot points for wear regardless of accumulated mileage Steering linkage pivot points should be checked each time the axle assembly is lubricated TIE ROD AND TIE ROD END INSPECTION A Check seals visually for any indication of damage also check to make sure that the seal is securely seated on the socket If the cross tube end has a grease fitting replace damaged seals Ends not having greasing provisions the entire tie rod end should be replaced if seals are damaged or loose IMPORTANT Rockwell does not recommend attempts to salvage damaged ends by repacking and replacing the boot seal on non greasable ends B 1 Check the turning torque value between the ball stud and the ball cavity If torque value is less than five 5 inch pounds the cross tube end assembly should be serviced 2 No lateral or vertical movement should be found in any tie rod assembly when checked by hand Leverage or prying with a tool can produce vertical movement in most tie rod ends which is inherent in their design Use of tools for checking free play is not recommended 3 Permanently lubricated and extended l
103. is with LO aligned with the arrow position 2 is medium low position 3 is medium high and HI is the highest setting Separate slip ring end frame and stator assembly from drive end frame and rotor assembly oeparate stator from end frame by removing three stator lead attaching nuts Figures 9 and 10 and 11 and12 show Figure 9 End frame view with stator removed Two rectifier bridge type with two terminal regulator Page 5 Figure 10 End frame view with stator removed Three rectifier bridge type with two terminal regulator Figure 11 End frame view with stator removed Two rectifier bridge type with regulator end with stator removed 6 Place tape over bearing and shaft to protect from dirt Use pressure sensitive tape and not friction tape that would leave a gummy deposit 7 Inspect all leads for burned connec tions or opens and brushes for excessive wear Inspect springs for distortion or discoloration Replace as required Clean brushes with a soft dry cloth if they are to be reused During servicing and reassembly hold brushes and springs in holder with a pin or toothpick inserted through end frame hole REGULATOR CHECK Check first the voltage adjustment connector body for opens Remove the connector three terminal DELCOTRON INTEGRAL CHARGING SYSTEM regulator body from the regulator and check with ohmmeter using the middle range scale as shown in Figure 13 C
104. knuckle After this has been done and the tires are lowered to the ground the lower bushing should be re greased to purge and fill the thrust bearing e Models with Sealed Knuckle Pins These assemblies should be greased with the tires on the ground Apply grease pressure until new grease is seen purging from the thrust bearing seal and from the upper shim pack area e Tie Rod Ends Apply grease pressure until new grease is seen purging from the boot area e Easy Steer On Highway Models Before the new axle is placed in service grease knuckles as in sealed king pin procedure above After a 4 000 mile 6 500 km break in period the knuckles should be carefully re greased as follows A With the tires off the ground slowly feed grease into each bushing area while turning the wheels from extreme right to left and back again lock to lock This will eliminate small air pockets and improve grease distribution B Lower tires to ground and re grease both top and bottom bushings taking care to thoroughly lubricate the thrust bearings e Easy Steer On Off Highway Models Follow sealed knuckle pin procedures above LUBRICATION 2 FRONT DRIVE STEERING AXLES t CARDAN UNIVERSAL CONSTANT VELOCITY JOINT UNIVERSAL JOINT LUBRICANTS 0 617 A or 0 617 B All universal joints Cardan and Constant Velocity types Knuckle bushings or bearings cross tube end assemblies axle shaft thrust washers and wheel bearings e Driv
105. lockwashers that secure the cover to the body Caution the cover is under a spring load and should be held while removing the screws 9 Remove the cover 13 and the three piston springs 14 Note Some SR 1 piece numbers have one large piston spring 10 Remove the small piston 15 and the small and large O rings 16 11 Remove the large piston 17 Remove piston O rings 18 amp 19 D m CLEANING amp INSPECTION Wash all metal parts in mineral spirits and dry Inspect all parts for excessive wear or deterioration Inspect the valve seats for nicks or burrs Check the springs for cracks or corrosion Replace all rubber parts and any part not found to be serviceable during inspection Use only genuine Bendix replacement parts ASSEMBLY Refer to Figure 2 Prior to assembly of the SR 1 Spring Brake Valve lubricate all o rings o ring grooves and piston bores with Dow Corn ing 55 M Pneumatic Grease Bendix No 291126 Note All torques specified in this manual are assembly torques and can be expected to fall off after assembly is accomplished not retorque after initial assembly torques fall 1 Assemble the check valve 4 and valve spring 2 and install in body 2 Apply pipe sealant to the socket head pipe plug 1 and install in the body Tighten to 130 170 inch pounds torque Install inlet and exhaust valve assembly 7 in valve 4 Secure the exhaust cover 5 with two 10 24 phill
106. o CHAMBER STUD WASHER CHAMBER CLEVIS PIN CAM HEAD WASHER CHAMBER STUD NUT CLEVIS PIN COTTER DOUBLE HEAD CAM SMALL SPACE WASHER CAM NEEDLE BEARING LOCK GROOVE RING SHOE RETURN SPRING BRAKE SHOE AND LINER ASSEMBLY ANCHOR PIN LOCK ANCHOR PIN FELT A SCREW RETAINER ANCHOR PIN FELT 4 ANCHOR PIN LOCK ANCHOR PIN BRAKE SPIDER 17 BRAKES F M M NO 4 J Remove chamber bracket mounting cap screws and lock washers Remove bracket K Remove needle bearings only if replacement is to be made by pressing out with a suitable sleeve ASSEMBLY A Install new cage and needle bearing assemblies if replacement is necessary B Locate and secure with cap screw and lock washers the air chamber mounting bracket and tighten cap screws securely C Lubricate needle bearings with lubricant specification of 0 615 or the equivalent D Install slack adjuster on cam so that shoes are in a fully released position and install cam washer and cam groove lock ring E Mount air chamber on bracket and secure with chamber mounting stud nuts and washers F Connect slack adjusting lever to air chamber DISASSEMBLY pushrod clevis with clevis pin and cotter key Pis TEMOVe SOS Springs G Install brake shoes with anchor pins and secure B Remove lock rings retainers and felts from pins with felts felt retainers and pin groove anchor pins loc
107. occur LEAKAGE CHECK With the air system fully charged and the parking control valve in the release position coat the exhaust port and around the valve corner with a soap solution Slight leakage is permitted If the SR 1 Spring Brake Valve does not function as described above or leakage is excessive it is recommended that it be returned to the nearest Bendix authorized distributor for a new remanufactured valve If this is not possible the valve can be repaired with genuine Bendix parts in which case the following should prove helpful Note maintenance kit for the SR 1 Spring Brake Valve is available from any authorized Bendix outlet parts necessary for minor repair are included REMOVAL 1 Prior to removing the SR 1 apply the parking brakes and drain all the vehicle reservoirs 2 Identify all air lines before disconnecting 3 Remove the two mounting bolts from the SR 1 and remove the valve DISASSEMBLY Refer to Figure 2 1 Remove the socket head pipe plug 1 2 Remove the check valve spring 2 and the check valve 4 3 Remove the two phillips head screws and remove the exhaust cover 5 Separate the exhaust diaphragm 6 from the cover Remove the inlet and exhaust valve assembly 7 Remove the inlet and exhaust valve cap nut 8 and separate the cap nut o ring 9 7 Remove the valve stop 10 valve spring 11 and inlet and exhaust valve 12 8 Remove the four phillips head screws and
108. of a 15 G open end wrench on adjusting bolts B Upon reassembly first actuate brake to center shoes in drum C A Adjust liners out until a slight drag can be felt while drum is in rotation Back off adjusting bolt until drum can rotate freely oubsequent adjustments to compensate for lining wear may be made by moving shoe in or out by turning the eccentric cam in direction desired FSH brakes which not equipped with the parking lever feature usually have an upper coil spring rather than the U spring CARE AND MAINTENANCE H SERIES BRAKES The Hydraulic Brake commonly referred to as the plain H is a light duty two shoe type brake mounted on a backing plate which also serves as a dust shield Adjustable anchor pins provide a means of centering the brake shoe arc in relation to the drum and secondary or minor adjustments are made by rotating the eccentric cam which bears on the brake shoe web or pin in the shoe web HYDRAULIC BRAKE LAYOUT BRAKE SHOE mem Teal RETURN SPRING BRAKE SHOE ECCENTRIC ADJUSTER WHEEL CYLINDER ASSEMBLY 2 Ert uec BRAKE SHOE AND LINING ASSEMBLY GUIDE PIN SPRING WASHER BACKING PLATE ASSEMBLY ANCHOR PIN ADIUSTABLE BRAKE SHOE C WASHER ANCHOR PIN GUIDE PIN WASHER GUIDE PIN LOCK 9 BRAKES F M M NO 4 DISASSEMBLY made to both properly locate the curvature of the lining to A Disconnect brake shoe return spring t
109. of vehicle operation loads area temperature etc are clearly and completely stated when applying to our Engineering Department for an optional lubricant recommendation SINGLE GRADE LUBRICANTS High viscosity single grade oils S A E 140 or S A E 90 should only be used in warm climates where no cold weather is encountered Low viscosity single grade oils S A E 70W S A E 75W S A E 80W or S A E 85W should only be used in cold climates where no warm weather is encountered Refer to the Recommended Lubricants chart for LUBRICATION temperature limitations of each grade of oil MULTIGRADE LUBRICANTS Multigrade oil must be used where vehicles operate in both cold and warm weather between oil changes multigrade oils are used the complete specification including viscosity stability in service of each viscosity grade listed must be met Refer to the Recommended Lubricants chart for temperature limitations of each grade of oil GEAR LUBRICANTS FOR LOW TEMPERATURE OPERATIONS IMPORTANT For drive units utilizing the low temperature lubricants oil seals and gasket materials must be in excellent condition to insure against the loss of these lower viscosity oils Use oils that meet all the requirements of Rockwell Specification 0 76 J or 0 76 K Further the use of thinning agents i e kerosene gasoline or any other dilutants that lower the viscosity of the lubricant IS NOT PERMISSIBLE Refer to the Recommended
110. on the dial indicator 4 Establish backlash at 006 012 15mm 30mm by adding or subtracting gaskets General rule A Chelsea 010 gasket will change backlash approx 006 020 gasket changes backlash approx 012 m 006 012 POINTE INDICATE lt SIDE MOVEMENT ALTERNATE INDICATORS 006 012 P T O INPUT 006 PLUNGER 012 TYPE POINTER INDICATES DEPTH TRANS GEAR 1 MISSION GASKET PACK AS REO ID P T O CASE Fig 11 NOTE When using a 220 260 or 270 Series P T O with the New AJ gear designation on an Allison Automatic transmission with a six bolt opening a special gasket 35 41 is supplied When installed with the P T O this gasket reduces the need for backlash adjustment 270 AND 800 SERIES Remove the Dump Back Plate on the side of the housing and rock the P T O Input Gear with your hand Correlate this backlash to the unmounted backlash found in Step 3 on page 7 Use Gaskets to get backlash feel as close to unmounted condition as possible NOTE The 270 AAJ amp BAJ come with a special gasket 35 4 1 which when installed with the P T 0 on a six 6 bolt opening on an Allison automatic reduces the need for backlash adjustment 10 2 GEAR BOLTS 822 832 amp 852 An inspection hole is provided in the P T O housing for feeling the mounted backlash Rock the P T O Input Gear with your hand and correlate this backla
111. over the knuckle counterbore with the rubber lip facing up Using a suitable sleeve and a bronze drift tap the seal into the knuckle until it bottoms against the bushing or counter bore D Repeat this procedure by reversing the knuckle for the lower seal NOTE In the absence of a suitable driver do not tap the seal in with a hammer See the seal in the opening and cover it with a rigid flat metal plate Tap the plate with a hammer directly over the seal until the seal is flush with the machined surface Do not drive the seal any further EASY STEER BUSHING KNUCKLES A Follow instructions for bronze bushed knuckles A B and C B Using a suitable sleeve and a bronze drift tap the seal into the knuckle bore until it is flush with the machined surface as shown in Figure 23 16 BRONZE MACHINED SURFACE Figure 23 EASY STEER RETROFIT INTO NON SEALED AXLE DESIGNS ONLY A A driver is required to position the seals in the knuckle bore B Position the seals against the bushings as shown CIRCUMFERENTIAL GREASE GROOVE TO OUTSIDE OF KNUCKLE TOP amp BOTTOM BUSHING Figure 24 THRUST BEARING SEAL ASSEMBLY NOTE Aluminum beam axles employ integral thrust bearing and seal assembl we fnm Figure 25 NOTE Some of the thrust bearings used in front axles have the word TOP stamped on the flat face of the bearing retainer The sta
112. part showing signs of wear or deterioration OPERATING AND LEAKAGE TESTS While holding a foot brake valve application 1 Coat exhaust port with soap solution leakage of a one 1 inch bubble in three 3 seconds is permitted 2 Coat body and cover with soap solution No leakage permitted between body and cover If the valve does not function as described or if leakage is excessive it is recommended that it be replaced with a new or remanufactured unit or repaired with genuine Bendix parts REMOVING AND INSTALLING REMOVING Block vehicle wheels and or hold vehicle by means other than air brakes Drain all ail brake system reservoirs Disconnect air lines from valve Hemove mounting bolts then valve INSTALLING Mount valve with exhaust port pointing down securely tighten mounting bolts Connect air lines to valve brake valve application line to top port brake chamber line to side ports DISASSEMBLY QR VALVE 1 Using wrench on square portion of exhaust port remove cover 2 Remove spring spring seat and diaphragm Remove cover O Ring QR 1 VALVE 1 Remove four screws 2 Remove spring and spring seat if so equipped 3 Remove diaphragm 4 Remove cover O Ring CLEANING AND INSPECTION Clean all metal parts in mineral spirits Wipe all rubber parts clean It is recommended that all rubber parts and any other part showing signs of wear or deterioration be replaced with genuine Bendix parts A
113. parts of the cranking motor wiring circuit should be checked before disassembling the magnetic switch Dated March 1966 Section VII ELECTRICAL SYSTEM DISASSEMBLY 1 Remove the two nuts from the coil terminals and the one from the center stud Lift the base and contact stud assembly from the switch housing Remove the remaining Keps nut from the top of the switch housing and pull the center stud out The contactor plate and shaft can now be removed without disturb ing coil leads and terminal studs REPAIR 1 Check the contact surfaces Pitted or burned contacts should be resurfaced with a smooth file Should the contact or disc be burned or rough the disc should be reversed on the shaft to provide a new contact surface This is done by compressing the spring back of the disc and removing the snap ring Make sure the snap ring is seated in the shaft groove when reassembling 2 With an ohmmeter check resistance of the operating coil The values should agree as shown in the switch characteristic table Coils not checking out to the values as shown in the switch characteristic table indicate replacement of the coil and shell assembly REASSEMBLY AND TEST Reassemble the switch in the reverse order of disassembly with special care on the following 1 Make sure the fiber spacer is in place with the coil leads between the spacer and shell 2 The contactor plunger must move freely on the center stud D
114. planetary axles with a common wheel end housing bowl oil level are initially lubricated fill each wheel end directly with the specific amount of lubricant listed in the following chart before vehicle is put back into operation Use the amount listed under housing bowl for drive units only DO NOT FILL THE AXLE THROUGH THE DRIVE UNIT OR HOUSING BOWL ONLY OUTER HOUSING OUTER HOUSING ENDS BOWL ENDS BOWL MOCEL OUTER HOUSING OUTER HOUSING SERIES ENDS BOWL ENDS BOWL Capacity Capacity Capacity Capacity PerEnd Capacity Per End Original New Per End Capacity Per End MODEL SERIES Original New Capacity Capacity U S Pints U S Pints Litres Litres U S Pints U S Pints Litres Litres PR 53 PS 250 PSM 826 19 5 PR 60 PRS 165 PR 251 S PRM 1756 7 19 5 PR 253 PR 108 PRLC 1756 7 18 5 PRLC 614 PR 256 PR 111 PRM 1314 5 20 5 PR 112 PRM 1615 20 5 PRLC 344 PS 260 PR 145 PSM 1044 5 20 5 PS 150 PR 270 PRLC 823 20 5 PR 150 PRM 672 3 PS 270 PSM 1614 20 5 PR 151 PRM 672 3 PS 310 17 0 PR 153 PR 350 PRM 672 3 PRC 3795 6 22 5 PS 200 PR 400 RC 1925 15 0 PR 200 NEM 5 26 5 PR 205 ll PRM 676 7 PS 500 PSC 4564 27 5 PR 207 50 459 PRM 676 7 PR 501 30 0 PR 208 PR 502 PRM 676 7 PRC 4805 29 0 PR 209 PR 700 30 0 PRLC 675 PR 250 PRM 1756 7 t For correct lubricant specification see Pages 11 and 12 28
115. proper facilities to produce a quality assembly It is necessary to properly assemble fittings into the tube and straighten before welding to be sure parts are centralized This can be done by mounting shaft assembly on center and straightening at fittings until ends of tube run concentric within about 005 TIR The welding of the tube in the fittings must provide for adequate strength and prevent distortion which could cause excessive runout t is often desirable to tack weld and recheck for runout before proceeding with final weld After welding the entire drive shaft should be straightened to the following limits See Fig 25 005 TIR On shaft neck 015 TIR On ends of tubing 3 from welds 010 TIR In center of tube These runouts should be taken with entire drive shaft assembly mounted on master attaching flanges or yokes selected for dynamic balance to eliminate as much unbalance as possible During balancing the drive shaft again should be mounted on these selected flanges or yokes CHECK STRAIGHTNESS OF SHAFT DIAL AT LOCATIONS SHOWN 005 ASSEMBLING UNIVERSAL JOINT 1 Seal If unnecessary to install a new kit make sure that four new seals are installed in the journal retainers rv onam o 5 ERE VEN demo Mer 2494 nU n re are FIGURE 26 2 JOURNAL CROSS With the relief valve facing the flange yoke insert one trunnion of
116. ps 1 23 37 P 19 SHIFTER SPRING ues TT ITO CT DERE 1 24 51 22 need Mops 1 25 63 16 POPPED 22 E EE ee aes 1 26 378003 LOCKWASHER nez Ime REY E T 1 27 378969 INDICATOR 5 pub Vue S awe 1 28 378004 FLAT WASHER TP rrt 1 29 500409 6 HEX CAPSCREW e 24 X96 ed ieu d e sex rmm e n 1 30 Potes ue SHIFTER PLATE ASS Y For 3 BG 1 328803 2X SHIFTER PLATE ASS Y For Arrangements 4 amp 5 31 28 P 49 SO AING ass i sone ys OS wen E Bod ctus ductu bes 1 32 378430 10 HEX CAPSCREW 46 18 17 4 A R As required ____ 220 SERIES 410 220 _ PARTS LIST amp SPECIFICATIONS BASIC MODEL 220 INPUT GROUP BASIC MODEL 220 LAH INPUT GROUP 220 M SERIES INPUT GEAR CHELSEA 220 SERIES 55 PARTS LIST amp SPECIFICATIONS P410 220 Description uS Quantity 328156X PRESSURE LUBRICATION lg M MEC EE 1 MS 9 35 IDLER SHAFT Pressure Lube 1 N S 500118 3 PLUG OW Hole soos yx eee er See E MES E eus Ds 1 N S 328075X OIL LINE Flexible 24 Long Ghee ie dude i dne 1 328346 10X CABLE CONTROL ASS Y Includes 1 378502 Knob 10X 10 Foot Cable 328380X CABLE CONTROL MOU
117. seals do not pop when being lubed move the driveshaft laterally in all four directions and pull or push on the drive shaft in the direction opposite to the journal cross seal not relieving while lube gun pressure is being applied to the alemite fitting increase in line pressure also be necessary Drive Shaft Assembly opicer factory assembled drive shafts are lubricated at the plant prior to shipment However shipping handling and installation of the drive shaft assembly into the vehicle usually results in some loss of lube Therefore it is recommended that all universal joints be relubricated after installation of the drive shaft prior to putting vehicle in service assemblies hanics add iring seals s and other gs and imdi ricated filled with Journal and Bearing Kits opicer replacement universal joint kits contain only enough grease to provide needle bearing protection during storage It is therefore necessary to completely lubricate each replacement kit prior to assembly into the drive shaft yokes Each journal cross lube reservoir should be fully packed with a recommended grease and each bearing assembly should also be wiped with the same grease filling all the cavities between the rollers and applying a liberal grease coating on the bottom of each race After the kits are installed into the driveshaft yokes and prior to placing into service they should be relubed through the zerks using the same grease
118. should be made to remove the bearing The bearing cap seals are removed by pressing them toward the inside Note The high pressure seal back up washer will also be displaced with the seals and should be recovered for reinstallation with new seals Page 35 SHEPPARD POWER STEERING SERVICE MANUAL S 73 NOTE For removing seals and backup washer press in d this direction WAT SOL 235096 LET BACK UP WASHER 476 77 washer and the wan messvee on sena NOTE Dirt amp high pressure oil 4209 salt seals to be seat installed installed from this from this side side NOTE Backup ADDITIONAL SALT SEAL 235033 A a 2 20 ON 5 74 Reassembly of actuating shaft and bearing cap with integral salt seal A second salt seal and an umbrella style seal are used on some model steering gears The illustration to the left details this seal arrangement Seal replacement is the same as detailed below except the second salt seal is installed in the bearing cap Take backup washer and reinstall with under cut down as shown Take a piece of round stock 2 long and turn to 1 615 and smooth one end Put the piece of round stock in the bearing end against the backup washer Set the bearing cap on a press and evenly install the dirt seal lip out from the other end until it rests against the backup washer Evenly install the salt seal lip out into the bea
119. size an old pinion of suitable size can be used if available onto shaft so end of coupling or cylinder butts against edge of retainer Tap end of coupling with hammer driving retainer towards armature and off snap ring Fig 7 Remove snap ring from groove in shaft using pliers or other suitable tool If snap ring is too badly distorted during removal it may be necessary to use a new one when reassembling clutch 8 Hemove the armature and clutch from the lever housing 9 Separate the solenoid from the lever housing Heavy Duty Clutch Positork Drive and Spline Drive Motors 1 Note the relative position of the solenoid lever housing and nose housing so the motor can be reassembled in the same manner 2 Disconnect field coil connector from solenoid motor terminal and lead from solenoid ground terminal RETAINER SHOULDER CUPS CUPPED PINION STOP SPLIT WASHER SPRING PINION COLLAR SLEEVE AND SHELL ASSEMBLY Figure 14 Disassembled view of early type heavy duty sprag clutch drive assembly BAFFLE RETAINER CUPS CUPPED STOP SPRING SPLIT WASHER COLLAR SLEEVE AND SHELL ASSEMBLY FiBigaireo15rDisassepblededew odtate e type type heasytdubpeygac ei terdvmve ly SPACER CUP WASHER CUPPED PINION T ait SPLIT SPRING PINION WASHER AND SHELL ASSEMBLY WASHER Figure 16 Disassembled view of DR 250 drive Page 7 HOLD IN WINDING PULLIN WINDING
120. softness under normal parking and storage temperatures The following greases meet all of these conditions Texaco Thermotex EP 1 or Shell Darina 1 A suitable grease can also be obtained under Rockwell Part No A 1 779 W 283 Optional 0 645 Vehicles operating in extremely cold weather below 40 F may require a grease conforming to this Rockwell specification Part No 2297 X 4574 The following grease meets this specification Mobil 28 Refer to Recommended Lubricants pages 6 and 7 LUBE INTERVALS e On highway Change whenever seals are replaced when brakes are relined or at 100 000 miles 160 000 e Off highway Change every 12 months maximum whenever seals are replaced or when brakes are relined However the change interval may be shorter depending on severity of operations This can be determined by initially scheduling an inspection of internal parts and lubricant every two months until the first 12 month period is up At each inspection look for contaminated or hardened grease or for lack of grease 15 LUBRICATION CAM MASTER CAM BRAKES On Highway and Off Highway P TYPE S CAM BRAKE AUTOMATIC SLACK ADJUSTER LUBRICANTS StandardO0 61 7 A or 0 617 B Manual slack adjusters camshaft roller journals metal or nylon camshaft bushings Standard 0 616 Anchor pins where specified Standard 0 616 A Automatic slack adjusters internal parts Optional 0 645 Extreme cold weather grease for autom
121. terminal the terminal nearest the alternator body ____ 8 Route the white wire lead through the alternator housing and attach it to the alternator negative output terminal ____ 9 Replace the regulator into the housing by reversing the procedure in Steps 1 through 5 above except for Step 2 Do not reconnect the trio lead at this time Tape and securely tuck trio lead away at this time Copyright 1982 DYNAMOTE CORP 2 68 section X 12 81 INSTALLATION INSTRUCTIONS 3 5 5 3 MODIFICATION INSTRUCTIONS FOR LEECE NEVILLE 2000JB continued 10 Alternator is now properly modified for installation of Dynamote harness Connect BLUE wire from Dynamote harness to BLUE connection terminal Proceed to Section 3 5 1 BLUE Regulator Lead Newly Installed x 6 32 Screw WHITE Connection Terrninal Newly Installed GREEN Jumper Diode Trio Spiel BLUE Connectior Terminal Regulator Top Plate Diode Trio Lead not connected Regulator Circuit Board Positive Field Brush Termina Negative Field Brush Terminal Figure 3 5 5 3A Figure 3 5 5 3B 3 5 5 4 ALTERNATOR MODIFICATION INSTRUCTIONS FOR LEECE NEVILLE SERIES 4000JA 000JA Internal 77973 The purpose of this modification is to provide a means to ground negative field brush permanently for use with positive switching regulators 22221 Disconnect the battery grounding cable and remove the alternator from the engine mounting brackets If alternator can be left on v
122. the new pinion and cage assembly with the correct shim pack into the carrier as follows IMPORTANT Remember that all Rockwell drive pinion and gear sets are manufactured and sold only in matching sets Therefore if either a pinion or a ring gear should require replacement both must be replaced in a matching set INSTALL PINION amp CAGE ASSEMBLY A Position the correct shim pack between the pinion cage and carrier IMPORTANT Use a minimum of three 3 shims per pack If the pack is made up from various thicknesses of shims locate thinnest shims on both sides of the pack for maximum sealing ability B Install the pinion and cage assembly with shims into carrier and tap into position with soft mallet C Install pinion cage capscrews Tighten capscrews to the correct torque D After the differential and gear assembly is installed into carrier make a gear tooth contact check ASSEMBLE DIFFERENTIAL AND GEAR IMPORTANT The ring gear must be heated before assembling onto the case half otherwise damage to the case half will result 15 SINGLE REDUCTION DRIVE UNIT Proper service replacement of the differential ring gear onto the differential case half is necessary for correct gear adjustment and longer drive unit service life For correct installation Rockwell recommends heating the ring gear in water to approximately 160 180 F for about ten minutes before assembly This will allow an easier fit of the gear over the
123. the journal cross into the bearing hole in the yoke lug from the inside between the lugs and tilt until the trunnion of the journal cross will clear the hole in the opposite yoke lug 015 13 0t0 915 FIGURE 25 FIGURE 27 3 NEEDLE BEARING AND RETAINING SUB ASSEMBLY Insert from outside of yoke Press into place with an arbor press or tap with a soft round drift taking care not to mar any surfaces 4 LOCK STRAP AND CAP SCREWS Assemble and bend the lugs of the lock strap up against the flat of the cap screw If the joint appears to bind tap the lugs lightly to relieve any pressure of the bearing on the end of the journal INSTALLATION Weal FIGURE 28 1650 SERIES JOURNAL CAPS WITH LOCK FLATS When installing new journal kit caps into yoke ear holes the lock flat on two of the journal caps must be kept in alignment with the locking flats near the front of the yoke ears Proper location of locking flats will assure that the journal cap will not rotate The installation of a drive shaft into the vehicle does not present any unusual mechanical difficulties Before actual installation the drive shaft should be checked for the following items 1 No damage or dents on drive shaft tubing which could cause unbalance If the dents are severe enough they can weaken the tube and a failure might occur under torque load 2 Splines should slide freely with slight drag from spline seal 3 Bearings should f
124. the seal After tightening the thru bolts remove the brush retaining pin to allow the brushes to fall down onto the slip rings Assemble the slinger fan pulley washer and nut Hold the shaft with a hex wrench inserted into the hex hole in the shaft end then tighten the nut to 70 80 Ib ft MAGNETIZING THE ROTOR IMPORTANT The rotor normally retains magnetism to provide voltage build up when the engine is started After disassembly or servicing however it may be necessary to reestablish the magnetism To magnetize the rotor connect the Integral Charging System to the battery in a normal manner then momentarily connect a jumper lead from the battery positive post to the Integral Charging System relay terminal identified This procedure will restore the normal residual magnetism in the rotor INTEGRAL CHARGING SYSTEM BENCH CHECK The Integral Charging System may be checked on the bench for output by connecting an ammeter in the circuit and a voltmeter from the BAT terminal to ground then following the procedure in the TROUBLESHOOTING PROCEDURES section DELCOTRON INTEGRAL CHARGING SYSTEM 16 285 Service Bulletin 470 USE THIN WALL TUBE IN SPACE BETWEEN GREASE CUP AND HOUSING TO PUSH BEARING INTO DIMENSION SHOWN PARTIAL VIEW u A 3 RECTIFIER END FRAME Figure 21 Slip ring end bearings Figure 22 Slip ring end bearing and seal locations location Page 10 DELC
125. too great for rated axle capacity Fatigued by pass valve spring in pump Low oil level in steering system Air in system Caster and camber degree incorrect Metal or foreign material caught in actuating valve Actuating valve worn or chipped by dirt Broken reversing springs in steering gear Hemove piston and clean relief valve seats or in piston of steering gear Foreign material in relief valve Bent or damaged reversing springs Page 13 SHEPPARD POWER STEERING SERVICE MANUAL Remedy Tighten or replace belts Replace pulley s and belts keep belt tight Follow Hydraulic Supply Diagnosis procedures Refer to pump servicing procedures Correct loading practices Align front end Locate and correct cause of overheating Repair or replace king pins and tie rods Refer to servicing instructions Lighten load or install larger steering gear Replace with flow control valve assembly Refer to pump servicing instructions Fill oil reservoir as required See Lubrication Bleed system and check for cause of air See final adjustments Correct to Specifications Remove actuating valve Clean and check parts for damage If damage is excessive replace damaged parts as required Replace reversing springs and damaged parts Refer to repair procedures to check for additional damage replace damaged parts Clean relief valve Check for impact or accident damage Replace damaged parts see Inspection Paragraph Sympto
126. ver is on front cover No 1 208U Same as No 208U except less locking feature EBER EAST PRODUCTS LIMITED TILLSONBURG ONT N4G 4H8 s 1 2 oa designed especially Section VIII MISCELLANEOUS for Huntington Rubber Hooks Precision made from high quality steel with a special hot zinc bright finish Attractive appear ance or easily painted in your shop if desired This heavy duty hardware accurately lits the Huntington Rubber Hood Hooks Also available chrome plated on special order HOOD BRACKET thre NEL Short stem up type ANCHOR BOLTS 12 gauge zinc TD ANCHOR BOLTS Ya NC x 12 HH plated steel X NF x 2 HH HRC 028 112 f Cad PI Bolt PI Bolt Use with all hooks W Self Locking 15 W Self Locking Nut Use with HRC Nut Use with HRC Nos 68D842 Nos 670794 deni 68D842 1101 eee eer and 101376 BRACKET and 68D638 Stem up type 12 gauge zinc plated steel HRC No 028 561 Use with all hook ANCHOR BRACKET 14 gauge zinc plated steel HRC No 277 A 80 1 1 Use with HRC Nos 67D794 4 UE 670794 1101 and did 11 HOOD 9 BRACKET 3 Dia Stem down type 12 gauge zinc 7 plated steel 133 2 HRC No 28 A 382 A 8 Use with ali hooks Dia fet 16 4 HOOD BRACKET Stem down type with slot Zinc plated 12 ga steel HRC No 28A400 Use with all hooks ANCHOR PIN Zinc plated steel HRC No 179 A 54 Use with HRC Nos 68D842 68D842 1101 an
127. volt systems Self Contained Power Unit Portable self contained inverter charger on wheels with batteries Will run power tools on average usage for one to two days before recharge 1800 watts of 120 VAC Inverter Charger Units Combination inverter battery chargers from 800 to 1800 watts for 12 or 24 VDC systems Section X F2106D INSTALLATION INSTRUCTIONS 11 81 SECTION 3 INSTALLATION INSTRUCTIONS DYNAIOTE SERIES A DYNAMIC INVERTERS FOR INSTALLATION ON VEHICLES AND BOATS WITH 12 VOLT NEGATIVE GROUND ELECTRICAL SYSTEMS ONLY 3 0 READ THE INSTRUCTIONS FIRST The Dynamote Dynamic Series A AC Power Inverter is a precision engineered and manufactured instrument capable of providing reliable AC electric power for thousands of hours However in order for the inverter to perform its job reliably it is very important that each component of the system be installed carefully and that each step be performed correctly Therefore before proceeding with the installation it is suggested that you take a few minutes to familiarize yourself with the components of the system and how they are to operate when properly installed 3 0 1 IMPORTANT NOTE There are nine distinct steps which must be followed in sequence to assure proper installation and operation of the entire system These steps are summarized below and described in detail beginning on the next page Select inverter location NO Route harness to alternat
128. wide and 1 32 of an inch deep and the slots cleaned out to remove any trace of dirt or copper dust As a final step in this procedure the commutator should be sanded lightly with No 00 sandpaper to remove any burrs left as a result of the undercutting procedure NOTE The undercut operation must be omitted on cranking motors having Test Specifications 2412 2415 3501 3564 3574 and 3599 as listed in Delco Remy Service Bulletins IM 186 1M 187 and IM 188 Do not undercut commutators on motors having these specifications The armature should be checked for opens short circuits and grounds as follows 1 Opens Opens usually caused by excessively long cranking periods The most likely place for an open to occur is at the commutator riser bars Inspect the points where the conductors are joined to the commutator bars for loose connections Poor connections Cause arcing and burning of the commutator bars as the cranking motor is used If the bars are not too badly burned repair can often be effected by resoldering or welding the leads Page 8 CRANKING MOTORS 1M 153 Service Bulletin in the riser bars using rosin flux and turning down the commutator in a lathe to remove the burned material The VOLTMETER CARBON PILE i AMMETER BATTERY Figure 19 Checking solenoid hold in and pull in windings Note Terminal locations may vary insulation should then be undercut
129. wire by putting a ring type A 87 terminal connector on one end Connect this wire terminal to the negative field terminal by using the negative brush terminal screw Wire terminal must be under the insulating washer so that good electrical contact is made to the brush terminal 8 Locate the black lead connecting the ceramic portion of the voltage regulator to the positive output terminal of the alternator See Figure 3 5 5 1A Remove and discard this wire 9 Thread WHITE wire to the exterior rear of the alternator by using convenient ventilating holes or else drill a hole in the end plate and use a rubber grommet to pass the leads through Make sure the lead is routed and secured go that it will not interfere with moving rotor parts 10 Reassemble the alternator by reversing procedures 2 thru 5 Connect WHITE wire protruding through rear of alternator to ground or alternator negative output terminal Use 1 Regulator Terminal as BLUE wire from DYNAMOTE Harness connector terminal DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 3 5 5 1 MODIFICATIONS FOR DELCO REMY 2751 SERIES continued 12 81 Eliminate this wire Terminal 1 EM BLUE connection terminal VOLTAGE ADJUSTMENT f EE mf BI Eliminate E EE trio mn dX j Figure 3 5 5 1A Delco Remy Figure 3 5 5 1B Delco Remy 2751 275 Type 200 BEFORE MODIFICATION Type 200 AFTER MODIFICATION 3 5 5 2 ALTERNATOR MODIFICATION INSTRUCTIONS
130. with two as follows The No 1 circuit portion is that portion of the separate supply and delivery circuits for service and valve between the spring seat which contacts the plunger and secondary braking which provides the driver with a graduated the relay piston the No 2 circuit portion is that portion control for applying and releasing the vehicle brakes between the relay piston and the exhaust cavity The E 10 Dual Brake Valve Fig 3 is similar to the E 6 Dual The No 1 circuit portion of the valve is similar in operation to Brake Valve except that a metal coil spring housed in an a standard single circuit air brake valve and under normal upper body assembly replaces the rubber spring used in the operating conditions the No 2 circuit portion is similar in E 6 valve The use of a metal coil spring and the upper body operation to a relay valve assembly provides greater travel and therefore provides the driver with a less sensitive feel when making a brake Both No 1 and No 2 circuit portions of the Brake Valve use application The E 10 Dual Brake Valve is generally used on common exhaust protected by an exhaust diaphragm busses where smooth brake applications contribute to passenger comfort 7 CONTROL TP 3 TRACTOR PROTECTION t m Hes 1 wen SUPPLY I l RESERVOIR RESERVOIR OPERATION APPLYING NORMAL OPERATION NO 1 CIRCUIT PORTION When the brake treadle is depressed the
131. 0006 4282 00006 3056 11451 4442 60920 4442 15200 4442 14200 4323 00417 4722 37008 Harness Control Field Grounding 16 White Wire 1 Bat Isolator Defeat 16 Black Wire 20 Fuses ABU 40 Fuses ABU 40 Fuses AGC 15 Holders Spare Fuse Holders Spare Fuse Brackets Tie Down Lugs RB 257 Lugs B 71 Lugs B 87 Rubber Cap 1 4 20 x 3 8 Bolt 4520 27000 4722 40008 1 4 20 Kept Nut 14 x 1 Screws gt gt gt gt HD X X X X X KK x X X X X X X KK x X X X X X X x X X X X X x X X X X X X KK x X X X X X X KK x 4442 16600 4 7211 4760 14000 Lugs F 72 Relay High Amp Bypass Ty R Optional Figure 3 0 3A HARDWARE KIT CONTENTS 3 0 4 Start your installation with the first step and follow each step through in sequence to successful final testing As it is completed check off each step in the space provided adjacent to the step number of the test warranty registration card DO NOT PROCEED TO ANOTHER STEP UNTIL ALL PREVIOUS STEPS HAVE BEEN SUCCESSFULLY COMPLETED Copyright 1981 DYNAMOTE CORP 2107 Section X 11 81 INSTALLATION INSTRUCTIONS 3 1 0 SELECT INVERTER LOCATION Place the inverter in a convenient location such as in the vehicle cab or in a service compartment outside Do not secure the inverter or tie it down at this time and do not connect the harness to the inverter Be sure that 3 1 1 the harness will reach to
132. 1 SPRING BRAKE VALVE c pt ix COVER 13 PISTON ZPRHINGS PISTON SPRING MM 1 4 DELIVERY EXTERIOR VIEW Figure 1 eS L2 The SR 1 Spring Brake Valve is used in dual or split air brake systems equipped with spring brake actuators The function of the SR 1 is to supply a specific limited hold off pressure to the spring brakes and in the event of loss of No 1 service air pressure to modulate the spring brakes through the use of the service brake valve The valve has four identified 1 4 N P T F ports and a diaphragm protected exhaust port Two 5 16 diameter holes are provided in the integral mounting bracket of the valve body The SR 1 must be mounted with the exhaust port down toward the road surface OPERATION INITIAL AIR SYSTEM CHARGE Upon initial charge air from 1 amp 2 service reservoirs flows through the park control valve and enters the SR 1 supply port Air entering the supply port flows past inlet and exhaust valve B to the underside of piston B and out the delivery port of the SR 1 to the emergency air connection at the spring brake actuator Note that the springs above piston B force it into contact with inlet and exhaust valve B In the position shown the exhaust is closed and toe inlet is open Air flowing from the No 1 reservoir only enters the reservoir 4 9 O RING PISTON 151 he EC
133. 1 con BATTERY AMMETER wv am C oe 6 GR UD GM VN UD ED AER ao gt TERMINALS 9 R TERMINAL i L Figure 4 Typical wiring diagram showing internal circuits Three rectifier bridge type ducts Transistor TR2 then turns on and TR1 turns off With TRI off the field current and system voltage decrease and 01 then blocks current flow caus ing TRI to turn back The field cur rent and system voltage increase and this cycle then repeats many times per second to limit the to the ad justed value s ms Capacitor C1 smooths out the voltage across R3 resistor R4 prevents excessive current through TRI at high tempera tures and diode D2 prevents high in duced voltages in the field windings when TRI turns off OPERATING PRINCIPLES THREE TERMINAL REGULATOR Typical wiring diagrams are shown in Figures 5 and 6 The basic operating principles are explained as follows With the Integral Charging System operating a c voltages initially are generated in the stator windings by residual magnetism in the rotor The diodes in the rectifier bridge change the stator a c voltages to a d c voltage which appears between ground and the BAT terminal speed increases current is provided for charging the battery operating electrical accessories Current also flows from the stator and rectifier br
134. 11 12 Connect the RED wire from the Dynamote harness to the positive output B terminal of the alternator The ONLY other wire that can be attached to this terminal is the 4 AWG wire to the Relay if that is installed Connect the GREEN wire from the Dynamote harness to the negative ground B terminal of the alternator Leave any previously attached wires connected to this ground terminal NOTE The B terminal of the alternator and the negative battery terminal must be securely grounded to the engine block Remove the wire from the alternator FIELD TERMINAL Tape the end of this wire to prevent electrical short and secure the wire It will no longer be used as the field will be regulated from the inverter Crimp the appropriate terminal in the hardware kit to the BLUE 16 Dynamote harness wire and attach to the Field Terminal of the alternator from which the wire was removed in Step 7 There should be no wire attached to the FIELD terminal except the BLUE harness wire If there is a negative Field Terminal on the alternator check to see that it has been grounded to the negative B terminal of the alternator If not use a piece of 16 AWG wire and the ring terminals provided in the hardware kit to accomplish this NOTE If the alternator has an internal regulator the modification instructions referenced in Figure 3 3 1A accomplish the grounding of the negative field lead Attach the ORANGE wire from the Dyn
135. 12 jumper wire 1 The Relay is the high amperage bypass relay and is a cylindrical silver solenoid contactor It is installed either in the 4 2500 Dynamic Installation Kit or independently near the alternator under the hood It can be found by following the wiring from the POSITIVE terminal of the alternator 2 Theengine and ignition should be OFF for this test 3 The small terminals on the relay are the coil terminals and the large terminals are the contacts 4 Check the voltage from the positive to the negative coil terminal of the relay With the inverter START button depressed there should be an audible click and the voltage should be 10VDC or higher Without the START button depressed the voltage should be 0 If these conditions are present go on to Step 5 If the voltage is O with the START button depressed carefully check the wiring to the positive relay coil terminal the one that is not grounded This should come from the ACC terminal in the rear of the inverter If the wiring is correct then go through the K2 Relay checkout procedure to be sure that there is voltage at the ACC terminal when the START button is depressed 5 Check the voltage from the relay contact that is wired to the alternator POSITIVE 4 terminal to GROUND Without the START button depressed the voltage should be 10VDC or higher DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 2 06 282 1000 4 3 5 4 3 6 4 3 7 RELAY
136. 16 e axle not mounted under vehicle Or Or e noload 1 3 16 to 5 16 11 16 to 3 16 final reading final reading 3 Camber angles of FF 931 FF 941 FL 931 and 11 16 to 3 16 3 16 to 11 16 FL 951 axles under rated load final reading final reading e axle mounted under vehicle 4 Camber angles of FF 931A and FF 941A aluminum 13 16 to 1 16 5 16 to 9 16 beam axles under rated load final reading final reading e axle mounted under vehicle IMPORTANT Camber is not adjustable ROCKWELL DOES NOT APPROVE OF CHANGING THE CAMBER ANGLE BENDING OF STEEL OR ALUMINUM BEAMS Bending the axle beam to alter camber angles is detrimental to the integrity of the axle beam If camber angles of models mentioned do not meet specifications shown in the chart contact your area Rockwell Technical Service Representative for assistance Most other models have a 10 nominal camber on the left and right sides for condition 1 Conditions 2 and are proportionally higher CASTER Caster settings are determined by the vehicle manufacturer generally manually steered vehicles operate best at 1 to 2 1 2 positive caster Power steered vehicles are generally set between 2 and 4 1 2 positive caster Center point models FE970 and FF971 are the only exceptions These operate best at 1 2 to 2 caster 16900 and 17100 series axles have 30 caster machined into the axle center All other models
137. 2 68D842 1101 and 66D638 mx ium RTLAND OREGON 97207 503 246 5411 TELEX 36 g 4 ANCHOR PIN Zinc plated steel HRC No 179 A 54 Use with HRC Nos 680842 680842 1101 660638 ANCHOR PIN Chrome plated steel HRC No 179 55 Use with HRC Nos 68D842 68D842 1101 and 66D638 Plants in Portland Oregon and Seattle Washington EP ae OB a COE 0457 PrivtedinUSA t RECESSED HANDLES Sect Van VIII MISCEICE ANEIOdVS 7 L TE Do ve a Folding T Handles in a rectangular steel pan stainless stcel spring holds handle in folded position M t 21 Poign e T se repliant dans soucoupe rectangulaire 3 en acier Un ressort retient la poign e en position ferm e 5630 Profondeur 3 4 Deep No 4814 Voir polgn es No 80 et No 260 AU VERSO DE CETTE PAGE pour substitut 12372 73 SEE CVERLEAF for No 80 and 280 which may be used as substitute to Nos 12372 73 1 Dia VARIATIONS TO ILLUSTRATED MODEL Variations du mod le illustr No 12372 B Plain RH illust 12372 C Locking RH No 12373 B Plain LH No 12373 C Locking LH et Poign e chrom e encastr e dans plaque de montage No 12372 5 Plain RH en non plaqu Chromed handle in a plain steel recessed mounting plate Folding D ring handles in round Poig
138. 21 Plug 2 5 7605 7922 Control Valve 1 6 7605 7923 opring 1 7605 7924 Seal Kit Includes 2 O Ring and 1 Seal 1 8 7605 7925 opring 1 9 7605 7926 Pressure Plate Includes Ring Brushing 1 10 7605 7927 Cartridge Kit Includes Ring Rotor Vane Kit Consists of 12 Vanes and 2 O Ring 1 11 7605 7928 2 12 7605 7929 1 13 7605 7930 Retaining Ring 1 14 7605 7931 Bearing 1 15 7605 7932 Retaining Ring 1 16 7605 7933 Shaft 1 17 7605 7934 1 7605 5256 Power Steering Pump Section IV STERING SYSTEM Note Your chassis Vechicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts 10 Part No 7603 1470 7602 7938 7605 2422 8874 3044 7602 6948 7610 1781 7605 1921 7810 3698 8203 5010 7808 0916 7610 1782 7605 0497 8874 3074 7605 1064 7605 1185 SECTION V Section V 13 12 11 10 8 9 Description Lock Nut 1 2 20 Washer 1 2 Fuel Tank Strap 50 Gal 3 8 NPT to 1 2 Tube 90 Elbow Hose Fitting 1 2 Tube 1 2 1 0 Hose Fuel Tank Cap Fuel Level Sender Gasket Fuel Tank 50 Gal 5 8 1 0 Hose Hose Fitting 5 8 Tube 3 8 NPT to 5 8 Tube 90 Elbow Fuel Tank 100 Gal Not Shown Fuel Tank Strap 100 Gal Not Shown Fuel System 8V 71TA o D amanina NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis m
139. 3 11 231483 18mm x 75mm 277 319 Lb Ft 2050 14 73 264 500358 19 231421 9 7 8 9x3 1 2 543 652 Lb Ft 2110 9 60 73 11 231482 20 80 397 457 Lb Ft 2150 16 73 164 500358 21 231421 10 1 12x 4 810 976 Lb Ft 2210 9 65 73 11 231481 22mm x 90mm 534 575 Lb Ft Tru Stop Brake Applications Form 3119 1 5 84 opicer Flange Bolts are Special Heat Treated Grade 8 Bolts Do not substitute inferior grade bolts DANA CORPORATION TOLEDO OHIO 43692 Front Suspension Section Il 20 440 Lb Capacity FRONT AXLE All Models 1 2 345 6789 10 14 12 13 PAA ee 1516 17 S EAE pe 22 ee E 298 gt 18 19 20 Item Part No Description Qty 1 7605 1350 opring Hanger 2 2 7810 6394 RH Frame Shock Bracket Shown 1 7808 1978 LH Frame Shock Bracket 1 3 7601 7831 H H C S 1 2 13 x 1 1 2 4 4 7602 7938 Hard Washer 1 2 4 5 8850 1008 Hex Nut 1 2 13 4 6 7604 1781 Mounting Stud 4 7 7810 3750 Rubber Bushing 8 8 7601 7822 Hard Washer 5 8 4 9 7604 6339 Lock Nut 5 8 18 8 10 7605 1258 Shock Absorber 2 11 7804 6731 Spring Assembly 2 12 7801 7734 opring Clip Seat 2 13 7810 1645 Spring Clip 4 14 7605 0175 opring Hanger 2 15 8820 1555 H H C S 7 16 20 x 2 1 2 12 16 8855 1012 Lockwasher 7 16 12 17 8850 1307 Hex Nut 7 16 20 12 18 7801 7662 Spring Seat 2 19 8850 1312 Hex Nut 3 4 16 16 20 7810 6397 RH Axle Shock Mount Shown 1 7808 1979 LH Axle Shock Mount 1 21 7604 1780 Spring Pin 6 22 88
140. 3T Constant Mesh amp For Deep Mount 220QEAM use case 1 P 167 ASSEMBLY ARRANGEMENT CHELSEA Pump Mounting Suffix Ti JmMouozzazrnrzxeco 220 SERIES PARTS LIST amp SPECIFICATIONS PUMP ADAPTOR FLANGES amp OUTPUT SHAFTS Flange Assembly Item No 43 21 P 118 328580X 328580X 328333X 328580X 328583X 328584X 328328X 328328X 328589X 328710X Output Shaft Item No 38 3 P 349 3 P 281 3 P 284 3 P 282 3 P 283 3 P 284 3 P 282 3 P 284 3 P 282 3 P 282 3 P 283 Capscrew amp Dimensions Quantity Required Four Item No 44 378447 8 46 18 x 115 378447 8 94s 18 x 11 5 378447 8 5 6 18 x 115 378447 7 545 18 x 114 378447 8 SAg 18 x 115 378447 7 8Ag 18 x 114 378447 8 515 18 x 114 378447 8 5465 18 x 115 378447 7 516 18 x 174 378447 8 3Ag 18 x 114 378918 Studs amp 328711X washers amp nuts P410 220 Conversion Kit A 328591 6X 328591 10X 328591 11X 328591 16X 328591 18X 328591 20 328591 21 328591 26 328591 23 328591 17 328591 25X All Conversion Kits include items listed plus Item No 45 Oil Seal 28 P 52 Item No 42 Gaskets 22 P 24 1 amp 22 P 24 2 amp Item No 41 Bearing Cup 550221 All Flange Assemblies use Item No 40 Cone Bearing 550397 EXCEPT which uses 550698 Item No 39 378391 Lockring used on standard shaft OPTIONAL FIELD CONVERSION KIT FOR HOLLY GOVERNOR DRIVE 48 Item Pari Number
141. 4850 5050 5250 5450 5650 5850 6100 6350 160 60 _ 5 2000 2100 2290 2600 3060 3850 E 75 25 38 2725 2875 3100 3450 3850 4350 5350 8000 105 35 43 1 2775 3250 3400 3850 5000 3300 3425 3550 3700 3850 4100 4350 4650 5000 5350 5800 6450 130 50 055 25 40 2850 3750 5900 0 60 3700 3850 3975 4200 4500 4900 5300 5725 6200 7000 105 735 43 Leece Ne Ville 1 2222222 2700 3100 3675 4350 3900 4100 4250 4500 4700 4950 5200 5500 5900 6350 6950 7650 130 50 50 PES 2200 2375 2650 3050 Ay 3600 3750 3850 4000 4150 4300 4500 4650 4850 5050 5300 5550 140 60 65 Figure 2 4H Copyright 1981 DYNAMOTE CORP 2104 Section IX GENERAL INFORMATION 10 81 Sec 2 5 2 5 OPERATING GUIDELINES Follow these four basic rules and your Dynamic Inverter will provide continuous satisfactory performance at its rated capacity 2 5 1 2 9 2 2 5 3 2 5 4 Inverter Model Code A30 BLACK GREEN A40 A60 1 0 BLACK GREEN ALL BROWN AC Hard wiring Use an alternator and Inverter capable of sufficient power for all your requirements See Section 2 4 for guidelines in selecting proper alternator and Inverter Remember that too small an alternator will limit motor starting and provide erratic voltage output Turn the alternator fast enough to generate the required power The Inverter does not generate power so you must provide the input necessary for the desire
142. 500357 7 Lockwasher 4 iH T 500448 9 Slotted Screw 4 328388 32X Installation Kit AIR SHIFT Installation Sketch for 822 832 900 910 and 920 Series Using New Williams Valve 68 P 28 Name Plate 378356 Tube 378414 Pressure Nut 6 Places Protection Valve Opens at 60 70 P S 378416 Hex Nipple 7 7 328864 Valve Assembly man 378415 7 500750 1 379130 Bracket 2 Nylon Tubing Street Tee 379131 1 Reducer Bushing 2 Places H Switch Male Connector 6 Places 378307 Wire 378301 Pressure Terminal 378978 i Indicator Light 500376 6 Hex Nut 4 4 1500357 7 Lockwasher 500448 9 Slotted Screw 4 4 Ground 328388 28X installation Kit Connect to Cylinder to Note Tube reusablieaslongasnylon Shit P T O Out of Gear tubing is removed from the tube nut 378884 Fuse Holder Caution When installing nylon tubing 4 avoid sharp angles exhaust and manifold anton or systems important When this installation is used on vehicles with automatic transmissions the P T O drive gear must be stopped before shifting Template for control plate on page 38 Warning Connect directly to air supply Do not use tubing between air supply and pressure protection valve 34 AIR SHIFT Installation Sketch for 100 220
143. 5T Allison 6 20 5 P 248 15T 2 P 179 28T 220 EDA 5 P 633 27T Mack T 2000 Series 6 48 17 6528 5 P 248 15T 2 P 179 28 2200 5 P 276 22T Spicer 8012 amp 8016 6N P 171 5 L H 5 P 317 15T 2 P 190 27T 220 EAD 5 P 504 20 Spicer R8516 5 175 L H 5 P 503 15T 2 P 479 27T 220 5 P 226 25T Allison 4700 A Series 6 25 5 P 248 15T 2 P 179 28T 220 5 P 551 25T General 6 8 20 9 15 2 179 28 220 5 P 552 25T Allison 6 259 15T 2 P 179 28T MEDIUM HIGH SPEED 220 LAB 5 P 227 21T General all 5 or 5 7 5 20 5 P 394 18T 2 P 388 25T 220 LAH 5 P 202 25T General all 6 or 6 8 6 or 6 8 20 5 394 18T 2 P 388 25T 220 LDD 5 686 22T Spicer 1214 2 amp 4A 5 85 209 5 P 394 18T 2 P 388 25 220 LAK 5 P 226 25T Allison 4700A Series 6 25 5 P 394 18T 2 P 388 25T 220 LDA 5 P 633 27T T 2000 Series 6 48 17 6528 5 394 18T 2 P 388 25T HIGH SPEED 220 PAB 5 P 227 21T General all 5 or 5 7 5 20 5 P 316 20T 2 P 256 23T 220 PAH 5 P 202 25T General all 6 or 6 8 6 or 6 8 20 5 316 20T 2 256 23T 220 5 P 686 22 Spicer 1214 2A amp 4A 5 85 209 5 P 316 20T 2 P 256 23T 220 PAK 5 P 226 25 Allison 4700 Series 6 259 5 316 20T 2 P 256 23T 220 5 P 633 27T T 2000 Series 6 48 17 6528 5 316 20T 2 P 256 2
144. 6 0 76 D _ Without Common Wheel End Housing Oil Levels 0 76 C or 0 76 D for Wheel Ends 0 76 0 76 or 0 76 B flor housing TRANSFER CASES 0 62 0 63 222000012222 2 25 000 miles 1666 hours T The lube intervals listed are considered maximum for ideal operating conditions Unusual Drain factory fill axle lube from new or reconditioned axles after first 1000 to 3000 miles of temperatures or operating conditions will require other reccmmendations Severe off road operation Replace oil filter t employed every time the o is changed applications may require some components to be iubricaled every day A regular lubrication Change lube at indicated intervals or wnenever seals are replaced or brakes relined which 1500 hours or Spring amp Fall a 1500 hours or Spnng amp Falle schedule for particular vehicles and operations can be determined by analysis of lube sam ever occurs first ples taken from the assembly at specified intervals uu Lubricants listed are recommended for average temperatures and operating conditions Alter 4 000 mile final lube procedure regular common carrier on highway service only Check the manual for optional lubricants eWhichever comes first elf yearly mileage is over 60 C00 eeelf yearly mileage is under 60 000 30 31 LUBRICATION ROCKWELL INTERNATIONAL Heavy Vehicles Components Operations Rockwell International Corporation 2135 West Maple Ro
145. 6 500371 3 HEX NUT 24 pel re USE 500398 10 CAPSCREW 4 16 1 UN po 2 N S 328170 155X P T O MOUNTING KIT for R Housing ipi uenis P GASKET amp SEAL KIT N S 328356 13X Must be Ordered S pdrale conan 4 pieces Item 11 2 pieces 14 1 1 piece each Items 12 31 15 amp 37 N S Not Shown 220 SERIES CHELSEA P410 220 P T O PITCH MODELS amp GEAR DATA X Pitch No 3 Pitch amp Item No 5 Item No 4 Mode Sliding Input Gear Application Pressure Angle Drive Gear Output Gear LO LO SPEED ieu di 220 CAB 5 P 227 21T General all 5 or 5 7 5 20 5 P 320 14T 2 P 283 29T 220 5 P 319 26T General all 6 or 6 8 6 or 6 8 20 5 P 320 14T 2 P 283 29T 220 CAJ 5 P 569 25T Allison 6 20 5 P 320 14T 2 P 283 29T 220 CDD 5 P 686 22 Spicer 1214 2 amp 4A 5 85 20 5 P 320 14T 2 P 283 29T 220 CAK 5 P 226 25T Allison 4700 A Series 6 259 5 P 320 14T 2 P 283 29 220 CDA 5 633 27T Mack T 2000 Series 6 48 17 6528 _ 5 P 320 14T 2 P 283 29T LOW SPEED 220 5 P 227 21T General all 5 or 5 7 5 20 5 248 15T 2 P 179 28T 220 EAH 5 P 202 25T General all 6 or 6 8 6 or 6 8 20 5 248 15T 2 P 179 28T 220 EDD 5 P 686 22T Spicer 1214 2A amp 4A 85 20 5 248 15T 2 P 179 28T 220 5 P 569 2
146. 605 1718 Front Rider Cushion Black 7605 1749 Front Rider Cushion Red 7605 1750 Front Rider Back Black 7605 1751 Front Rider Back Red 7605 3373 Seat Belt Rider amp Jump Seat 7605 2430 Seat Belt Retractor Rider amp Jump seat Not Shown 7605 3375 Seat Belt Driver Seat Not Shown 7605 33743 Tether Strap Driver Seat Not Shown 7611 6880 Female Dovetail 7605 4099 Striker Plate Cab Interior Model D 350 Qty RFK HH HA _ KH KH N po a Section MISCELLANEOUS Heater Assembly 2 a CONTROL PANEL IN CAB Item Part No Description Qty 1 7605 7457 Core 1 2 7605 7458 Defroster Grille 1 3 605 7459 Heater Grille 1 4 7605 7460 Control Panel Knob 3 5 7605 7461 Elbow Not Shown 2 6 7605 7462 Blower Switch 1 7 7605 7463 Control Panel 1 8 7605 7464 Blower Assembly 1 9 7605 3757 Heater Support 1 10 7605 3924 Heater Cover 1 11 8820 1002 Hex Head Capscrew 12 12 7605 5376 Hose Clamp 2 13 7605 1601 Hose 5 8 AR 14 7605 3793 Heater amp Kit 1 7605 7465 Heater Defroster Control Cable Not Shown 1 7605 7466 Heater Control Cable Not Shown 1 1 7605 7467 Water Valve Not Shown Note Your chassis Vehicle Identification Number N I N or Serial Number on older chassis must be supplied when ordering replacement parts Section VIII MISCELLANEOUS Owner s Manual Installation amp Shifting Options Printed in U
147. 67 1001 Lube Fitting 6 23 7604 1706 H H C S 3 8 24 x 5 1 4 2 24 8851 1106 Castle Nut 3 8 24 2 25 8863 1309 Cotter Pin 3 32 x 3 4 2 26 7800 6279 Bushing 2 NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts SectionII Front Axle FL 931 All Models Lud MN T Item Part No Description Qty Item Part No Description 1 Key 3 Key Steering Knuckle DR Lower 2 7605 2007 Steering Arm LH Ross Gear 1 19 Nut Tie Rod End 7605 1996 Steering Arm LH Spicer Gear 1 20 7605 2009 Arm Cross Tube L H Ross Gear 3 Cotter Pin 3 7605 2010 Arm Cross Tube L H Ross Gear 4 Nut Steering Arm Ball 1 7605 1998 Arm Cross Tube L H Spicer Gear 5 Lockwasher 12 7605 1999 Arm Cross Tube L H Spicer Gear 6 Capscrew 12 21 Tie Rod End Assembly 7 Grease Fitting 4 Tie Rod End Assembly L H 8 Steering Knuckle Cap 4 22 7605 2000 Cross Tube Assembly Items 3 19 21 23 24 25 Knuckle Cap Gasket 4 23 Bolt Steering Cross Tube 9 Brushing Knuckle 4 24 Clamp Steering Cross Tube End 10 Nut Steering Knuckle Draw Key 4 25 Nut Steering Cross Tube Clamp 11 Seal Knuckle Pin Upper Assembly 2 26 Knuckle Pin 12 Shim 005 2 27 7605 2001 Stop Screw Axle Center 13 Shim 010 2 28 7605 2002 Locknut Stopscrew Shim 030 2 29 7605 2003 Knuckle Steering Assembly L H Sh
148. 7604 4297 8871 1252 8871 1325 7605 3891 7605 3372 8127 7407 7811 3671 7605 0481 8871 2302 7605 0506 7811 3415 7605 1104 7604 2399 7605 2404 7604 2396 7604 2403 7604 2396 8126 0137 7605 2811 7605 2812 7605 1663 8688 3030 7605 3804 Description CAB SECTION Parking Brake Valve Air Pressure Gauge Low Pressure Switch 3 8 Tube 3 8 90 Elbow 5 8 Tube 3 8 NPT 90 Elbow 1 2 Tube 3 8 90 Elbow 1 2 Tube 1 4 NPT 90 Elbow 1 4 NPT Bulkhead Union 1 4 Tube 1 4 NPT 90 Elbow 3 8 NPT Bulkhead Union 5 8 Tube 3 8 NPT 90 Elbow 3 8 NPT Pug Square Head 1 4 NPT 1 8 NPT Reducer 1 4 Tube 1 8 90 Street Elbow Treadle Valve 3 8 Tube 1 4 NPT Straight 5 8 Tube 3 8 NPT Straight 1 2 Tube 1 2 NPT Straight 3 8 NPT 1 4 NPT Reducer 3 8 NPT Branch Tee Stop Light Switch 1 8 NPT Street Tee 1 4 Tube 1 8 90 Elbow 1 4 Tube 1 4 NPT Straight 3 8 Tube 1 4 90 Elbow 3 8 Tube 1 8 NPT Straight 3 8 Tube 1 4 90 Elbow Isolated Air Release Valve MAIN SECTION Air Reservoir Air Reservoir Quick Release Valve Spring Brake Valve 1 2 NPT 3 8 NPT Reducer Model D 350 Air System Schematic Section VI BRAKE SYSTEM Qt Item Part No 6 7810 3575 1 7 8452 1057 2 8 7810 3577 3 9 8668 3293 6 10 7605 0492 2 11 7605 2815 1 12 7605 2818 1 13 7605 2816 9 2 14 7811 3650 2 15 7811 3670 2 16 7604 2396 2 17 7811 3415 2 19
149. 7810 3453 1 20 7604 2394 22 7604 2398 1 24 7605 3389 6 25 7605 0481 2 26 7811 3648 1 27 7810 3443 3 28 7605 0506 1 29 8871 1253 1 30 8871 1251 2 31 7605 1138 2 32 7605 1183 2 34 8871 2302 4 35 8871 1384 1 36 7604 2413 1 383 7810 3452 1 9 7605 0505 40 7605 1099 41 7605 3596 2 42 7605 3595 3 43 7605 2404 1 44 7605 2808 1 45 7810 3106 1 46 8871 1103 4 X 2 Isolated Description Check Valve Safety Valve Automatic Drain Valve Double Check Valve Manual Drain Valve Pressure Regulator Service Relay Valve Quick Release Double Check Valve Brake Hose 24 Brake Hose 36 3 8 Tube 1 4 NPT 90 Elbow Stop Light Switch 3 8 Tube 3 8 NPT 90 Elbow 1 2 Tube 3 8 NPT Straight 1 2 Tube 3 8 NPT 90 Elbow 3 8 NPT 1 2 NPT 90 Elbow 1 2 Tube 1 2 NPT Straight 1 2 Tube 1 2 NPT 90 Elbow 5 8 Tube 1 2 NPT 90 Elbow 3 8 NPT Branch Tee 1 2 NPT Plug Square Head 1 4 NPT Plug Square Head 3 8 NPT 1 4 NPT Reducer 1 2 NPT Street Tee 3 8 NPT 1 4 NPT Reducer 1 2 NPT 1 4 NPT Reducer 1 4 NPT 1 4 NPT 90 Elbow 1 2 NPT 1 4 NPT 90 Elbow 1 2 NPT Branch Tee 1 2 NPT 1 4 NPT Reducer 3 8 Tube 1 2 NPT 90 Elbow 1 4 NPT Branch Tee 1 4 Tube 1 4 NPT Straight 1 2 NPT Bracket W eldment Pressure Regulator 1 2 NPT 90 Street Elbow NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis Must be supplied when ordering rep
150. 8 It is not necessary to obtain the exact voltage specified in these bulletins as an accurate interpretation can be made by recognizing that if the voltage is slightly higher the r p m will be proportionately higher with the current remaining essentially unchanged However if the exact voltage is desired a carbon pile connected across the battery can be used to reduce the voltage to the specified value If more than one 12 volt battery is used connect the carbon pile to only one of the 12 volt batteries If the specified current draw does not include the solenoid deduct from the ammeter reading the specified current draw of the solenoid hold in winding Make disconnections only with the switch open Interpret the test results as follows Interpreting Results of Tests 1 Rated current draw and no load speed indicates normal condition of the cranking motor 2 Low free speed and high current draw indicate a much friction tight dirty or worn bearings bent armature shaft or loose pole shoes allowing armature to drag Figure 10 Rerhoving retainer from snap ring 4 Shorted armature This can be further checked on a growler after disassembly Grounded armature or fields Check further after disassembly Failure to operate with high current draw indicates A direct ground in the terminal or fields Frozen bearings this should have been determined by tu
151. 83 15 7 0 B 140 12 5 5 2090 12 0 5 B 150 3Vo 1 5 F 3100 16 7 5 C 100 12V 6 0 F 3110 26 12 5 D 100 12 6 0 F 3200 22 10 5 D 140 12 6 0 F 4700 40 19 0 E 100 15 7 0 4710 32 15 0 105 12 6 0 7900 40 19 0 150 9 4 0 7910 32 15 0 300 13 6 0 FS 4711 32 15 0 E 350 22 10 5 FDS 75 14 6 5 E 370 22 10 5 FDS 85 15 7 0 F 30 6 3 0 FDS 90 14 6 5 F 35 7 3 5 FDS 750 7 3 0 37 7 3 5 FDS 1600 23 11 0 38 10 4 5 FDS 1800 35 16 5 F 46 10 4 5 FDS 1805 35 16 5 F 50 10 4 5 FDS 2100 35 16 5 F 53 12 5 5 G 161 21 10 0 F 54 11 5 0 G 340 24 11 0 F 56 14 6 5 one pint 0 47 liters of lubricant to pinion cage when new or reconditioned drive unit is installed T For correct lubricant specification see Pages 19 23 25 LUBRICATION LC MODEL SCENE G 341 22 10 5 53300 15 7 0 G 361 91 10 0 53500 6 3 0 H 100 20 9 5 53521 9 4 5 H 140 21 10 0 53547 9 4 5 H 150 11 5 0 53600 7 3 25 H 162 20 9 5 53625 434 2 25 H 170 27 12 5 54400 15 7 0 H 172 27 12 5 55400 20 9 5 H 200 28 13 0 55600 20 9 5 H 240 22 10 5 56219 22 10 5 H 262 23 11 0 56400 20 10 5 H 300 26 12 5 56410 20 10 5 340 22 10 5 56434 13 6 0 H 350 24 11 5 56450 26 12 0 H 360 24 11 5 56461 26 12 0 H 370 24 11 5 58200 21 10 0 L 100 23 10 5 58300 21 10 0 L 140 24 11 5 58415 26 12 0 L 155 24 11 5 58822 22 10 5 L 172 27 12 5 59722 26 12 0 L 200 31 14 5 65300 14 6 5 L 240 22 10 5 65356 23 11 0 L 300
152. A Fill axle housing to the correct level with specified lubricant B Lubricate universal joint C Drive the vehicle unloaded for one to two miles at speeds not to exceed 25 miles per hour to thoroughly circulate the lubricant throughout the assembly NEW AND RECONDITIONED AXLE SERVICE The original rear axle lubricant should be drained at the end of the drive away or before the maximum of 3 000 miles prior to placing the vehicle in regular service Drain the lubricant initially used in the assembly following reconditioning at the same interval Completely drain the lubricant while the unit is warm Fill axle housings to bottom of level hole with specified lubricant with the vehicle level REGULAR AXLE SERVICE Hefer to Field Maintenance Manual No 1 rication for recommended service interval Lub Completely drain the lubricant while the unit is warm Some newer model axles have a smaller tapped and plugged hole located near and below the housing lubricant level hole This smaller hole has been provided for the use of a lubricant temperature indicator only and should not be used as a fill or level hole MAGNETIC DRAIN PLUGS Magnetic drain plugs perform the vital function of trapping small metallic particles that circulate in the lubricant through the gears and bearings causing rapid wear and premature failure The magnet must be strong enough to firmly hold the particles under service conditions We recommend plug
153. ACLE RECEPTACLE HOLD DOWN INVERTER BRACKET BOLTS VOLTAGE REGULATOR ADJUSTMENT Figure 2 2 5A Dimensions shown are for A40 40 A60 and MPA60 2 2 6 Mounting Configuration Figure 2 2 5B A30 and MPA 30 dimensions are H 9 3 4 W 14 D 15 Diagram 2 2 6A below shows the mounting dimensions for the A30 Series Diagram 2 2 6B below shows the mounting dimensions for the A4 0 A60 Series vou FRONT PANEL Figure 2 2 6A A40 amp A60 SERIES am 0 0 ai 22211 FRONT PANEL Figure 2 2 6B 2 2 Miscellaneous Installation hardware spare fuses warranty statement and registration card and instruction manual accompanies each new inverter The manual should be kept with the inverter at all times COPYRIGHT 1983 DYNAMOTE CORPORATION Section IX F8302 GENERAL INFORMATION 1 83 Sec 2 3 2 3 SELECTION OF ALTERNATOR AND INVERTER AMPERAGE REQUIREMENTS OF VARIOUS LOADS Average amps for operating various frequently used loads are shown in Figure 2 3A below Air Conditioners Automatic Pilot Blender Broiler Coffee Maker 12 cup Fry Pan Depthmeter Drills 1 4 to 1 2 Electric Blankets Fans Grinders Heaters Water Space Hot Plate Element Impact Wrench Ice Maker Irons Hand ooldering Microwave Ovens Radar Radios Ranges per element Refrigerator Sanders Saws Sabre Builders Sewing Machine Skillet TV Sets Toasters Vacu
154. AXLE HUB ASSEMBLY DRIVE AXLE HUB ASSEMBLY TRAILER SHOWN LUBRICANTS otandard 0 76 C or 0 76 D Optional 0 76 E 0 76 F 0 76 J or 0 76 K Also 0 76 0 76 A or 0 76 B if drive axle has a common hub axle housing oil level and axle requires these lubes for proper operation Refer to Recommended Lubricants pages d and 7 13 LUBRICATION LUBE INTERVALS Check every 1000 miles 1600 km and change whenever oil becomes contaminated drive unit lube is changed seals are replaced brakes relined or at least once a year LUBE PROCEDURES The following will assure that oil lubricated wheel bearings are initially lubricated after servicing and before vehicle is put back into operation e Axles Wipe a film of oil on the inner shoulder of the spindle to prevent rust behind the inner bearing cone e Drive Axle Hubs With Oil Fill Holes Pour one pint 0 473 liters of oil same as used in drive unit directly into each hub Drive Axle Hubs Without Oil Fill Holes Pour the specific amount of recommended drive unit lubricant through the carrier or housing bowl oil fill hole Next tilt the vehicle to the right and to the left enough to allow the oil to flow into the hub cavities This may be accomplished by jacking up the axle from each end Keep the axle in each tilted position for one minute to allow all the hub cavities to fill Approximately one pint 0 473 liters of oil will be trapped in each hub cavity With the vehicle back on
155. C TACHOMETER RELAY If an electronic tachometer which is driven from an alternator AC tap or an alternator tachometer tap is used in the system a Dynamote Relay 524 1160 must be used when the Dynamic Inverter is installed The relay provides for proper reading of the tachometer s both when the inverter is OFF and when it is ON The relay has two identical sets of contact so it can be used with either one or two tachometers An adjustable trim pot is provided on each set of contacts for accurate adjustment At a convenient location near where the relay is to be mounted cut the wire presently leading from the tachometer to the alternator AC tap Attach the two parts of this wire according to the diagram below If two tachometers are used attach one tachometer to each side of the relay board as shown Relay 4 1160 To AC Tap On Alternator SR On Atternator Tach 1 lt _ 6 5 To Tach 2 Internal Schematic of Relay 4 1160 to BROWN Wire is from DYNAMOTE Harness Figure 3 5 3A For adjustment With inverter OFF increase engine speed to normal operating speed Note the tachometer reading Turn inverter ON and adjust trim pot on side of relay so that tachometer reads the same with the inverter ON as it reads with the inverter OFF Repeat procedure for second tachometer Return to Section 3 5 1 Step 2 Copyright 1981 DYNAMOTE CORP 11 82 3 5 4 DIAGRAMS FOR EXT
156. D 157 9 4 25 forward 39 18 5 SFD 375 23 11 0 rear 36 17 0 SFD 450 36 17 0 SRT 235 45 21 0 SFD 460 29 13 5 SRT 335 44 20 5 SFD 3020 31 14 5 SSHD SFD 4600 28 13 0 forward 34 16 0 SFD 4700 28 13 0 rear 28 13 0 SFDD 3020 131 114 5 ST 170 SFDD 4600 128 113 0 forward 55 26 0 SFDD 4640 3412 116 0 rear 43 23 3 SFDD 4700 28 113 0 ST 270 amp 280 eSFHD forward 55 26 0 forward 117 18 0 rear 55 26 0 rear 1612 7 5 STHD eSHHD 126 112 0 forward 34 16 0 SL 100 rear 28 13 0 forward 40 18 9 SU 170 rear 37 16 1 forward 55 26 0 SLD 28 13 0 rear 43 23 3 SLDD 128 113 0 SU 270 amp 280 eSLHD forward 55 26 0 forward 3212 115 25 rear 55 26 0 rear 32 15 0 SUHD SQ 100 forward 34 16 0 forward 40 18 9 rear 28 13 0 rear 37 16 1 SUDD 433 1855 SQD 22 10 5 SW 170 SQDD 122 110 5 forward 55 26 0 eSOHD rear 43 23 3 forward 434 116 0 SW 270 amp 280 rear 31 14 5 forward 55 26 0 SQHP rear 55 26 0 forward 40 19 0 rear 36 17 0 SQTT 335 44 21 0 tAdd two pints 1 liter of lubricant to inter axle differential housing when new or reconditioned drive unit is installed in addition to specified amount of lubricant in housing Pinion shaft 6 above horizontal centerline tFor correct lubricant specifications see Pages 19 23 Add one pint 0 47 liters of lubricant to pinion cage when new or rereconditioned drive unit is installed 27 LUBRICATION PLANETARY STEERING AND RIGID AXLES t REFERENCE ONLY IMPORTANT To assure that the wheel ends of
157. D terminal is grounded 1f all wiring conditions are correct then the alternator is faulty or the belts are slipping b If BLACK and RED are greater than 14 2VDC and BLUE is greater than 12VDC verify that BLUE is the only wire connected to FIELD positive terminal C If BLACK and RED are less than 13 5VDC and BLUE is less than 10VDC CB3 is defective and should be replaced DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 3 6 2 HARNESS amp ALTERNATOR CHECKOUT WITHOUT 4 2600 continued 7 With engine still running at about 1000 RPM remove commutation fuses on inverter and push Dynamote Start Button Voltage readings should be as follows Ground GREEN post to Battery BLACK post 12 12 8VDC Ground GREEN post to Alternator B RED post 15 OVDC or greater Ground GREEN post to F Out BLUE post 12 12 8VDC Ground GREEN post to Ignition ORANGE post 12 12 8VDC Ground GREEN post to Accessory BROWN post 12 12 8VDC Trouble Shooting Tips for Step 7 1 If BLACK post voltage is above 12 8VDC harness is wired improperly or K3 Relay if used is not functioning properly Correct this defect before proceeding This step assures proper disconnect of alternator output from vehicle battery when inverter is energized 2 If RED post voltage reads below 15 OVDC harness wiring is incorrect or alternator may be defective Correct wiring defect if any at this time Alternator defect if any w
158. DIFF BEARING Some models may employ anly the thrust screw wich may replace ihe thrust screw and block assembly ROCKWELL SINGLE REDUCTION DRIVE UNITS CARE AND MAINTENANCE SINGLE REDUCTION CARRIER REMOVAL DIFFERENTIAL CARRIER FROM HOUSING A Remove plug from bottom of axle housing and drain lubricant B Remove the axle shaft stud nuts lockwashers and tapered dowels IMPORTANT To loosen the dowels hold a 1 1 2 inch diameter brass drift against the center of the axle shaft head INSIDE THE CIRCULAR DRIVING LUGS Strike the drift a sharp blow with a 5 to 6 pound hammer or sledge 172 inch diameter brass hammer is an excellent and safe drift CAUTION Do not hit the circular driving lugs on the shaft head this may cause the lugs to shatter and splinter Do not use chisels or wedges to loosen the shaft or dowels this will damage the hub shaft and oil seal C Remove the axle shaft from the drive unit and housing D Disconnect universal at pinion shaft E Remove carrier to housing stud nuts and washers Loosen two top nuts and leave on studs to prevent carrier from falling F Break carrier loose from axle housing with rawhide mallet The Rockwell Single Reduction Final Drive employs a heavy duty hypoid drive pinion and ring gear The differential and gear assembly is mounted on tapered roller bearings The straddle mounted pinion has two tapered roller bearings in front of the pinion teeth which take the
159. DISASSEMBLY 1 Remove end plate from slip ring end frame INTEGRAL CHARGING SYSTEM REPAIR 2 DELCOTRON INTEGRAL CHARGING SYSTEM or 1B 116 IMPORTANT Remember that an over heated battery will overcharged even though no charging circuit defects are present If battery is not defective or overheated connect a voltmeter between Integral Charging System BAT terminal and ground With all accessories turned off increase engine speed as required to obtain maximum voltage reading If voltage exceeds 15 volts on a 12 volt system or 30 volts on a 24 volt system remove Integral Charging System for repair as covered under heading of INTEGRAL CHARGING SYSTEM REPAIR Hold shaft with hex wrench inserted into hex hole in end of shaft while removing shaft nut Remove washer pulley fan and slinger Remove four thru bolts from drive end frame Service Bulletin 16 285 If voltage does not exceed the values listed in Step 4 preceding adjust voltage to a lower value by removing voltage adjusting cap reinserting into connector body Then check battery condition after a service period of reasonable length such as one week Figure 8 is for purposes of illustration only and shows the cap adjusted for the lowest setting The actual adjustment as shipped from the factory may be in some other position such as position 3 depending on the application requirement The lowest setting
160. DRI LOC BOLTS OR IN THE THREADED HOLES 3 Tighten the Dri Loc case bolts to the specified torque value recommended for the same regular bolt Dri Loc will not alter the torque requirement Refer to Fastener Torque Chart at the end of this manual NOTE No cure time is required for Dri Loc bolts prior to rebuilding the axle and returning it to service Reuse of Dri Loc Bolts or Use of Regular Bolts and Liquid Adhesive 1 Wipe excess oil residue from the bolts and threaded holes in the case The bolts and holes should be relatively oil free however no special cleaning is required When reusing Dri Loc bolts it is not necessary to remove the Dri Loc residue from the threads 2 Apply liquid adhesive to the threaded holes only by letting four or five drops run down the side of each hole Before threading in the bolts visually check to make sure that the liquid adhesive has contacted the threads IMPORTANT Do not apply liquid adhesive to the bolt since trapped air in the hole will create back pressure and blow out the liquid adhesive as the bolt advances 3 Tighten the bolts to the specific torque value rec ommended for that size bolt Liquid adhesive will not alter the torque requirement Refer to the Fastener Torque Chart at the end of this manual NOTE No cure time is required for liquid adhesive prior to rebuilding the axle and returning it to service Rockwell 2297 C 3747 liquid adhesive is available in ten 10
161. E PIER A a ae Pa har ed cm ms Figure 34 A small hydraulic jack under a block of wood can be used beneath the knuckle to provide the necessary NOTE Normal seating of the thrust bearing seal lift Keep lifting the knuckle until the dial indicator and shims will increase the end play reading after a short time in service reading levels of PROCEDURE FOR MEASUREMENT OF KNUCKLE AND END PLAY WITH TIRE AND WHEEL ASSEMBLY MOUNTED A Securely block vehicle to prevent rolling B Place a jack under the axle beam as close as possible to the knuckle end being checked and jack the vehicle up until the tire is clear of the floor C Attach a dial indicator to the axle beam with a C clamp or magnetic base Figure 36 Figure 35 CAUTION When using a hydraulic jack be sure that the axle is supported by two jack stands Raising the end in this manner may cause an axle supported only in the center to tip and fall causing personal injury F Repeat Steps A through E with the knuckle in the full right and left turn positions This is necessary to be sure that no binding or excessive play is present D during turns Figure 36 Place the dial indicator plunger on top of the king pin cap or knuckle forging so that its line of action is approximately parallel to the king pin center line IMPORTANT If binding exists or zero end play is measured anywhere in the full travel of the E knuckle r
162. E Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts Section MISCELLANEOUS Air Horns Models Item Part No Description Qty 1 7605 0109 Air Horn Grover 2 7605 1142 Air Horn Hadley 2 2 7605 2586 Air Valve 1 3 7605 0110 Bracket Kit for Grover Air Horns 1 NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts DUPLEX Electric Wipers Models Item Part No Description 1 7605 0281 Wiper Motor L H 7605 0282 Wiper Motor 2 7605 3781 Wiper Arm 3 7605 3616 Wiper Blade 4 7605 0279 Pantograph Adapter Kit Not Shown D 605 5126 Washer Jet Not Shown NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts m Section VIII MISCELLANEOUS Mirror Assembly Three Arm Unit Models m7 Item Part No Description 1 7808 1477 Head amp Loop Assembly Includes Items 3 4 2 7810 3424 Mounting Bracket Kit 3 7611 7325 Flat Mirror Head 4 7611 7324 Mirror Head mo MIO NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts NOTE Your chassis Vehicle Identification Number
163. E OF ITS PRODUCT OR FROM ANY OTHER CAUSE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THESE LIMITATIONS MAY NOT APPLY TO YOU ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED ARISING BY LAW COURSE OF DEALING COURSE OF PERFORMANCE USAGE OR TRADE OR OTHERWISE INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO A PERIOD OF ONE 1 YEAR AFTER FIRST INSTALLATION OR EIGHTEEN 18 MONTHS FROM DATE OF MANUFACTURE WHICHEVER COMES FIRST SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU NO PERSON AGENT OR DEALER IS AUTHORIZED TO GIVE ANY WARRANTIES ON BEHALF OF MANUFACTURER OR TO ASSUME FOR MANUFACTURER ANY OTHER LIABILITY CONNECTION WITH ANY OF ITS PRODUCTS UNLESS MADE IN WRITING AND SIGNED BY AN OFFICER OF MANUFACTURER SPECIAL NOTICE TO PURCHASER REGARDING WARRANTY PROCEDURE It is absolutely necessary that the requirements of Paragraph 1 1 above be complied with for warranty to be in effect MAKE SURE THE INSTALLER HAS COMPLETED AND SIGNED YOUR PORTION OF THE WARRANTY INITIATION CARD CERTIFYING THAT THOSE REQUIREMENTS HAVE BEEN COMPLIED WITH If any trouble occurs with this product during installation or before the warranty has expired follow these instructions With model number and serial number available for reference as well as all
164. EARING TAPERED KNUCKLE PINS 900 910 930 and 970 Models Figure 7 1 Knuckle Upper 7 Expansion Plug Lock Bushing Ring 2 Knuckle Pin Sleeve 8 Expansion Plug 3 Upper Dust Cap 9 Knuckle Lower 4 Knuckle Pin Nut Bushing 5 Shims 10 Tapered Knuckle Pin 6 Thrust Bearing 11 Knuckle Spindle A Tapered knuckle pins must be removed from the bottom side of the knuckle 1 On some models it will be necessary to remove the brake components to provide clearance for knuckle pin removal Refer to brake manual for brake disassembly Figurel Figure 8 F Remove the knuckle pin sleeve and lift off steering B Remove the knuckle pin cover capscrews cover and knuckle thrust bearing spacing washers and cover gasket backplate assembl C C Knuckles employing lower expansion plugs and lock f rings 1 Remove the lock ring with a pair of snap ring pliers 2 Dislodge and remove expansion plug with a small drift D Remove knuckle pin cotter key and nut Figure 9 eco um J Figure 11 G Inspect the grease seals for tears rips and deterioration Do not remove the seals from the steering knuckle unless replacement is necessary or if the knuckle is to be rebushed If a seal must be removed pry it out with screwdriver Figure 12 Figure 9 E Drive knuckle pin out by use of drift on upper end Bronze drift should be used to avoid any damage to hreadd Figure 10 Figure 12 H Bushing Remova
165. ED Fig 6 CABLE OUT P T O ENGAGED Fig 7 Install the wire control bracket found in either the 328380X or 328380 1 X wire control parts bag Fig 8 Line the cable up with the wire control bracket and shifter lever disengaged position on the P T O cover assembly Fig 9 NOTE It may be necessary to change the position of the shifter lever on the P T O To do this remove the shifter cover from the unit This will prevent the possible loss of the poppet and or spring into the transmission if the shifter post assembly should be pushed through the cover when reinstalling the lever 17 Fig 7 WIRE SHIFT P T O s continued 9 10 11 shift the P T O to the engaged position to see how much of the cable casing must be cut to allow the lever enough travel to shift in and out completely casing need only go just beyond the bracket whereas the wire must be long enough to go through the swivel pin in the shifter lever Fig 10 NOTE In some instances the cable control may not be long enough Chelsea has available four longer lengths than the standard ten foot cable These come in five foot increments i e 328346 15X 15 foot cable When the length of the casing has been determined pull the wire back through until the case can be cut without cutting the wire Use a hacksaw or heavy pair of side cutters to cut the casing Fig 11 NOTE The cable can be held by a bench vise as long a
166. ERNALLY REGULATED ALTERNATORS The diagrams which follow in this section show the essential features and terminals of frequently used externally regulated series of alternators Using the diagrams proceed to the installation instructions contained in Section 20 1 Diagram 3 5 4A shows the Motorola 85 2009R Series Diagram 3 5 4B shows the Motorola 125 106 Series Diagram 3 5 4C shows the Leece Neville 4000AA Series Diagram 3 5 4D shows the Leece Neville 7000AA Series Diagram 3 5 4E shows the Leece Neville 8000AA Series Copyright 1982 DYNAMOTE CORP F8206B Section X 6 82 INSTALLATION INSTRUCTIONS RED BLUE GRN GROUND THIS TERMINAL Output St ator 12V 68 84A Neg Grd 8 Fld Diode 12 SA 201 8SA 2009 Figure 3 5 4A DIAGRAM OF MOTOROLA 8SA 2009R Output GROUND THIS TERMINAL REGULATOR 12V 120A 24V 70 12V 85A Neg Grd Ins 8 Fld Diode 12 SA 106 8SA 2004R 8SA 3006P Figure 3 5 4B DIAGRAM OF MOTOROLA 12SA 106 F8124 Section X 12 81 INSTALLATION INSTRUCTIONS 3 5 4 continued 1 2 13 HELICOIL INSERT GROUND THIS TERMINAL DIA SHAFT 4000AA Figure 3 5 4C DIAGRAMS OF LEECE NEVILLE 4000AA SERIES ALTERNATORS GROUND THIS TERMIN 7000 Figure 3 5 40 DIAGRAMS LEECE NEVILLE 7000 SERIES ALTERNATORS DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 3 5 4 12 81 GROUND T
167. ESSURE ME Relube spline at the intervals prescribed above Apply grease gun pressure to lubrication zerk until lubricant appears at pressure relief hole in welch plug at sleeve yoke end of spline Illustration B At this point cover pressure relief hole with finger and continue to apply pressure until grease appears at sleeve yoke seal Illustration C This will insure complete lubrication of spline C Center Bearings Initial lubrication is done by the bearing manufacturers No attempt is made to add or change grease within the commercial bearing itself However when servicing a driveshaft in the field with a new center bearing it is necessary to fill the entire cavity around the bearing with waterproof grease to shield the bearing from water and contaminants The quantity should be sufficient to fill the cavity to the extreme edge of the slinger surrounding the bearing Lubricants used must be waterproof Consult your grease supplier for recommendation SERVICE INSTRUCTIONS opicer needle bearing joints are simple in construction easily removed from the vehicle and readily disassembled and reassembled without the use of any special tools or any special mechanical knowledge FIGURE 13 2 Double End Yoke Type U Bolt Construction Hemove the U Bolts Nuts and Lock Washers from the End Yokes Slide the Sleeve Yoke toward the shaft to free the Bearings from their seats between the shoulders i
168. GATIVE NEGATIVE BRUSH BRUSH CONNECTING NUT EN 416 GRE WIRE REGULATOR HOUSING s Figure 3 5 5 4B 2110 Section X INSTALLATION INSTRUCTIONS 10 83 3 6 0 CHECKOUT OF HARNESS INSTALLATION AND ALTERNATOR OUTPUT Put Auto Manual Switch in Manual position See 2 2 2 1 This is one of the most important steps in the installation Its purpose is to insure that the harness is properly connected to the alternator and that the alternator functions properly Proper performance of this step will help to pinpoint installation errors and prevent possible damage to the inverter To help you in doing this checkout correctly a summary of the readings to be taken is provided in tabular form after Section 3 6 10 in Figure 3 6 10 THE RESULTS OF THIS CHECKOUT PROCEDURE MUST BE RECORDED ON THE WARRANTY INITIATION CARD AND RETURNED TO THE DYNAMOTE OFFICE FAILURE TO DO SO WILL PREVENT THE INVERTER WARRANTY FROM BECOMING EFFECTIVE There are two ways to perform the Harness and Alternator Checkout Procedure 1 Using the 4 2600 Dynamic Inverter Test Module See Section 3 6 1 2 Using a standard V 0 M Volt Ohm Meter with scales of 15VDC 5OVDC and IOOVDC Fluke 8020A or Simpson 463 or equivalent See Section 3 6 2 3 6 1 CHECKOUT OF HARNESS INSTALLATION WITH DYNAMOTE 4 2600 DYNAMIC INVERTER TEST MODULE If the Dynamote 4 2600 Dynamic Inverter Test Module is available perform the following steps for checkout of harness installa
169. HIS TERMINAL Y4 20 UNC 2A THD AC TERMINALS 4 20 UNC 2 A TH D INSTALL JUMPER WIRE 6 60 8 WOODRUFF KEYSEAT 8000AA Figure 3 5 4E DIAGRAMS OF LEECE NEVILLE 8000AA SERIES ALTERNATORS DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 F2116B Section X 12 81 INSTALLATION INSTRUCTIONS 3 5 5 1 ALTERNATOR MODIFICATION INSTRUCTIONS FOR DELCO REMY 2751 SERIES TYPE 200 The purpose of this modification is to provide a means to ground the negative field brush permanently for use with positive switching regulator 1 Disconnect the battery grounding cable and remove the alternator from the engine mounting brackets lf alternator can be left on vehicle be sure to disconnect the battery grounding cable 2 Remove four thru bolts from drive end frame on the alternator 3 Separate slip ring and frame and stator assembly from drive end frame and rotor assembly During modification and reassembly hold brushes and springs in holder with a pin or toothpick inserted through end frame hole 4 Separate stator from end frame by removing three stator lead attaching nuts 5 Place tape over bearing and shaft to protect from dirt Use pressure sensitive tape and not friction tape that would leave a gummy deposit 6 Remove the diode trio from the alternator and discard It will not be used for this installation 7 Prepare a 12 inch length of WHITE 16
170. IMENSION Y 1 863 DIMENSION X 1 492 ASSEMBLY D Position brake shoe assembly over spider and A Install new nylon bushing in brake spider if tap anchor pin into position with brass punch required using suitable tool flat in line with lock screw hole See special instructions if combination lining has been used B Install roller cam followers and retainer springs See instruction relative to roller cam followers E Install lock screws tighten securely and thread where drums have been refaced and oversize with lock wire F Position felts retainers and install lock rings C Install large washers felt and washer on cam end of cam shaft Install assembly through Reano spider and bracket H Install slack adjuster on splined end of cam shaft and adjust as required ADJUSTMENT A New liners should be circle ground to CORRECT POSITION OF CHAMBER PUSH ROD less than drum diameter required to obtain 8096 contact Adjust cam as AND SLACK ADJUSTER IN OFF POSITION B Adjust slack adjusters or levers to obtain free running clearance When travel increases from liner wear to the maximums listed in the table below readjust CHAMBER STROKE AT WHICH BRAKE SHOULD BE READJUSTED Chamber Size Brake Roto Effective Area Diaphragm Chamber chamber 9 1 3 8 1 1 2 1 1 2 12 1 3 8 1 1 2 1 1 2 16 1 3 4 1 3 4 17 8 20 1 3 4 17 8 24 13 4 1 3 4 1 7 8 B minus A equals one half inch p
171. ING SPECIFICATIONS Bushing Removal and Installation Tool Dimensions Ail Dimensions in Inches Reamer Tool Dimensions All Dimensions in Inches Axle Model 20 001 20 0005 0 001 0 001 0 001 850 1477 1552 8 50 8 50 8 30 FE 970 Dern Bushing 830 1595 175 _ Same as FF 931 EasySteer 941 7 7 as FF 031 Same as FF 931 930 170 1912 _ 1025 1025 1780 1912 _ 10 25 8 90 Same as FF 931 Same as 941 Dew Delrin Bushing 01 198 2116 _ FL 901 Dern Bushing Same as 901 10 1 1987 2116 1987 2116 Same as FL 931 Same FL941 11 316 1223 Same as FF 931 Same as 931 NOTES 1 On Models equipment with Delrin bushings the reamer and the removal installation tool are not required 15 GREASE SEAL INSTALLATION IMPORTANT Do not install seals until bushings have been reamed seals will be damaged during reaming BRONZE BUSHING KNUCKLES A Place steering knuckle bottom side up in a vise equipped with soft metal protectors Position upper knuckle boss top end down between jaws of vise and lock securely NOTE Seals must be oriented as shown Reversal of a seal will prevent purging of grease B With the top end of the knuckle held firmly in this position place the seal
172. INSTALLATION Continuity Check 378969 Indicator 15 100 220 260 812 381 410 420 and 431 Series AUTOMATIC TRANSMISSIONS Pressure Lube Hose Power Shift 00 04 22123 P T O Openings for Automatic 8 24 26 Circuit Check for Power Shift 5 2020000 0 0 0000 0 27 29 INDICATOR LIGHT INSTALLATION TEMPLATE Lever and Wire Control 220 260 812 100 300 321 322 340 350 3 0 381 410 420 431 450 and 611 Series Indicator Light nemen seni Indicator Light Dash Drilling P T O Shifting Procedure atenta retraite diaeta Suet unu at AIR SHIFT INSTALLATION A NES AVA NeT 999999995999 sls PPP P LL s 32138 LOOSE IN THIS BOOKLET Mounting Gaskets Sun Visor Decal 1981 DANA CORPORATION FOREWORD Since it is our major objective to show
173. LATION OF STEERING AND TIE ROD ARMS A Press fit key into steering arm and tie rod arm keyway near the small end of the taper B Insert arms into knuckle NOTE It is possible to mistakenly reverse the left hand and right hand tie rod arms Distinction between left and right arm can be made by visualizing the tie rod assembly position On center point models FE970 and FF971 the tie rod ball stud is assembled into the arm from the top side i e the ball stud is above the arm This is also true for FU series axles with tie rod ends that are rebuildable All other models have tie rod assemblies that install from the bottom side i e the ball stud is below the arm Assemble nuts and torque to specification IMPORTANT The correct torque range must be reached on steering arms and tie rod arms Torques below minimum will not seat the tapers properly and reduce service life D Install cotter keys If the cotter hole does not align with the nut castellation advance the nut to the next castellation not exceed the maximum specified torque value Do not back nut off for cotter key hole alignment TIE ROD ASSEMBLY AND INSTALLATION Tie rod assemblies with straight tubes contain left hand threads on one end and right hand threads on the other These mate with similarly threaded tie rod ends The ends therefore are not interchangeable This type of assembly does not require removal from the arm for toe in adjustme
174. LICENSE PL LIGHT lA 7 SOLENOID p i T t FUEL PUMP OPTION 1 BATTERY 9 vs SELECTOR C SL Uu CL IGNITION RELAYS GNITION RELAY 2 CLEARAMC PARK NG LIGHT RELAY 8 wi LIGHT RELAY 5 Ej T E Tes o dm ge ab pea G2B WARNING ee ALARM c _ RED SWITCH H uns 3 e 5 2B 4 af 4 b FLASHER TERMINAL BLOCK BAC UP LIG 4T LEVEL STARTER Lm LE 7 TURN SIGNAL 2 1 H BATTERIES 7 eas at 4 o I OPTIONS TURN SIGNAL POWER PANEL CRANKING MOTORS Service Bulletin 1M 153 Figure 4 Cross sectional view of motor with intermediate duty clutch 35 MT Note different attaching bolt construction than Fiqure 5 the nose housing With this arrangement it is necessary to partially disassemble the motor to provide access to the attaching bolts when relocating the nose housing To accomplish this remove the electrical connector the screws attaching the solenoid assembly to the field frame and then remove the thru bolts from the commutator end frame Separate the field frame from the remaining assembly and pull the armature away from the lever housing until the pinion stop rests against the clutch pinion This will clear the nose housing at
175. NG COVER OPTIONAL HOUSING COVER O RING BEARING OUTPUT SHAFT ROLL PIN OUTPUT SHAFT GEAR RETAINING PIN QUAD RING HOUSING BRACKET PITMAN ARM LOCKING NUT LOCKWASHER SOCKET HD CAPSCREW HEX NUT PITMAN ARM SETSCREW SOC HD UNLESS OTHERWISE SPECIFIED TOLERANCES ON DIMENSIONS ARE ONE PLACE DEC CX 060 R H SHEPPARD CO INC HANOVER U S A TWO PLACE DEC XX 030 THREE PLACE DEC 010 ANGLES 119 FRACTIONS 1 64 R M S IN MICRO INCHES MATERIAL MODEL NO REQ DRAWN BY DRAWING NO PER UNIT R CE EREREM SCALE CHECKED BY CHANGE DATE 7 SHEPPARD POWER STEERING SERVICE MANUAL 10W 40 API SD SE MIL SPEC L 2104C OIL SPECIFICATIONS FORMERLY MS LUBRICATION STEERING GEARS The lubricant used in the power steering system is the medium by which hydraulic pressures are applied and relieved under control to effect steering assist In addition the lubricant also lubricates moving parts and dissipates heat which reduces efficiency and accelerates wear It is of the utmost importance to use a lubricant specified and approved by R H Sheppard Co Inc in the Sheppard Steering Gear The Sheppard Gear requires the use of 10W 40 API SD SE Motor Oil Highway vehicles should have the oil changed twice a year or every 50 000 miles Off highway vehicles will require more frequen
176. NTACT GEARS UNLOADED GEARS LOADED With adjustments properly made pinion at correct depth The pattern on the coast side of teeth will appear the and backlash set at 010 the above contacts will be same width as the drive side shown above however the procured The area of contact favors the toe and is over all length will be centered between the toe and heel centered between the top and bottom of the tooth of gear tooth The hand rolled pattern shown above gears unloaded oet used hypoid gear to have the tooth contacts to will result in a pattern centered in the length of the tooth match wear patterns Hand rolled patterns of used when the gears are under load shown at right The gears will be smaller in area and should be at the toe loaded pattern will be almost full length and the top of end of wear patterns pattern will approach the top of the gear tooth INCORRECT TOOTH CONTACT c A high contact indicates pinion is A how contact indicates pinion is too too far out Set the pinion to the deep Set the pinion to the correct correct depth by removing shims depth by adding shims under the under the pinion cage Slight out pinion cage Slight inward movement ward movement of hypoid gear may of the hypoid gear may be necessary be necessary to maintain correct to maintain correct backlash backlash 19 INSTALL THRUST SCREW QR BLOCK A Remove carrier from stand and position with back face of hypoid or spiral beve
177. NTING PARTS KIT Contains items anes See 1 33 50 P 17 BRACKET Wire Control o rdc Eee eR aor Rs Ts 34 50 P 19 BRACKET Swivel aub ie ee a 1 N S 378019 PIVOT PIN keene ta eura cl 35 378326 HEX NUT 20 ETT PR 1 N S 500568 4 SET SCREW 14 20 1 POPE 221 36 500396 8 CAPSCREW Hex Hd 4 20 347 1 37 GASKET Mounting 010 95 35 9 2 GASKET Mounting 020 thick exe sees ion besa N S 3281701 P T O MOUNTING KIT Standard Mount 1 500398 30 CAPSCREW 16 4 OLOR 1 378041 4 CAPSCREW 16 7 jT 1 378478 15 STUD qom mom Pop 9 9 9 9 9 3 4 9 8 o 9 5 t A Aat af 22 2 s 378018 WASHER Copper deua pasas Menos ets d PUT 6 500371 3 212 24 eX 2 500398 12 CAPSCREW 36 16 174 TT Meat bie 2 N S 328170 26X P T O MOUNTING KIT Deep Mount IR PE 1 500398 29 CAPSGREW 95 46 X 994 ernie 4 Sends 1 378041 15 CAPSCREW 36 16x634 zd 378478 14 STU cu E rs ee d 2 378018 WASHER Copper PT Q pM
178. No 2 inlet valve and allow air to flow out the No 2 delivery port BALANCED NO 1 CIRCUIT PORTION When the No 1 delivery pressure acting on the piston Wil amma 9808 SERVICE ERVOIR OC PIPING DIAGRAM Figure 5 equals the mechanical force of the brake pedal application the No 1 piston will move and the No 1 inlet valve will close stopping the further flow of air from the No 1 supply line through the valve The exhaust valve remains closed preventing any escape of air through the exhaust port BALANCED NO 2 CIRCUIT PORTION When the air pressure on the No 2 side of the relay piston approaches that being delivered on the No 1 side of the relay piston the relay piston moves closing the No 2 inlet valve and stopping further flow of air from the supply line through the valve The exhaust remains closed as the No 2 delivery pressure balances the No 1 delivery pressure When applications in the graduating range are made a balanced position in the No 1 portion is reached as the air pressure on the delivery side of the No 1 piston equals the effort exerted by the driver s foot on the treadle A balanced position in the No 2 portion is reached when air pressure on the No 2 side of the relay piston closely approaches the air pressure on the No 1 side of the relay piston When the brake treadle is fully depressed both the No 1 and No 2 inlet valves remain open an
179. O NOT USE OIL OTHER LUBRICANT 3 With the cupped washer and return spring in place and the O ring on the contact basepush the base over the center stud Make certain the O ring is properly seated and the coil terminals in place Secure assembly by tightening the Kep nuts on the terminal screws then tightening the two nuts on the center stud Form 2826 2 Section VII Rev 5 69 ELECTRICAL SYSTEM SWITCH CHARACTERISTICS SWITCH S001 49065 001 49125 5001 49245 5001 49325 MAGNETIC SWITCH BATTERY BASIC WIRING DIAGRAM RECOMMENDED WIRE SIZES Lead A No 12 Wire MOTOR VOLTAGE Total Length of B Wires feet 15 feet 20 feet No 000 3 29 feet Section MISCELLANEOUS bumper Models Item Part No Description Qty 1 7605 1489 otainless Steel Bumper 1 2 7605 1668 12 x 1 1 2 LG Chrome PlatedChrriage Bolt 4 3 7905 1666 Bumper Bracket 1 4 7602 7938 12 Hard Washer 10 5 8852 1208 12 13Cas PI Locknut 10 6 8820 1067 12 13 x YLG Cas Hex Head Capscrew 6 NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts MISCELLANEOUS Tow Hook Models Item Part No Description Qty 1 7604 5673 Hook L H Shown 1 7604 5674 Tow Hook R H Not Shown 1 2 37 10x1 3 4 Hex Head Capscrew 6 3 34 Hardened Flat Washer 6 4 32 10 Hex Nut 6 NOT
180. O SECONDARY SLAVE GEAR 5 Ep ea MAIN STEERING GEAR B R MAIN GEAR SECONDARY GEAR LINE NO 2 TO LINE FROM PUMP ACTUATING CYL HEAD END ACTUATING SHAFT PISTON OF MAIN GEAR ACTUATING VALVE ACTUATING PISTON CYLINDER HEAD BEARING CAP CYLINDER HEAD RETURN LINE PLUNGER PRESSURE RELIEF TO RESERVOIR CHECK VALVE RETURN LINE TO SECONDARY GEAR OIL PASSAGES TO RELIEVE PRESSURE LINE NO 1 TO AROUND PINION GEAR BEARING CAP END LIN NO 2 OF MAIN GEAR OUTPUT SHAFT RETURN LINE AND PINION FROM MAIN GEAR Page 53 SHEPPARD POWER STEERING SERVICE MANUAL INTEGRAL SLAVE GEARS The Sheppard Integral Slave Gears are quite simple in operation and require few repairs major components in the slave gear are the power piston and the pinion gear output shaft assembly Disassembly of the slave gear requires the removal of the cylinder heads and the pinion cover or mounting bracket The pinion gear output shaft assembly is removed and the piston is pulled out of the housing bore The output shaft bearings are serviced using the same procedures used for the master gear On reassembly the timing marks on the piston rack and the pinion gear must be carefully timed some slave gear models use seal rings on the ends of the power piston New seals are installed by placing the O ring expander in S 126 the piston groove and installing the square cut s
181. ON e For off highway brakes 20 4 4 22 or 26 in diameter the use of meter type fittings which have a maximum of 40 Ib 18 14kg pressure relief at shut off is recommended e Lubricate current model automatic slack adjusters through grease fitting until old grease is purged and new grease emerges through the pressure relief fitting On models without pressure relief fitting the pawl assembly must be removed to allow old grease to be purged through the pawl slot e DURA MASTER AIR DISC BRAKES LUBRICANTS Standard 0 616 A Internal parts of brake caliper and automatic slack adjuster See Stopmaster Lubricants Standard 0 637 olide pins slide pin retainers powershaft and slack adjuster worm wheel splines See Cam Master Lubricants Optional 0 645 Extreme cold weather use for internal parts of brake caliper and automatic slack adjuster See Stopmaster Lubricants Refer to Recommended Lubricants pages and 7 LUBE INTERVALS e Automatic slack adjuster 25 000 miles 40 000 km or every three months and or at regular chassis lube intervals e Brake actuating components caliper 50 000 miles 80 000 km or every six months e Caliper slide pins slide pin retainers powershaft and slack adjuster worm wheel splines At brake reline and caliper overhaul LUBE PROCEDURES At regular lube intervals lubricate caliper actuating components and slack adjuster through grease fittings until lube purges through pressure rel
182. ONS GENERAL HEADING INDEX VOLUME 2 ENGINE Duplex List of Common Parts V 71 Operator s Manual V 71 Highway Service Manual Fire Apparatus Chassis Operator s Manual Jacobs Engine Brake TRANSMISSION HT700D Series Service Manual HT700 Series Parts Catalog GENERAL HEADING INDEX VOLUME 3 DRIVE LINES Duplex Drive Lines Spicer Service Manual Spicer Trouble Shooting Guideline FRONT AXLE Front Suspension Front Axle Rockwell Field Maintenance Manual No 2 Lubrication REAR AXLE Single Reduction Drive Unit Field Maintenance Manual No 5 STEERING Sheppard Power Steering Service Manual Duplex Power Steering Pump FUEL SYSTEM Duplex Fuel System BRAKE SYSTEM Model D 350 Air System Schematic Duplex Brakes Bendix Service Data Field Maintenance Manual No 4 ELECTRICAL SYSTEM Duplex Electrical Circuit Schematic Duplex Alternator Delco Remy Cranking Motor Delco Remy Charging System Leece Neville Switches WHEELS AND TIRES Firestone viii MISCELLANEOUS TAB INDEX VOLUME 3 CHASSIS PUMP HYDRAULICS Qr uw ou 92 Oo 10 11 13 14 15 16 17 20 21 22 23 24 25 26 2f 28 Duplex Bumper Duplex Tow Hooks Air Horn Electric Wiper Mirror Assembly Cab Exterior Exterior Cab Lights Cab Interior Heater Assembly PTO Body Hardware Electrical Tools and Equipment Lights Siren PA Intercom Butterfly Va
183. OPERATING AND LEAKAGE CHECK NOTE Depending upon installation it may be easier or necessary to completely remove check valves so that the following checks may be made With air pressure present at outlet side of check valve and the inlet side open to atmosphere coat the open end of the check valve with soap suds a 1 bubble in 5 seconds is permissible If the check valve does not function as described or leakage is excessive it is recommended that it be replaced with a new unit or repaired with genuine Bendix parts available at Bendix V S outlets REMOVING AND INSTALLING REMOVING Block and hold vehicle by means other than air brakes Completely drain all reservoirs Disconnect air lines at single check valve and remove INSTALLING Check and if necessary clean or replace air lines to valve Install valve making certain that it is installed correctly with respect to the desired air flow An arrow indicating the direction of air flow is cast into the body of the valve DISASSEMBLY Unscrew cap nut from body and remove grommet or gasket Remove shims if present disc valve or steel ball valve seat if present spring and valve stop bushing if present CLEANING AND INSPECTION Wash all metal parts in mineral spirits Rubber parts should be wiped clean Inspect ball or disc valve and seat for signs of wear or deterioration Check spring for cracks corrosion or distortion Inspect body and cap nut for crack
184. OTRON INTEGRAL CHARGING SYSTEM Service Bulletin 1G 285 IMPORTANT Read the introductory paragraphs on page 4 before proceeding with either one of these sections UNDERCHARGED BATTERY OVERCHARGED BATTERY This condition as evidenced by slow cranking and low specific gravity readings can be caused by one or more of the following conditions Insure that the undercharged condition has not been caused by accessories having been left on for extended periods Check the drive belt for proper tension If a battery defect is suspected check per Delco Remy Service Bulletin 1B 115 or 1B 116 respec 1 Check the battery per Delco Remy Service Bulletin 1B 115 or 116 IMPORTANT Re member that an overheated battery will be overcharged even though no charging circuit defects are present If an obvious overcharge condition exists as evidenced by excessive water usage and if the battery is not overheated and not de fective remove the Integral Charging Sys tively tem for repair as covered under heading of Inspect the wiring for defects Check all connec tions for tightness and cleanliness including the cable clamps and battery posts Connect a voltmeter from BAT terminal to ground zero reading indicates an open between INTEGRAL CHARGING SYSTEM REPAIR voltmeter connection and battery If previous Steps 1 through 5 check satisfactorily check Integral Charging System as follows a Disconnect battery gr
185. OTTER PIN GASKET COTTER PIN KNUCKLE PIN NUT AKES TORE ARUNUS STEERING ARM BALL STEERING ARM COTTER PIN PRASE CHANDER STEERING ARM KEY BUSHING YOKE PIN SLEEVE LOCK WASHER STEERING KNUCKLE WHEEL BRG AXLE CENTER OIL SLINGER NUT SHIM BRAKE CHAMBER YOKE COTTER PIN CAMSHAFT AND CHAMBER BRACKET SET SCREW BRAKE SPIDER STEERING ARM NUT COTTER PIN THRUST BRG SPIDER BUSHING WASHER FELT SEAL FELT SEAL RETAINER WASHER BRAKE CAMSHAFT BRAKE SHOE AND LINING ASSY UPPER BRAKE SHOE RETURN SPRING HUB TO DRUM BOLT STOP SCREW LOCK NUT SNAP RING CROSS TUBE ASSY WHEEL HUB BRAKE DRUM SPACER 3 COTTER PIN OUTER WHEEL SLACK ADJUSTER SW 9 2 TIE ROD END NUT BRG CUP LOCK WASHER V FELT SEAL RETAINER Y OUTER WHEEL BRG SEAT f CLAMP NUT ADJUSTING NUT WASHER CROSS TUBE ARM PIERCED LOCK i LOCK WASHER WASHER BRACKET BUSHING SQUARE KEY ae LOCK WASHER CAP SCREW KNUCKLE PIN LOCK WASHER BUSHING TIE END ASSY SET SCREW EXPANSION PLUG RETAINER SPRING SPIDER TO KNUCKLE RIVET Ca RING RETAINER OIL SEAL FELT INNER WHEEL BRG WHEEL STUD INNER WHEEL BRG CUP BRAKE SHOE AND NUT LINING ASSY LOWER LOCK WASHER CAP SCREW RETAINER SPRING BRAKE SHOE ROLLER RETAINER ROLLER RETAINER SPRING FELT BRAKE ANCHOR PIN PERMANENTLY SEALED STRAIGHT KNUCKLE PIN DESIGN GREASE FITTING STEERING KNUCKLE
186. Page 3 DELCOTRON INTEGRAL CHARGING SYSTEM 1G 285 Service Bulletin TROUBLESHOOTING PROCEDURES Close adherence to the following procedures in the order presented will lead to the location and correction of charging system defects in the shortest possible time Only a portion of these procedures need be performed It will never be necessary to perform all the procedures in order to locate the trouble A basic wiring diagram showing lead connections is shown in To avoid damage to the electrical equipment always observe the following pre cautions e Do not polarize the Integral Charging System e Do not short across or ground any of the terminals in the charging circuit except as specifically instructed herein e Make sure the Integral Charging System and battery have the same ground polarity e When connecting a charger or a booster battery to the vehicle battery connect negative to negative positive to positive Trouble in the charging system will show up as one or more of the following conditions A undercharged battery as evidenced by slow cranking and low specific gravity readings B overcharged battery as evidenced by excessive water usage AMMETER INTEGRAL CHARGING SYSTEM INTEGRAL CHARGING SYSTEM Figure 7 Typical wiring diagram showing basic lead connections VOLTAGE LER ADJUSTMENT fiers SET 5 is ENLARGED VIEW TOP OF VOLTAGE ADJ
187. QUIK GARD OFFER PROTECTION AGAINTS OVERLOAD AND SHORT CIRCUIT Qwik Gord UNIPOLAR WITH PILOT LIGHT VISI TRIP 120V CA 10 000 A P C 30 AMPS PART NO 00130 1 Section VIII MISCELLANEOUS 1 82 OWNER S CERTIFICATE OF WARRANTY INITIATION Sec 1 1 1 VERTER MODEL OWNER I VERTER SERIAL ADDRESS ALTERNATOR MODEL CITY ATED AMPERAGE STATE ZIP I certify that I installed the above listed A Series Inverter on the date shown in accordance with installation instructions in the A Series Inverter Installation Manual that the Inverter v 1S operating properly after installation and that required harness and alternator check out cata were recorded on the warranty initiation card and sent to DYNAMOTE Corporation I Salling Company Name Signature of Installers 0 _____ WARRANT Y INITIATION CARD DYNAMOTE SERIES A A INVERTERS Inverter Model READ VOLTAGE FROM BLACK RED Inverter Serial to to o Condition GREEN GREEN ternator Model Rated Amperage Ignition OFF Inverter ia E 9e Start Button pushed ahicle Ignition OFF no other N odel action taken Use Engine ON at 1000 RPM C ner Engine ON at idle Inv Name erter Start But pushed Address Engine On 1000 up to 2500 RPM Commutation fuses remov
188. RT COUPLED JOINT Kit Journal amp Bearing FIGURE 6 ALTERNATE YOKE CONSTRUCTIONS BEARING CAP BEARING CAP SNAP RING U BOLT CAP amp BOLT FIGURE 7 ALTERNATE COMPANION FLANGE FLANGE YOKE CIRCULAR TYPE RECTANGULAR TYPE FIGURE 8 UNIVERSAL JOINT SEALS 2220 lt v x ZR 77 5 7 222 EEEN D sal lt n n gt t E RUBBER SEAL Figure 9 LUBE SPECS Don t Neglect Spicer Drive Shaft Lubrication Lack of adequate or proper lubrication is among the most common causes of U Joint and drive shaft failure Proper servicing of the drive shaft is an essential part of vehicle maintenance and should not be overlooked in routine shop procedure Universal Joints In the Vehicle or Application To insure proper lubrication of all four bearing assemblies on Spicer universal joints it is essential that mechanics add lubricant until it appears at all journal cross bearing seals Illustration A This assures removal of dirt particles and other contaminants that may find their way into the bearings and indicates to the mechanic that the bearings are fully lubricated Do not assume that bearing cavities have been filled with new lubricant unless flow is noticed around all four bearing seals Spicer journal cross seals are designed to relieve However if all the
189. Relubricate Per Lube Specs if Check on Components Indicate They Are Serviceable Replace if not 9 No Immediate Fix Use of Anti Seize Lubricants on Bearing O D initially Helps 10 Re Align to have a Minimum 1 Running Angle 11 Replace 12 Roller Lock Replace Assy 13 Yoke Deflections Under Load Use Larger Joint 14 Use Spicer Glidecote Slip Spline 15 Increase Driveshaft Assy Length to Position Slip Spline Head Towards U Joint 16 Check for Male Slip Member with Longer Spline 17 Design Inadequate for Application 18 Install Two Piece Driveshaft with Shaft Support Brg 19 Use Larger Diameter Tube 20 Design Limitation Due to Axle or Trans Shaft Requirement 221 Shim Drive Train Components to Equalize 22 U Joint Angles 22 Stralghten and Balance 23 Check with Trans or Axle Mfg Replace Shaft Brg 24 Revise Power Plant Mounting Scheme 25 Check U Joint Flex Effort for Looseness 26 Torque Bearing Retention Method to Spec 22827 Use Wide Angle Yokes 28 Check Installed Length and Adjust Driveshaft Length to Provide Proper Slip Conditions 29 Re Align Mounting Brkt to Frame Cross Member to Eliminate interference 30 Replace U Joint Kits 31 Replace Tube 32 Normal Wear Replace 33 Check O E M Maint Manual or Alignment Arrows on Slip Yoke and Male Slip Shaft for Correct Yoke Phasing 34 2 Pc 3JT Driveshafts Adjust Shaft Lengths to 50 50 or 40 60 Split 35 R
190. S Standard of The Industry Since 1904 Universal joint failures as a rule are of a progressive nature which when they occur generally accelerate rapidly resulting in a mass of melted trunnions and bearings Some recognizable signs of universal joint deterioration are 1 Vibrations Driver should report to maintenance 2 U Joint Looseness End play across bearings 3 U Joint discoloration due to excessive heat build up 4 Inability to purge all four trunnion seals when re lubing U joint ltem 2 thru 4 should be checked at re lube cycle and if detected reported to the maintenance supervisor for investigation Experience with universal joint failures has shown that a significant majority are related to lubricating film breakdown This may be caused by a lack of lubricant inadequate lube quality for application inadequate initial lubrication or failure to lubricate properly and often enough Failures which are not a result of lubrication film breakdown are associated with the installation angles and speeds and manufacturing discrepancies Drive shaft failures through torque fatigue and bending are associated with overload excessively high U joint angles and drive shaft lengths excessive for operating speeds The trouble shooting chart in this bulletin is intended to provide service people with an aid to enable them to associate complaints with some of the probable causes and probable corrections Which through normal vehicle
191. S A 681 379135 CONTENTS GENERAL INFORMATION PAGE 000 Transmission Tag amp Horsepower e Torque RPM Conversion chart 2 zuKeSculeqm INSTALLATION INSTRUCTIONS Application Questions e Mounting 7 8 Checking Backlash 2 20 24400000 e e eser sn sns 9 Adapter Plates Filler Blocks Adapter Mounting Adapter ASSCMDIY asse cscx trium Ia Ra US UIS RE 13 Lubricant in Transmission Inspect P T O Installation Tips for Automatic Transmissions eenn eene WIRE SHIFT P T O s Continuity Check 378969 Indicator 8 nna Cable Control Installation Instructions 2 00 1 0 0 0 010000000000000000 00000 00 11000 100000 ies 29 AIR SHIFT
192. SHAFT 16 PITMAN ARM PITMAN ARM WASHER BOLT OUTPUT SHAFT Page 48 PITMAN ARM INSTALLATION INSTRUCTIONS LOCKWASHER NO 120731 MED T TORQUE SPECIFICATIONS MODEL 188 ONLY MODEL NO NO TORQUE NUT HEX NUT 219776 250 FT LBS Mm 2410101 450 FT LBS 491 USE LOK CEASE NEVER SEEZ OR WHITE LEAD BETWEEN ARM AND NUT IN THE THREADS OF THE NUT AND ON THE THREADS OF THE OUTPUT SHAFT TORQUE SPECIFICATIONS ODEL NO BOLT NO WASHER NO TORQUE BOLT TO M 592 S 5 j 20 NF 1 LG GRADE 8 2 2420891 2261811 USE LOK CEASE NEVER SEEZ OR WHITE LEAD BETWEEN BOLT AND WASHER IN THE THREADS OF THE OUTPUT SHAFT ANO ON THE THREADS OF THE BOLT R H SHEPPARD Co INC SHEPPARD POWER STEERING SERVICE MANUAL PITMAN ARM INSTALLATION INSTRUCTIONS CONT D TORQUE SPECIFICATIONS WASHERS BOLT NO TORQUE BOLT TO 292 2925 2261521 181441 LINEAE 2261581 271591 2 Men fest moras asomo USE LOK CEASE NEVER SEEZ OR WHITE LEAD ON THREADS OF SETSCREWS POINT A AND BETWEEN WASHERS POINT B PITMAN ARM TORQUE SET SCREWS TO 12 TO 15 FT LBS 16 TO 20 N M AFTER TORGUINE PROCESS eaa HEX SOCKET HEAD NYLOK SPOT LOK WASHER 2 REQUIRED AND SUPPLIED t 4 prox WITH PITMAN ARM OUTPUT SHAFT NOTE AFTER TORQUING THE SHAFT MAY BE RECESSED OR PROTRUDING EQMA
193. SHER AIR CHAMBER CAM END SNAP RING CAM BUSHING COTTER KEY BRAKE SHOE ROLLER ROLLER RETAINING SPRING SHOE RETURN SPRING GUIDE PIN C WASHER GUIDE PIN THICK WASHER GUIDE PIN THIN WASHER GUIDE PIN SPRING WASHER BRAKE SHOE AND LINER ASSEMBLY BACKING PLATE AND DUST SHIELD ASSEMBLY ANCHOR PIN C WASHER ECCENTRIC ANCHOR PIN 11 DISASSEMBLY A Remove shoe return spring B Remove C washers from guide pins and anchor pins Hemove brake shoe and liner assemblies Remove flat washers from guide pins Remove brake shoe rollers and springs if necessary to replace F Disconnect cam lever assembly by removing first the spring lock washer and the clevis pin Remove the cam lever cam and cam washer Remove cam bushing only if replacement is necessary BRAKES F M M NO 4 ASSEMBLY Install camshaft bushing if removal was made Install cam and spacer washers Assemble guide pin washers and position shoes over anchor pins and guide pins Assemble guide pin and anchor pin washers and C washers Hook brake shoe return spring between shoes Install cam lever assembly and washer and secure with spring groove lock OWD MIT ADJUSTMENT On the T Fabricated Steel Brake each shoe must be adjusted to center the brake shoe arc with the drum A Loosen cam bracket bolts Apply full air Hold air and tighten bol
194. SSEMBLY OR VALVE 1 Position spring seat over the diaphragm and then install into body 2 Install spring and cover O Ring 3 Install cover tighten securely Torque to 150 400 inch pounds QR 1 VALVE 1 If valve is equipped within spring and spring seat a Position spring in body b Position diaphragm over spring seat c Install O Ring in cover groove install cover and tighten screws evenly and securely Torque to 30 60 inch pounds 2 f valve is not equipped with spring and spring seat a Install diaphragm b Install O Ring in cover groove install cover and tighten screws evenly and securely Torque to 30 60 inch pounds 3 Perform tests as outlined in Operating and Leakage Tests section IMPORTANT PLEASE READ When working on or around brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended pressure and always wear safety glasses when working 4 Never attempt to disassemble a component until you have read understand recommended procedures Some components contain powerful springs and inj
195. Start engine and allow it to operate at fast idle speed 3 With engine running turn steering wheel from left to right and return making three complete cycles to remove all air from the steering system 4 Stop engine Reconnect the drag link Following these procedures will ensure that the piston bottoms in both directions of steer opens the relief valve in the piston and allows the air to escape to the reservoir and into the atmosphere A Check and adjust the relief valve plungers as required speed 2 With full weight of the vehicle on all wheels turn the steering wheel in one direction until a high pressure hiss is heard or the axle stops contact 3 Turn the relief valve plunger in or out until the high pressure hiss is heard when there is 1 8 to 3 16 inch clearance between the axle stops B 4 Repeat this procedure for the opposite direction of steer and adjust the relief valve plunger on the opposite end of the steering gear Turning the plungers in will increase the space between the axle stops Turning the plungers out will decrease the clearance between the stops Do not turn the slotted plungers out beyond flush with the plunger boss or a leak will occur Axle stops should only be adjusted in accordance with the manufacturer s specifications After relief valve plunger adjustment always check to ensure that the road wheels and tires have adequate clearance between suspension brake and frame
196. Stop Button 13 Fuel Switch to Fuel Relay Coil 18 Dimmer Switch to Left Hi Beam 18A Dimmer Switch to Right Hi Beam 18B Dimmer Switch to Hi Beam Indicator Light 19 Dimmer Switch to Left Low Beam 19A Dimmer Switch to Right Low Beam 22 Horn Button to Horn Relay 24 Circuit Breaker to Horn Relay 25A Circuit Breaker to Stop Light Switch 26 otop Light Switch to Steering Column Turn Signal Switch 29 Horn Relay to Electric Horn 31 Circuit Breaker to Ignition Relay 1 amp Fuel Pressure stat 31A Ignition Relay 1 to Nartron Warning Alarm amp Fuel Pressure stat 33 Ground System in All Harnesses 39 Speedometer to Front Axle Wheel Sensor 40 Speedometer to Front Axle Wheel Sensor 41 Tachometer to Alternator A C Phase Post 43 Front Air Gauge to Front Air Tank Pressure Sender 44 Rear Air Gauge to Rear Air Tank Pressure Sender 45 Warning Alarm to Front Low Air Warning Light 45A Front Low Air Warning Light to Front Air Tank Low Pressure Switch 46 Warning Alarm to Rear Low Air Warning Light 46A Rear Low Air Warning Light to Rear Air Tank Low Pressure Switch 50 Circuit Breaker to Windshield Wiper Switches 51 Circuit Breaker to Windshield Washer Switch 5 Windshield Washer Switch to Washer Fluid Bottle 54 Circuit Breaker to Left amp Right Door Jamb Switches 54A Left Door Jamb Switch to Interior Courtesy Light 54B Right Door Jamb Switch to Interior Courtesy Light 55 Circuit Breaker to Engine Enclosure Light Switch 56 Circuit Breaker to Heater Blower Motor S
197. T O for lever control The internal shifting mechanism for wire is not designed for heavy forces usually encountered with lever control linkage 14 CONTINUITY CHECK 3 8969 and 379110 INDICATOR SWITCHES In order to insure that the switch is functioning properly the following procedure can be used with the unit on a bench or installed 1 Use a continuity checker battery type either meter or light Attach one 1 probe to the screw on the 3 8969 or 379110 Indicator Switch 2 With the other probe make contact with the shifter cover or housing see Figs 1 amp 2 3 Actuate shifting device and the meter or light should be actuated when P T O gear is engaged see Figs 43 amp 4 4 Shift unit out of gear and the meter or light should return to normal as shown see Figs 1 and 2 This test procedure can be used to check Chelsea wire lever and air shifter covers although an air source would be necessary for the latter If a meter is not available the light in the 328751 X can be used see Figs 2 amp 4 A six volt battery is all that is necessary for a power source 15 Fig 3 POSITIVE BATTERY CONNECTION TET NEGATIVE 77 BATTERY CONNECTION UN SUPE WIRE SHIFT P T O s Cable Control Installation Instructions 1 Find a suitable area on the dash to install the cable control and the control plate indicator light NOTE The location of the ca
198. T ll m LARGE PISTON T O RINGS 16 lt _ E53 P VALVE 112 TT VALVE ME S SPRING 11 a Ta r8 PISTON 17 18 26 MI ga CHECK VALVE STOP 101 E II 3 4 41 O RING HU 42 t CHECK VALVE 25 SPRING 2 CAP NUT NOLO 8l c PIPE PLUG 11 INLET EXHAUST EXHAUST VALVE i7 DIAPHRAGM COVER 61 SECTIONAL VIEW Figure 2 Ll n a 1 pressure builds With No 1 reservoir pressure below approximately 55 P S I the spring above piston A forces it into contact with inlet and exhaust valve A causing the exhaust to seal and the inlet to open With air system pressure above approximately 55 P S I in No 1 amp 2 service reservoirs piston A has moved against the force of the spring above it allowing the inlet of valve A to close and opening the hollow exhaust passage through piston A OPERATION AIR BRAKE SYSTEM FULLY CHARGED When air pressure beneath piston B is approximately 95 P S I piston B rises slightly against the force of the springs above it allowing the inlet of valve B to close The exhaust through valve B remains closed closing of the inlet portion of valve B retains approximately 95 P S l in the hold off cavity of the spring brake actuators while allowing full air system pressure to build elsewhere e Note Other spring brake hold off pressures are supplied according to the vehicle manufacture
199. TION LUBRICANTS Standard 0 61 7 A Preferred Optional 0 617 B Acceptable 0 617 A has a consistency which is preferred to take advantage of its slumping characteristic and for insurance against the possibility of fretting corrosion in wheel bearings 0 617 B has a consistency which may be preferred for ease of packing wheel bearings Refer to Recommended Lubricants Pages 6 and 7 LUBE INTERVALS The frequency of lubricant changes depends upon individual operating conditions speeds and loads Change whenever seals are replaced when brakes are relined or at 30 000 miles 48 000 km If yearly mileage is less than 30 000 miles change twice a year spring and fall For low mileage trailer operations i e Container and Piggyback grease may not need changing until every 50 000 miles 80 500 km or two years However check grease twice a year spring and fall for contamination and change if required LUBE PROCEDURES 1 At rebuild time before installing wheel bearings onto the spindle coat the bearing journals with a film of grease to deter fretting corrosion 2 Pack bearing with pressure packer if possible lf a packer is not available pack the bearing by hand forcing the grease in the cavities between the rollers and cage from the large end of the cone 3 Pack the hub between the two bearing cups with grease to the level of the cups smallest diameter e OIL LUBRICATED Fonts fd a NON DRIVE
200. TM 5 4210 227 24 amp P 5 TECHNICAL MANUAL ORGANIZATIONAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR 85 AERIAL LADDER FIRE FIGHTING TRUCK NSN 4210 00 965 1254 HEADQUARTERS DEPARTMENT OF THE ARMY 5 NOVEMBER 1986 Publication TM 5 4210 227 24 amp P 1 TM 5 4210 227 24 amp P 2 TM 5 4210 227 24 amp P 3 TM 5 4210 227 24 amp P 4 TM 5 4210 227 24 amp P 5 COMPLETE MANUAL TABLE OF CONTENTS Section ONOOOR WD mv Section Title Introduction Tabulated Data Chassis Assembly Pump Assembly Ladder Assembly Hydraulic System Electrical System Pneumatic System Ladder Calibration and Adjustments Illustrations General Information Engine less major assemblies Fuel System and Governors Air Intake Systems Lubrication System Cooling System Exhaust System Electrical Equipment Instruments and Protective Systems Sections 8 through 11 not included Special Equipment Operation Tune up Preventive Maintenance Troubleshooting and Storage General Information Description and Operation Preventive Maintenance General Overhaul Information Disassembly of Transmission Rebuild of Subassemblies Assembly of Transmission Wear Limits and Spring Data Allison Automatic Transmission HT 700 Series Parts Catalog Supplemental Parts Information Drive Line Fron
201. USTMENT CAP SHOWN IN LO POSITION Figure 8 Voltage adjustment cap A UNDERCHARGED BATTERY This condition as evidenced by slow cranking and low specific gravity readings can be caused by one or more of the following conditions 1 Insure that the undercharged condition has not been caused by accessories having been left on for ex tended periods 2 Check the drive belt for proper tension 3 If a battery defect is suspected check per Delco Remy Service Bulletin 1B 115 or IB 116 4 Inspect the wiring for defects Check all connections for tightness and cleanliness including the cable clamps and battery posts 5 Connect a voltmeter from BAT terminal Integral Charging System to ground zero reading indicates an open between voltmeter connection and battery 6 If previous Steps 1 through 5 check satisfactorily check Integral Charging System as follows a Disconnect battery ground cable b Connect an ammeter in the circuit at the BAT terminal of the Integral Charging System c Reconnect ground cable battery Page 4 d Turn on accessories Connect a carbon pile across the battery e Operate engine at moderate speed as required usually 4000 generator r p m or more and adjust carbon pile as required to obtain maximum current output IMPORTANT Initial voltage build up is by residual magnetism in the rotor Increase the speed as re quired to obtain maximum current output
202. USTMENTS The Sheppard Power steering gear requires no adjustment The relief plunger adjustment is provided for differences in tire sizes If the original equipment tire size is changed the relief plungers should be readjusted to ensure that the steering pressure is relieved in the steering gear before the road wheels reach their maximum steering angles Follow the procedures detailed under Relief Valve Plunger Adjustment in the final adjustments section Page 9 SHEPPARD POWER STEERING SERVICE MANUAL GENERAL DIAGNOSIS Whenever steering complaints are encountered it is important that the complete steering system be inspected Special body or equipment installations should also be considered for their affect on steering performance The steering system consists of the Sheppard Integral Power Steering Gear a hydraulic supply pump with pressure and flow controls and an oil reservoir the front axle and mechanical components and the steering column or input shaft and connecting linkages The front tires and wheels must also be considered as part of the total steering system Steering performance can be affected by out of line conditions anywhere in the total steering system Other factors outside the steering system can also contribute to poor steering performance Many times a steering gear is removed and disassembled needlessly because an organized diagnosis procedure has not been followed Start your diagnosis by l Defining the com
203. WA 98119 206 282 1000 Sec 2 0 11 82 2 0 INTRODUCTION AND PRINCIPLE OF OPERATION continued volts DC Both AC and DC voltages are regulated simultaneously by the Dynamote Voltage Regulator If AC output voltage is below or above 120 volts battery charging voltage will be reduced or increased proportionately For determining proper voltage settings after the inverter is installed see Section 3 8 Checkout Inverter Operation 2 1 SPECIFICATIONS 1 DC rectified AC Input 45 volts A40 60 volts A30 60 2 Input Source 12 volt alternator 3 Input Electrical System From 12 volt negative ground alternator systems only 4 Input Voltage Regulation Solid state voltage regulator inside inverter 5 Output Simultaneous output of a 120 volt AC 596 60 Hz 1 Hz and b 14 2 volt DC for vehicle system battery charging 6 Output Voltage Regulation Solid state voltage regulator inside inverter 7 Output Frequency Regulation Solid state crystal controlled oscillator inside inverter 8 Output Wave Form Modified square wave with no limitations on operation of electronic or electromechanical loads Filters are available for wave form modification to sine wave if required 9 Ambient Air Requirements Full load capability at 120 F ambient if properly vented Output may be derated above 120 F 10 Cooling Air Requirements Exhaust air must be vented away from the ambient Intake air must be true ambient and must be the amount
204. WO I Model 3A 17 Dana Corporation Drivetrain Service Division P O Box 321 Toledo Ohio 43691 P4304 DSD S T 25M WEATHERLY INDEX 086 Parts List Section VIII 410 220 MISCELLANEOUS March 1984 220 Series Supersedes P410 A22 Dated April 1979 220 Series Power Take Off Side Mounted S A E Six Hole One Speed Two Gears 220 SERIES CHELSEA P410 220 PARTS LIST amp SPECIFICATIONS t M AM A M s Rami 2 2 BASIC MODEL 220 INPUT GROUP BASIC MODEL 220 LAH INPUT GROUP 220 M SERIES INPUT GEAR PRINTED IN U S A 1984 DANA CORPORATION CHELSEA 220 SERIES a PARTS LIST amp SPECIFICATIONS 222 410 220 1 bri bd ee dede 1 1 166 Standard Mount 1 P 167 Extra Deep Mount 1 P 168 Deep Mount 1 P 406 Special Low Profile Clearance Mount 2 SHAFT OUIDUL iot 1 3 P 202 114 Rd uses 546 Key 500007 29 item 2a 3 GEAR Input doo dob Dau gre ad uaa sau d es dope dads 1 4 See Chart Pg 6 GEAR nn qa PE 1 5 GEAR Drive aiu our E es 1 6 4 45 DRIVESHAFT SPACER oL 1 7 9 P 39 IDLER SHAFT No Pressure Lube pp TIN TH nal E 1 8 14 36 NEEDLE BEARING SPACER E TROPPI 1 9 328273X BEARING COVER Open End audes 21 P 130 amp 550221 1 10 328274X BEARING COVER Clos
205. X TORQUE SPECIFICATIONS MODEL NO CAPSCREW TORQUE TO TORQUE NUT TO 292 2925 LOCKWASHER CAPSCREW USE LOK CEASE NEVER SEEZ OR WHITE LEAD BETWEEN PITMAN ARM AND NUT IN THE THRDS OF THE NUT AND ON THRDS OF THE OUTPUT SHAFT CAPSCREW HEX SOCKET HEAD NOTE AFTER TORQUING END Or PITMAN ARM 5 24 UNF X 3 LONG 16 OF SHAFT WHEN NEW PITMAN ARM E TORQUE SPECIFICATIONS MODEL NO RETAINER NO WASHER TORQUE RETAINER TO 450 FT LBS 610 2261851 USE LOK CEASE NEVER SEEZ OR WHITE LEAD BETWEEN PITMAN ARM AND RETAINER IN THE THRDS OF THE OUTPUT SHAFT AND ON THE THRDs OF THE RETAINER RETAINER HAND TORQUE ONLY DO NOT USE WRENCH R H SHEPPARD Co INC OUTPUT SHAFT 3 32 4925 5 DIM 5 592 25 13254 55 DIM ro 49 SHEPPARD POWER STEERING SERVICE MANUAL Bleeding air from system The steering gear by design is self bleeding however in some installations where the gear is positioned at an odd angle or where the piston does not make a full stroke in the cylinder bore air can be trapped in the steering gear To avoid this possibility the air should be bled from the system anytime the oil has been changed or the steering system is repaired After reinstalling the steering gear on the vehicle but prior to connecting the drag link to the pitman arm bleed the air fr
206. YOUT CHAMBER BRACKET SLACK ADJUSTER ANCHOR CHAMBER BRACKET NYLOM BUSHING LOCK RING CAM SPACING CAM SPACING WASHER THIN WASHER FELT ANCHOR FELT CAM SPACING WASHER THICK ANCHOR PIN FELT RETAINER CHAMBER CLEVIS PIN COTTER KEY CHAMBER BRACKET CAP SCREW CHAMBER BRACKET CAP SCREW WASHER o um ASSEMBLY CHAMBER CLEVIS PIN CHAMBER ATTACHING STUD DUST SHIELD SEGMENT SH DUST SHIELD LINER ASSEMBLY ATTACHING CAP SCREW SHOE ROLLER ATTACHING SPRING CLIP SHOE ROLLER FOLLOWER BRAKE SPIDER SPIDER CAM CAM NYLON BUSHING CAM GROOVE LOCK RING CAM HEAD FLAT WASHER SHOE RETURM SPRING DISASSEMBLY D Remove anchor pins and shoe assemblies E Unhook cam follower retainer spring and remove roller cam follower A Remove shoe return spring B Remove lock rings retainers and felts from anchor pins F Remove cam end lock ring washer and slack C Cutlock wire and remove anchor pin lock screws adjuster 13 Remove cam shaft with felt washer for felt and l H BRAKES F M M NO 4 Remove nylon bushing from spider only if replacement is necessary See suitable tool for both the removal and installing of nylon bushings large washer from spider Hemove washers and felts from cam shaft and spider BUSHING REMOVAL AND INSTALLATION TOOL Suitable Length D
207. a note of this value NOTE The value calculated in item 2 will establish a standard shim pack thickness without a variation This value will be used in calculating the shim pack thickness used with a new pinion and gear set 3 Observe the PC or variation number on the new pinion locations of the PC number are shown above Add or subtract this Number as indicated by the variation sign add subtract from the calculated standard shim pack thickness determined in item 2 The resulting answer indicates the thickness in thousandths of the new shim pack to be used Refer to the following examples which cover all the possible combinations of or original and new PC variations EXAMPLES OF CALCULATION EXAMPLE NO 1 Original Pack Thickness 030 Original Variation PC 2 002 otandard Pack Thickness 0280 New Variation PC 5 005 New Pack Thickness 033 EXAMPLE NO 2 Original Pack Thickness 030 Original Variation PC 2 002 otandard Pack Thickness 032 New Variation 5 005 New Pack Thickness 037 EXAMPLE NO 3 Original Pack Thickness 030 Original Variation PC 2 002 otandard Pack Thickness 028 New Variation PC 5 005 New Pack Thickness 023 EXAMPLE NO 4 Original Pack Thickness 030 Original Variation PC 2 002 otandard Pack Thickness 032 New Variation PC 5 005 New Pack Thickness 027 After calculating the shim pack thickness assemble
208. a post which has battery voltage with the ignition ON or OFF his will allow the battery to drain through the voltage regulator gt E 3 B 5 If the reading with the Auxiliary Start But Black ton depressed is 0 then the harness leads to the K3 relay should be switched z check out K3 If meter reads voltage relay Section 4 3 5 If voltage reading is outside proper limits follow Voltage Regulator Checkout Procedure Section 4 3 7 If meter reading is outside proper limits re check wiring of ORANGE wire to be sure it is ired to a source of battery voltage with the ignition ON Ignition Orange For Switch Positions 7 10 start the engine and run at approximately 1500 1800 RPM Also turn ON vehicle headlights to put some load on the vehicle charging system ML Yes 14 0 50 4 2 VDC If meter reading is outside proper limits follow procedure to check out and adjust oltage Regulator Section 4 3 12 If meter reading is outside proper limits repeat test on Position 7 3 6 1A INSTALLATION AND INVERTER CHECKOUT USING 4 2600 DYNAMIC INVERTER TEST MODULE continued oc teen antl 3 6 1A INSTALLATION AND INVERTER CHECKOUT USING 4 2600 DYNAMIC INVERTER TEST MODULE continued Switch Terminal Inverter Start Button Depressed Remarks 02 84 Bt Yes If meter reading is ou
209. ad Troy Michigan 48084 U S A Section Ill REAR AXLE DUPLEX REAR AXLE RSA 340 Suspension All Models 1 2 ED NG BEET ETE 3 wi 4 5 6 7 8 9 Item Part No Description Qty 1 7605 3867 Frame Hanger LHF RHR 2 2 7605 3868 Frame Hanger RHF LHR 2 3 7605 3866 Load Cushion 4 4 4605 3857 Saddle Assembly LH Shown 1 7605 3858 Saddle Assembly RH 1 5 7605 3861 Front Bolt Short 4 6 7605 3860 Lower Axle Pad LH Shown 1 7605 3859 Lower Axle Pad RH 1 7 7605 3862 Rear Bolt Long 4 8 7605 3865 Flat Washer 16 9 7605 3864 Locknut 8 10 7605 3863 Dowel Pin Not Shown 2 NOTE Your chassis Vehicle Identification Number V I N or Serial Number on order chassis must be supplied when ordering replacement parts NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts Part No 7605 2744 7605 2745 7605 2746 7605 2747 7605 2748 7605 2749 7605 2729 7605 2696 7605 2750 7605 2751 7605 2752 7605 2753 7605 2754 7605 2755 Section III Section III Description Drive Pinion Nut Pinion Cage Cover amp Seal Assembly Item 4 Gasket Oil Seal Bearing Cone Outer Bearing Cup Outer Cage amp Cup Assembly Items 6 12 Bearing Cage Shim Washer Capscrew Shim Bearing Cup Inner Bearing Cone Inner Drive Gear amp Pinion Assembly Specify Ratio Rear Drive Pinion Bearing Washer Sn
210. ages and steering malfunctions at a later date Due to the close tolerances between mating parts it is advisable to have all parts at the same temperature for reassembly Clean machined parts individually to avoid damage due to bumping together Use clean solvent to wash parts Dry parts with compressed air Nicks or burrs must be removed with a fine hand stone before assembly Use only clean motor oil to coat parts to ease assembly O rings seals and gaskets should be replaced as a part of any repair All hoses lines and the reservoir and filter should be cleaned before reinstalling repaired steering gear or after pump replacement Inspection A careful visual inspection of all steering gear parts must be made Worn parts as well as any parts that show signs of stress or fatigue must be replaced Caution Steering gears that have been accident damaged should be considered suspect Impact loads transmitted through the front axle and steering linkage into the steering gear can stress parts to a point just short of failure Further use is unsafe and replacement of the steering gear assembly and pitman arm is strongly recommended Distorted pitman arms broken or bent reversing springs twisted output shafts broken or cracked rack and pinion gear teeth are some signs of impact damages Broken or damaged mounting brackets should not be replaced without further investigation Steering Gear parts inspection may reveal problems in other areas
211. akes two rollers are used one on each pawl DISASSEMBLY Equal alignment is completely controlled by the design of the actuating lever and the only adjustment necessary is through connecting linkage to lever arm A Disconnect and remove brake shoe return springs B Remove brake shoes and liner assemblies 19 BRAKES F M M NO 4 DM DUPLEX MECHANICAL BRAKES The DM brake is a two shoe mechanical brake designed for either service or parking use The shoes are actuated by a lever and wedge and are self aligning The two shoes are interchangeable and do an equal amount of work in either forward or reverse direction The adjusting bolts in the abutment bracket provide a means for adjusting the brake shoe clearance with the drum DM BRAKE LAYOUT BRAKE SHOE AND ADJUSTING NOTCH LEVER WEDGE LINER ASSEMBLY CLIP SPRING ASSEMBLY BRAKE SHOE RETURN SPRING BRAKE SHOE LEVER ADJUSTING BOLT ABUTMENT PIN ADJUSTING BOLT ADJUSTING BOLT SLOT COVER BACKING PLATE AND ABUTMENT BRACKET ASSEMBLY 20 DISASSEMBLY D A Disconnect brake shoe return springs F B Remove shoe and liner assemblies C Remove levers and wedge assembly D Remove abutment pins E Screw out adjusting bolts ASSEMBLY A A Lubricate and install adjusting bolts Use specification 0 615 B B Position abutment pins adjusting bolts C Install shoes on backing plate with web pressure
212. aking adjustments PRECAUTIONARY NOTE IMPORTANT PLEASE READ When working on or around brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended pressure and always wear safety glasses when working 4 Never attempt to disassemble a component until you have read and understand recommended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools 5 Use only genuine Bendix replacement parts and components A Only components devices and mounting and attaching hardware specifically designed for use in hydraulic brake systems should be used B Replacement hardware tubing hose fittings etc A should be of equivalent size type and strength as the original equipment 6 Devices with stripped threads or damaged parts should be replaced Repairs requiring machining should not be attempted 50 03 68 1 79 Section VI BRAKE SYSTEM Field Maintenance Manual No 4 Brakes Use Only Genuine Rock
213. al are serviced in the same manner as the fixed miter gear assembly Refer to the fixed miter section of this manual for complete details T BOX INPUT MITER DISASSEMBLY amp REPAIR 5 165 SHEPPARD POWER STEERING SERVICE MANUAL The two halves of the T box miter are serviced the same as the fixed miter cap and the swivel miter cap Follow repair instructions previously outlined 5 166 When the miter housing is reassembled to the steering gear the backlash must be adjusted to zero Remove or install housing to bearing cap gaskets shims to obtain zero backlash Once the miter housing is in place and the gear clearance has been checked and adjusted the second input shaft and miter cap is installed Again the gear clearance must be adjusted by removal or addition of gaskets shims to obtain zero backlash Fill the miter housing with Fiske Multi Purpose Grease or an equivalent waterproof lubricant until a small quantity comes out the relief valve opposite the lube fitting 5 168 Page 66 SHEPPARD POWER STEERING SERVICE MANUAL Available from the R H Sheppard Co Inc Pitman Arm Installation Tool Set 5 169 e Easy to use Assures accurate torque settings e Fill your requirements now e must for the busy shop Model _ Washer Washer Bolt Part No Fig 2 Fig 3 Fig 1 No 191 192 292 39 252 2925 352 3925 2261611 2261521 Set No 1 372 382 392 491 181463 9 16 18NF x 3 Lg 7 271591
214. al assembly for the following 1 Pitted scored or worn thrust surfaces of differential case halves thrust washers spider trunnions differential gears Thrust washers must be replaced in sets The use of a combination of old and new washers will result in premature failure 2 Wear or damage to the differential pinion and side gear teeth Always replace differential pinions and side gears in sets D Inspect axle shafts for signs of torsional fractures or other indication of impending failure REPAIR A n the interest of safety and preserving the service of drive axle assemblies Rockwell recommends that axle assemblies not be repair welded Repair welding can detract from the structural integrity of a component particularly as to heat treated parts where the benefit of heat treatment may be nullified by the welding Since it can be extremely hazardous and detrimental to repair weld components of any kind repair welding can be approved only where stringent controls are imposed and equipment customarily located at manufacturing facilities is employed so as to minimize the potentially detrimental effects of repair welding In deciding whether to repair or scrap any damaged part always keep in that we as manufacturers never hesitate to scrap any part which is in any way doubttul B Hex nuts with rounded corners all lock washers oil seals and gaskets should be replaced at the time of over
215. amote harness to a 12 volt source which is hot only when the ignition is on This can be the switched side of the ignition switch the ACC terminal on the ignition switch Use ring terminals provided in the hardware kit If Autothrottle is used attach brown lead from Dynamote control harness to black lead from 4 306 harness Reconnect the battery negative ground cable at this time Proceed to Section 3 6 CHECKOUT OF HARNESS INSTALLATION AND ALTERNATOR OUTPUT unless your installation involves a battery isolator Section 3 5 2 or an electronic tachometer relay Section 3 5 3 3 5 2 INVERTER MODIFICATION INSTRUCTIONS WHEN BATTERY ISOLATOR IS USED IN THE SYSTEM 1 Open the inverter by removing the front back and top panel fasteners Carefully lay the front and back panels down and remove the top panel DYNAMOTE CORPORATION 1200 w Nickerson Seattle WA 98119 206 282 1000 Section X F8122A INSTALLATION INSTRUCTIONS 12 81 3 5 2 INVERTER MODIFICATION INSTRUCTIONS FOR BATTERY ISOLATOR continued 2 Remove the small BLACK 16 AWG wire between Terminal Strip Pin 6 in the front of the inverter and the B Terminal in back of the inverter 3 Attach a 16 AWG or larger wire from Terminal Strip Pin 6 directly to the BATTERY POSITIVE or to one of the battery terminals on the battery isolator Terminals are available in the hardware kit for this purpose 4 Close the inverter cabinet 3 5 3 INSTRUCTIONS FOR INSTALLATION OF ELECTRONI
216. ance and with or without metal clips at the three studs may be specified for use in the same Integral Charging oystem and the different types are interchangeable Page 7 Figure 16 Checking diode trio Figure 17 Parts stack up and ohmmeter check Stator and diode trio removed The ohmmeter check of the rectifier bridge and of the diode trio as previously covered is a valid and accurate check Do not replace either unit unless at least one pair of readings is the same CAUTION Do not use high voltage to check these units such as a 110 volt test lamp ROTOR FIELD CHECKS To check for opens connect the test lamp or ohmmeter to each slip ring If the lamp fails to light or if the ohmmeter reading is high infinite the winding is open Fig 19 WINDING The winding is checked for short circuits or excessive resistance by connecting a battery and ammeter in series with the DELCOTRON INTEGRAL CHARGING SYSTEM edges of the two slip rings Note the ammeter reading and refer to Delco Remy Service Bulletin 1G 187 for specifications An ammeter reading above the specified value indicates shorted windings a reading below the specified value indicates excessive resistance If the winding is shorted replace the rotor An alternate method is to check the resistance of the field by connecting an ohmmeter to the two slip rings Fig 19 If the resistance reading is below the specified value the winding i
217. ap Ring Capscrew Carrier to Housing Short Capscrew Carrier to Housing Capscrew Carrier to Housing Stud Carrier to Housing Not Shown Nut Carrier to Housing Not Shown Washer Carrier to Housing Thrust Block Adjusting Screw Nut Differential Bearing Adjusting Nut L H Capscrew Washer Differential Bearing Adjusting Nut Lock Capscrew gt eS SS Se JJ J Rear Axle R 170 S 170 U 170 Part No 7605 2756 7605 2757 7605 2700 7605 2702 7605 2703 7605 2704 7605 2758 7605 2759 All Models Description Washer Dowel Carrier amp Cap Assembly Items 26 27 Gasket Carrier to Housing Silastic Differential Bearing Adjusting Nut R H Plug Carrier Filler Magnetic Drain Plug Breather Assembly Axle Housing Differential Bearing Cup L H Differential Bearing Cone L H Differential Case Bolt Long Washer Differential Case Assembly Items 3 39 51 Specify Ratio Side Gear thrust Washer Spider Differential Bearing Cone R H Differential Bearing Cup R H Pinion Thrust Washer Pinion Gear Side Gear Capscrew Gear to Case Washer Gear to Case Nut Gear to Case Differential Case Bolt Short No Spin Unit Replaces Items 41 42 45 46 47 Carrier Overhaul Kite Items 1 3 4 5 6 8 11 12 13 15 30 36 37 41 42 43 44 45 46 47 Gasket amp Shim Kit Items 3 8 11 30 Q Section III REAE AXLE Fi
218. apt to damage parts it saves wear on you the repairman and makes disassembly and reassembly a much smoother and easier operation Some further points which may or may not be included and which could also be necessary in the reassembly portion of the manual are the torques for bolts and the end play of the output shafts and input gears with tapered bearings The following chart shows the necessary torques for different sizes of bolts SIZE TORQUE 1 2 85 95 lbs ft 7 16 55 60 lbs ft 3 8 30 35 Ibs ft Adjusting the end play of the shaft is a simple matter of setting a dial indicator on the output shaft and checking the movement of the shaft between the two sets of tapered bearings Therefore if the shaft is in a vertical position the end play would be the up and down movement which should not be any greater than 006 Any greater or lesser amounts would make it necessary to add or subtract gaskets The input gear 42 5380 430 etc can be adjusted in the same manner by using different sizes of spacers Finally the exploded views in every manual are taken from the parts lists Corresponding part numbers can therefore be found in the proper parts list 1979 DANA CORPORATION PARTS LIST amp SPECIFICATIONS ASSEMBLY ARRANGEMENTS Figure 2 us a _ BASIC MODEL 2L INPUT GROUP BASIC MODEL A22 amp A23D INPUT GROUP A24 SERIES INPUT GEAR Figure 1 3 DISASSEMBLY A22 26 Series
219. ar oversize roller cam followers thicker wear plates or wear plate shims depending on brake design should be installed when the liners become approximately 5096 worn ROLLER CAM FOLLOWERS S Head Cam Cast Shoes Part No Size O D 1199 A 625 Standard 1 250 1199 M 937 Plus 1 8 125 1 375 1199 Z 910 Plus 1 4 250 1 500 1199 A 911 Plus 1 2 500 1 750 Install when liners are approximately 5096 worn S Head Cam Pressed Shoes TN ia ie Part No Size O D 1779 R 18 Standard 1 250 1779 C 81 1 8 Oversize 1 375 1779 D 82 1 4 Oversize 1 500 1779 E 83 1 2 Oversize 1 750 Install when liners are approximately 50 worn BRAKES F M M NO 4 Flat Head Cam mm pai alu TEE Sime fri PES E i x t i mu E 7 xe E ua TH En Part No Size O D 1779 K 63 Standard 1 245 1779 X 102 1 16 Oversize 1 307 1199 A 3563 1 8 Oversize 1 370 Roller cam followers are available in four sizes each having been designed for a specific purpose Standard 1 250 otandard rollers are used when installing standard lining with standard drums X lining with 1 16 oversize drums and XX lining with 1 8 oversize drums If the drums were previously refaced and oversize rolers later installed the oversize rollers must be removed and standard rollers insta
220. ary piston O ring 28 in the piston O ring groove E 6 VALVE ONLY 4 Install the rubber spring 27 concave side down in the primary piston 22 and place the spring seat 26 flat side up over the rubber spring 5 Install the primary piston spring seat nut 25 with its hex closest to the spring seat and rotate clockwise until the top surface of the spring seat is even with the top surface of the piston Set aside 6 Install large 30 and small 31 O rings on relay piston 20 7 Place relay piston spring 21 if used in concave portion of relay piston and install relay piston through No 1 inlet exhaust assembly 33 and into under side of upper body 8 Place screwdriver blade up in vise Place stem 17 in relay piston upper body sub assembly over the blade of the screwdriver with blade engaged in the slot in the head of the stem 9 Place the washer 24 over the stem This washer should be installed in all valves 10 Install primary return spring 23 in upper body piston bore 11 Install the primary piston rubber spring sub assembly steps 4 amp 5 over the stem into the upper body piston bore 12 Compress the primary and relay pistons into the upper body from either side and hold them compressed either manually or mechanically SEE THE CAUTIONARY NOTE UNDER STEP 11 IN THE DISASSEMBLY SECTION OF THIS MANUAL 13 Place the stem spring 19 over the spring seat nut 25 and the spring seat 18 o
221. as explained in 3 5 1 Step 2 Note 3 The harness for the larger capacity inverters includes three BLACK AWG 4 wires Two of these marked at the ends with RED and GREEN tape If these wires are shortened be sure to color code the ends properly b Alternators with internal regulators must be modified before the inverter harness can be installed Please refer to Section 3 3 1 Figure 3 3 1A c Instructions for the installation of the inverter harness begin with Section 3 5 1 Drawings of specific alternators showing the location of the terminals referenced in the instructions are listed in Figure 3 5 0A Copyright 1981 DYNAMOTE CORPORATION 3 5 ATTACH HARNESS TO ALTERNATOR continued 11 81 Motorola 8SA20009R See Figure 3 5 4A Motorola 125 106 See Figure 3 5 4B Neville 4000AA Series See Figure 3 5 4C Neville 7000AA Series See Figure 3 5 4D Leece Neville 8000AA Series See Figure 3 5 4E Figure 3 5 0A INDEX TO EXTERNALLY REGULATED ALTERNATOR DIAGRAMS 3 5 1 BASIC INSTALLATION STEPS 1 Disconnect the battery negative ground cable from the vehicle system battery NOTE 1 If a battery isolator is used in the electrical system the inverter must be modified as shown in Section 3 5 2 NOTE 2 If an electronic tachometer which is driven from an alternator AC tap or an alternator tachometer tap is used in the system a Dynamote Relay 4 1160 must be used when the Dynamic Inverter is in
222. at average continuous speed of alternator at full load is less than 8000 RPM d Smallest alternator pulley diameter should be 2 1 2 Specially made 2 1 2 diameter double groove pulleys are available from Dynamote Tighten pulley nut to alternator manufacturer s specifications if specification is unavailable tighten to 40 to 50 foot pounds Tighten drive belts by applying pressure to the rear housing or stator Set belt tension to engine manufacturer s recommendations f this information is not available tighten belts to the point at which the alternator fan cannot be turned by hand or approximately 100 pounds of belt strand tension 3 4 0 INSTALL AUTOMATIC THROTTLE If used An automatic throttle provides automatic increase in engine speed to a preset RPM when the inverter is energized It is designed for stationary use only and should not be used while underway IT MUST ALWAYS BE WIRED THROUGH THE NEUTRAL SAFETY SWITCH OF THE VEHICLE TRANSMISSION If the automatic throttle is used refer now to automatic throttle instruction manual NOTE Brown wire from Dynamic Inverter Harness is to be attached to black wire from Autothrottle Harness If automatic throttle is not used proceed to harness installation instructions Section 3 5 3 5 0 ATTACH HARNESS TO ALTERNATOR Installation of all Dynamic Inverters is exactly the same electrically The only differences will be that some installations will require the K3 High Amperage Bypass Relay
223. atic slack adjuster internal parts See Stopmaster Lubricants Standard 0 637 Worm wheel and camshaft splines A metallic based temperature resistant anti seizing compound The following grease meets this specification Southwest SA 8249496 Refer to Recommended Lubricants pages and 7 LUBE INTERVALS On Highway Brakes Every 50 000 miles 80 000 km or every six months depending on severity of service For brakes with extended lube features on regular common carrier type vehicles and the Q Series brakes change every 100 000 miles 160 000 km Automatic slack adjusters Every chassis lube interval every brake assembly lube interval at reline or at least every 25 000 miles 40 000 km or three months whichever comes first Off Highway Brakes and automatic slack adjusters For all components change grease every four months maximum whenever seals are replaced or when brakes are relined However the change interval may be shorter than four months depending on the severity of operation This can be determined by initially scheduling an inspection of internal parts and lubricant every two weeks until the first four month period is up At each inspection look for contaminated or hardened grease or for lack of grease LUBE PROCEDURES Care must be exercised when lubricating camshaft bushings and anchor pins Over lubrication could cause lubrication saturation of brake linings and possible safety problems 16 LUBRICATI
224. ations vary considerably and the vehicle manufacturer s recommendations must be followed carefully at all times Back pressure and operating temperature are two additional factors that must be considered during the diagnosis of power steering problems High back pressures will restrict the movement of the piston in the power steering gear and this back pressure must be overcome before steering power is available Back pressure is caused by restrictions to oil flow A clogged oil filter undersized fittings and lines pinched lines and high flow rates are possible causes of back pressure High system oil temperatures reduce the overall efficiency of the steering pump and the steering gear High temperatures are caused by restriction to flow or inadequate system oil capacity to allow for heat dissipation during normal operation supply pump which constantly operates at maximum pressure relief will also generate more heat than can be dissipated Various types of pressure gauges and flow meters are available and can be used to diagnose power steering problems A pressure gauge which reads at least 3000 PSI and a flow meter with a capacity to 10 GPM are used to check pressures and oil flow A shutoff valve downstream from the pressure gauge makes it possible to isolate the steering pump from the steering gear and by closing the valve maximum pump relief pressure can be read A simple thermometer in the reservoir will indicate system oil temperatures
225. aust heat Hardened steel flat washers should be substituted for spring lock washers on bracket and alternator as mounting hardware Flat washers tend to provide and retain greater surface tension Correct belt alignment is essential for maximum alternator and belt service life The center line of all pulleys related to the alternator drive must be within 1 32 of true center see Figure 3 3 2A Dual belts are recommended for heavy duty alternators Best results are obtained if the belts wrap the alternator pulley 100 or more Lesser wrap induces belt slippage belt and alternator bearing wear see Figure 3 3 2B ENGINE 90 ALTERNATOR PULLEY AND a DRIVE PULLEY MUST BE a IN LINE WITH EA ae Gaon OTHER SUGGESTED BELT WRAP AT LEAST 100 FOR BEST BELT DRIVE lE Figure 3 3 2A Figure 3 3 2B DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 Section X 2108 INSTALLATION INSTRUCTIONS Sec 3 3 INSTALL PROPER ALTERNATOR ON ENGINE continued 2 Pulley Ratio The diameters of the crankshaft pulley and the alternator pulley will determine alternator RPM for a given engine speed The largest possible crankshaft pulley and the smallest possible alternator pulley are most advantageous For full output with Dynamic Inverter Models A30 A40 and A60 use single 5 8 belt or double 3 8 or 1 2 belts b Do not drive alternator in excess of 10 000 RPM c Design the installation so th
226. available installation test readings dial the DYNAMOTE toll free WATS line 1 800 426 2838 and advise the receptionist that the call is regarding WARRANTY SERVICE ASSISTANCE Copyright 1982 DYNAMOTE CORPORATION DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 F2100C Section IX GENERAL INFORMATIO N 11 82 Sec 2 0 SECTION 2 GENERAL INFORMATION DYNAMIC INVERTERS 2 0 INTRODUCTION AND PRINCIPLE OF OPERATION 2 0 1 Your new DYNAMOTE Series A Inverter is designed to provide 120 volt 60 Hz AC power from the DC rectified AC output of a standard 12 volt electrical system 12 volt alternator in a vehicle or boat The inverter is compact lightweight and operates silently It be placed any convenient location in the vehicle or boat Inverters when installed in a 12 volt electrical system according to these instructions can safely operate all electric tools lights appliances electronic and heavy motor loads up to their rated capacity Models are available to provide continuous 120 volt power up to 60 amps 2 0 2 The relationship of a Dynamic Inverter to the vehicle electrical system is illustrated by the two diagrams below Ignitken Switch LN Figure 2 0 2A Inverter OFF AMERICAN INVERTER Alternator Battery Baitery Los E Vehicle Regulator AMERICAN INVERTER VAC 60 Hz Figure 2 0 2B Inverter ON Nominal alternator output voltage Inver
227. be at idle when P T O is engaged See transmission manufacturer s instructions for special procedures IMPORTANT Failure to follow proper shifting or operating sequences will result in premature P T O failure with possible damage to other equipment Make sure to block any moving or raised device that may injure a person working on or under the truck A lever or its linkage may be accidentally moved causing movement of the device which could cause injury to a person near the device AIR SHIFT Installation Sketch for 340 and 350 Series Using New Williams Valve 378414 Pressure Protection Valve Opens at 60 70 P S I 378416 Hex Nipple Note Tube nutisreusableaslongasnylon Bushing 2 Places 52 4 379131 1 d 378360 Male 378356 Tube Nut 6 Places Connector 6 Places Note Direction of Arrows tubing is not removed from the tube nut Caution When installing nylon tubing avoid sharp angles exhaust and manifold Systems Template for control plate on page 38 Warning Connect directly to air supply Do not use tubing between air supply and pressure protection valve 3 To Ports on Shifter Cover A 378415 7 Bua 4 C e 28 0 G7 ae ces O Bogey 122 Bip 0M i f l i iat 4 a Nylon Tubing To Shifter Cover Ass y _ 378969 Indicator Switch for 340 Ser Or 3791 10 Indicator Switch for 350 Ser Note Furnished in _ Shifter Co
228. bearing has the snap ring on the bearing In this case the bearing is pressed into the housing until the snap ring contacts the housing The needle bearing in the pinion cover is removed using a bushing removal tool An Owatonna puller is illustrated Note The bearing should not be removed unless it is going to be replaced A new bearing is pressed into place flush with the face of the bearing bore and against the spacer in the bore of the pinion housing Note Some Series 5 steering gears use a double row needle bearing where the needle rollers are loose During service care must be taken to ensure that the needle rollers are installed in the bearing housing which they came out of Use chassis lube to hold the needle rollers in the bearing races during reassembly Note 59255 bearing has the snap ring on the bearing In this case the bearing is pressed into the cover until the snap ring contacts the cover The output shaft seal is installed with the shaft in place To protect the seal wrap the splined end of the shaft with greased paper and slide the seal into place over the shaft The seal can be drawn into place using the retainer and the allen screws Alternately tighten the allen screws until the seal is in place and the retainer is secured to the housing Page 43 SHEPPARD POWER STEERING SERVICE MANUAL Typical overhaul seal kit Put a light coat of motor oil in the cylinder bore Carefully install piston in
229. ble control and the control plate should be as close to each other as possible and easily accessible by the driver or operator but should not be an obstacle to driver movement nor interfere with other controls instruments or equipment 2 Drill a 1 2 5 diameter hole for the control cable 3 Install the control cable on the dash using the hex nuts supplied with the cable The knob can then be screwed into place The length of cable Fig 2 can then run through the firewall and back to the dee P T O making sure it is kept away from the exhaust moving parts etc Fig 1 2 NOTE Do not kink the cable In order for the cable to operate properly there can be no bends smaller than 6 inch radius Total bends in the cable should not exceed 3600 example four 900 bends in cable 4 Using the template found on page 30 drill the necessary holes for the control plate indicator light Fig 3 amp 4 Fig 3 six bolt wire shifts with the exception of the reversibles dual shift units and some gear boxes Fig 4 Fig 5 16 WIRE SHIFT P T O s continued 5 Install the control plate indicator light on the dash using the hardware supplied in the 328751 Xparts bag Fig 5 Determine from which direction the cable must come in order for the unit to be disengaged when the knob is all the way in NOTE The shifter must always be installed in the following manner CABLE IN DISENGAG
230. bly Remove the lube fitting and four bolts and lock washers from the miter shaft cover Carefully turn and pull miter shaft and cover from the miter housing Drive roll pin from miter gear and pull gear off miter shaft Remove shims gaskets and lay aside Pry locating pin out of the bearing retainer ring and pull from the cover Page 56 SHEPPARD POWER STEERING SERVICE MANUAL Turn bearing retainer counter clockwise to remove from the cover tap the miter shaft and bearing out of the miter cover Remove seal from miter cover Carefully tap or press miter shaft out of the bearing For reassembly reverse the order of disassembly installing new parts as required The bearing retainer is tightened to remove any possibility of end play or movement Reinstall the locating pin to lock the retainer to the miter cap It may be necessary to drill a new hole through the cover into the retainer 5 136 Page 57 SHEPPARD POWER STEERING SERVICE MANUAL Remove the miter housing from the bearing by removing the bolts and lock washers which pass through the miter housing Two bolts and lock washers are located inside the miter housing and must be removed before the housing can be separated from the bearing cap Carefully turn and with a soft hammer tap the housing off the bearing cap 138 Remove the ring seal and the self locking nut and washer from the actuating shaft and remove the miter gear from the s
231. body lf worm gear is to be pressed from shaft note dimension from end of shaft to gear before proceeding TYPE 35 40 55 WITH RIVITED COVER AND BALL INDENT LOCK MECHANISM DISASSEMBLY 1 2 3 4 9 6 7 8 Remove rivets holding the covers Remove welch plug Before removing ball indent lock mechanism measure and note distance from top of lock screw head to slack adjuster body Remove ball indent lock mechanism screw Remove spring and ball Before removing worm shaft measure height from top of adjusting screw to the slack adjuster body This measurement is important as it serves as a reference when the worm shaft is reassembled Press out worm shaft from worm by pressing on end of worm shaft opposite the adjusting nut Remove worm and slack adjuster worm gear CLEANING AND INSPECTION Wash all parts in mineral spirits and dry Inspect parts and replace any part showing signs of wear or deterioration TYPE 20 TO 30 WITH POSITIVE LOCK MECHANISM AND RIVETED COVER ASSEMBLY 1 2 Place worm and worm gear in Slack Adjuster body Position and press the worm shaft worm shaft lock and spring into the worm and Slack Adjuster body The recess in the worm shaft lock must be lined up with the pin in the Slack Adjuster body before pressing into position Make certain that when pressing the worm shaft into the body that the height measurement between the top of the adjusting screw and slack adjuster body is the same before and
232. bottle cartons 10 cc per bottle from Rockwell International Florence Distribution 22 CARE AND MAINTENANCE Center Florence Kentucky 41042 Liquid adhesive is presently available at your local dealer IMPORTANT When servicing drive units assembled with Dri Loc bolts or liquid adhesive in threaded case holes where the bolts do not require removal Check each bolt for tightness by applying the minimum amount of torque specified for that size fastener If the bolt does not rotate it is satisfactory If the bolt rotates to any degree it must be removed from the case halves and liquid adhesive must be applied to the threaded hole Use the procedures under Reuse of Dri Loc Bolts or Use of Regular Bolts and Liquid Adhesive Further if bolt removal becomes difficult due to worn bolt heads or unusually high breakaway torques the locking strength of either liquid adhesive or Dri Loc bolts can be reduced by heating Heat the bolt for only a few seconds at a time while trying to loosen it DO NOT EXCEED 350 F MAXIMUM Heating should be done slowly to avoid thermal stresses in the differential case and gears Application of heat reduces the strength of liquid adhesive and Dri Loc below recommended installation torque Rockwell does not recommend removing bolts with an impact wrench or by striking with a hammer 6 Rockwell SINGLE REDUCTION DRIVE UNITS SINGLE AXLES AND REAR REAR TANDEM UNITS FASTENER TORQUE CHART
233. bricant B Place the bearing cups over the assembled dif ferential bearing cones then position the differential assembly in the carrier C Insert bearing adjusting nuts and turn hand tight against bearing cups D Install bearing caps in the correct location as marked and tap lightly into position If bearing caps do not position property adjusting nuts may be cross threaded caps reposition the adjusting nuts Forcing caps into position will result in irreparable damage to the carrier housing or bearing caps E Install flat washers where used and stud nuts or capscrews Tighten stud nuts or capscrews to correct torque ADJUST DIFFERENTIAL BEARING PRELOAD M A Using dial indicator at backface of gear looser the bearing adjusting nut on the side opposite gear only sufficient to notice end play on the indicator B Tighten the same adjusting nut only sufficient to obtain 000 end play C Check gear for runout If runout exceeds 008 remove differential and check for cause D Tighten adjusting nuts one notch each from 000 end play to preload differential bearings If the drive gear is not going to be replaced we suggest the established backlash recorded be fore disassembly be used For new gears the new backlash should be initially set at 010 Adjust backlash by moving the gear only This is done by backing off one adjusting ring and advancing the opposite ring the same amount
234. builds beneath the piston to overcome the setting of the regulating spring the piston will move causing the inlet valve to unseat open and allow air to flow out the delivery port As long as air pressure at the supply port and beneath the piston remains above the specified closing pressure the inlet valve will remain open NOTE PR 2 and PR 4 closing pressure is noted on the label affixed to the valve Opening pressures of the valves are higher than closing pressures The pressure ranges are noted below PR 2 Opening pressure 15 20 psi higher than closing pressure PR 3 amp PR 4 Opening pressure approx 10 psi higher than closing pressure PR 3 Check valve will retain maximum pressure in downstream reservoir If for any reason system air pressure is decreased below the specified closing pressure the regulating spring will move the piston closing the inlet valve The remaining air pressure at either the supply or delivery side depending upon where the pressure drop has occurred will be retained PREVENTIVE MAINTENANCE Every three months 900 operating hours or 25 000 miles whichever if first it is recommended that the operation and leakage checks described in this manual be performed OPERATING AND LEAKAGE CHECKS OPERATING CHECKS 1 Provide a pressure gauge and drain valve at the supply side and delivery side of the pressure protection valve being checked 2 Build up the air system to full pressure and shut off t
235. can also be used to confirm 4 4 0 the diagnosis of a faulty vehicle voltage regulator circuit board Copyright 1981 DYNAMOTE CORP 12 81 4 4 0 DYNAMIC INVERTER ELECTRICAL SCHEMATICS Following is an Index of Inverter Electrical Schematics Model Figure Number A30 70A 4 4A 40 120 4 4 60 120 4 4 MPA30 70A 4 4D MPA40 120A 4 4E MPA60 120A 4 4F 4 5 0 DYNAMIC INVERTER WIRING DIAGRAMS AND PARTS LIST Following is an Index of Inverter Wiring Diagrams and Parts List Model Figure Number A30 70A 4 5 0A A40 120A 4 5 0B A60 120A 4 5 0C MPA30 70A 4 5 0D MPA40 120A 4 5 0E MPA60 120A 4 5 0F Parts List all models 4 5 0G F2136B Section XI TROUBLESHOOTING AND SERVICE Fig 4 5 00 DYNAMIC INVERTER PARTS LIST Circuit Designation F1 F2 F5 F6 F1 F2 F5 F6 F3 F4 F5 Optional Dynamote Part 4092 40502 4092 40502 4092 40502 4095 24712 4093 10147 4093 10147 4093 74610 4095 74606 4093 10825 4093 10825 4121 43700 4121 14005 4121 23720 4121 11183 4121 43700 4121 11186 4121 14005 4121 22030 4121 43700 4121 10751 4121 20410 4681 10025 4681 00247 4681 08020 4681 09005 4681 06910 4602 20110 4200 06400 4200 06400 4200 02150 4200 02150 4200 02150 4282 00005 4282 00005 4282 00003 4282 00003 4282 00003 4685 43051 4685 01156 4685 02030 4685 42592 4685 41051 4685 02030 4685 43051 Description MPA MPA 30 Output Capacitor Output Capacitor XFMH Input Capac Commuta
236. ced proceed as follows a Straight knuckle pin models 901 921 931 941 and 951 continue from here b Tapered knuckle pin models 900 910 930 and 970 start on STRAIGHT KNUCKLE PINS 901 921 931 941 951 970 amp 971 Series Models Oo gie Figure 2 Draw Key Upper 7 Thrust Bearing Knuckle Pin 8 Expansion Plug Knuckle Bushing 9 Expansion Plug Upper Lock Ring King Pin Cap 10 Knuckle Bushing Shims Lower Draw Key Lower 11 Knuckle Spindle Straight Knuckle Pin Removal Figure 3 Figure 3 B Straight knuckle pins may be removed from the bottom of the knuckle where adequate clearance is provided however on some models such as those with riveted backing plates less work is involved by tapping the knuckle pin out the top of Knuckle In either case the adjacent parts such as air chambers hydraulic lines or fittings etc that might cause an obstruction to the knuckle pin must be removed first Refer to brake manual for brake disassembly Draw Key Removal Two per King Pin 1 Plain draw keys should be driven out from the small end D shaped using a steel drift and a brass hamme Figure 4 Threaded draw keys current model axles should be removed as follows a Loosen locknut and turn it out to the end of the threads The end of the nut should be flush with the draw key end b With a brass drift and a hammer firmly strike the end of the nut to loosen the dra
237. certain that when pressing the worm shaft into the body that the height measurement between the top of the adjusting screw and slack adjuster body is the same before and after removal 5 Install cover and retaining ring in groove of body 6 Install new lockwasher on worm nut in body and tighten Bend up at least 2 tabs of lockwasher one of which should fit in groove of body 7 Install plunger spring thrust washer and plunger in lock hole 8 Install cam lock in body Install pin 9 Lubricate Slack Adjuster as outlined in Preventive Maintenance section TYPE 35 40 55 WITH RIVETED COVER AND BALL INDENT LOCK MECHANISM ASSEMBLY 1 Place worm and worm gear in slack adjuster body 2 Press the worm shaft into the worm The indents in the worm shaft must be lined up with the ball lock hole Make certain that when pressing the worm shaft into the body that the height measurement between the top of the adjusting screw and slack adjuster body is the same before and after removal 3 Install covers and rivet securely 4 Install ball spring and ball indent lock mechanism Turn adjusting screw allowing ball to fully engage indent in shaft Check for full engagement by tightening lock mechanism screw to same dimension as noted in step 3 of Disassembly instructions 5 Before installing welch plug grease bottom of shaft Install new welch plug 6 Lubricate Slack Adjuster as outlined in Preventive Maintenance section
238. cleaning inspection and lubrication of brake equipment should be established by the operator on the basis of past experience and severity of operation Linings and drums parts particularly subject to wear depreciation To compensate for this wear brakes should be adjusted as frequently as required to maintain satisfactory operation and maximum safety Adjustments should provide uniform lining clearance correct travel of levers and proper equalization Brakes should be cleaner inspected lubricated and adjusted each time the hubs are removed During a major overhaul the following parts should be carefully checked and replaced with Genuine Replacement Parts as required 1 Backing plates for distortion and backing plates or spiders for looseness or sheared rivets 2 Anchor pins for wear or misalignment 3 Brake shoes for wear at anchor pin holes wear pads or lever contact areas 4 Cam shafts and cam shaft bearings or bushings for wear 5 Shoe return springs should be replaced at the time of overhaul 6 Brake linings for grease saturation wear and loose rivets or bolts 7 Drums for cracks scoring or other damage Prior to reassembling the following parts should be LIGHTLY COATED with brake lubricant Specification 0 615 or the equivalent 1 Adjustable anchor pin bearing surface 2 Cam or shoe abutments Cam shaft needle bearings and nylon bushings Cam roller follower shafts and journals ha
239. components Page 50 SHEPPARD POWER STEERING SERVICE MANUAL FINAL ADJUSTMENTS STEERING GEARS WITH MITER INPUT Fixed Miter Gears Relief Valve Plunger Adjustment Steering gears using the fixed location miter gear arrangement have a nonadjustable relief plunger in the miter end of the steering gear Proper relief adjustment can be made by lengthening or shortening the drag link Relief plunger adjustment for the opposite end of the steering gear are made by adjusting the relief plunger as detailed in the foregoing paragraphs Swivel Miter and T Box Meter Relief Valve Plunger Adjustment The relief valve plunger used with the swivel and T box miters uses an adjustable relief valve plunger Access to this adjustment is gained by removing the two housing retaining clamps and lifting the housing off the steering gear bearing cap To make the adjustment the retaining clamp bars are reinstalled and the bolts are torqued to specifications Start the engine and turn the actuating shaft using a socket and ratchet on the actuating shaft nut Use a screwdriver to turn the plunger in or out of the bearing cap until the proper clearance is obtained at the steering knuckle axle stop When the adjustment has been completed stop the engine and reinstall the miter housing at its original location Note The miter housing in most cases will be indexed to the bearing cap with a roll pin which passes through the clamping bar and enters a dril
240. culations when using the pinion setting gauge 4 Modify the nominal gauge dimension 4 809 by the Pinion Cone Variation Number etched on the pinion i e P 3orP C 5 This P C number indicates the variation in thousandths of an inch from the nominal mounting distance of that specific gear set Add or subtract this value as indicated by its sign from the nominal gauge dimension established in Step 3 This will give the corrected pinion gauge dimension Example P C 3 4 809 003 4 812 Example P C 5 4 809 005 4 804 5 Install the pinion and cage assembly into carrier using the original shim pack that was removed when the unit was disassembled Tighten all pinion cage cap screws or stud nuts to the specified torque was removed when the unit was disassembled Tighten all pinion cage cap screws or stud nuts to the specified torque Assemble the pinion setting gauge and step plate if required into the differential bearing bores using proper adapter discs Refer to Technic Aid Section 8 Aid 19 for specifics on adapter discs Adjust the micrometer arbor so it is directly over and at a 90 angle to the pinion nose or step plate ADAPTER DISC y i ASSEMBLY 7 Run the micrometer down to measure the distance to the pinion or step plate Make note of this measurement and use the following procedures to calculate for correct shim pack thickness If a step plate is required
241. d 66D638 HOOD BRACKET Stem flat type 12 gauge zinc plated steel HRC No 028 562 Use with all hooks ANCHOR BRACKET 11 gauge zinc plate I HRC No 277 A 80 Use with HRC Nos 680842 68D842 1101 and 66D638 50 1 50 4 Eu HOOD BRACKET Stem up special length type 12 gauge zinc plated steel ANCHOR PIN Chrome plated steel HRC No 179 A 55 No 028 750 Use with all hooks ANCHOR BRACKET Chrome plated steel HRC No 277 A 80 2 Use with HRC Nos 68D842 68D842 1101 and 660638 RUBBER CORP PREIS BOX 570 PORTLAND OREGON 97207 503 246 5411 e TELEX 36 0457 Use with HRC Nos 68D842 680842 1101 and 66D638 Plants in Portland Oregon and Seattle Washington TUI PrivtedinuSa RECESSED HANDLES SectR Vian VIII MISCEBEANEUUSS Folding T Handles in a rectangular steel pan A U E A stainless stcel spring holds handle in folded position Profondeur 3 4 Deep Poign e en T se repliant dans soucoupe rectangulaire 3i en acier Un ressort retient la poign e en position ferm e 4874 5630 Voir polgn es No 80 et No 260 AU VERSO DE CETTE PAGE pour substitut 12372 73 SEE CVERLEAF for No 80 and No 280 which may be used as substitute to Nos 12372 73 1 VARIATIONS TO ILLUSTRATED MODEL Var
242. d AC output Use an automatic throttle for stationary applications or a GUARDIAN for underway applications to assure safe operation Keep it cool Solid state components are affected by temperature The Inverter has an internal cooling fan which will cool the components if sufficient cooling air is provided to the intake louvers If installed in a cabinet provide intake louvers equal in area to the louvers on the chassis end panels and provide an air route for the fan s output away from the Inverter louvers thus preventing recirculation of hot air through the Inverter Air flow requirements are set forth in Section 2 2 Use the right size wire for your entire installation Wire which is too small will starve your system and provide poor results even though you follow the other three rules The wire in the harness of each Inverters of sufficient size for the length of the harness provided However if the harness length is extended larger wire must be used according to the following wire size chart The wire size chart should be followed explicitly Wire Distance Color Inverter to Alt 21 40 41 60 61 100 RED 6 2 6 2 6 RED 2 4 1 0 4 1 0 BLUE GREY 14 10 15 amps 14 14 30 amps 10 10 45 amps 8 8 60 amps 6 6 Figure 2 0 Harness Wire Size Required DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 Copyright 1981 DYNAMOTE CORP 11 82 2 6 2 6 OPTIONAL MODIFICATIONS
243. d below oil level additional lubricant will be required 2 Run the P T O for 5 10 minutes and check for oil leaks and noise 3 Should a quiet P T O become noisy after the universal joint connection is made check the P T O driveline components for an out of phase condition excessive or unequal joint angles or possibly worn parts in the driven accessory 4 Re torque all mounting bolts nuts cap screws and set up inspection routine of the P T O driveline components and the driven auxiliary equipment NOTE Anticipate slight increase in P T 0 noise level as oil thins out at operating temperatures Fig 20 S DL En Fig 20 P T O Installation Tips For Automatic Transmissions The procedure for installing a P T O on an automatic is basically the same as for a mechanical transmission Power take offs for automatic transmissions are assembled with a special drilled input shaft which allows the input gear to be pressure lubricated during operation see page 21 After installing a P T O on automatic transmission connect pressure lubrication hose to the P T O and the transmission per installation instructions shown on page 22 of this booklet WARNING Adapter assemblies are never used on an automatic transmission because they do not have pressure lubricated design features WARNING Use only wire control with P T O made for wire cable control If lever is desired order P
244. d drawkeys should be 1 32 minimum to 1 8 maximum below the forged surface of the axle center boss If the key falls out of this range drive it out and replace it with the appropriate size Use a sharp pointed steel punch to indent the forging in 3 places around the drawkey hold Figure 31 This partially collapses the hole and wedges material against and behind the drawkey to prevent the key from backing out Figure 31 Tapered King Pin A Smear chassis grease on the tapered section of the pin and insert the pin from the bottom of the knuckle B Smear chassis grease on the inside and outside of the king pin sleeve and insert it into the upper bushing bore over the king pin C Install king pin nut and torque only enough to seat the king pin for end play measurement D Measure end play per procedure page 21 and adjust if necessary E Torque nut to specification and install cotter key If the cotter hole does not align with the nut castellation advance the nut Do not back the nut off Rockwell does not recommend measurement of clearance tolerances on steering knuckles with shim gauges feeler gauge These will not give an accurate reading of end play Use only a dial indicator Procedure for Measurement of Knuckle End Play NOTE End play is the free movement of the steering knuckle up and down along the axis of the king pin Some end play is required to prevent binding of the knuckle while turning and to pro
245. d for direct operation remote operation or a combination of both The lock is designed so there is no concern about accidental lockouts because the inside thumb latch kicks out automatically when the door is slammed The split tumbler allows locking or unlocking from inside or outside Provision is made for vertical or thumb rotary locking and unlocking from the inside And the mechanism is enclosed to minimize damage from foreign ob jects The striker is designed for primary and secondary latching capability Accessories for this lock are independent pillar locking cylinders single or double remote control levers and recessed paddle handles and L type handles both available key locking or non key locking Available for left or right hand installation Left hand shown Specify when ordering No 206U and VARIATIONS Right hand shown left opposite Section 1 Page 14 TCP 6 77 No 206U with striker standard No 2 206U Same as No 206U ex cept with stainless steel non key locking inside handie No 24 5551 No 207U Same as 206U cept with one remote control lever on back cover No 208U control levers Same as No 206U cept with two remote No 1 206U Same as 206U cept with cut off lock button No 1 206 11 No 3 206U Same as No 206U cept less locking fea ture No 1 207U Same as 2070 cept remote control le
246. d full reservoir pressure is delivered to the actuators RELEASING NO 1 CIRCUIT PORTION With the brake treadle released mechanical force is removed from the spring seat graduating spring and No 1 piston Air pressure and spring load moves the No 1 piston opening the No 1 exhaust valve allowing air pressure in the No 1 delivery line to exhaust out the exhaust port RELEASING NO 2 CIRCUIT PORTION With the brake treadle released air is exhausted from the No 1 circuit side of the relay piston Air pressure and spring load move the relay piston opening the No 2 exhaust valve allowing air pressure in the No 2 delivery line to exhaust out the exhaust port PREVENTIVE MAINTENANCE EVERY 3 MONTHS 25 000 MILES OR 900 OPERATING HOURS Clean any accumulated dirt gravel or foreign material away from the heel of the treadle plunger boot and mounting plate Using light oil lubricate the treadle roller roller pin and hinge pin Check the rubber plunger boot for cracks holes or deterioration and replace if necessary Also check mounting plate and treadle for integrity Apply 2 to 4 drops of oil between plunger and mounting plate do not over oil EVERY YEAR 100 000 MILES OR 3 600 OPERATING HOURS Disassemble clean parts with mineral spirits replace all rubber parts or any part worn or damaged Check for proper operation before placing vehicle in service SERVICE CHECKS OPERATING CHECK Check the delivery pr
247. d of brake cam shaft 3 Rotate the slack adjuster by turning the adjusting nut 4 Slide the slack adjuster off of the spline end of the brake cam shaft B INSTALLATION 1 Install Slack Adjuster on brake cam shaft so the adjustment screw and grease fitting if so equipped are accessible for servicing 2 Install retaining mechanism on end of brake cam shaft to hold Slack Adjuster in place Turn adjusting nut to line up yoke pin hole with arm hole Install yoke pin and cotter pin 4 Refer to steps 3 and 4 under Service Tests and make sure the proper adjustments are made after installing a Slack Adjuster es SLACK ADJUSTER REPLACEMENT When replacing one type of Slack Adjuster with another type it is necessary to match or exceed the torque rating and match the arm length yoke pin diameter offset spline diameter and width It is also necessary to make certain that there is adequate clearance at released and full stroke DISASSEMBLY AND ASSEMBLY NOTE Disassembly and assembly instructions apply only to assemblies with riveted covers Assemblies with welded covers are considered non serviceable and are replaced as an assembly TYPE 20 TO 30 WITH POSITIVE LOCK MECHANISM AND RIVETED COVER DISASSEMBLY 1 Remove rivets holding covers 2 Remove welch plug 3 Before removing worm shaft measure height from top of adjusting screw to the slack adjuster body This measurement is important as it serves as a reference when the worm shaft is r
248. differential case pilot without the use of a press and without damaging the case and ring gear mating surfaces The gear should not be pressed or driven on the case as this would cause excessive metal particles to lodge between the gear and case thus resulting in gear runout Proper installation should therefore incorporate preheating the gear as described above to assure correct interference fit and to eliminate metal pick up A Rivet the hypoid gear to the case half with new Rockwell rivets Rivets should not be heated but always upset cold When the correct rivet is used the head being formed will be at least 1 8 larger in diameter than the rivet hole The head will then be approximately the same height as the preformed head Excessive pressure will cause distortion of the case holes and result in gear eccentricity Tonnage required for squeezing cold rivets These pressures are approximate for annealed steel rivets and pressure can be adjusted to suit individual working conditions DIAMETER OF RIVET TONNAGE REQUIRED 716 22 1 2 30 9 16 36 5 8 45 Final pressure should be held for approximately one minute to make sure the rivet has filled the hole After installing rivets check for proper fit between gear and case half Using a feeler gauge 003 maximum thickness check for gap between back face of gear and case flange Check at four equally spaced locations around the assembly If gauge can be inserted more tha
249. djusters they may apply as system pressure drops Never connect or disconnect a hose or line containing air pressure lt may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone Never attempt to disassemble a component until you have read and understand recommended procedures Use only proper tools and observe all precautions pertaining to use of those tools Some components contain powerful springs and injury can result if not properly disassembled Heavy Vehicle Systems Group Section BRAKE SYSTEM Service DV 2 AUTOMATIC RESERVOIR DRAIN VALVE STANDARD DV 2 ADAPTER SEALING RING picos pum AR mum REM DV 2 WITH HEATER TOP RESERVOIR SIDE RESERVOIR INLET amp EXHAUST VALVE VALVE GUIDE 3 5 COVER B LIT T WIRE STEM EXHAUST THERMOSTAT LEAD WIRE PORT HOUSING DV 2 WITH HEATER amp THERMOSTAT Figure 1 DESCRIPTION reservoir using the side port of the valve The DV 2 is also The DV 2 Automatic Reservoir Drain Valve ejects moisture and contaminants from the reservoir in which it is connected It operates automatically and requires no manual assistance or control lines from other sources The automatic
250. e Check battery voltage It should read 13 5 to 14 2 volts DC If it does not adjust CB3 otart Inverter Start engine and manually increase engine speed to approximately 1500 RPM equivalent to engine speed at about 30 MPH Depress the Start Button The inverter should START that is you should hear the inverter hum the indicator light should turn ON the cooling fan should be exhausting air through the fan shroud in the rear chassis panel and the voltmeter should register AC voltage up to 130 volts If the inverter does not START refer to Troubleshooting Section 4 Check for proper charging voltage with Inverter ON With vehicle engine still running at approximately 1500 RPM and with inverter ON allow 3 5 minutes of inverter operation for charging voltage to stabilize With inverter still ON using an accurate DC voltmeter check voltage on vehicle system battery It should read 14 0 14 2 volts DC If it does not adjust CB1 If this does not correct the problem refer to the Troubleshooting Section 4 Check AC voltage stability under load With inverter still operating at 120 volts output apply the normal AC load you intend to operate on the inverter If actual load is not available simulate the actual load with an equivalent wattage and type of load resistive or inductive If AC load does not operate properly or if inverter output voltage drops more than 10 volts or if inverter shuts off when AC load is applied remove AC load tu
251. e sun visor POWER TAKE OFF OPERATION VEHICLE STATIONARY I Mechanical Transmission 1 A power take off is and should be operated as an integral part of the main transmission 2 Before shifting the power take off into or out of gear disengage the clutch and wait for transmission or P T O gears to stop rotating Il Automatic Transmission with Manual Shift P T O s Includes Air Shift On automatic transmission the gears in the transmission turn when the transmission is in neutral therefore gear clashing will occur if the power take off is shifted into gear at this time WARNING Use only wire control with P T O made for wire cable control lf lever control is desired order P T O for lever control The internal shifting mechanism for wire is not designed for heavy forces usually encountered with lever control linkage Do not attempt to work on an installed power take off with the engine running 31 A With Converter Driven Gear 1 Shift transmission lever into any of the drive positions This will stop transmission gear from turning Shift power take off into gear Shift transmission into neutral This will start transmission gears turning B With Engine Driven Gear 1 Shift P T O into gear before starting engine This procedure should eliminate gear clash lil Automatic Transmission with Power Shift P T O s Engage P T O with engine at idle speed Power Shift P T O s Engine must
252. e Cutout Transformer Isolated Transformer Isolated Transformer Transformer Isolated Main SCHs Main SCHs Control Head Receptacle Output Receptacle Test Module Receptacle Quick Disconnect Black Quick Disconnect Red Quick Disconnect Green Quick Disconnect Lugs MPA Section XI TROUBLESHOOTING AND SERVICE A30 SERIES COMPONENT LAYOUT PCBS LOW VOLTAGE CUT OUT REPLACES 4 IN MPA UNITS 40 60 SERIES COMPONENT LAYOUT Cil n 4 STUD H pACHIe D7 8 ran le F OUT eruta p N i a PCBS LOW VOLTAGE CUT OUT REPLACES PCB4 IH MPA UNITS 1 1 ini LE LOAD DEMAND TM 5 4210 227 24 amp P 5 By Order of the Secretary of the Army JOHN A WICKHAM JR General United States Army Official Chief of Staff R L DILWORTH Brigadier General United States Army The Adjutant General DISTRIBUTION To be distributed in accordance with Special List U S GOVERNMENT PRINTING OFFICE 1991 0 281 486 43348 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL PINPOINTWHEREITIS IN THIS SPACE TELL WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE
253. e Position Shaft Support Bearing DRIVETRAIN SERVICE DIVISION DANA DANA CORPORATION 7 Joint Kits Attaching Recommended Hardware Torque SNAP RING 1280 1310 1330 1350 1410 1480 1550 Seres K Ex 5 200X 5 153X 5 213X 5 178X 5 160X 5 188X 5 155X 10 7 29 2 94 28X 2 04 28X 2 94 28 3 94 18 3 94 18 3 94 28 3 94 28 14 17 Ft 14 17 Ft 14 17 Ft 20 24 Ft 20 24 Ft 32 37 Ft 32 37 Ft Spicer Recommended Kit No U Bolt Ass ys U Bolt Nut Torque Lb Lb Lb Lb Lb Lb Lb Spicer Recommended Kit No Strap Kit Ass y Bolt Torque 1210 5 443 2 70 18X 13 18 Lb Ft 1280 5 200 2 70 18X 13 18 Lb Ft 1310 5 153X 2 70 18X 13 18 Lb Ft 1330 5 213X 2 70 18X 13 18 Lb Ft 1350 5 178X 3 70 28X 30 35 Lb Ft 1410 5 160X 3 70 28X 30 35 Lb Ft BEARING STRAP 1480 5 188X 3 70 38X 55 60 Lb Ft 1550 5 155 3 70 38X 55 60 Lb Ft 1610 5 438X 5 70 28X 55 60 Lb Ft 1710 5 442 6 5 70 28X 130 135 Lb Ft 1760 5 469 6 5 70 28X 130 135 Lb Ft 1810 5 510 6 5 70 28X 130 135 Lb Ft Spicer Recommended Kit No Cap amp Bolt Ass ys Bolt Torque 1650 5 165 5 70 18X 77 103 Ft Lb 1850 5 185 8 70 18X 110 147 Ft Lb 1850 5 227 8 70 18X 110 147 Ft Lb 1910 5 216 N S S 110 147 Ft Lb 1950 5 339 9 70 18X 271 362 Ft Lb 2010 5 371X N S S 102 118 Lb Ft amp BOLT 5 340 9 70 28 744 844 Ft Lb 2110 5 372 N S S 171 197 Lb Ft 2150
254. e connections as shown in Figure 23 or Figure 24 2 Momentarily flash a jumper lead shown in blue color in Figure 23 or Figure 24 drive will now shift into cranking position and remain so until the battery is disconnected 3 Push the pinion or drive back towards the commutator end to eliminate slack movement 4 Measure the distance between drive and drive stop Figs 25 26 and 27 5 Adjust clearance by removing plug and turning shaft nut Figs 26 and 27 Although typical specifications are shown always refer to 1M 188 1M 187 or 1M 186 for specifications applying to specific models CRANKING MOTORS 1M 153 Service Bulletin NOTES CO 1 2 1 WDS amp PS 1 2X 131 132 16 1 2 52 1FD Reprinted 10 83 PRINTED IN U S A Page 12 Delco Remy Tests of Section VII ELECTRICAL SYSTEM DELCOTRON INTEGRAL CHARGING SYSTEM INTRODUCTION The Integral Charging System or generator illustrated in Figures 1 and 2 features a solid state regulator that is mounted inside the slip ring end frame The regulator voltage setting can be adjusted externally by repositioning a voltage adjustment cap in the slip ring end frame This feature is covered in detail in Only one wire is needed to connect the Integral Charging oystem to the battery along with an adequate Trademark of General Motors 40 5 Series 150 Type Figure 1 Typical integral charging system ground return An R terminal is pr
255. e from splined axle position shaft end into differential nest Allow splines of E Install component side gear and thrust washer tool to engage with spline of one side gear only pull 1 Le Z E pr ay Ai 2 5 EN Md Md db Sakae uw DEDE ee t uu X PT Fm e 4 7 vy y Fa E EG C Using a suitable socket and torque wrench rotate differential nest while observing scale on torque wrench 16 SINGLE REDUCTION DRIVE UNIT Correct rolling resistance of differential assembly is 50 lb ft torque maximum applied to one side gear This applies to all differential assemblies Side View End View D A suitable checking tool can be made by cutting an axle shaft to an appropriate length and welding a nut on the end to accept a wrench socket INSTALL BEARING CUPS IN CARRIER LEG BORES A Temporarily install the bearing cups threaded adjusting rings where employed and bearing caps Tighten the capscrews to the proper torque B The bearing cups must be of a hand push fit in the bores otherwise the bores must be re worked with a scraper or some emery cloth until a hand push fit is obtained Use a blued bearing cup as a gauge and check the fits as work progresses Once the cups fit properly remove the bearing caps 17 INSTALL DIFFERENTIAL AND GEAR ASSEMBLY A After checking related parts coat the differential bearing cones and cups with specified rear axle lu
256. e in the yoke otherwise there is danger of damaging the bearing 3 JOURNAL CROSS 5 Remove by sliding it to one side of the yoke and tilting it over the top of the yoke lug 454 Apareis ACTI SERVICE INSTRUCTIONS fenes Mortis nnd e ds p LINE UP ARRO YOKE LUGS IN LIN eae FIGURE 16 2 ARROW MARKS Make sure arrow marks are stamped on the shaft and sleeve yoke before removing the slip joint If arrow marks are not readily seen mark both members so that when reassembled they will be in exactly the same relative position since the sleeve yoke lugs must be in the same plane as the stub ball yokes to prevent excessive vibration in operation DISASSEMBLING UNIVERSAL JOINT 1 LOCK STRAP 98 Bend down the locking lugs with a screwdriver and remove the cap screws 73 Si 1g FIGURE 19 FIGURE 18 11 SERVICE INSTRUCTIONS CLEANING AND INSPECTION 1 Clean All Parts Use a suitable cleaning fluid Allow the parts to remain in the cleaner for some time to loosen up any particles of grease or foreign matter Remove any burrs or rough spots from any machined surfaces 2 Needle Bearings Do not disassemble Clean with short stiff brush and blow out with compressed air Work a small quantity of lubricant 140 S A E Oil into each bearing cap and turn the needle bearing on the trunnion to check wear Replace if worn 3 Journal Cross Because worn needle bearings used w
257. e pressure protection valve is a normally closed pressure control valve which can be referred to as a non exhausting sequence valve These valves are used in many different applications An example would be in an air brake system to protect one reservoir or reservoir system from another by closing automatically at a preset pressure should a reservoir system failure occur The valves can also be used to delay system pressure The PR 2 and PR 4 pressure protection valves have one 1 4 N P T F supply port and one 1 4 N P T F delivery port which are identified Both valves are provided with two 9 32 mounting holes through the body The closing pressure of the PR 2 is externally adjustable while the PR 4 has a fixed setting CAP Hil a o E E PISTON met ON PR 3 or PR 4 PR 3 PRESSURE SPRING N N REGULATING a 2 708 Yia dp SPRING S eret d piston Au mL a EXHAUST 4 PLUG PIST LE 2 PISTON PLUG NM SUE PISTON gr O RING O RING E VALVE VALVE PISTON 4 STEM N 7 RE mms XS TM XN SER ia Sel RATS MAR S TRY VALVE YO 4 2 OPERATION Air entering the supply port is initially prevented from flowing out the delivery port by the inlet valve which is held closed by the pressure regulating spring above the piston When sufficient air pressure
258. e primary piston 22 15 Disassemble the primary piston by rotating the spring seat nut 25 counterclockwise Separate the spring seat nut spring seat 26 rubber spring 27 and remove the piston O ring 28 16 Remove the large 30 and small 31 O rings from the relay piston 20 17 Remove the retaining ring 32 securing the No 1 inlet and exhaust valve assembly 33 in the upper body and remove the valve assembly CLEANING AND INSPECTION 1 Wash all metal parts in mineral spirits and dry 2 Inspect all parts for excessive wear or deterioration 3 Inspect the valve seats for nicks or burrs 4 Check the springs for cracks or corrosion 5 Replace all rubber parts and any part not found to be serviceable during inspection using only genuine Bendix replacement parts ASSEMBLY Prior to reassembling lubricate all O rings O ring grooves piston bores and metal to metal moving surfaces with Dow Corning 55 M pneumatic grease Bendix piece number 291 126 NOTE All torques specified in this manual are assembly torques and can be expected to fall off after assembly is accomplished Do not retorque after initial assembly torques fall 1 Install the No 1 inlet and exhaust assembly 33 in the upper body and replace the retaining ring 32 to secure it sure the retaining ring is seated completely in its groove 2 Install the large 30 and small 31 O rings on the relay piston Install the prim
259. e replaced with a new or remanufactured unit or repaired with genuine Bendix parts available at Bendix outlets REMOVAL 1 Check the vehicle wheels or park the vehicle by mechanical means Drain all air system reservoirs 2 Identify and disconnect all supply and delivery lines at the brake valve 3 Remove the brake valve and treadle assembly from the vehicle by removing the three cap screws on the outer bolt circle of the mounting plate The basic brake valve alone can be removed by removing the three cap screws on the inner bolt circle DISASSEMBLY Fig 2 1 If the entire brake valve and treadle assembly was removed from the vehicle remove the three cap screws securing the treadle assembly to the basic brake valve 2 Remove the Phillips head screw 9 securing the exhaust diaphragm 10 and washer 11 to the exhaust cover 12 3 Remove the four screws that secure the exhaust cover 12 to the lower body 4 Remove the No 2 inlet and exhaust valve assembly 13 from the lower body 5 Remove the four hex head cap screws securing the lower body to the upper body and separate the body halves 6 Remove the rubber seal ring 14 from the lower body 7 E 6 VALVE ONLY While applying thumb pressure to the No 1 piston lift out and up on the three lock tabs of the No 1 piston retainer 15 E 10 VALVE ONLY Fig 4 8 A While depressing spring seat 7 remove retaining ring 8 B Remove spring seat and coil spr
260. e systems should be used B Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as the original equipment 6 Devices with stripped threads or damaged parts should be replaced Repairs requiring machining should not be attempted SD 03 66 1 81 Section VI Heavy Vehicle Systems Group BRAKE SYSTEM Service Data Formerly SD 6 SAFETY VALVE PRESSURE SETTING ee Wen eM M M mur DESCRIPTION The Safety Valve protects the air brake system against excessive air pressure build up The valve consists of a spring loaded ball valve subjected to reservoir pressure which will permit air to exhaust reservoir pressure to atmosphere if reservoir pressure rises above the valves pressure setting which is determined by the force of the spring OPERATION To illustrate the operation of the Safety Valve we shall assume that the Governor cut out pressure is set at 125 psi A Safety valve with a setting of 150 psi could then be used Should system pressure rise to approximately 150 psi air pressure would force the ball valve off its seat and allow reservoir pressure to vent to atmosphere through the exhaust port in the spring cage When reservoir pressure decreases sufficiently the spring force will seat the ball check valve sealing off reservoir pressure This would occur at approximately 135 psi for the 150 psi valve It is important to note tha
261. e units differentials Standard 0 76 0 76 A or 0 76 B Optional 0 76 C 0 76 D 0 76 E 0 76 F 0 76 J or 0 76 Refer to Recommended Lubricants on pages 6 and 7 LUBE INTERVALS e steering universal joints Knuckle bearings or bushings The frequency of lubricant changes depends upon individual operating conditions speed and loads Change whenever seals are replaced when brakes are relined at 30 000 mile 48 000 km or 2 000 hour intervals If yearly mileage is less than 30 000 miles or 2 000 hours of operation change twice a year spring and fall e Crosstube end assemblies otandard greasable type 3 000 miles 4 800 km or 200 hours of operation e Drive units differentials 25 000 to 30 000 miles 40 000 to 48 000 km or 1600 to 2000 hours of operation when yearly use is in excess of 60 000 miles 96 500 km or 4000 hours Otherwise change twice a year spring and fall Wheel bearings refer td page 12 e Universal joints and drive lines refer td page 24 LUBE PROCEDURES e Cardan steering joints 1 Check for looseness 2 Apply grease until new grease purges from all seals 3 If grease does not purge at seals manipulate the U Joint until purging occurs 10 LUBRICATION 4 f above is not successful remove cup or joint and check old grease If grease appears rusty gritty or burnt replace the complete universal joint e Constant velocity steering joints To apply new grease remove axle shaft from housi
262. eal ring cu over it Page 54 SHEPPARD POWER STEERING SERVICE MANUAL You will have to carefully work the piston ring past the pinion gear opening in the cylinder bore While r maintaining pressure on the end of the piston use the blunt end of a wooden stick to press the piston seal into the ring groove As the piston ring is compressed into the ring groove the piston will slide further into the bore until the piston ring has passed the pinion gear opening Note Due to the nature of the seal material it will stretch as it is fitted to the ring groove If you let the piston set with the seal rings in place they will contract and it will become easier to install it in the piston bore APPLICATION CYLINDER HEAD AND BEARING CAP CYLINDER HEAD AND BEARING CAP STEERING GEAR COVER MOUNTED STEERING GEAR COVER MOUNTED STEERING GEAR COVER MOUNTED STEERING GEAR COVER MOUNTED STEERING GEAR COVER MOUNTED STEERING GEAR COVER STANDARD STEERING GEAR COVER STANDARD STEERING GEAR COVER STANDARD STEERING GEAR COVER STANDARD STEERING GEAR COVER STANDARD MITER ACT SHAFT LOCK NUT Page 55 SIZE 9 16 24NF 3 8 24NF 7 16 20NF 1 2 20NF 9 16 18NF 5 8 18 5 8 IINC 7 16 20NF 1 2 20NF 9 16 18NF 5 8 18NF 5 8 1 INC TORQUE SPECIFICATIONS SHEPPARD POWER STEERING SERVICE MANUAL FIXED MITER DISASSEMBLY amp REPAIR Make reference marks on the miter cover and the miter housing to aid in realignment during assem
263. eassembled 4 Press out worm shaft from worm by pressing in on the end of the worm shaft opposite the adjusting screw nut 5 Remove worm shaft worm shaft lock and worm lock spring 6 Remove worm and slack adjuster worm gear from slack adjuster body TYPE 35 WITH POSITIVE LOCK MECHANISM DISASSEMBLY 1 Remove retaining ring holding the cover cover nut and gear in place Remove set screw in worm nut Depress worm lock and remove lock nut pin Hemove worm lock and worm lock spring Unscrew worm nut Remove worm shaft worm and gear from slack adjuster body OX 9v 25 59 19 7 8 Before removing worm shaft measure height from top of adjusting screw to the slack adjusted body This measurement is important as it serves as a reference when the worm shaft is reassembled Press out the worm shaft from worm by pressing on the end of the worm shaft opposite the adjusting screw nut TYPE 35 AND TYPE 55 WITHOUT RIVETED COVER AND BALL INDENT LOCK MECHANISM DISASSEMBLY 1 2 3 4 5 9 f Remove cam lock pin cam lock thrust washer plunger spring and plunger Bend up tab of lock washer and remove worm nut Remove retaining ring and cover Before removing worm shaft measure height from the top of adjusting screw to the slack adjuster body This measurement is important as it serves as a reference when the worm shaft is reassembled Remove worm and shaft and slack adjuster gear Remove plunger and plunger spring from
264. eckout procedures in Section 6 Sign your name and the company name and address certifying that the installation was properly completed and enter the date of installation Fill in and sign the Owner s Certificate of Warranty Initiation card from the first section of the manual Mail the stamped self addressed warranty initiation card to DYNAMOTE CORPORATION DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 Section XI F2133D TROUBLESHOOTING AND SERVICE 11 82 SECTION 4 SERVICE AND TROUBLE SHOOTING INSTRUCTIONS FOR DYNAMOTE SERIES A DYNAMIC INVERTERS 4 1 0 General Information PLEASE READ CAREFULLY The only reason to be at this point in the manual is that the inverter and or vehicle charging system are not working properly If this is a new installation and has not yet been in service be sure to go through the checkout procedures in Section 3 6 before proceeding further If you have completed the checkout procedure in 3 6 and the inverter still does not work continue with this section If the inverter has been in service and working properly prior to this failure and if the installation has not been tampered with such as for servicing the vehicle in some way then the likely cause of failure is in the inverter and can be found through the trouble shooting procedure It is easiest to troubleshoot the inverter while it is installed in the vehicle or boat as the electrical system provides a power source
265. ector Page 4 R P M INDICATOR Sc AMMETER VOLTMETER P a SWITCH C SOLENOID CRANKING MOTOR Figure 9 No load test circuit TROUBLESHOOTING THE CRANKING CIRCUIT Before removing any unit in a cranking circuit for repair the following checks should be made Battery To determine the condition of the battery follow the testing procedure outlined Service Bulletin 1B 115 or 1B 116 Insure that the battery is fully charged Wiring Inspect the wiring for damage Inspect all connections to the cranking motor solenoid magnetic switch ignition switch or any other control switch and battery including all ground connections Clean and tighten all connections as required Magnetic Switch Solenoid and Control Switches Inspect switches to determine their condition From the vehicle wiring diagram determine which circuits should be energized with the starting switches closed Use a voltmeter to detect any open circuits Thermostat or Overcrank Protection To check the thermostat for continuity detach wiring harness connector and connect an ohmmeter to the two thermostat terminals on the motor The ohmmeter should read zero If not thermostat is open circuit DO NOT check thermostat when hot since it is supposed to be open circuit above certain temperatures Motor f the battery wiring and switches in satisfacto
266. ectric electronic parts supply house Hefer to alternator manufacturer s service manual for details of checking and repairing alternator diodes F8119 section X 12 81 INSTALLATION INSTRUCTIONS 3 6 2 HARNESS amp ALTERNATOR CHECKOUT WITHOUT 4 2600 continued 9 compare your readings with the following summary given in Figure 3 6 2A to to to to Condition GREEN GREEN GREEN GREEN Inverter Start to Button pushed Ignition OFF no other action taken Engine ON at 1000 RPM Engine ON at idle Inverter Start Button oushed Engine ON 1000 RPM up to 2500 RPM Commutation Fuses removed Inverter Start Button pushed Figure 3 6 2A SUMMARY OF TEST VOLTAGE READINGS 10 Reinstall commutation fuse If all steps check out correctly CONGRATULATIONS harness is properly attached to the alternator system and the alternator is capable of operating the inverter properly BE SURE ALL CHECKOUT DATA IS RECORDED ON THE WARRANTY INITIATION CARD BEFORE PROCEEDING DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 3 7 0 3 7 1 3 7 2 3 7 9 3 7 4 3 7 5 3 7 6 3 8 0 CHECKOUT INVERTER OPERATION 8 84 Put Auto Manual Switch in Manual position See 2 2 2 1 Disengage Automatic Throttle if used by disconnecting autothrotte linkage from carburetor Check battery charging voltage with inverter OFF Turn inverter OFF and increase engine speed to about 1000 RPM medium fast idl
267. ed Inver i ter Start But State r art i Bornes CERTIFICATE OF PROPER INSTALLATION 1 certify that 1 The figures above are the results of the Harness Check Out Procedure Section 3 6 of the Installation Instructions as performed by me 2 7 at the alternator checked out properly according to the Alternator Check Out Procedure _ection 3 6 of the Installation Instructions That the entire Inverter power system worked properly after installation 4 The Owner s Certificate of Warranty Initiation has been filled out and signed t gned Date of Installation Company Name Address rag PP MN m NO POSTAGE NECESSARY IF MAILED BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 8847 SEATTLE WA POSTAGE WILL BE PAID BY ADDRESSEE DYMMAOTE THE ELECTRONIC POWER MOLISE 1200 W NICKERSON SEATTLE WASHINGTON 98119 4 m e vis alls OWNER S INSTALLATION OPERATION SERVICE MANUAL A Series Dynamic Inverters gt DYNAMOTE CORPORATION 1200 W Nickerson DVMANMAOTE Seattle WA 98119 206 282 1000 Section VIII MISCELLANEOUS 1 0 1 1 1 2 1 3 1 4 1 5 F2265D 12 82 SECTION 1 DYNAMOTE LIMITED WARRANTY LIMITED WARRANTY DYNAMOTE CORPORATION Manufacturer warrants to the original user that each DYNAMOTE Product is free from defects in materials and factor workma
268. ed dried inspected and are to be immediately assembled can be coated with light oil to prevent corrosion lf these parts are to be stored for any length of time they should be treated with a good RUST PREVENTIVE and wrapped in special paper or other material designed to prevent corrosion ALUMINUM BEAM GALVANIC CORROSION PROTECTION The following recommendations are for protection against galvanic corrosion of the steel aluminum contact points on aluminum beam axles Using an aluminum spacer between the steel spring and the axle beam will eliminate galvanic corrosion on the axle beam f it is necessary for the steel spring to be in direct contact with the aluminum axle it is recommended that the spring pad area be treated with a zinc chromate paint The entire spring pad as well as the inner surface of the dowel and U bolt should be covered The U bolt should be used with flat washers that are cadmium plated and dichromate converted per Federal Specification QQ P 416 Type Il The clearance space between the U bolt and the holes in the axle spring pad should be filled with a rust preventive compound such as Texaco Compound L to prevent water from standing in this space INSPECTION It is impossible to overstress the importance of careful and thorough inspection of steering knuckle components prior to assembly Thorough visual inspection for indications of wear or stress and the replacement of such parts as are necessary wi
269. ed with the pinion shaft on the horizontal centerline unless otherwise stated to top of filler neck on earlier models and bottom of the tapped level hole on later models If the pinion shaft angle is something other than listed or the specific axle lube capacity is not given refer to the guide lines mentioned ETETE and 4 Proper Lubricant Levels for pinion angle versus proper fill plug hole to be used After determining the proper plug hole fill the axle with the specified lubricant to bottom of that hole The lubricant capacities of two similar axles in the same series may vary considerably due to design changes and the vehicle manufacturer s installation The actual service capacity may be accurately determined by carefully measuring the amount of specified lubricant necessary to fill the assembly to the correct level and measuring the lubricant again as it is drained from the unit The vehicle should be on a level floor when this inspection is made NOTE For the best distribution of lubricant and to assure that axle wheel end components are wet before putting the vehicle back into service tilt the axle from side to side after filling with oil Keep the axle in each tilted position for one minute to allow all wheel cavities to fill SINGLE AXLES t REFERENCE ONLY CAPACITY CAPACITY CAPACITY CAPACITY CAPACITY CAPACITY MODEL U S Pints Litres MODEL U S Pints Litres MODEL U S Pints Litres A 150 5Vo 2 5 580 15 7 0 B 100 10 4 5 F 5
270. ed End Includes 21 P 131 amp 550221 1 22 24 1 BEARING COVER GASKET 010 thick A R 11 22 P 24 2 BEARING COVER GASKET 020 thick A R 22 P 24 3 BEARING COVER GASKET 015 thick AR 12 28 P 52 SEALS PUDE 1 13 31 27 THRUST WASHER D EE REOR RE 2 14 35 8 SHIFTER COVER GASKET Pee 1 15 378391 DRIVESHAFT LOCKRING ra n RARI RR RR 1 328297 6 NEEDLE ROLLER REPLACEMENT KIT 50 Rollers c Stereo sub 1 16 378545 NEEDLE ROLLER 2 sets 19 per eger of dose Gs mE 2 Sets 17 378430 10 HEX CAPSCREW Nylock 546 18 1 vp PER 8 18 SET SGREW 5154 0 crake sue sinha CIA Aa ete Sale 1 378452 3 fa Deep Mount 378452 5 Extra Deep Mount 378452 7 Standard Mount 19 550221 BEARING CUP ed canes be dms Dua uides Lou st 2 20 550397 BEARING CONE Open pos 1 21 500532 BEARING CONE Closed End 40 1 328805 1X SHIFTER ASS Y Wire Control For arrangements 3 amp 6 Contains items 22 thru 31 CPP 1 328805 2X SHIFTER ASS Y Wire Control For arrangements 4 amp E TN Contains items 22 thru 22 34 74 COVER mro
271. ed Standard foot plate or yoke support and Newark Hold down available QUIC PAC holder also available 970 Model U 45FNH Model NASA 40F tt Ay t Scott Aviahon Lancaster Model 45 Spring Model 40 NASA Spring Chps Model U Back Piate Special Bracket for Scott 4 5 Model F Foot Plate Nylon coated clips Model NH Newark Hold down F Foot Plate Ps 1 Model U 45YNH Model US 45F 5 Model US 45Y Newark Hold down in with ar Model 45 Spring Clips Model S Spring instead of top clip Model S Spring instead of top clip cylinder in the WALKAWAY bracket show Model U Back Piale U Back Plate Model U Back Plate ing hold down straps around the botto Model Y Yoke Support Modet F Foot Plate Model Y Yoke Support and regulator Model NH Newark Hold down i Note See mounting and ordering instructions page 15 TO MODIFY OLD STYLE OLD STYLE THE FOLLOWING ITEMS MAY BE PURCHASED SEPARATELY WALKAWAY BRACKETS BRACKET Models 15J 30J 45J and 50 with Model F Foot Plate p i 1 Cut off existing bracket at point where vertical back bends to Model C form horizontal yoke support Clip only Attach new base plate Model F using existing holes in bracket Model Y New holes may be drilled in Yoke Support d dei iiM NR einda bracket to match up with hotes only i lind in the foot plate base plate 2 nut
272. egulator VVR box from the front panel of the inverter by removing the four screws at the corners 2 Remove the VVR Circuit Board from the box by removing the two screws on the outside of the box 3 Check the fuse on the VVR Circuit Board and replace if blown If not proceed to the next step 4 With the ignition ON inverter OFF and the inverter harnesses still connected check the voltage from the connector pin 4 GREY wire to GROUND The pin next to the edge of the circuit board is pin 5 If the voltage reads 10 volts or more proceed to Step 5 If there is no voltage the voltage regulator has failed in the open position and should be replaced 5 To determine if the voltage regulator is regulating properly start the engine and run at approximately 1500 RPM Turn on a moderate load such as the headlights With the inverter OFF check the voltage from the inverter B BLACK terminal post to GROUND GREEN If the voltage is other than 13 8 to 14 2VDC try to adjust it by turning the screw on the grey potentiometer on the vehicle voltage regulator circuit board with a very small screwdriver or knife blade If the voltage cannot be adjusted to approximately 14 2VDC the voltage regulator circuit board should be replaced NOTE The inverter voltage regulator PCB1 inside the inverter front panel is identical to the vehicle voltage regulator and can be used to replace the vehicle voltage regulator until another board can be obtained It
273. ehicle be sure to disconnect the battery grounding cable 2 Remove the positive and negative output terminal nuts so terminal tabs from regulator can be removed See Figure 3 5 5 4A ___ 3 Remove the diode trio connector wire from diode trio terminal on top of the regulator 4 Remove the regulator black aluminum assembly from the white ceramic brush holder housing see drawing by removing the two nuts securing the terminal tabs underneath the brush holder housing ___ 5 Prepare a 12 length of 16 AWG WHITE wire by putting a ring tongue lug connector for a 6 stud on one end B With a 17 64 open end wrench loosen and remove the negative brush contact nut see Fig 3 5 5 4B The negative brush is the brush nearest the 90 angle of the regulator housing DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 3 5 5 4 MODIFICATION INSTRUCTIONS FOR LEECE NEVILLE 4000JA amp 7000JA continued 12 81 C Attach the lugged end of the WHITE wire to the negative brush stud and replace and securely tighten the brush contact nut D Drill a 1 8 hole in the bottom of the regulator ho sing on the positive terminal side See Figure 3 5 E Thread the 16 WHITE wire down through the newly drilled 1 8 hole in the bottom of the regulator housing 6 Replace regulator into regulator housing A Replace the regulator into the ceramic housing making sure the 900 angle of the regulator is to the rear of the br
274. eld Maintenance Manual No 5 Single Reduction Drive Unit Hypoid Gearing Rockwell International where science gets down to business ee ee m m ce ee ee Oe EXPLODED VIEW DRIVE PINION FLANGE DRIVE PINION DRIVE PINION DRIVE PINION OIL FILLER PLUG DIFF CASE HALF DIFF BEARING DIFF BEARING CUP AND SUNGER ASSEMBLY GASKET OUTER BEARING INNER BEARING PILOT BEARING DIFF BEARING COTTER KEY CAPSCREW DRIVE PINION OUTER DRIVE PINION PILOT BEARING WASHER ADJUSTING NUT LOCK DIFF SIDE GEAR BEARING CUP PILOT BEARING SNAPRING CAPSCREW DIFF BEARING LOCK WIRE Eg CAPSCREW DIFF SIDE GEAR NI HARDENED WASHER COTTER KEY THRUST WASHER ps DIFF CARRIER AND E LOCKWIRE DIFF SIDE GEAR i PINION CAGE COVER DRIVE PINION THRUST WASHER BEARING CAGE DRIVE PINION NUT ae sees DIFF PINION PINION CAGE COVER OIL SEAL sims THRUST WASHER Fi DRIVE PINION E DRIVE GEAR DIFF SPIDER DIFF PINION BEARING SPACER e 52 E UA CN 3 GEAR TO CASE BOLT DRIVE PINION INNER DIFF CASEBOLT BEARING CUP SHORT x NEP la CN 167 THRUST BLOCK 1 9 ADJUSTING SCREW A NM bet THRUST BLOCK DIFF CASE THRUST BLOCK AGJUSTING FLANGE HALF SCREW JAM NUT GEAR TO CASE DIFF CASE BOLT BOLT NUT LONG DIFF BEARING PEE RE DIFF BEARING CUP LOCKWIRE
275. emove shims as required to obtain end play of 001 to 025 F Zero the dial indicator Measure the knuckle clearance end play by using a suitable lever to lift the knuckle while observing the dial indicator Make a note of the measurement On axles in service the end play may increase to a IMPORTANT After measuring knuckle clearance end play of over 025 add shims between upper knuckle pin boss and axle center end as required to obtain an end play of 001 025 02 64 mm through full range of turn 21 maximum of 065 1 70 mm at which time it will be necessary to re shim end play back to 001 025 02 64 mm NOTE Both knuckles should be checked If a reading of over 065 is taken remove the tire and king pin cap and remeasure as per rebuild procedure If the reading is still over 065 then reshim to specifications INSTALLATION OF KING PIN CAPS WELSH PLUGS AND RETAINERS IMPORTANT Before king pin caps and or welsh plugs are Installed recheck drawkeys and king pin nut to be sure the final staking or torquing procedure has been completed Omission of the final king pin securing steps may result in damaged or broken king pins and axle centers KING PIN CAPS AND COVERS A Align king pin caps and gaskets and assemble to knuckles with capscrews and washers 1 Gaskets do not have a top or bottom orientation and may be installed in either position 2 Caps do require orienting the flat side
276. ended that a torque wrench be employed for assembly of the adjusting nut and jam nut Tighten the adjusting nut to 100 lb ft torque while rotating the wheel in both directions to be sure all bearing surfaces are in contact Loosen the nut completely and then re torque to 50 Ib ft while rotating the wheel FINAL BEARING ADJUSTMENT The final bearing adjustment is designed to result in 001 to 010 end play Always be sure that this end play has been obtained after the jam nut has been torqued or when the cotter pin has been installed IMPORTANT Failure to obtain end play as specified Will cause bearing overload and premature failure A For axles that have single nut construction back off adjusting nut 1 6 to 1 8 turn Install cotter and measure end play adjusting if necessary B For axles that have double nut and lock construction back off adjusting nut 1 4 to 1 3 turn Assemble wheel bearing lock ring if used jam nut lock and jam nut Tighten jam nut to torque specified below Measure end play and adjust if necessary LB FT TORQUE MAX NUT SIZE MIN C Bend the jam nut lock over the jam nut and over the adjusting nut if no lock ring is used For assemblies using a dowelled adjusting nut pierced lock washer and no jam nut lock washer torque jam nut as follows measure end play and adjust if necessary LB FT TORQUE MIN MAX NUT SIZE STEERING STOP ADJUSTMENT Rockwell axles a
277. ension without first modifying it to a workable value The Nominal Pinion Mounting Dimension i E 7 875 indicates the proper distance from the center of the ring gear to the bearing shoulder on the pinion However because the opinion setting gauge measures the distance from the ring gear center to the nose of the pinion rather than the bearing shoulder it becomes necessary to subtract the length of the pinion head from the Nominal Pinion Mounting Dimension in order to establish the correct nominal or gauge dimensions to work with 13 SINGLE REDUCTION DRIVE UNIT To accurately install and adjust the pinion and cage assembly in a typical single reduction carrier using a pinion setting gauge follow these procedures 1 Record the Nominal Pinion Mounting Dimension and the original shim pack thickness for future reference 2 With a micrometer or vernier scale measure the length of the pinion head from its nose to its bearing shoulder Mark the spot on the pinion nose from which this measurement was taken Later when using the pinion setting gauge measure to or clamp step plate to this same spot for consistency in the calculations 3 oubstract the measured pinion head length from the Nominal Pinion Mounting Dimension to establish the pinion nominal gauge dimension Repeating the example in the illustration this would be 7 875 3 066 4 809 The remainder 4 809 is the basic value or Nominal Gauge Dimension used for cal
278. epower speed and rotation requirements of the accessory to be driven Based on intermittent service 5 APPLICATION QUESTIONS Here are some of the questions that are relevant to the Proper Selection of a Transmission Mounted Power Take Off 1 What is the make and model of your transmission 2 Which P T O opening will be used 3 What accessory is to be driven How much horsepower is required to drive the accessory 5 What is the required rotation of the P T O 6 What is required P T O output shaft speed as a percent of engine speed 7 What is the required method of shifting the P T O cable lever of air Once all of the answers to these questions have been determined a transmission mounted P T O can be selected to meet the horsepower speed and rotation that you require Having made the selection of a P T O you are ready to start the installation P T O Drive Gear Location The standard location for the P T O drive gear in the transmission is 1 to the front 2 to the rear of vertical center line transmission SAE 8 Bolt Standard SAE Power Take Off Apertures TO FRONT DRIVE GEAR Driver Gear Driver Gear on left on right side of side of transmission DRIVE GEAR TO REAR MOUNTING P T O TO TRANSMISSION For 6 or 8 Bolt Applications o EXIT 1 Drain the oil from the transmission and remove the P T O aperture cover plate See Fig 1
279. equency Drain flush and refill with 10W 40 motor oil Check back pressure see Hydraulic Supply Diagnosis section of this manual Check maximum oil flow see Hydraulic Supply Diagnosis section Refer to pump servicing instructions Check for restriction in pump supply See high operating temperatures Change to 10W 40 motor oil Increase engine speed momentarily to extend vanes and start pump action Usually a temporary and infrequent occurrence and not cause for pump repair or replacement Relocate line Repair steering column Replace damaged parts as required Adjust relief plungers see final adjustments Polish flow divider valve to remove foreign particles and burrs Refer to pump servicing instructions valve to hang up in the bore Replace flow divider spring Refer to pump servicing instructions Replace with flow divider valve assembly which includes by pass spring Refer to pump servicing instructions Repair or replace relief valve as required Refer to pump servicing instructions Symptom Hard Steering Wheel steering hard in one or both directions Wheel steering hard in one direction Metal or foreign material in relief ball seat Steering extremely light in one or both direction Possible cause Loose belts Worn pulley s due to belt slipping Faulty supply pump Front axle overloaded Faulty steering geometry High operating temperature Bent or damaged king pins and tie rods Front end load
280. er the reaming operation is completed Figure 19 135 165 135 165 Figure 19 EASY STEER BUSHING INSTALLATION Steel Beam Axle FF 941 FG 943 FG 941 FF 942 FF 943 FF 944 Models Figure 20 STEP3 UPPER amp LOWER BUSHING REAM DIAMETER STEP 1 UPPER KNUCKLE BOSS BUSHING DEPTH gt E INSTALLATION MARKED Figure 20 A Press upper bushing into knuckle approximately 1 8 and relieve pressure Bushing can now be pressed to the desired depth of 352 1 382 from the top of the machined surface B Place knuckle bottom side up and follow same procedure as step 1 to a depth of 352 1 382 from the bottom machined surface Ream bushings to specified diameter see page 15 Assemble the upper and lower grease seals as per instructions on page 16 after reaming Aluminum Beam Axles 941 A Models Press upper bushing into knuckle approximately 1 8 and relieve pressure The bushing can now be pressed to the desired depth of 445 1 475 B Place knuckle bottom side up and follow same procedure as step 1 to a depth of 290 1 320 C Ream bushings per specifications on page 15 All other Models 13 For all other models follow the bronze bushing sealed king pin design installation procedure for installation and use chart page 15 for new bushing diameter NOTE Easy Steer retrofit kit may contain king pin seals which are not part of the original design of the axle assembly The Easy Stee
281. er of turns If total turns is 5 or less the ratio is low Over 5 turns is high ratio Page 19 SHEPPARD POWER STEERING SERVICE MANUAL DISASSEMBLY Review your diagnosis The diagnosis section of this manual has been placed in the front of the Sheppard Power Steering Service Manual to emphasize the importance of proper diagnosis Repair time and down time as well as total repair costs can be reduced if needless disassembly and steering gear parts replacements can be avoided Before removing the steering gear from the chassis you must be certain that the hydraulic supply system is operating correctly and that all mechanical components are in good repair Caution The Sheppard Integral Power Steering Gear is a precision machined assembly and care must be taken during repair to keep it free of dirt and foreign material All internal parts must be handled carefully to avoid damages to machined surfaces Nicks or burrs can cause damages to mating parts and must be removed with a fine hand stone before reassembly Working on a soft cardboard or plywood surfaced workbench is advisable Follow disassembly procedures as required It may be necessary on some installations to remove the pitman arm before the steering gear is removed from the chassis In all cases it is important that a suitable puller is used when the pitman arm is removed Snap on puller P N CG 283 The pitman arm may be located on the output shaft by two Socket head retaining set
282. erial designed to prevent corrosion INSPECT It is impossible to overstress the importance of careful and thorough inspection of drive unit parts prior to reassembly Thorough visual inspection for indications of wear or stress and the replacement of such parts as are necessary will eliminate costly and avoidable drive unit failure A Inspect all bearings cups and cones including those not removed from parts of the drive unit and replace if rollers or cups are worn pitted or damaged in any way Remove parts needing replacement with a suitable puller or in a press with sleeves Avoid the use of drifts and hammers They may easily mutilate or distort component parts If any of the following bearing conditions exist bearings must be replaced 1 Large ends of rollers worn flush to recess or radii at large ends of rollers worn sharp o 2 a Visible step wear particularly at the small end of the roller track b Deep indentations cracks or brakes in bearing cup and or cone surfaces 3 Bright rubbing marks on the dark phosphate surfaces of the bearing cage 5 Spalling or flaking on bearing cup and or cone surfaces CARE AND MAINTENANCE B Inspect hypoid gears for wear or damage Gears which are worn ridged pitted or scored should be replaced When necessary to replace either the pinion or gear of hypoid set the entire gear set should be replaced C Inspect the differenti
283. ermined in Section II Side View a Output Trans C 2 15 2 5 4 6225 6 25 10 8725 9 297 or 3 18 b Input axle x b 2 15 3 4 6225 9 13 6225 3 69 or 3 41 Plan View mW Vx 4 b et Side View a En b To effectively control the non uniform motion effects of a cardan U joint operating at an angle it is necessary to keep U joint angles on each end of the drive shaft as equal to one another as possible Good drive shaft installation practice limits the inequality of these angles to be the equivalent of a single U joint operating at 3 To determine the effective cancellation of the universal joint angles your drive shaft installation use the following Effective cancellation 8 o amp 177 2 Where 3 18 true U joint angle transmission out put as determined in Sect 3 41 true U joint angle axle input as determined Sect 16 Effective cancellation 3297 3 69 10 87 13 61 2 74 1 65 1 39 Cancellation of the two U joint angles in this illustration is well within accepted limits If your results exceeds the recommended 3 equivalent it could be a source of torsional excitation Shimming of axle is recommended to equalize the angles 5 UNIVERSAL JOINTS TROUBLE SHOOTING CHART Repeat U Joint Failure k T Pu
284. ery tight Reconnect the Cathode GROUND lead f Reconnect the gate lead 4 3 10 DIODE CHECKOUT PROCEDURE Tools Required Ohm Meter or Continuity Tester 7 16 socket wrench or open end wrench screwdriver 1 Open inverter by removing the front and top panel fasteners Carefully lay the front panel down on its face and remove the top panel 2 A DIODE Rectifier is a semiconductor device which functions as an electrical one way street ANODE CATHODE 5575 will conduct For stud mounted diodes with normal or standard polarity the stud is the CATHODE and the tab or flag is the ANODE See diagram below For stud mounted diodes with reverse polarity the stud is the ANODE and the flag or tab is the CATHODE See diagram below DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 4 3 10 DIODE CHECKOUT PROCEDURE continued A diode which is not stud mounted but rather has axial leads conducts in the direction CT the band on the diode indicating the CATHODE end the end opposite indicating the ANODE Following is the polarity of the diodes in the Dynamic Inverters Diode Polarity D1 Standard D2 Axial Leads D3 D4 Heverse D5 D6 Standard D7 D8 Standard D9 D10 Axial Leads 3 The diodes can be located using the wiring diagram Figures 4 5 0A to F Not all models have all ten diodes 4 Diodes should be removed from the heat sink or chassis before test
285. es and the 17100 axle 50 000 miles 80 500 km or 12 months whichever comes first Easy Steer models FF and FG 941 and 943 in regular common carrier on highway service only Grease when axle is new and again after a 4 000 mile 6 500 km break in period only IMPORTANT The recommended greasing procedures must be followed Refer to page 9 Also greasable cross tube end assemblies used in Easy Steer axles must still be greased every 50 000 miles 80 500 km or 12 months whichever comes first If periodic knuckle pin greasing is desired with on highway Easy Steer models follow the 50 000 mile sealed knuckle pin interval Easy Steer models FD FF FG and FL 941 942 943 and 944 Series in on off highway service grease every 50 000 miles 80 500 km or 12 months whichever comes first 8 LUBRICATION LUBE HERE OR HERE PERMANENTLY LUBRICATED GREASABLE CROSS TUBE END Cross Tube End Assemblies Greasable type 50 000 miles 80 500 km or 12 months whichever comes first Permanently lubricated non greasable type do not require lubrication however periodic inspection of the sealing boot is recommended at 96 000 mile 154 000 km intervals e Wheel Bearings Refer to page 12 LUBE PROCEDURES e Models with Conventional Straight and Tapered Knuckle Pins To assure proper purging of old grease and contamination from upper and lower bushings the wheels should be raised off the ground while greasing the
286. es can be encountered Oil flow for the Sheppard steering gears are outlined below by Model number The indicated Model numbers correspond with the Model number cast into the steering gear housing Oil flow requirements remain the same for all similar Models and do not change from installation to installation Follow the O E M Truck Manufacturer s recommendations Low Pressure Series Model Oil Flow GPM U S Minimum Maximum High Pressure Series Model Oil Flow GPM U S Minimum Maximum Dual Systems Model Ratio Oil Flow GPM U S Minimum Maximum Model Ratio Oil Flow GPM U S Minimum Maximum 188 1 9 192 2 2 292W 292 Low 4 5 5 5 392W 292 Low 5 0 6 0 191 2 2 2 7 252 292 ALL 3 2 4 0 Slave High 4 0 5 0 Slave High 4 0 5 0 39 3 6 4 4 372 382 352 3 6 4 4 491 4 3 5 3 392 ALL 3 6 4 4 372 382W 292 Slave Low 5 0 6 0 492W 492 Low 6 0 7 0 High 4 0 4 5 Slave High 5 0 6 0 51 4 8 6 0 492 ALL 4 3 5 3 392W 392 Low 5 0 6 0 592W 592 Low 8 0 9 0 59 5 7 7 0 592 ALL 5 7 7 0 Slave High 4 0 5 0 Slave High 7 0 8 0 Minimum flow is checked at operating temperature while steering from full left to full right with the engine at idle To determine low or high ratio disconnect the master gear drag link turn the steering wheel from full left to full right and count the numb
287. ese tests it should be replaced K2 CONTROL RELAY CHECKOUT PROCEDURE Tools Required Voltmeter with 0 15VDC scale 7 16 socket or open end wrench screwdriver 1 If there is a control fuse on the inverter front panel check it first 2 Open the inverter by removing the front top and back panel fasteners Carefully lay the front and back panels down and remove the top panel 3 he engine and ignition should be OFF for this test DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 F2139B section X 12 81 4 3 4 4 3 5 TROUBLESHOOTING AND SERVICE K2 RELAY CHECKOUT PROCEDURE continued 4 Locate the K2 Relay It is approximately I x x3 encased in clear plastic and located on the bottom left side of the inverter 5 Depress and release the start button and visually confirm that the relay contacts are moving If the contacts do not move the relay should be replaced 6 With the START button depressed check the voltage from the ACC terminal at the rear of the inverter to GROUND It should read 10 VDC or higher If not the relay should be replaced 7 With the START Button depressed check the voltage from the F Out terminal at the rear of the inverter to GROUND t should read 10VDC or higher If there is no voltage at the F Out terminal and if the Voltage Regulator has checked good then replace the K2 Relay KS RELAY CHECKOUT PROCEDURE Tools Required Volt Ohm Meter with 0 15VDC scale screwdriver
288. essure of both No 1 and No 2 circuits using test gauges known to be accurate Depress the treadle to several positions between the fully released and fully applied positions and check the delivered pressure on the test gauges to see that it varies equally and proportionately with the movement of the brake pedal After a full application is released the reading on the test gauges should fall off to zero promptly It should be noted that the No 1 circuit delivery pressure will be about 2 PSI greater than the No 2 circuit delivery pressure with both supply reservoirs at the same pressure This is normal for this valve IMPORTANT A change in vehicle braking characteristics or a low pressure warning may indicate a malfunction in one or the other brake circuit and although the vehicle air brake system may continue to function the vehicle should not be operated until the necessary repairs have been made and both braking circuits including the pneumatic and mechanical devices are operating normally Always check the vehicle brake system for proper operation after per forming brake work and before returning the vehicle to service LEAKAGE CHECK j Make and hold a high pressure 80 psi application 2 Coat the exhaust port and body of the brake valve with a soap solution 3 Leakage permitted is a one inch bubble in 3 seconds If the brake valve does not function as described above or leakage is excessive it is recommended that it b
289. evers permit 360 rotation Later models of the B W lever incorporate a self locking device operated by the adjusting screw wrench Service on these units should be obtained through the vehicle manufacturers Bendix Westinghouse or Mid land Rockwell does not supply service or parts for these assemblies The Rockwell enclosed adjustable lever allows 69 degree rotation of the cam shaft from the initial position This permits sufficient adjustment to compensate for approximately 5 16 lining wear To obtain additional adjustment the lever is moved 4 serrations or 1 spline and readjusted as required Sees se P ADJUSTMENT Adjust bolt locks at 1 4 turn intervals One notch or 1 4 turn provides 0025 movement at the shoe center When the adjustment limit is reached loosen clamp bolt and remove lever Adjust lever to original position and move back four serrations on shaft or one full spline Tighten clamp bolt and adjust as required LINING WEAR INDICATOR DIAL amp POINTER A ee ii ee o a ee a ae il v tie cen x ae 114 Tg k SLACK LEVER x POINTER i BRAKES F M M NO 4 The use of a lining wear indicator dial and pointer on slack adjusters of cam actuated brakes will show the progressive degree of brake lining wear The dial and pointer when properly installed will onl
290. ew 3 Position the release pin over ball valve Screw body with ball into the spring cage Tighten securely 4 Adjust for proper setting see Adjustment section ASSEMBLY ST 3 NON ADJUSTABLE VALVE 1 Install spring release pin in spring cage 2 Position ball valve in body and screw spring cage onto body 3 Hold spring cage in soft jawed vise and tighten body securely TO RAISE PRESSURE SETTING 1 Loosen lock nut 2 Turn adjusting nut clockwise to obtain correct pres sure setting 3 Tighten lock nut TO LOWER PRESSURE SETTING 1 Loosen lock nut 2 Turn adjusting nut counter clockwise to obtain correct pressure setting 3 Tighten lock nut TESTING OF REBUILT SAFETY VALVES Perform operating and leakage checks ADJUSTMENT OF SAFETY VALVE NOTE The ST 3 Safety Valve is not adjustable The pressure setting of the Safety Valve is stamped on the cover wrench flat closest to the pipe thread The vehicle manual may also provide the proper pressure setting If setting is not known determine governor cut out pressure setting and adjust Safety Valve so that the RELEASE PIN THREAD oafety Valve closes at a pressure setting somewhat above governor cut out pressure setting See Operation section To adjust the Safety Valve must be connected to ana system with air pressure in excess of desired setting lt is important that an accurate gauge be used to check pressure settings while m
291. exceeds the maximum relief pressure setting of the pilot operated relief valve the valve opens and excess pressure is bled off into the oil return circuit through the pinion gear bore of the steering gear One bolt and a square ring seal connect the exhaust side of the valve to the pinion gear housing of the steering gear Two bolts and a square ring seal connect the high pressure side of the valve to the cylinder head of the steering gear The valve is disassembled for cleaning and inspection by removing the valve end plug and withdrawing the relief valve and compensating spring Page 46 SHEPPARD POWER STEERING SERVICE MANUAL When the pressure relief valve is reassembled to the steering gear housing it is important that attaching bolts are properly torqued The single cap screw attaching the relief valve to the pinion housing of the gear must be installed and torqued to specifications first The two cap screws attaching the relief valve to the cylinder head are then installed and torqued This procedure will avoid causing distortion which could lead to binding of the relief 8 114 valve in its bore TESTING INTEGRAL RELIEF VALVE HERMONE TER 1 Connect pressure gauge and flow meter into the steering circuit as illustrated 2 Close valve on gauge assembly and read supply pump relief pressure Caution A malfunctioning pressure relief valve may not relieve pump pressure and closing the shutoff valve may cause severe pum
292. except as noted above Short Circuits Short circuits in the armature are located by use of a growler When the armature is revolved in the growler with a steel strip such as a hacksaw blade held above it the blade will vibrate above the area of the armature core in which the short circuit is located Shorts between bars are sometimes produced by brush dust or copper between the bars These shorts be eliminated by cleaning out the slots Grounds Grounds in the armature can be detected by the use of a 110 volt test lamp and test points If the lamp lights when one test point is placed on the commutator with the other point on the core or shaft the armature is grounded Grounds occur as a result of insulation failure which is often brought about by overheating of the cranking motor produced by excessively long cranking periods or by accumulation of brush dust between the commutator bars and the steel commutator ring Figure 20 Forcing snap ring over shaft FIELD COIL CHECKS The various types of circuits used are shown in the wiring diagrams of Figure 11 The field coils can be checked for grounds and opens by using a test lamp Figure 21 Forcing retainer over snap ring Grounds If the motor has one or more coils normally connected to ground the ground connections must be disconnected during this check Connect one lead of the 110 volt test lamp to the field frame and the other lead to the field connector
293. f a two piece drive shaft assembly between the transmission Main or Auxiliary and the forward rear axle the joints on this shaft should be assembled In Phase unless otherwise specified by the manufacturer of the vehicle 3 The inter axle drive shaft yokes must be In Phase FIGURE 30 CHECKING DRIVESHAFT ANGLES The procedure to check drive shaft angles for proper universal joint operating angles follows 1 Remember to check drive shaft angles both with the tractor fifth wheel unloaded and loaded with a trailer 2 To determine drive shaft angles a spirit level protractor is required When angles are read from the 0 mark for example measuring inter axle shaft angle 5 record and use the angle shown on the protractor When angles are read from either of the 90 marks vertically for example measuring yoke angles do not record the angle shown on the protractor since the 90 marks must 4 If a vehicle has drive shafts that do not have intersecting angles but parallel angles throughout the drive line system the yokes or flanges must be held parallel to within 1 of each other INSTALLING DRIVESHAFT 1 Drive Shaft Assembly Place in a pair of centers and check the Shaft for runout if not previously done during assembly The runout on the Tube should not be more than 015 indicator reading and on the neck of the Slip Stub Shaft the runout should not be more than 005 indicator reading Mark the high and low poi
294. g between reservoir and pump body Lubricant milky or white in appearance Oil forced out of reservoir Air in system Engine Oil in power steering reservoir Gear driven pump Possible cause Clogged oil filter in reservoir high back pressure Pinched or restricted oil return line Damaged quad ring seal Damaged bronze bearings Worn or damaged oil seal Replace damaged parts Damaged oil seal Oil seal heat damaged Loose or damaged bushing on pump drive shaft Seal or gasket damaged Water entry through reservoir venting system Clogged oil filter Loose pump drive belts Bleed air from system Faulty supply pump Cavitation Repair pump per pump service instruction Relief plungers of steering gear not adjusted properly Operating temperatures too high Faulty seal at pump drive shaft Faulty seal at accessory shaft driving supply pump Page 11 Remedy Replace filter Increase change frequency Locate and correct Check back pressure Replace quad ring seal Replace Bronze bearings Polish output shaft or replace to remove bronze deposits Replace seals Lube bearing cap more often Replace oil seal Check operating temperature Repair pump per pump service instructions Replace damaged parts Clean vent system or replace cap assembly Change oil and oil filter Increase change intervals Adjust belts or replace Check for air leak on suction side of supply pump Chec
295. gral Charging System and the two are completely interchangeable RECTIFIER BRIDGE CHECK Omit for overcharged battery Note that each rectifier bridge has a grounded heat sink and an insulated heat sink The insulated heat sinks are connected together and electrically are connected to the output or BAT terminal Figure 16 Checking diode trio DELCOTRON INTEGRAL CHARGING SYSTEM To check the rectifier bridge disconnect the regulator jumper lead on three terminal regulator end frame then connect the ohmmeter to a heat sink and one of the three terminals Figs 17 and 18 Then reverse the lead connections to the same heat sink and same terminal If both readings are the same replace the rectifier bridge by detaching the necessary screws and nuts A good rectifier bridge will give one high and one low reading Repeat this same test between the same heat sink and the other two terminals and between the Service Bulletin 1G 285 Figure 15 End Frame view with stator removed Three rectifier bridge type other heat sink and each of the three terminals This makes a total of six checks with two readings taken for each check on each rectifier bridge Check the other two rectifier bridges in the same manner IMPORTANT If rectifier bridge is constructed with flat metal clips at the three studs press down very firmly onto flat metal clips and not onto threaded stud Fig 18 Rectifier bridges differing in appear
296. h burnishing bars or balls Honing this method does not work well with the Easy oteer bushing material and does not provide proper 4 After the reamer sizes most of the upper bushing alignment of the bores This can be used as a last resort support the reamer so that it does not drop to the but must be done dry no lubricant and with new stones bottom bushing as it completes the cut 5 After the upper bushing has been sized gently slide REAMING PROCEDURE the reamer through until it engages the bottom bushing Repeat steps 3 and 4 for the bottom REAM UPPER BUSHING FIRST Figure 21 bushing Push Down Lightly 6 Slide the reamer out through the bottom If the reamer must be pulled back up through the bushing do so only while rotating the reamer in reverse Any other way will damage the bushings 7 Clear bushing debris from bores before installing seals REAM LOWER BUSHING SECOND Figure 22 Push Down Lightly Figure 21 1 Position the knuckle in a vise with soft metal shims to protect the knuckle It is preferable to have the king hole vertical 2 Gently slide the reamer pilot through the upper bushing until the reamer cutters begin to engage the upper bushing 3 Begin rotating the reamer and applying a light downward pressure with your hand at the same time Do not force the reamer by applying too much downward force The reamer can be rotated at any speed but should be done smoothly 14 REAM
297. haft Mark the bearing cap and bearing retainer to indicate the locking pin hole location and remove the retainer locking pin Page 58 SHEPPARD POWER STEERING SERVICE MANUAL Remove bearing retaining nut from the bearing cap Remove the shims laying on top of the bearing and lay aside for reuse Remove remaining bolts and lockwasher attaching the bearing cap to the steering gear housing Turn the actuating shaft and bearing cap out of the steering gear Carefully tap or press the actuating shaft and bearing out of the bearing cap If necessary for replacement press the bearing off the actuating shaft Page 59 SHEPPARD POWER STEERING SERVICE MANUAL If the fixed plunger in the bearing cap is damaged it can be removed by pulling out the locking pin and pulling the plunger out of the bearing cap Tap the high pressure actuating shaft seal out of the bearing cap if replacement is required Press a new seal in the bearing cap with the lip of the seal facing inside Carefully install the actuating shaft and bearing through the seal and into the bearing cap Replace bearing retainer and install locking pin Reinstall the shimns on the bearing surface and install the miter gear and washer and retaining nut and torque to 60 ft Ibs Page 60 SHEPPARD POWER STEERING SERVICE MANUAL Reinstall the miter housing to the bearing cap Caution Do not neglect to reinstall the bolts and lockwashers i
298. haft from cage B Remove outer bearing from cage C Remove spacer or spacer combination from pinion shaft 4 eee es LE TE Hi 4 D If necessary to replace rear thrust bearing bearing remove with suitable puller ea or radial E Remove oil seal assembly from bearing cover PREPARE FOR REASSEMBLY CLEAN INSPECT AND REPAIR Parts having ground and polished surfaces such as gears bearings shafts and collars should be cleaned in a suitable solvent such as kerosene or diesel fuel oil GASOLINE SHOULD BE AVOIDED Do NOT clean these parts in a hot solution tank or with water and alkaline solutions such as sodium hydroxide orthosilicates or phosphates We do NOT recommend steam cleaning assembled drive units after they have been removed from the housing When this method of cleaning is used water is trapped in the cored passage of the castings and in the close clearances between parts as well as on the parts This can lead to corrosion rust of critical parts of the assembly and the possibility of circulating rust particles in the lubricant Premature failure of bearings gears and other parts can be caused by this practice Assembled drive units cannot be properly cleaned by steam cleaning dipping or slushing Complete drive unit disassembly is a necessary requisite to thorough cleaning ROUGH PARTS Rough parts such as differential carrier castings
299. half round hole and under locating ears Be sure that mounting faces are cleaned of rust paint and other foreign material The U bolts are assembled over the bearing races to retain them in the end yokes Spring lock washers and nuts should be used with these U bolts at assembly The following torque loads are suggested for use with these parts 14 to 17 Ibs ft 20 to 24 Ibs ft 32 to 37 lbs ft 5 16 24 Thread 3 8 24 Thread 7 16 20 Thread These torque loads are somewhat lighter than normally used with these thread sizes however the lower torques are required to prevent bearing race distortion ASSEMBLING SLIP JOINT ON SHAFT Lubricate the splines thoroughly refer to page 9 and assemble on the Shaft BE SURE that the arrows or marks on the Shaft and Slip Joint are in line since the Sleeve Yoke Lugs must be in the same plane as the Stub Ball Yoke lugs to prevent excessive vibration The cork washer should be replaced if necessary before assembling with the dust cap and steel washer on the Sleeve Yoke YOKE LUGS IN LINE 5 o INSTALLATION UNIVERSAL JOINT PHASING See Fig 29 When U joints or yokes are assembled to their shafts in the same plane they are in phase When they are assembled to the shaft in different planes they are out of phase To obtain vibration free operation check the following 1 Yokes or flanges between the main and auxiliary transmission must be In Phase 2 In the case o
300. haul Use only genuine Rockwell replacement parts for satisfactory service For example using gaskets of foreign material generally leads to mechanical trouble due to variations in thickness and the inability of certain materials to withstand compression oil etc C Remove nicks mars and buffs from machined or ground surfaces Threads must be clean and free to obtain accurate adjustment and correct torque fine mill file or India stone is suitable for this purpose Studs must be tight prior to reassembling the parts D When assembling component parts use a press where possible E Tighten all the nuts to the specified torque Where lockwire is employed use soft iron locking wire to prevent possibility of wire breakage F The burrs caused by lock washers at the spot face of stud holes of cages and covers should be removed to assure easy reassembly of these parts SILICONE RTV GASKET APPLICATION NOTE Where silicone RTV gasket material is used Dow Silastic No RTV 732 Black and General Electric No RI V 14783 Black meet our requirements However silicone RTV is also available in bulk under Rockwell part number 1199 Q 2981 in 10 oz tubes part number 1250 X388 or in 3 oz tubes part number 1199 T 3842 SERVICE Removal of all gaskets including silicone RIV is accomplished by peeling or scraping the used gasket off both mating surfaces Application of silicone RTV gasket material is as follows 1 Remove dir
301. he engine 3 While watching the gauges on the supply and delivery sides of the valve slowly begin to exhaust pressure from the delivery side Note that both gauges will show pressure loss until the closing pressure of the pressure protection valve is reached The pressure protection valve should close at approximately 5 psi the pressure indicated on the valve s label or in the vehicle handbook The gauge on the delivery side of the valve should continue to show loss of pressure while the gauge on the supply side should stop at the same pressure as the setting of the valve PR 3 only Build pressure up again and shut off engine Slowly exhaust air from the supply side of the PR 3 The gauge on the delivery side of the valve should remain at the highest pressure previously attained LEAKAGE CHECKS 1 Build up the air system to full pressure and shut off the engine 2 Apply a soap solution around the cap of the pressure protection valve A one inch bubble in three seconds or longer is acceptable PR 3 No leakage permissable at bottom of valve 3 Drain the air pressure from the delivery side of the pressure protection valve and disconnect the air line to it 4 Apply a soap solution to the delivery port one inch bubble in five seconds or more is acceptable GENERAL If the pressure protection valve does not operate as described or leakage is excessive it is recommended that a replacement be obtained at the nearest Au
302. he bushings and contacts the armature shaft Oil can be added to each wick by removing a pipe plug which is accessible on the outside of the motor DELCO REMY Available as an optional feature are oil reservoirs for the bronze bearings which makes available a larger oil supply thereby extending the time required between lubrication periods Another optional feature is O rings which can be added to resist entry of dirt and moisture into the entire motor assembly When the oil reservoirs and O rings are included the motor will provide long periods of attention free operation Many models feature seal between the shaft and lever housing and all models have a rubber boot or linkage seal over the solenoid plunger The seal and the boot when used together prevent entry of oil into the motor main frame and solenoid case allowing the motor to be used on wet clutch applications Four kinds of clutches a heavy duty sprag a Positork drive an intermediate duty type and a splined drive may be used with enclosed heavy duty type cranking motors All four types are moved into mesh with the ring gear by the action of the solenoid The pinion remains engaged until starting is assured and the solenoid circuit is interrupted In case of a butt engagement with the heavy duty sprag clutch or Positork drive the motor will not be energized to prevent damage to the pinion and gear teeth The spline drive is normally used on gas turb
303. he drum and obtain the proper clearance B Remove anchor pin C washers and guide pin locks and washers Each shoe must be adjusted to center the brake shoe arc in relation to the drum Adjust cam to bring lining into contact with the drum and rotate anchor pin sufficiently to relieve drag Repeat until additional rotation of anchor pin will no longer relieve drag Lock anchor pin lock nut and back off cam sufficiently to permit wheel to turn freely C Remove brake shoe and lining assemblies D Remove anchor pin lock nuts lock washers and anchor pins E For complete disassembly remove cap screws washers and wheel cylinder assembly and disconnect hydraulic lines Subsequent adjustments to compensate for lining wear are made with the eccentric cam only Turn cam to bring lining into contact with the drum Back off sufficiently to permit REASSEMBLY free rolling drum Repeat on opposite shoe A Position wheel cylinder install cap screws and lock washers and tighten securely Re connect hydraulic lines ECCENTRIC CAM ANCHOR PIN ADJUSTMENTS ADJUSTMENTS B Insert anchor pins and install washers and lock nuts Punch marks must be together and wrench flats in line C Position shoe and lining assemblies and install washers and lock rings D Back off adjusting cams and position shoes on push rods in wheel cylinder E Hook shoe return spring in brake shoe web holes ADJUSTMENT Following overhaul or when new linings are
304. heel cylinders Fir complete disassembly disconnect the hydraulic lines remove wheel cylinder cap screws and wheel cylinder H Remove brake adjusting bolts D Holding the shoe against the brake backing plate with ASSEMBLY one hand after guide bolt cotter keys have been removed remove the guide bolt nut and washer with A Install wheel cylinder and push rods Tighten wheel the other hand cylinder cap screws securely E Allow the springs to rotate the shoe abutment end B Install adjusting bolts and turn in fully until the spring tension is released C Position lever so that ends mate with pushrod at top and adjusting bolt at the bottom There are right and left hand levers D Hook short ends of both springs into brake shoe we b holes Hook long end of upper spring on spider and long end of lower spring in adjusting bolt end Lean abutment ends of shoe web against spider abutment are bolts F With both hands rotate shoe and liner assembly over lever pressure bottom and guide bolt into position against the lever G Hold shoe and liner assembly against lever with one hand and install washer and nut on guide bolt with the other H Tighten guide bolt nut so that shoe and lever will have clearance of 015 When the spring type guide bolt washer is used tighten the guide bolt nut until the cotter pin can be inserted in the guide pin l Lock guide bolt nut with cotter key and connect
305. heel to toe Liner installation should be checked with a 002 feeler gauge to assure liner and shoe contact INSTALLING BOLTED LINERS The same precaution should be taken with bolted liners as with riveted liners New lock washers should be used and nuts tightened to the following 3 8 dia Brass Bolt 220 280 Ib in or 18 23 Ib ft 14 dia Brass Bolt 80 100 Ib in or 7 8 Ib ft CIRCLE GRINDING When liners are installed on brake assemblies not provided with adjustable anchor pins the liners should be circle ground to provide the correct liner and drum contact With the cam in the full release position the liner should be ground 070 less than the drum diameter If 80 of the liner has not cleaned up the cam should be adjusted and the liners ground until 80 contact of the drum diameter is obtained The 80 contact must be continuous and in the middle of the lining USE OF OVERSIZE LINERS Automotive and Trailer Series To compensate for material removed when refacing brake drums X 1 16 oversize and XX 1 8 oversize liners are furnished by the lining manufacturers When oversize liners are used the drums should also be machined in increments of 1 16 RADIUS increased 1 16 Enlarging the drum diameter will permit the cam to rotate beyond its maximum lift when the lining becomes worn This can result in sticking cams or cam roll over Cam Roll over To avoid this condition and obtain maximum lining we
306. i en ae ee TIL ie D PINION ANGLE LESS THAN 7 PINION ANGLE MORE THAN 7 FILL TO CARRIER FILL PLUG HOLE FILL TO HOUSING FILL PLUG HOLE Refer to Pages 3 and 4 AMBOID AND HYPOID GEARING FRONT MOUNTED SINGLE REDUCTION PLANETARY AXLE APPLICATION Note Use same guidelines as mentioned above for pinion angle vs fill plug hole HYPOID GEARING PINION STANDARD HYPOID GEARING PINION INVERTED FRONT MOUNTED SINGLE REDUCTION TANDEM AXLES FORWARD REAR AXLES LUBE HOLE LUBE HOLE NOT SHOWN HYPOID GEARING WITH INTER AXLE DIFF HYPOID GEARING WITH INTER AXLE DIFF AND PUMP FORCED LUBRICATION 20 LUBRICATION FRONT MOUNTED DOUBLE REDUCTION AND 2 SPEED AXLES FILL HOLE IN CARRIER FILL HOLE IN HOUSING TOP MOUNTED DOUBLE REDUCTION SINGLE AXLES OR REAR REAR OFTANDEMS HYPOID AND SPIRAL BEVEL GEARING HYPOID AND SPIRAL BEVEL GEARING TOP MOUNTED DOUBLE REDUCTION TANDEM AXLES FORWARD REAR AXLES HYPOID GEARING WITHOUT HYPOID GEARING WITH INTER AXLE DIFFERENTIAL INTER AXLE DIFFERENTIAL 21 LUBRICATION LUBRICANTS e Drive unit gearing Standard 0 76 0 76 A 0 76 B Optional 0 76 C 0 76 D 0 76 E 0 76 F 0 76 J 0 76 K Output bearings two tapered bearing design only Standard Same as above plus 0 622 Refer to the following intervals and procedures Refer to Recommended Lubricants pages 6 7 LUBE INTERVALS e All new and reconditioned units Drain and refill initial fill lubrican
307. iations du modele illustr No 12372 B Plain RH illust No 12372 C Locking RH 12373 B Plain LH No 12373 C Locking LH Poign e chrom e encastr e dans plaque de montage Chromed handle in a plain steel recessed mounting plate Poign es en D se repliant dans soucoupe circulaire Folding D ring handles in round pan 2 i _Stock 0 19 1 SS 79 M 79 5 219 1 No 279 S Diam Total on Outside Djam 6 3 16 4 15 16 4 1 16 6 3 16 4 1 16 Re bord Flange width 3 4 1 8 1 2 3 4 1 2 Tige 3471 as FINISHES Plain steel in stock Shank 34 lg Profondeur 1 2 Deep Cad and chrome available Poids Weight LB 3 4 1 5 16 1 FAUCHER amp FILS INDUSTRIES 1964 tures G 7 MONTR AL TORONTO EDMONTON VANCOUVER ere e MEN ZI HANDLES Flush Type 7 c ip H d 4 mr 3 ett t 2 4554 LPS d Uo Vine e ati uten f 4 17 E rA arte Alas hebes e n 5 Y peth ro tales A ANE ert es D X ut e t bad 4 4 4 n el r PT o i g 5 ub 9c 2 5 a S c 2 e y z CN Pow VY Sao 2 gt N 5 o gd SY ON M D o 2 c A o o Uu ex
308. icle will determine which oil fill level plug hole should be used LUBRICATION Except for Top Mounted or pinion inverted type carriers use the following information to locate the fill level hole Measure the drive pinion angle if angle is less than 70 above horizontal use the hole located in the side of carrier If the angle is more than 70 above horizontal use the hole located in the axle housing bowl Note Some axle models have only one lube fill hole which is located in the housing bowl With these models use this lube filler hole for all pinion angles axles employing Top Mounted or pinion inverted type carriers the fill level hole is always located in the axle housing bowl Some axle models have a small tapped and plugged hole located near but below the housing lubricant level hole This smaller hole has been provided for the use of a lubricant temperature indicator only and must not be used as a fill or level hole After filling the axle with lubricant drive the vehicle unloaded for one 1 or two 2 miles 1 6to 3 2 km at speeds not to exceed 25 miles per hour 40 kph to thoroughly circulate the lubricant throughout the axle and carrier assemblies REGULAR AXLE SERVICE Follow New and Reconditioned Axle procedures except for initial 1000 3000 mile 1600 4800 km drain and flush instructions Change lubricant at recommended intervals LUBRICANT CHANGE SCHEDULE There are very practical reason
309. ide of the thrust bearing facing down slide the bearing between the lower face of the axle center and the upper face of the lower knuckle yoke Figure 28 IMPORTANT The thrust bearing must be seated on the face of the lower knuckle yoke On axles WITHOUT thrust bearing seals the bearing should always be installed in the axle with the closed retainer face up and the cage face with the opening dowr Figure 28 M M egg 14 BLOWS ee ee Rl Figure 28 SHIM ASSEMBLY Figure 29 Shims must now be positioned between the upper axle center face and the upper knuckle yoke Shims are used 18 to limit the vertical movement of the knuckle with respect to the axle center and king pin Some clearance in this area is required however to allow grease to purge from the upper bushing area Carefully inspect shims new or used to be sure none kinked bent or torn Discard any that are damaged Select a quantity of shims to obtain as little vertical end play as possible Lift the knuckle in position and slide the shim pack between the axle center boss and the knuckle upper yoke Figure 29 Alignment of the king pin hole in the knuckle and axle center is now required for king pin installation While looking down through the king pin hole shift the knuckle to align it with the axle center Now align the shims to be flush with the axle center around the entire circumference of the king pin ho
310. idge through resistor R1 and resistor R4 to turn transistor TR1 on The stator then supplies d c field current through the diode trio the field TR1 and then through the diodes in the rectifier bridge back to the stator As the speed and voltage increase the voltage between R2 and R3 increases to the value where zener diode D1 con ducts Transistor TR2 then turns on and TR1 turns off With TR1 off the field current and system voltage decrease and D1 then blocks current flow causing TR1 to turn back on The field current and system voltage increase and this cycle then repeats many times per second to limit the voltage to the adjusted value DELCOTRON INTEGRAL CHARGING SYSTEM Service Bulletin 1G 285 Capacitor C1 smoothes out the voltage across R3 resistor R4 prevents excessive current through TR1 at high temperatures and diode D2 prevents high induced voltages in the field windings when TH1 turns off BATTERY 2 DIODE TRIO 1 R TERMINAL um Figure 5 Typical wiring diagram showing internal circuits Two rectifier bridge type BATTERY 2 gt TERMINALS R TERMINAL gem c Se 2 UD um UR GN Figure 6 Typical wiring diagram showing internal circuits Three rectifier bridge type
311. ief fittings At brake reline or caliper overhaul with wheel removed use the following procedures Caliper Assembly 1 Insert the appropriate Rockwell slack adjuster template or a 060 090 gauge between the brake piston and inboard lining 2 Apply grease through the slack adjuster fitting until grease purges at the pressure relief fitting 17 LUBRICATION 3 Hold down the pressure relief fitting and continue applying grease until it purges through the powershaft cap seal Discontinue grease gun pressure and wipe off all excessive grease from the caliper assembly Automatic Slack Adjuster Assembly 1 Apply grease through the slack adjuster fitting until grease purges from the pressure relief capscrew in the side of the slack housing Discontinue grease gun pressure 2 Wipe off all excessive grease from the slack adjuster housing 7 SPRING SEATS BUSHING TYPE METAL NYLON AND DELRIN LUBRICANT Standard 0 74 Optional 0 73 Use 0 73 S A E Grade 140 if 0 74 S AE Grade 250 is not available However it will be necessary to check oil levels more frequently when using the lighter grade 140 lubricant Refer to Recommended Lubricants pages and 7 LUBE INTERVALS As required Keep reservoir filled with specified oil e ROLLER BEARING LUBRICATION LUBRICANT Standard 0 617 B Refer to Recommended Lubricants pages 6 7 LUBE INTERVALS Whenever wheel bearings are lubricated or
312. ight line pushing action The bushing is pushed into the gear housing so that the inside face of bushing is flush with inside face of gear housing Install a new Quad ring in the groove in the gear housing The quad ring is a stuff fit and at first glance may appear to be too large Press a new bronze bearing into the pinion cover The bronze bearing should be recessed 1 2 inch below the face of the cover on all 292 392 and 492 steering gears The 592 bearing is recessed 5 16 All other bearings are installed flush with the face of the cover Page 41 SHEPPARD POWER STEERING SERVICE MANUAL VARIATION SERIES 5 HOUSING REPAIR The output shaft oil seal used in the Series 5 Gear is of the metal clad type and is held in the housing with a retainer and four allen head screws 5 94 replace the seal remove the four screws the retainer and pull the output shaft out of the housing Use a long straight tip screwdriver to lever the seal out of the housing bore 5 96 If the needle bearing in the housing is to be replaced the output shaft seal must be removed to gain access to the bearing locating snap ring in the housing Remove the snap ring from the housing and press the bearing out of the housing Page 42 SHEPPARD POWER STEERING SERVICE MANUAL On reassembly the snap ring is installed first and the bearing is pressed into the housing until it contacts the snap ring Note 59255
313. ill be determined in Step 8 below 8 DO NOT PUSH OR RELEASE START SWITCH WHEN ENGINE IS ABOVE IDLE FOR THIS TEST With commutation fuses removed and inverter Start Button depressed as in Step 7 above slowly increase engine speed Voltage from GREEN post to RED post should increase to about IOOVDC at or below 2500 engine RPM Do not increase engine speed in excess of 100VDC reading and maintain this condition only long enough to check voltage output This step assures that alternator diodes are satisfactory and that the alternator can provide the voltage necessary for proper operation of the inverter Readings should be as follows Ground GREEN post to Battery BLACK post 12 12 8VDC Ground GREEN post to Alternator RED post Up to 100VDC Ground GREEN post to F Out BLUE post 12 12 8VDC Ground GREEN post to Ignition ORANGE post 12 12 8VDC Ground GREEN post to Accessory BROWN post 12 12 8VDC NOTE Failure to obtain the specified reading is an indication of improper wiring or a defective alternator If voltage is above 15VDC at idle but does not increase to 100VDC at higher engine speeds the alternator is defective usually caused by open or shorted diodes The remedy is to replace the faulty alternator diode s Most alternators have six diodes three with forward polarity and three with reverse polarity It is best to replace a complete set of three diodes when replacing Use 200 PIV diodes available from an auto el
314. im 015 2 7605 201 1 Knuckle Steering Assembly R H Ross Gear 14 Seal Steering Knuckle Lower Assembly 2 7605 2004 Knuckle Steering Assembly R H Spicer 15 Thrust Bearing 2 Gear 16 Cotter Pin 4 30 7605 2005 Ball Steering Arm 1 3 4 Dia 17 7605 1997 Axle Center 1 7605 2006 Knuckle Pin Kit Items 5 6 8 9 10 11 12 13 18 Key Steering Knuckle DR Upper 2 14 15 18 26 NOTE Your chassis Vehicle Identification Number V I N or Serial Number on order chassis must be supplied when ordering replacement parts Section Il FRONT AXLE 6 Rockwell Field Maintenance Manual No 2 Non Driving Front Axles All Models Conventional and Sealed Knuckle Pins TUBULAR AXLE BASIC CAPACITY LETTER BRAKE TYPE C 7000 Ibs DESIGN VARIATION Refer to D 9000 lbs If letter appears Technical Aid F 12 000 13 200 Ibs here it indicates a Section 6 G 14 300 14 600 Ibs Aid 59 L 16 000 20 000 Ibs U 29 000 Ibs major design change Aluminum Beam BASIC SERIES SPECIFICATION NUMBER 931 1 MAJOR NUMBER DESIGN VARIATION VARIATION 0 Tapered knuckle pin 1 Straight sealed knuckle pin 1 Straight knuckle pin and new tie rod assembly 2 Special spindle and wheel ends 2 Sealed knuckle pin construction 3 5 drop from spindle inter 3 Larger centers and knuckles section to pad 4 Easy Stee
315. ine applications and can be engaged into the turbine spline gear before the turbine gear has coasted to a stop DIVISION OF GENERAL MOTORS CORPORATION ANDERSON INDIANA 1M 153 Service Bulletin CRANKING MOTORS Figure 2 Cross sectional view of motor with DR 250 heavy duty drive 50 MT Some model use heavy duty sprag clutch illustrated in Figures 14 and 15 MAINTENANCE Under normal operating conditions no maintenance will be required between engine overhaul periods At time of engine overhaul motors should be disassembled inspected cleaned and tested as described succeeding paragraphs ADJUSTABLE NOSE HOUSING Two methods are employed to attach the nose housing to the lever housing As shown in the cross sectional views Figure 2j Figure and Figure 4 one method attaches the nose housing to the lever housing by means of bolts located around the outside of the housing To relocate the housing it is only necessary to remove the bolts rotate the housing to the desired position and reinstall the bolts The bolts should be torqued to 13 17 lb ft during reassembly In this type of assembly the lever housing and the commutator end frame are attached to the field frame independently by bolts entering threaded holes in the field frame In the second method where the intermediate duty clutch is used the lever housing and commutator end frame are held to the field frame by thru bolts ex
316. ined largely upon the type of machinery being used type of operation and severity of service The lubricant change interval could be for example one day maximum or three months maximum This can be determined by initially scheduling daily or weekly inspections of the universal joints shaft and slip yoke parts Check seals bearings splines etc and check condition of grease or for lack of grease Also check to make sure that grease purges from all four bearing and seal positions of the cross LUBE PROCEDURES Universal Joints 1 2 3 4 Check for looseness Apply grease until new grease purges from all seals If grease does not purge at seals manipulate the U joint until purging occurs If above is not successful remove cup or joint and check old grease If grease appears rusty gritty or burnt replace the complete universal joint e Slip yokes and splines 1 2 Check for looseness or sideplay Apply grease until purging takes place at air hole in end of slip yoke 10 STEERING SHAFT UNIVERSAL JOINTS GREASE STEERING SHAFT UNIVERSAL JOINT 24 LUBRICATION LUBRICANTS Standard 0 617 A Optional 0 617 B Refer to Recommended Lubricants on pages 6 and 7 LUBE INTERVALS Every 30 000 miles 48 000 km if yearly mileage is over 30 000 miles otherwise twice yearl LUBRICANT CAPACITIES OF ROCKWELL COMPONENTS Lubricant capacities are given as a guide only All measurements are taken still fill
317. ing The components of the piston and actuating valve assembly can now be cleaned and inspected The reversing springs and the relief system parts are the only replaceable parts in the piston The reversing springs should be flat Bent or dished springs are an indication of severe impact damages and all components of the steering gear should be inspected for damages Page 28 SHEPPARD POWER STEERING SERVICE MANUAL Carefully reassemble the piston Place two reversing springs on the center of the adjusting nut in the piston Put a new O ring seal on the valve positioning pin and screw the pin into the piston until the top of the pin is below the surface of the piston Reinstall the actuating valve in the piston with the long locating slot in line with the valve positioning pin Turn the valve positioning pin until it lines up with the slot of the valve and the valve slides into the reversing springs Note Some Short Series 3 and 4 pistons also use a tapered valve positioning pin which is adjustable These pistons can be identified by the piston plug which uses seal rings These pistons will also have a control valve with a maximum inch and three quarters diameter Place the two reversing springs on the nose of the valve Screw the adjusting nut into the piston until the nut contacts the reversing springs and the valve has no end play Now turn the adjusting nut to line up your reference marks and the locking pin will enter the origina
318. ing 5 9 Using a 3 8 wrench hold the lock nut 16 on the threaded end of the stem 17 in the primary piston 2 Insert a screwdriver in the exhaust passage through the center of the valve and engage the slotted head of the stem 10 Remove lock nut 16 spring seat 18 stem spring 19 primary piston 2 and primary piston return spring 6 Remove 0 ring 34 11 Remove adapter 1 Remove 0 ring 4 from adapter CAUTION Before proceeding with the disassembly refer to Figure 4 and note that the lock nut and stem are used to contain the No 1 piston return spring stem spring and the relay piston spring The combined force of these springs is approximately 50 pounds and care must be taken when removing the lock nut as the spring forces will be released It is recommended that the primary piston and relay piston be manually or mechanically contained while the nut and stem are being removed E 6 VALVE ONLY 12 Using a screwdriver to restrain the stem as in step nine remove the lock nut 16 spring seat 18 and stem spring 19 13 Remove the relay piston 20 relay piston spring 21 primary piston and primary piston return spring 23 from the upper body Use care so as not to nick seats NOTE Certain E 6 valves do not have a relay piston spring 21 If none is found none should be replaced 14 Onvalves manufactured after October 7 1976 a small washer 24 will be found in the cavity in the lower side of th
319. ing Figure 4 3 10A on the following page gives the proper Ohm Meter readings Copyright 1981 DYNAMOTE CORP METER METER Section XI TROUBLESHOOTING AND SERVICE POLARITY METER NOTE 1 SURE STUD OF DIODE IS REMOVED BEFORE TESTING DIODE 2 REVERSE POLARITY DIODES WILL HAVE AN R IN THEIR NUMBER R3720 OR IN1184R ALSO ALL DIODES MOUNTED A DYNAMOTE CHASSIS WILL BE REVERSE POLARITY DIODE EXCEPT THE PIONEER 205 Figure 4 3 10 DIODE CHECKOUT PROCEDURE AND READINGS Section XI F2144D TROUBLESHOOTING AND SERVICE 11 82 4 3 11 ALTERNATOR DIODE TEST PROCEDURE FOR THIS TEST DO NOT PUSH OR RELEASE START SWITCH WHEN ENGINE IS ABOVE IDLE Tools Required Voltmeter with 0 100 VDC scale 1 Remove the commutation fuses from the inverter front panel 2 Start the engine and run at approximately 1500 RPM 3 Check the voltage from the POSITIVE terminal on the alternator to GROUND With the START button depressed the voltage should read 80 to 110VDC If not the alternator diodes bad and should be replaced This should be done by an alternator repair shop NOTE If Step 3 is difficult because of the distance from the alternator to the inverter the alternator voltage can be read from the A terminal inside the rear of the inverter 4 3 12 VEHICLE VOLTAGE REGULATOR PCB3 CHECKOUT PROCEDURE Tools Required Voltmeter with 0 15VDC scale screwdriver 1 Remove the Vehicle Voltage R
320. ing and spring seat and the QR 1 valve which in its standard configuration does not employ a spring or spring seat Figure 1 BRAKE CHAMBER I meam M MH me imme Tet QR 1 VALVE BRAKE VALVE EXHAUST PORT QR 1 VALVE Note AH 1 Valves with a pressure differential employ a spring and spring seat Porting consists of one 1 brake valve port two 2 delivery ports and one 1 exhaust port OPERATION When a brake application is made air pressure enters the brake valve port the diaphragm moves down sealing the exhaust At the same time air pressure forces the edges of the diaphragm down and air flows out the delivery port When air pressure being delivered beneath the diaphragm equals the pressure being delivered by the brake valve above the diaphragm the outer edge of the diaphragm will seal against the body seat The exhaust port is still sealed by the center portion of the diaphragm when the brake valve application is released the air pressure above the diaphragm is released back through the brake valve exhaust air pressure beneath the diaphragm forces the diaphragm to rise opening the exhaust allowing air in the chambers to exhaust PREVENTIVE MAINTENANCE Every 12 months 100 000 miles or 3600 operating hours disassemble valve wash metal parts in mineral spirits wipe rubber parts dry It is recommended that all rubber parts be replaced Inspect all parts and replace any
321. installed the initial adjustment should be carefully 10 CARE AND MAINTENANCE THE CAM MASTER T SERIES BRAKES The I series brake is an air actuated two shoe brake each shoe employing a one piece liner of uniform thickness These brakes are either unit mounted with all component parts assembled on a backing plate or spider or have inboard cam supports where operation warrants locating the air chambers toward the axle centers Some sizes of T brakes employ fabricated shoes with hardened steel cam roller followers while other sizes employ either heat treated malleable cast shoes with hardened cam follower wear pads or cam roller followers Anchor pins of two different designs are used in various sizes of T series brakes Some sizes use eccentric pins while others use fixed anchor pins The T series brakes are re equipped with Rockwell enclosed adjustable levers when shoe liner thickness does not exceed 7 16 The Rockwell enclosed adjustable lever on these will permit the maximum liner wear T series brakes with thicker liners up to and 2 1 2 are with slack adjusters BRAKE LAYOUT BRACKET BOLT LARGE SMALL BOLT NUT SMALL BOLT LOCK WASHER BRACKET BOLT SMALL AIR CHAMBER LARGE BOLT SHAKE MOUNTING BRACKET PROOF WASHER LARGE BOLT LOCK WASHER LARGE BOLT NUT CAM SPACING WASHER ENCLOSED ADJUSTABLE LEVER AIR CHAMBER CLEVIS PIN STUD NUT LOCK WA
322. ips screws and lockwashers Tighten to 20 30 inch pounds torque 5 Install exhaust diaphragm 6 into the exhaust cover 6 Place inlet exhaust valve 12 in the body Install the valve spring 11 and valve stop 10 7 Install o ring 9 on cap nut and install cap nut 8 in body Tighten to 100 125 inch pounds torque 8 Install the small and large o rings 16 on the small diameter piston 15 and install piston in the body 9 Install large o ring 18 and small o ring 19 on the large diameter piston and install piston in the body 10 Install the piston springs 14 in their respective pistons 11 Secure the cover to body using four 1 4 20 phillips head screws and lockwashers Tighten to 50 80 inch pounds torque TESTING THE REBUILT SR 1 SPRING BRAKE VALVE Test the rebuilt SR 1 Spring Brake Valve by performing the operation and leakage test outlined in the Service Checks section of this manual IMPORTANT PLEASE READ When working on or around brake systems and componenis the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended pressure and alway
323. irst 5 With the inverter START button depressed check the voltage from the BLUE wire on the voltage regulator circuit board to ground Voltage should read 10 volts or more there is no voltage the voltage regulator has failed in the open position and should be replaced 6 If voltage at the BLUE wire is 10 volts or more depress the inverter START button again and check the voltage from the F OUT terminal inside the rear of the inverter to GROUND If the voltage at this terminal is not the same as the voltage at the BLUE wire on the voltage regulator then the K2 Relay is faulty and should be replaced Copyright 1981 DYNAMOTE CORP 2140 section XI 12 81 4 3 8 4 3 9 ANODE TROUBLESHOOTING AND SERVICE OSCILLATOR CIRCUIT BOARD CHECKOUT PROCEDURE Tools Required Voltmeter with 0 15VDC scale 7 16 socket wrench or open end wrench screwdriver 1 Open inverter by removing the front and top panel fasteners Carefully lay the front panel down on its face and remove the top panel 2 The engine and ignition should be OFF for this test 3 Locate the SCR gate leads These are the small white leads to the SCRs which have a plastic connector in the lead Separate this lead by disconnecting the plastic connector 4 With the START button depressed read the voltage to GROUND from each gate lead connector on the part of the gate lead which is connected to the Oscillator Circuit Board The voltage should be between 2VDC and
324. ish CLEARANCE 010 070 Figure 27 Checking pinion clearance on spline drive motor Before pressing the bearing into place dip it in SAE No 20 Also tangent wicks if present should be soaked with SAE No 20 oil Insert the wick into place first and then press in the bearing DO DRILL REAM or MACHINE sintered bearings in any way These bearings are supplied to size f drilled or reamed the I D inside diameter will be too large also the bearing pores will be sealed over It is not necessary to cross drill a sintered bearing when used with a tan gent wick Because the bearing is so highly porous oil from the wick touching the outside bearing surface will bleed through and lubricate the shaft Page 11 CRANKING MOTORS Service Bulletin 1M 153 Middle bearings are support bearings and prevent armature deflection during cranking As compared to end frame bearings the clearance between middle bearing and shaft is large and the clearance provides a loose fit when assembled PINION CLEARANCE There are no provisions for adjusting pinion clearance motors using the intermediate duty clutch Fig 5 However all types should be checked after reassembly to make sure the clearance is within specifications In correct clearance where not adjustable indicates excessive wear and worn parts should be replaced To check pinion or drive clearance follow the steps listed below 1 Mak
325. itel n CGU EET SEED HOOD BRACKET Short stem up type 12 gauge zinc plated steel HRC No 028 112 P Use with all hooks ANCHOR BOLTS 4 NF x 2 HH Cad PI Bolt W Selt Locking Nut Use with HRC E 2 ihre ANCHOR BOLTS V4 NOx 1V2 HH 1 Cad PI Bolt 12 W Selt Locking Nut Use with HRC 2 Nos 680842 Nos 67D794 HOOD 68D842 1101 i S and 101376 DET d and 680638 Stem up type 12 gauge zinc plated steel HRC No 028 561 Use with all hook 45 ANCHOR BRACKET 14 gauge zinc plated steel HRC No 277 A B0 1 Use with HRC Nos 670794 Fade 67D794 1101 and 71D1376 1 3 HOOD 16 I 14 BRACKET 37 Dia Stem down type 12 gauge zinc 7 plated steel 155 2 HRC No 28 A 382 5 Use with ali hooks 3 3 2 15 Dia 32 Dia 1 HOOD BRACKET Stem down type with slot Zinc plated 12 steel HRC No 28A400 Use with all hooks HOOD BRACKET Stem flat type 12 gauge zinc plated steel HRC No 028 562 Use with all hooks HOOD BRACKET Stem up special length type 12 gauge zinc plated steel HRC 028 750 Use with all hooks RUBBER CORP 570 PO ANCHOR BRACKET 11 gauge zinc plate l HRC No 277 A 80 Use with HRG Nos 68D842 68D842 1101 and 66D638 50 1 50 4 9897 ANCHOR BRACKET Chrome plated steel HRC No 277 A 80 2 Use with HRC Nos 68D84
326. ith a new journal cross or new needle bearings used with a worn journal cross will wear more rapidly making another replacement necessary in a short time always replace the journal cross and four needle bearings caps as a unit journals and bearings a Journal and Bearing Kit is available The use of the Kit insures having the correct individual parts when required and saves valuable time TYPICAL FAILURES LACK OF LUBRICATION FIGURE 21 BRINNELLING FIGURE 23 MADE FIGURE 22 SLIP SPLINE GALLING Tb E a E ata ri af rii hr n 1 7 na y U Eu FIGURE 24 REBUILDING DRIVESHAFTS BALANCING The rebuilding of a drive shaft assembly usually consists of replacing worn journal cross and bearings with a new kit These kits replace the part of a drive shaft most subject to wear in operation The slight off center condition present in the journal cross assemblies makes it desirable to balance the assembly after installing new journal and bearing kits Generally unbalance resulting after installation of a journal and bearing kit is equivalent to the unbalance existing after straightening the shaft If balancing cannot be done it is advisable to check assembly for smooth operation in vehicle before it is put into operation It is sometimes necessary to revise drive shaft lengths when rebuilding a vehicle This job requires
327. justers contain four basic components the body worm gear and adjusting screw The adjusting screw is provided to adjust the slack caused by the wear of the brake lining All Slack Adjusters utilize the worm and gear principle and fundamentally differ only torque limit specifications A type 20 slack adjuster has a limit of 20 000 inch pounds torque a type 30 slack adjuster has a limit of 20 000 inch pounds torque etc Slack Adjusters are manufactured with various arm lengths and in various configurations straight offset etc to satisfy various installation requirements Splines are available in several different types and sizes OPERATION When the brakes are applied air pressure forces the air chamber diaphragm and push rod to move this rotates the slack adjuster which in turn rotates the cam shaft This causes the S cam to spread the brake shoes which contact the brake drum When the brakes are released air pressure is exhausted from the air chamber The chamber return spring and the brake shoe return springs return the brake cam cam shaft slack adjuster and chamber push rod to the released position Section VI BRAKE SYSTEM Service Data MANUAL SLACK ADJUSTERS WORM GEAR ADJUSTING GEAR ADJUSTING SCREW MORM SHAFT SPLINE BALL INDENT TYPE SLACK ADJUSTER Figure 2 ADJUSTING MECHANISM The adjusting mechanism of a Slack Adjuster consists of an adjusting screw worm shaft worm and slac
328. k adjuster worm gear Turning the adjusting screw nut on the end of the worm shaft rotates the worm shaft and worm The worm meshes with and rotates the slack adjuster worm gear which is connected to the brake cam by a splined cam shaft The turning of the slack adjuster worm gear rotates the cam shaft and brake cam spreading the brake shoes compensating for brake lining wear There are two types of adjusting mechanisms used on Bendix Slack Adjusters currently manufactured The light to medium torque rated slack adjuster Fig 1 use a positive lock mechanism consisting of a spring loaded lock sleeve which when positioned properly engages the adjusting screw nut preventing the adjusting screw worm shaft from rotating The heavier torque rated slack adjusters Fig 2 utilize the lock ball or plunger and worm shaft indent principle adjust ment lock The lock ball or plunger must engage the indent on the worm shaft after the adjustment is completed An audible metallic click can be heard when engagement is made BRAKE ADJUSTMENT Using the Positive Lock Slack Adjuster Mechanism Wipe the adjusting screw nut and locking sleeve area clean Position wrench or socket over the adjusting screw and disengage the locking sleeve by depressing the lock sleeve Make the necessary adjustment by turning the adjusting screw with the locking sleeve depressed When adjustment is completed the adjusting screw nut should be positioned so the esa
329. k supply pump following Hydraulic Supply Diagnosis Adjust relief plungers see final adjustments Follow Hydraulic Supply Diagnosis procedures Repair pump Repair accessory drive Symptom Lubricating Oil discolored or smells bad High Operating Temperatures Oil in Reservoir Foaming No power steering on cold start Excessive pump pressure with steering gear in neutral position Wheel cuts restricted Erratic steering or no steering at all Check supply system as detailed in Hydraulic Supply Diagnosis section Possible cause Operating temperatures too high Change intervals too long Incorrect lubricant used Oil flow restriction Oil flow too high Air leak in suction side of supply pump Pump cavitating Oil overheating Incorrect lubricant Hydraulic supply pump vanes not extending Vane type pump only Pinched oil return line High back pressure Binding steering column Damaged actuating shaft bearing Relief plungers misadjusted Insufficient volume of oil being metered by flow divider to steering gear induced by foreign particles on flow divider valve causing Flow divider spring takes permanent set because of fatigue thereby allowing flow divider valve to move easily and reduce oil volume Broken by pass spring in flow divider Sticking pressure relief valve Page 12 SHEPPARD POWER STEERING SERVICE MANUAL Remedy Check and correct cause of overheating Increase oil change fr
330. king rings H Install anchor pin locking screws and lock wire C Cut lock wire anchor remove anchor pin lock Screws D Remove anchor pins and shoe assemblies E Remove air chamber mounting stud nuts and Connect brake shoe return springs lock washers ADJUSTMENT F Remove air chamber clevis pin cotter key Follow adjustment procedure as outlined under P clevis pin and air chamber Brake section located on bottom of page 14 G Remove cam end lock ring and flat washer H Remove slack adjuster lever l Remove cam by tapping out from rear 18 CARE AND MAINTENANCE DLM DUPLEX LEVER MECHANICAL BRAKES The DLM brake is a two shoe mechanical brake designed for use as either a control or parking brake Equal pressure is applied to both shoes through lever actuation in either forward or reverse rotation DLM brake shoes and springs are interchangeable Brake is fully enclosed to exclude dirt or foreign matter DLM BRAKE LAYOUT BRAKE SHOE RETURN SPRING BRAKE SHOE AND LINER ASSEMBLY ROLLER C Lift out brake shoe lever ASSEMBLY A Install brake lever over opposite pawl pin and position so that lever arm lies in backing plate depression B Install roller on remaining pawl C Install brake shoes D Connect brake shoe return springs in slots BRAKE ACTUATING LEVER nearest backing plate SOS ACTUATING PAWL RIVET i ACTUATING Note On smaller size DLM br
331. l 1 Delrin bushings require no tools for removal Bronze and Easy Steer bushings require a 5ton press and a simple tool See assembly section for details Fixture the knuckle rigidly with the king pin hole vertical Press the bushings out slowly with frequent stops to check alignment of CAUTION Do not strike these hardened steel pieces the Lh with us TI press directly with a steel hammer Personal injury from ram face chips or splinters may result Figure 10 PREPARATION FOR ASSEMBLY RECONDITIONING OF COMPONENTS Repair or reconditioning of any front axle components is not allowed Rockwell strongly recommends replacement of any component which is damaged or out of specification All of the major components are heat treated and tempered and cannot be bent welded heated or repaired in any fashion without experiencing a strength or fatigue life reduction This is a partial list of operations strictly prohibited on front axle components For further items or explanation contact your local Rockwell Technical Representative 1 Welding of or to steering arms tie rod arms steering knuckles king pins axle centers tie rod assemblies hubs drums or brakes 2 Hot or cold bending of spindles steering arms tie rod arms bull studs axle centers or tie rod assemblies for any reason 3 Redrilling and bushing of axle center king pin holes 4 Redrilling of draw key holes 5 Spray welding of bearing
332. l features e Compliance with Federal Motor Vehicle Safety Standard No 206 e Split tumbler for full control of locking and un locking from inside or outside e Remote control capabilities Recessed handles available for remote control e Automatic kickout of inside thumb locking when door is slammed to prevent accidental lock outs e Outside locking or unlocking with provision for pillar locking cylinder Feast Recessed handles fo remote contro of lock No 206 above SUPRA pM eStriker can be made to accommodate post design custom made with rod FD e Lock can be mounted on surface of door panel or or cable n contained between outer and inner skins of door eFully enclosed mechanism No 249 non locking S The Eberhard 206 Safety Siam Lock has been e designed and built to bring automotive safety standards to Truck cabs and passenger compartments Agricultural equipment e Construction equipment Motor homes No 250 key locking LIMIT E D 1 FAUCHER amp FILS INDUSTRIES 1964 MONTR AL TORONTO EDMONTON VANCOUVER No 55 LOCK left hand shown Inside handle No mortising required Built in pull handle integral with lock bushing Die formed steel bushing 17 striker bolt Size 3 3 8 high 2 wide 3 1 4 handle Weight 5 8 Ib 283 5 grams Both left and right hand models Available with reverse bolt when specified Also specif
333. l gear upward NOTE Current carrier designs employ only the thrust screw which may replace the thrust screw and block assembly B Remove adjusting screw and lock nut do C If a thrust block is employed place thrust block on rear face of hypoid gear and rotate gear until the hole in the thrust block is aligned with the adjusting screw hole CARE AND MAINTENANCE D Install thrust screw and lock nut and tighten thrust screw sufficient to locate thrust block firmly against back face of hypoid gear E To secure the correct adjustment of 010 015 clearance loosen adjusting screw or thrust screw 1 4 turn and lock securely with nut F Recheck to assure minimum clearance of 010 during full rotation of bevel gear CLEAN AND INSPECT HOUSING INSTALL DRIVE UNIT A Remove any accumulation of dirt grit or gum from housing bowl and sleeves Clean housing thoroughly with solvent and blow dry with compressed air B Inspect housing for cracks loose studs nicks and burrs at machined surfaces Remove nicks and burrs with stone or file Make all necessary repairs or parts replacement before installing drive unit in housing C Install new drive unit to housing gasket over housing studs Roll carrier into position on roller jack Start carrier into housing with four flat washers and nuts equally spaced Do not drive carrier into housing with a hammer at the carrier stud flange flange may easily be dis
334. l pin holes If the lock pin will not enter the original holes a second hole is provided and the adjusting nut can be drilled and the pin installed in this position The tip of the pin must be below the surface of the piston Install a new O Ring expander and a new square ring seal on the piston plug and install the plug in the piston Tighten plug securely Drill and pin the plug to the piston The tip of the pin must be below the surface of the piston Reinstall the relief valve seats balls and springs SHEPPARD POWER STEERING SERVICE MANUAL The valve positioning pin which locates and guides the actuating valve in the piston of the Series 5 gear is tapered This tapered valve positioning pin must be adjusted when the piston is reassembled Install a new O Ring Seal on the valve positioning pin and screw it into the piston until it is flush with the surface of the piston Make reference marks with a pencil on the piston and the pin and then install the actuating valve in the piston lining up the long guide slot in the valve with the guide pin When the valve positioning pin has entered the valve and the valve has bottomed check the valve for radial movement and freedom of movement over the valve positioning pin The valve positioning pin is adjusted 1 4 turn at a time until the valve has no radial movement and slides smoothly over the valve positioning pin Each time the valve positioning pin is adjusted the actuating valve wi
335. lacement parts Ot 2 VN NONNPMHIWHI NWARANAWOAPHNWWHRH NAD Section BREAK SYSTEM Hear Breaks 16 l ex 7 Series All Models Item Part No CONN MN BW NY NOR so WO 14 15 16 7605 5665 7605 2688 7605 2689 7605 5666 Description Break Shoe amp Living Assembly Washer Capscrew Dust Shield Inspection Plug Capscrew Washer Spacing Locking Camshaft Washer Spacing Slack Adjusting Seal Camshaft Brushing Camshaft Break Chamber Bracket L H Break Chamber Bracket R H Grease Fitting Gasket Chamber Bracket Break Spider R ee 4 24 25 26 27 28 20 30 3 Part No 7605 5667 7605 5668 7605 5669 Description Retainer Shoe Roller Roller Break Shoe Pin Break Shoe Return Spring O Ring Seal Camshaft Washer Camshaft Camshaft R H Camshaft L H Lock Ring Anchor Pin Retainer Anchor Pin Felt Felt Anchor Pin Brushing Anchor Pin Anchor Pin Break Shoe Return Spring Break Shoe Set Screw Anchor Pin Major Show Overhaul Kit Incl Items 1 18 24 30 NOTE Your chassis Vehicle Identification Number V I N or Serial Number on order chassis must be supplied when ordering replacement parts Qty Ne NNA HBR RRR NN WL Heavy Vehicle Systems Group Section VI BRAKE SYSTEM Service Data Formerly SD 5 RESERVOIRS Pom M gina oneri ree
336. le The shim alignment can only be done through the upper bushing Any protrusion of any portion of the shim will prevent the king pin from passing through and result in a damaged shim NOTE Shims are delicate and sharp Extreme caution should be exercised while aligning shims so as not to cut fingers or bend the Inside diameter of the shims Damage to the shims during this entire procedure requires disassembly and replacement of the damaged parts KING PIN INSTALLATION Straight King Pins A Smear clear chassis grease on the bottom half of the king pin and insert it slowly into the top of the knuckle King pins are marked with the Rockwell logo part number and the word top on the top end of the pin Rotate the pin to align the drawkey slots with the drawkey holes in the axle Slowly push the pin through the bushing seal and shim pack The pin should slide through the shim pack freely Any resistance greater than a hand push indicates misalignment Remove the pin and realign the components After the pin is inserted through the shim pack a brass hammer may be used to assist in installation Care must be taken not to dislodge the lower grease seal as the king pin enters the lower knuckle yoke Center the king pin in the knuckle to equalize the distance frm the top and bottom surfaces For knuckles with a bottom welsh plug arrangement increase the bottom gap to allow for assembly of the welsh plug and snap ring Lightly tap the
337. led hole in the miter housing This ensures that the miter housing is placed in its optimum position The locating pin will also keep the housing from turning in service During reassembly make sure that the locating pin is properly installed Caution Retorque the actuating shaft nut to proper specifications as it may have loosened during the adjustment procedures Torque the nut to 50 Ib ft F eT T 5 A Lx E 51 SHEPPARD POWER STEERING SERVICE MANUAL DUAL STEERING SYSTEMS Two integral steering gear units are sometimes used where high front axle loads or installation space limitations are encountered The secondary gear assembly differs from the master steering gear in that it does not have an actuating shaft nor does the piston have an actuating valve Both gears are connected to the steering linkage drag links pitman arms and rack and pinion gears Pressure to operate the secondary or slave gear is passed through ports in the cylinder head and bearing cap of the master gear and is routed through high pressure lines to the proper end of the slave gear Thus as the actuating valve of the master gear is moved to cause pressure build up on the piston of the master gear pressure is also directed to the slave gear piston Fig illustrates a typical dual steering gear layout Fig 2 illustrates a typical master gear and slave gear used in dual steering gear installatio
338. level surface add the appropriate amount of drive unit lubrication back into the carrier or housing bowl to bring the oil up to the proper level approximately two pints 0 946 liters eTrailer Axle Hubs Fill the hub with oil to the bottom edge of the plug hole in cap 5 TRANSFER CASES 4 gt A lt t TRANSFER CASE 4 SHAFT DESIGN LUBRICANTS Standard 0 62 or 0 63 Optional 0 76 Series Refer to Recommended Lubricants orl pages 6 and 7 LUBE INTERVALS Check every 1000 miles 1600 km Drain and fill every 12 000 to 25 000 miles 19 000 to 40 000 km 14 LUBRICATION LUBE PROCEDURES Pour recommended amount of lubricant less two pints through filler hole Add one pint of oil each to the power take off and de clutch assemblies if used If transfer case is not mounted under vehicle do not fill unit to specified level until after installation 6 BRAKES e STOPMASTER WEDGE BRAKES AND CHAMBERS On Highway and Off Highway M p MT D 7 A 5 4 e NS zz rH t y ERU Uy v PZL STOPMASTER WEDGE BRAKE AND AIR CHAMBER LUBRICANTS Standard 0 616 A A high temperature water proof grease NLGI Grade No 1 is recommended for lubricating the brake actuation system It should be a smooth textured corrosion resistant grease free of fillers and abrasives It should maintain a satisfactory
339. lex and be free from excessive bind A slight drag is the most desirable condition on a new universal joint This drag is from the bearing seals When rotating yoke lug deflections cause some additional clearance Excessive looseness is not desirable due to the resulting unbalance 4 Mounting flanges and pilots should be free from burrs paint and foreign substances which would not allow proper seating at assembly The drive shaft is mounted using flange bolts bearing cap screws or U bolts depending upon the size and construction These bolts must carry high torque loads and should be of quality material and properly torqued The following reviews requirements on these bolts 1 Flange Bolts Flange Bolts should be alloy steel equivalent to SAE Grade 8 high strength bolts These bolts used with spring lock washers and nuts provide the capacity required The nuts should be torqued to the following specifications 14 5 16 24 Thread 22 to 24 lbs ft 3 8 24 Thread 40 to 44 lbs ft 7 16 20 Thread 63 to 70 Ibs ft 1 2 20 Thread 98 to 108 lbs ft NOTE In cap and bolt construction joints Fig 7 be sure to torque the cap screws to 100 Ibs ft These joints are usually the Spicer 1650 Series interaxle assemblies 2 U Bolt Style Yokes On smaller size universal joints a U bolt style end yoke is used This construction permits easier assembly where the smaller size bearings allow its use The bearing race is seated in a
340. liter 10 centiliters 3 38 fl ounces 1 liter 10 deciliters 33 81 fl ounces 1 dekaliter 10 liters 2 64 gallons 1 hectoliter 10 dekaliters 26 42 gallons 1 kiloliter 10 hectoliters 264 18 gallons Square Measure 1 sq centimeter 100 sq millimeters 155 sq inch 1 sq decimeter 100 sq centimeters 15 5 sq inches 1 sq meter centare 100 sq decimeters 10 76 sq feet 1 sq dekameter are 100 sq meters 1 076 4 sq feet 1 sq hectometer hectare 100 sq dekameters 2 47 acres 1 sq kilometer 100 sq hectometers 386 sq mile Cubic Measure 1 cu centimeter 1000 cu millimeters 06 cu inch 1 cu decimeter 1000 cu centimeters 61 02 cu inches 1 cu meter 1000 cu decimeters 35 31 cu feet Multiply by To change To Multiply by 2 540 ounce inches Newton meters 007062 305 centimeters inches 394 914 meters feet 3 280 1 609 meters yards 1 094 6 451 kilometers miles 621 093 square centimeters square inches 155 836 square meters square feet 10 764 2 590 square meters square yards 1 196 405 square kilometers square miles 386 028 square hectometers acres 2 471 765 cubic meters cubic feet 35 315 29 573 cubic meters cubic yards 1 308 473 milliliters fluid ounces 034 946 liters pints 2 113 3 785 liters quarts 1 057 28 349 liters gallons 264 454 grams ounces 035 907 kilograms pounds 2 205 1 356 metric tons short tons 1 102 11296 Temperature Exact 5 9 after Ce
341. ll have to be pulled out of the piston far enough to disengage the valve positioning pin When the valve positioning pin is properly adjusted complete assembly of the piston as previously detailed for Series 5 Steering Gears VARIATION SERIES 5 PISTONS 5 53 30 31 SHEPPARD POWER STEERING SERVICE MANUAL VARIATIONS EARLY PRODUCTION PISTONS Note Variations Very early production steering gears may be fitted with piston rings They can be removed and discarded as they are no longer required 372 382 series steering gears with the step bore housing and piston flange will continue to use the piston ring The piston bottom plug should not be removed except in cases of severe oil contamination and for cleaning On reinstallation the plug must be pinned Pipe sealer should be used sparingly on the threads of the plug Mark the top adjustment nut and piston so that the nut can be reinstalled in its original position Caution Misadjustment of the top adjustment nut could cause erratic steering Carefully remove the pin locking the adjustment nut to the piston assembly SHEPPARD POWER STEERING SERVICE MANUAL Using a spanner wrench remove the top adjusting nut from the piston Note bottom adjustment nut inside piston should never be removed Remove the top reversing spring from the nose of the actuating valve Pull the actuating valve from the piston Do not force
342. ll eliminate costly and avoidable front end difficulties A Inspect the steering knuckles king pins steering arms and tie rod arms and replace if indications of weakness cracks or excessive wear is found Cracks can be located by die check magnetic particle or fluorescent particle inspection performed by a qualified technician Check spindle bearing diameters for size and condition Replace spindle if bearing diameters are under specification discolored from heat or severely scored If tie rod arm or steering arm has been removed inspect tapers for fretting pits If the tapered hole in the knuckle is fretted and pitted replace both the knuckle and the arm If only the arm taper is fretted replace only the arm If the king pin has worn through the bushing and into the knuckle replace the knuckle E Check the tightness of the steering connections such as cross tube arms steering arm etc F For units with sealed knuckle pins check knuckle pin seal for rips tears and excessive wear Do not remove the seals from the steering knuckle unless replacement is necessary or the knuckle is to be rebushed G Remove the thrust bearing seal from the thrust bearing case and inspect the seal for wear rips and tears On aluminum axles with integral seals do not remove seal H Check thrust bearing 1 Check knuckle bushings for wear flaking or scoring Compare diameter with correct specification if the bushing diameter
343. lled 1 16 Oversize 1 307 Flat Head Cam Only 1 16 oversize rollers are to be used when original standard liners are not worn enough for change but are used with worn or trued drums 1 16 oversize 1 8 Oversize 1 375 1 8 oversize rollers are to be used with the installation of standard liners with worn or trued drums which are 1 32 oversize 1 8 oversize rollers should be installed and the liners circle ground a few thousandths less than drum diameter 1 4 Oversize 1 500 Where X liners have been installed with 1 16 oversize drums and standard rollers these rollers should be removed and 74 oversize installed before the lining becomes worn to a point where the brake cam is no longer effective with the standard rollers 1 2 Oversize 1 750 Where XX liners and 1 8 oversize drums have been used the standard rollers should be removed when the liners become approximately 50 worn and 1 2 oversize rollers installed CARE AND MAINTENANCE CAM PLATE SHIMS When standard liners are installed with worn or trued drums or X or XX liners have been installed and are approximately 5096 worn shims or a combination of shims should be installed under each of the cam wear plates to permit the cam to be returned to the full release position Thickness Part Number 1 64 015625 2203 P 432 1 32 03125 2203 Q 433 1 16 0625 2203 R 434 PREVENTIVE MAINTENANCE A schedule for the periodic adjustment
344. lsius C subtracting 32 temperature PIN 060752 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
345. lus 30 2 21 21 4 one holf the stroke listed in chart 36 2 1 4 2 1 2 2 5 8 50 9 14 CARE AND MAINTENANCE THE CAM MASTER TRAILER AXLE POWER BRAKES The Trailer P series brake is a two shoe brake designed for use with power The shoes are fabricated steel and are mounted on individual anchor pins on either replaceable open spiders or fixed open spiders The air chambers are mounted on brackets that are welded to the beam and inner cam supports are adjustable for cam shaft alignment DISASSEMBLY A Remove shoe return spring B Remove lock ring retainer and felt from anchor pin if employed C Cut lock wire and remove anchor pin lock screw or drive out locking pin D Tap out anchor and remove shoe assembly E Unhook shoe web retainer spring and remove roller cam follower F Remove inner cam end lock ring washer and slack adjuster G Remove washers and felts from cam shaft and spider H Remove nylon bushing from spider only if replacement is necessary l If inner cam end nylon bushing is to be replaced remove bolts and separate adjustable support bracket and remove the bushing 15 Trailer brake shoe anchor pins depending on model may be either the stationary type secured by use of spider set screws or the free rolling type held in place by a locking pin The brakes are actuated by the S type constant lift cams which are forged integrally with the shaft and supported in nyl
346. lves Drain Valves Feecon Foam Systems Hale Pump and Valves Gauges Controls Water Tower Tip Bourdon Tube Relief Unloader Valve Directional Valves Selector Valves Pumps and Motors Solenoid Valves Regulators Oylinders Electrical Controls ix MAINTENANCE MANUAL SECTIONI 1 INTRODUCTION TABULATED DATA 1 1 INTRODUCTION 1 1 1 TM 5 4210 227 248 Organizational Direct Support and General Support Maintenance Manual for the 85 Aerial Ladder Fire Fighting Truck is divided into eight volumes These eight volumes are further subdivided into specific sections consisting of both Government and commercial literature TM 5 4210 227 10 Operator s Manual for the 85 Aerial Ladder Fire Fighting Truck is one separate manual consisting of four separate sections 1 1 2 This volume consists of 11 sections and is arranged as follows Drive Line Front Axle Rear Axle Steering System Fuel System 1 2 3 4 5 6 Brake System 7 Electrical System 8 Miscellaneous 9 General Information 1 1 O Installation Instructions 1 Troubleshooting and Service Drive Lines Models Section Description 1 Flange Transmission 2 Flange Yoke 3 Journal amp Bearing Kit 4 Front Propeller Shaft without Pump Center Bearing 4A Front Propeller Shaft with Pump 5 Flange Yoke 6 Companion Flange Pump Input 7 Companion Flange Pump Output 8 Flange Yoke 9 Rear
347. m m 1 8 N P T 5 15 5 1 MAIN PRESSURE 35 1 05 Kg cm u 1 8 110 240 P S I 7 7 16 8 Kg cm 24 OPENINGS Continued 4460 78T 6P 4 2333m 20 40 6 4 2333 25 f H 78T 6P 4 2333m 20 2 00 50 8mm 5 2 157 48mm Z LUBE TAP 1 8 5 15 P S 35 1 05 Kgicm MAIN PRESSURE 1 8 110 240 P S I 7 7 16 8 Kg cm 5000 SERIES M PRESSURE 1 4 N P T 100 215 P S I 7 14 4 Kg cm ic LUBE TAP 1 4 15 35 5 1 1 05 2 4 Kg cm 8000 SERIES LUBE TAP 3 8 16 60 P S I 1 1 4 2 Kg cm 8 6 7 MAIN PRESSURE 218 44mm 1 4 N P T 140 230 P S I 9 9 15 Kg cm 7 9 300 66mm _ a 2 1 Converter driven P T O Drive Gear 2 Engine driven P T O Drive Gear 25 OPENINGS continued MT 30 42 6 SPEED 3341 3441 57T 6P 4 2333m20 te MAIN PRESSURE 1 8 N P T 90 200 P S I 6 3 14 Kg cm 302 26mm LUBE TAP 3 4 12 20 P S I 1 4 Kg cm 540 4 SPEED LUBE TAP 3 4 RING 50 70 P S I 3 5 4 9 Kg cm T FITTING 378840 4 7 p 119 38mm MAIN PRESSURE 1 8 90 150 P S I 55T 6P 4 2333m 20 6 3 10 5 Kg cm 119 302 26mm MT 640 MT 650 4 amp 5 SPEED 64T 6P 4 2333m20 T FITTING 378880 LUBE TAP Before Nov 1974 s e MAIN PRESSURE USE T FITTING 378880
348. m Steering input not smooth seizing binding Darting wandering oversteering Possible cause Worn universal joint Universal joint not phased properly Low oil flow Pump cavitating Overheating Oil flow too high Air trapped in steering gear Looseness worn front end parts Front end alignment not correct Radial tire sidewall flex SHEPPARD POWER STEERING SERVICE MANUAL Remedy Check and replace as required See paragraph last page this section Idle speed too slow Drive belts slipping Supply pump not to specifications see Hydraulic Supply Diagnosis Correct pump supply Correct cause of overheating Supply pump not to specifications see Hydraulic Supply Diagnosis Bleed system see final adjustments Check and repair as required Align front end Caster Check tire pressure Check for out of line tread Contact tire manufacturer representative Excessive wear or damage in steering gear Check and repair as required Overloading Reduce loads Steering column u joint phasing incorrect See note end of this paragraph Mechanical bind in steering gear Check steering gear mounting for distortion Check for damaged or distorted steering gear components Note Universal Joints Universal joints are designed to operate best when the angle between the drive and driven shafts is a maximum of 20 to 25 degrees Angles greater than this will cause undesirable velocity changes between the two shafts
349. m A 2 Measure push rod movement stroke by manually extending push rod until brake shoes contact drum 3 Refer to chart below If Dim B is greater than allowable stroke indicated in chart below adjust oush rod movement stroke to 3 8 Slack Adj Arm Length Push Rod Movement stroke A Dim in B Dim in 1 1 2 1 1 4 After adjustment check for brake drag b striking the brake drum with a hammer When the brake shoes are away from the drum a ringing sound will be heard A dull sound indicates brake drag and requires readjustment until the drag is eliminated NOTE If the brakes cannot be adjusted per the above chart inspect the foundation brake and drum for worn or damaged components PREVENTIVE MAINTENANCE Every month 8000 miles or 300 hours check push rod travel Stroke should be short as possible without brakes dragging or chamber rod binding Adjust if necessary Every six months 500 000 miles or 1800 operatin hours lubricate slack adjuster with chassis lube N L G I rade 1 or 2 Apply a sufficient amount of grease to completely fill body cavity NOTE some Bendix Slack Adjusters manufactured without a lubrication provision in the body however the slack adjuster may be lubricated through the cover as follows 1 Remove rubber plugs from both covers and discard 2 Determine which side of slack adjuster is accessible for lubrication_and install Washer Pc No 230156 a
350. mped word TOP should NOT be used for bearing installation purposes Refer to the following instructions for proper bearing positioning 17 FRONT AXLES WITH THRUST BEARING SEALS A Before installing the thrust bearing seal assembly on the steering knuckle make certain the seal is assembled to the thrust bearing correctly B Hold thrust bearing with the opening between the bearing cage and the retainer up Then snap the seal securely over the opening Figure 26 BEARING RETAINER Figure 26 FRONT AXLES WITHOUT THRUST BEARING SEALS No sub assembly is required KNUCKLE TO AXLE CENTER ASSEMBLY A Clean knuckle and axle center bores of any dirt and debris and dry components B Place the knuckle in position on the axle center THRUST BEARINGS WITH SEALS With the seal positioned on top of the thrust bearing slide the bearing and seal assembly between the lower face of the renis center and the upper face of the lower knuckle yokd Figure 27 IMPORTANT The thrust bearing must be seated on the upper face of the lower knuckle yoke On axles WITH thrust bearing seals the seal must always cover the opening between the bearing cage and retainer Always install the bearing and seal assembly in the axle with the seal on top Figure 27 j 1 edere dA dues n a Pte i c P a Figure 27 THRUST BEARINGS WITHOUT SEALS With the open s
351. must be adjusted for the caster at assembly For maximum steering effort reduction easy steer axles should be set at 10 positive caster 26 TROUBLESHOOTING GUIDE 1a Rapid or Uneven Tire Wear e Incorrect toe in setting e Improper tire inflation e Unbalanced tires e improper Ackerman steering geometry e Tandem alignment b Toe in Control e When setting toe in it is important to neutralize the component and tire deflections by backing up and then going forward and rechecking the toe in This is especially important with radial tires The check and possible re set should be followed even if bearing plates are used 2 Hard Steering e Low power steering system pressure e Improper assembly of steering gear box e Inadequate or improper lubrication of knuckle pins Inadequate mechanical advantage of steering system in steering box ratio lengths of pitman arm and steering arm e Improper caster e Tight draglink or tie rod ends Worn thrust bearing 3 Rapid Wear of Cross Tube Ends e Inadequate or improper lubrication e Improper installation of add on steering cylinders type power 27 e Severely contaminative environment e Failure of protective rubber boot 4 Bent or Broken Cross Tube Broken Ball Stud Bent or Broken Steering Arm or Cross Tube Arm e Excessive power steering system pressure e Misadjusted power steering cut off e Operational curbing e Improper installation of add on power steering 5 Heavily Worn
352. n es en D se repliant dans soucoupe circulaire ad X tee y a CR gj P M ne i d Zo ONE esl PR t p 3 AT d 3 I 2 T 0 Ce a P NS 4 e t I d x 5 3 2 8 Stock NO 79 L 55 No 79 M No 79 S No 279 L No 279 S Diam Total Outside Djam Meme rr 6 3 16 4 15 16 4 1 16 6 3 16 4 1 16 Flange width 3 4 1 8 1 2 3 4 1 2 Tige 31 i FINISHES Plain steel in stock Shank 34 10 Profondeur 1 2 Deep Cad and chrome available Poids Weight LB 3 4 3 4 1 5 16 1 LIMIT E FAUCHER amp FILS INDUSTRIES 1964 vureo 7 MONTREAL TORONTO EDMONTON VANCOUVER vo Ae fy A sad 4 1 AM c ot we TRET T TA AM 1 rx T eh Let Bec is WAL y US ri c rent m wads 2 a es ENSEM Y Ra N La eate NR quy orta aca xD EX e t 4 by AE 3 HN s ne gt T6 D LET A m A o ipee uA CX OR p 2 ew DI 2 e M goce SRM Er EPIS TA uan eR Am DEG PETERS PAR ey A AL Ta nr A 4 ee tat RP rU C ve nul op N m s QE iy PG ANM DG Wa
353. n of the valve guide in the sump cavity closes the inlet valve The inlet valve and the exhaust valve are now closed Figure 3 Figure 3 When reservoir pressure drops slightly approximately 2 psi air pressure in the sump cavity opens the exhaust valve Figure 4 and allows moisture and contaminants to be ejected from the sump cavity until pressure in the sump cavity drops sufficiently to close the exhaust valve The length of time the exhaust valve remains open and the amount of moisture and contaminants ejected depends upon the sump pressure and the reservoir pressure drop that occurs each time air is used from the system Manual draining can be accomplished as follows Using a tool move the wire in the exhaust port upward holding it in until draining is completed The thermostat on the heated model DV 2 automatic drain valve will activate the heating element when the valve body reaches a temperature of approximately 450F and will deactivate the heating element when the valve body is warmed to approximately 85 F Figure 4 PREVENTIVE MAINTENANCE Every 1800 operating hours or 50 000 miles or every 6 months the automatic drain valve should be removed disassembled cleaned and lubricated Parts showing signs of wear or deterioration should be replaced If there is a filter screen in the adapter sitting it should be removed and discarded SERVICE CHECKS OPERATING TEST With system charged make several foot val
354. n one half the distance between the flange O D and gear pilot diameter the gear must be removed Check for cause correct and reassemble gear onto case half Differential case and gear bolts are available for service replacement of rivets The use of bolts greatly facilitates servicing these units CARE AND MAINTENANCE in the field and eliminates the need for special F Align mating marks position component case equipment necessary to correctly cold upset rivets half and draw assembly together with Consult chart for service bolt instruction shown with the four bolts or capscrews equally spaced torque chart on last page of manual NOTE If DRI LOC bolts are used refer to B Lubricate differential case inner walls and all procedures on pages 21 and 22 component parts with axle lubricant G Check assembly for free rotation of differential gears and correct if necessary H Install remaining bolts and capscrews tighten to the correct torque and lock wire l If bearings are to be replaced press squarely and firmly on differential case halves ROLLING RESISTANCE CHECK OF DIFFERENTIAL NEST A Place differential and ring gear assembly in a vise IMPORTANT Use soft metal covers over vise jaw to protect ring gear DIFFERENTIAL PINION AND SIDE GEAR ASSEMBLY C Position thrust washer and side gear in ring gear and case half assembly D Place spider with pinions and thrust washers in B Insert checking tool mad
355. n system Inverter harness improperly installed with RED wire at tached to battery and BLACK wire attached to alternator output Blown commutation fuses Inoperative K3 Relay Inverter voltage regulator in operative or fuse is blown Shorted SCR Oscillator circuit board inoperative Diode D5 or D6 open Diode D3 and or D4 shorted Diode D2 is open SOLUTION Check control fuse F5 on inverter front panel If there is no control fuse on the inverter go on to the next probable cause Follow procedure to check out K2 Relay see Section 4 3 4 See special note in Paragraph 4 3 0 and Section 3 5 2 Install RED and BLACK wires properly according to installation instructions Follow procedure to check commutation fuses Section 4 3 6 Follow procedure to check K3 Relay Section 4 3 5 Follow procedure to checkout voltage regulator Section 4 3 7 Follow procedure to checkout SCRs Section 4 3 9 Follow procedure to checkout oscillator board Section 4 3 8 Follow procedure to checkout Diodes D5 and D6 Section 4 3 10 Follow procedure to checkout Diodes D3 and D4 Section 4 3 10 Replace Diode D2 F2138C NO 5 10 11 SYMPTOM Low output voltage AC and DC Inverter will not turn off high out put voltage AC and DC Inverter will not turn off output vol tage normal Inverter turns on will not carry AC load High AC output vol tage low or normal DC output v
356. n the End Yokes Care should be taken not FIGURE 11 p ao e two 2 00 ournal Cross at both ends of the drive shaft e En REMOVAL FROM THE VEHICLE Yokes remain on the vehicle 1 Double Flange Yoke Types Bearing Cap and Snap Ring Construction Double Flange Yoke Type Joints are removed as a complete assembly by removal of the Companion Flange Bolts Nuts and Lock Washers which allows the assembly to slip out from between the Companion Flanges FIGURE 14 3 Double End Yoke Type Bearing Cap Construction Remove the cap screws lock plates and bearing and retaining cap sub assemblies from the transmission and axle end yokes Remove the drive shaft with the remaining journal crosses and bearings as a unit The end yokes remain on the vehicle rn nip THER REMOVAL OF THE SLIP JOINT 1 Slip Joint All Types Unscrew the dust cap from the sleeve yoke and slide the joint off the drive shaft BEARING CAP CONSTRUCTION 2 NEEDLE BEARINGS amp RETAINING CAP SUBASSEMBLY 6 Remove by using a large pair of channel lock pliers on retaining cap edges turn retaining cap and bearing sub assembly at the same time lifting upward to remove the sub assembly from the journal trunnion diameter and out of the yoke hole Turn the joint over and tap the exposed end of the journal cross 5 until the opposite needle bearing is free Use soft round drift with flat face about 1 32 smaller in diameter than the hol
357. n the end of the valve is positioned over the pin Position the remaining reversing spring on shoulder of the valve end Reinstall valve adjustment nut turning it clockwise into the piston until it is against the spring Align the reference marks on the nut and piston Then lock nut in place by installing the locking pin Be sure pin is below the outside edge of piston Page 33 SHEPPARD POWER STEERING SERVICE MANUAL PISTON VARIATION 372 382 SERIES STEP BORE The step bore 372 382 pistons are disassembled the same as the standard piston except the piston ring flange is factory located and installed and must not be removed S B7 The piston ring is replaceable in the case of wear or breakage Page 34 SHEPPARD POWER STEERING SERVICE MANUAL REPAIR SHORT SERIES BEARING CAP ASSEMBLY Separate the actuating shaft from the bearing cap The actuating shaft retainer is pinned to the bearing cap Use a 5 64 inch drill and drill through the pin Use a spanner wrench to remove the retainer You can fabricate your own spanner wrenches as required using discarded retainers and a piece of stock as a handle and two roll pins Drill through the retainer and drive the roll pins through the retainer Weld the stock material as a handle to the retainer 5 70 Carefully tap or press the actuating shaft and bearing out of the bearing cap The actuating shaft and bearing are not supplied separately No attempt
358. n with lock screw and lock wire or locking pin depending on type employed K Install felts retainers and lock rings if employed L Install shoe return spring ADJUSTMENT Follow adjustment procedure as outlined under P Brake section located on bottom of page 14 THE CAM MASTER HEAVY DUTY P SERIES BRAKES HEAVY DUTY P series brake is air actuated two shoe brake designed for heavy duty and special equipment where greater shoe and drum areas are necessary This heavy duty series ranges in diameter from 18 to 22 and in width from 4 to 7 The shoes are of heat treated malleable castings mounted on open spiders by individual anchor pins Each shoe has hardened cam pressure pads and employs two 3 4 tapered block liners The camshaft and air chamber support bracket is mounted directly on the brake spider making the assembly complete as a unit however the heavy duty brake may also be equipped with inboard cam supports where operation or axle design requires mounting the air chambers toward the axle centers On these HEAVY DUTY brakes cam pressure is applied to the shoe hardened wear pads through the double S cam which is supported in needle bearings 16 ka k CARE AND MAINTENANCE HEAVY DUTY P BRAKE LAYOUT CAM SUPPORT BRACKET BRACKET CAP SCREWS SUPPORT BRACKET SLACK ADJUSTER AND LOCK WASHERS TO SPIDER SPACER E 1 i MER T a ray AIR CHAMBER
359. nd Grease Fitting BW Pc No 244017 Alemite 1625 using Alemite tool 5254 to press grease fitting firmly in place in cover 3 Install steel plug Pc No 244400 in other cover making certain it is firmly in place 4 Lubricate Slack Adjuster Apply a sufficient amount of grease to completely fill body cavity SERVICE TESTS 1 Apply brakes and check that Slack Adjusters rotate freely and without binding 2 Release brakes and check that Slack Adjusters return to the released position without binding 3 With brakes released check that the angle formed by the Slack Adjuster arm and actuator push rod is 0 than 90 degrees All Slack Adjusters should e set at this same angle 4 With brakes applied check that the angle formed b the Slack Adjuster arm and actuator push rod is still ety greater than 90 degrees All Slack Adjusters should be set at this same angle REMOVAL AND INSTALLATION CAUTION Before attempting to remove Slack Adjusters proper precautions should be taken so that an automatic application of the actuators does not occur while removing or installing Slack Adjusters thus causing possible injury Decreasing air pressure can cause a sudden full brake application without warning Depending on type of system on vehicle it may be necessary to drain all air reservoirs or mechanically back off spring brake chambers A REMOVAL 1 Remove the chamber push rod yoke pin 2 Remove the retaining mechanism from en
360. nd exhaust ports Air flows into the emergency port of the spring brakes from the QR 1C Valve delivery ports Spring Brakes Applied When the spring brakes are applied supply line air pressure to the valve is exhausted through the park con SEALING DOUBLE CHECK B ALANCE RING DIAPHRAGM PORTIT SUPPLY PORTIT SEALING RING DELIVER QUICK RELEASE DIAPHRAGM trol valve As air Pressure is removed from one side of the double check valve and quick release diaphragms they flex in the opposite direction opening the balance and exhaust ports Spring brake emergency pressure is released at the exhaust port of the valve while the small amount of air trapped between the two diaphragms is released through the relay valve or brake valve exhaust Anti compounding When a service brake application is made with the spring brakes applied service air enters the balance port and flows through the valve into the emergency ports of the spring brakes This prevents the compounding of a service and spring brake application Service air passing through the valve flexes the double check and quick release diaphragms sealing the supply and exhaust ports When the service application is released air is exhausted from the spring brakes PREVENTIVE MAINTENANCE Every 12 months 100 000 miles or 3600 operating hours disassemble valve wash metal parts in mineral spirits wipe parts dry It is recommended that all rubber parts be replaced
361. nd the lower shoe the secondary acting shoe If the cam is ahead of the axle the lower shoe is the primary acting shoe On hydraulic brakes of the conventional type the front shoe is the primary or forward and the rear secondary or reverse shoe While riveting or bonding is the general method of attaching liners bolting is also used for certain applications New liners should be attached in the same manner as the original installation All liners on a vehicle should be replaced simultaneously to obtain the most desirable results SERVICE INSTRUCTONS FOR RIVETING Liner and shoe contact faces should be clean before clamping liner in position Rivets of the correct body diameter head size and shape length and material should be used On the earlier pressed steel shoes rivet holes are slightly smaller than the present punched holes It may be necessary to line drill the linings and shoes with a No 5 drill 2055 diameter If replacing bonded liners with riveted liners use the No 5 drill for new holes 1 Clamp the lining to the brake shoe with C clamps so the rivet holes in both pieces arc in alignment 2 Drive the rivets squarely into the holes with a 7 16 flat head drift 3 Make certain the lining is firmly clamped to the shoe locating the C clamps as close to the rivet holes as possible 4 Form the rivet heads with the correct tubular rivet set following the sequence shown in illustration below working from
362. ned as follows With the integral Charging System oper ating a c voltages initially are generated in the stator by residual mag INTEGRAL CHARGING SYSTEM Figure 3 Typical wiring diagram showing Two rectifier bridge type us us GM GN GN GA E GNU M V nt 6 ey DIODE TRIO e D E p on RECTIFIER BRIDGES INTEGRALE CHARGING SYSTEM GM UE VOLTAGE ADJUSTMENT TRI R EGULATOR BATTERY internal circuits Page 2 us m netism in the rotor Current then flows through the diode trio resistor R1 and resistor R4 to turn transistor TR1 The stator then supplies d c field cur rent through the diode trio the field TRi and then through the grounded diodes in the rectifier bridges back to the stator Also the diodes in the recti fier bridges change the stator a c volt ages to a d c voltage which appears between ground and the terminal As speed increases current is provided for charging the battery and operating electrical accessories As the speed and voltage increase the voltage between R2 and R3 increases to the value where zener diode D
363. ng then clean old grease from universal joint and repack by hand with new grease 3 PLANETARY AXLES T IL mmm cn a FUNS Ye minium CARDAN CONSTANT VELOCITY UNIVERSAL JOINT UNIVERSAL JOINT LUBRICANTS e 0 617 A or 0 617 B All steering universal joints Cardan and Constant Velocity types Knuckle sleeves bearings and bushings crosstube end assemblies yokes and flanges Wheel end gearing bearings and drive units differentials Use lubricants with viscosity grades 90 or below only in planetary axle wheel ends with a common wheel end axle housing oil level Lubricants with viscosity grades above 90 must be limited to the housing bowl area of axles without a common wheel end axle housing oil level Further an API GL 5 lubricant is recommended for all planetary axle wheel end gearing bearings and drive units Axles with common wheel end axle housing oil level otandard 0 76 C or 0 76 D Optional 0 76 E 0 76 F 0 76 J or 0 76 K Axles without common wheel end axle housing oil level Wheel end only otandard 0 76 C or 0 76 D Optional 0 76 E 0 76 F 0 76 J or 0 76 K Axle housing drive unit only otandard 0 76 0 76 A or 0 76 B Optional 0 76 C 0 76 D 0 76 E 0 76 F 0 76 J or 0 76 K Refer to Recommended Lubricants pages 6 and 7 LUBE INTERVALS e Cardan steering Joints every 200 hours of operation e Constant velocity steeri
364. ng a ring type terminal A87 connector on one end Connect this wire to the negative brush terminal on the voltage regulator by using the negative brush terminal screw Wire terminal must go under the insulating washer so that good electrical contact is made to the brush terminal 22 9 Locate the BLACK regulator jumper lead connected between the voltage regulator and the positive output BAT terminal of the alternator Remove and discard It will not be used 22210 Thread the end of the lead from Step 8 to the exterior rear of the alternator by using convenient ventilating holes or else drill a hole in the end plate and use a rubber grommet to pass the leads through Make sure the leads are routed and secured so that they will not interfere with moving rotor parts 222211 Reassemble the alternator by reversing procedures in steps 2 through 6 Attach WHITE lead from rear of alternator to ground or negative output terminal of alternator Use 1 Regulator Terminal as BLUE wire from Dynamote connection terminal Fiq 3 5 5 2A below is a schematic diagram of the Delco 4051 before modification Heturn to Section 3 5 1 v oitage Requlator Fositive rjrusn EI oo S wl Terminal Step 8 Diode reio Connector Step 7 two INSULATED SCREWS q oe Regulator Jumper tead Step 10 Voltage Regulator Negative Brush Termina Step 9 wf ee TERMINALS J W TERMINAL
365. ng a wrench on the hex portion of the body 4 DS 2 Disconnect air lines and remove the DS 2 INSTALLING 1 Replace the SL 5 or DS 2 in the port from which it was removed Do not install with the terminals pointing down 2 Secure electrical connections 3 Reinstall air line connections to DS 2 valve DISASSEMBLY Double Check Valve 1 Remove three cap screws and cap 2 Remove O Ring seal from cap 3 Remove shuttle valve CLEANING AND INSPECTION 1 Blow dust or other foreign material out of body Do not immerse in cleaning fluid 2 Inspect shuttle valve and O Ring and replace if deteriorated TEST Repeat Operating and Leakage Test IMPORTANT PLEASE READ When working on or around air brake systems and com ponents the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone 4 Never attempt to disassemble a component until you have read
366. ng joints every 1000 to 1500 hours of operation or twice a year spring and fall 11 LUBRICATION e Knuckle Bearings and Bushings Change whenever seals are replaced brakes are relined or every 100 to 200 hours of normal operation but as often as once a day in severe operations e Wheel end gearing bearings and drive units differentials Change whenever seals are replaced brakes are relined or every 1000 to 1500 hours of operation or twice a year spring and fall e Universal Joints and Drive Lines Refer to item 9 onl page 24 LUBE PROCEDURES e Cardan steering joints 1 2 3 4 Check for looseness Apply grease until new grease purges from all seals If grease does not purge at seals manipulate U joint until purging occurs If above is not successful remove cup or joint and check old grease If grease appears rusty gritty or burnt replace the complete universal joint e Constant velocity steering joints To apply new grease remove axle shaft from housing then clean old grease from universal joint and repack by hand with new grease e Planetary wheel ends Fill hubs through Fill Drain oil hole located at top and drain from same hole rotated to the bottom Fill until lubricant appears at Oil Level hole 4 WHEEL BEARINGS GREASE LUBRICATED 70 88 lum um A wi A LP NON DRIVE AXLE DRIVE AXLE HUB ASSEMBLY HUB ASSEMBLY 12 LUBRICA
367. ngle straight line is scribed all the way around the tire Lower vehicle on floor and then move the vehicle backward and then forward approximately ten feet Position trammel bar at rear of tires and adjust pointers to line up with scribe lines and lock in place scale should be set on zero Pointers must be to spindle height on the tire as shown Figure 25 ppp ADAM Figure 40 F Position the trammel bar at the front of the tires Adjust scale end so that pointers line up with scribe marks G Read toe in or toe out from scale Figure 41 B MINUS A EQUALS TOE IN Figure 41 same measurements be made with a steel tape measure at spindle height Toe in or toe out is the difference between the measurement taken at the front and rear of the tires If an adjustment is necessary loosen cross tube clamps and rotate cross tube as required and tighten clamps Move vehicle backward and then forward about 10 feet This is particularly important when setting the toe in on vehicles equipped with radial tires J Recheck toe in setting to make SURE it is correct NON DRIVING FRONT AXLE CAMBER SPECIFICATIONS FF FG FL Series CONDITIONS LEFT DRIVER S SIDE RIGHT SIDE 1 Camber angles machined into axles 3 4 nominal 1 4 nominal e less hubs e axle not mounted under vehicle e noload 2 Camber angles of axle equipped with hubs 3 4 7 16 11 4 7
368. nose housing so the motor can be reassembled in the same manner 2 Disconnect field coil connector from solenoid motor terminal remove solenoid mounting screws 3 Remove thru bolt or cap screws 4 Remove commutator end frame from field frame and field frame from lever housing COMMUTATOR BRUSH SERIES COIL 4 COMMUTATOR SERIES COIL 6 2 SLEEVE ASSEMBLY COLLAR SPRING STOP WASHER PINION SHELL JUMP SPRING AND BUSHING ASSEMBLY LOCK WIRE Figure 12 Disassembled view of 4 early type intermediate CRANKING MOTORS Service Bulletin 1M 153 3 On motors which have brush inspection plates remove the plates and then remove the brush lead screws This will disconnect the field leads from the brush holders Hemove the attaching bolts and separate the commutator end frame from the field frame duty sprag clutch drive SHELL AND SLEEVE ASSEMBLY COLLAR UMP SPRING PINION d i assembly 5 LOCK WIRE oeparate the nose housing and field frame from lever housing by removing attaching bolts 6 Remove armature and clutch assembly from lever housing 7 Separate solenoid from pulling apart lever housing by Figure 13 Disassembled view of late type intermediate dut spray clutch drive assembly 5 Remove nose housing attaching bolts and separate nose housing from lever housing 6 Slide a standard half inch pipe coupling or other metal cylinder of suitable
369. ns Fluid exhausted from the low pressure end of the master gear is routed through the low pressure pinion gear area of the slave gear and ther back to the reservoir Early production dual gear systems routed the exhaust fluid from the master gear pinion gear area directly to the reservoir Later systems route the exhaust fluid from the pinion gear area of the master gear through the pinion gear area of the slave gear and then to the reservoir The later production method of oil return flow provides faster warm up of the slave gear and offers further assurance that air entrapment in the slave gear is avoided The pressure relief check valve in the slave gear piston also allows entrapped air to escape to the low pressure side of the piston and be purged from the system Early slave gear pistons have two check valves Present versions have only one check valve which might be found on either end of the piston and is located in the piston end plug Pressure relief valve plungers are not required on slave gears as pressure relief is provided by the master gear Bleeding Air From System Dual Steering To bleed the air from the steering system on the vehicle after installing the steering gears the pitman alms may be installed if there is no clearance problem with the pitman arm striking any object using the full travel of the gear Install them by aligning the timing mark on output shaft with the timing mark on the pitman arm For torquing see pitman arm torq
370. nship if and only if the following requirements are complied with A The product is installed and checked out properly according to all guidelines instructions and checkout procedures set forth in the product Installation Operation Service Manual and B The installer records all checkout data required and completes signs and returns the warranty initiation card to the DYNAMOTE office within ten 10 days after installation Manufacturer s obligation under this warranty is limited to correcting without charge any part or parts of such products which shall be returned to its factory or one of its authorized service facilities transportation charges prepaid within one 1 year from first installation or within eighteen 18 months from date of manufacture whichever comes first provided examination discloses to Manufacturer s satisfaction that such parts were originally defective Correction of such defects by repair to or supplying of replacements for defective parts shall constitute fulfillment of all obligations to original user This warranty shall not apply to any of Manufacturer s products which must be replaced because of normal wear which have been subject to misuse negligence or accident or which shall have been repaired or altered outside of Manufacturer s factory unless authorized by Manufacturer MANUFACTURER SHALL NOT BE LIABLE FOR ANY CLAIMS LOSS DAMAGE OR EXPENSE WHATSOEVER RESULTING DIRECTLY OR INDIRECTLY FROM THE US
371. nside the miter housing Torque all bolts to specifications Reassemble miter housing cover using new gaskets and seals as required Healign all reference marks made during disassembly and install all locking pins Install the reassembled miter cover into miter housing with shim pack gaskets removed during disassembly and secure with two bolts and lockwashers Check back lash between miter gears by turning the miter shaft with your fingers Add or remove miter cover shims until zero backlash is obtained The miter gears should be dry and free of grease for this adjustment Page 61 SHEPPARD POWER STEERING SERVICE MANUAL The miter housing on the swivel miter input arrangement of the Sheppard Integral Power Steering Gear can be turned a full 360 degrees and clamped in the most desirable design location to compliment the steering column and U joint angles A clamping bar on each side of the miter housing clamps the housing to the bearing cap Three bolts pass through each bar and the bearing cap and thread into the steering gear housing Caution The steering should not be operated with these bolts removed or loosened High operating pressures may damage the bearing cap or bearing cap seals Install and torque miter cover bolts Install the miter lube fitting and fill miter with a good waterproof ball bearing grease i e Fiske Multi Purpose Grease or equivalent SWIVEL MITER DISASSEMBLY AND REPAIR 5 154 5 155
372. nt and solvent may dilute the lubricant Bearings must be replaced if any of the following conditions exist 1 Large ends of rollers worn flush to recess or radii at large ends of rollers worn sharpl Figure 13 poo ee f Xo E fr 44 aoe NUN SCENE N ur 1 ECC lg E M be as b X 1 hu ade ke D zr V E aloe ts i E Du Figure 13 2 a Visible step wear particularly at the small end of the roller track b Deep indentations cracks or breaks in bearing cup and or cone surfaces Figure 14 E J i 6 x ETE nay ee Mr J L 1 I k iB i i f S M ee x or FIGURE 14 11 3 Bright rubbing marks on the dark phosphate surfaces of the bearing cagel Figure 15 M EE Rum NET RO RN vom hi 5 i 4 1 E A ay i UN NA Er E 1 a ud a d i i 2 A j one xr 4 Figure 15 4 Etching or pitting on functioning surfaces Fiaure 16 1 SRS ERE scene Figure 16 NOTE Repeat bearing failures are a result of out of round hubs or spindles or indicate a poor a
373. nt and provides very fine adjustment Tie rod assemblies with drop center tube contain coarse pitch threads on one side and fine pitch on the other Ends for these are also not interchangeable This type of assembly requires removal from the tie rod arm for adjustment since the drop center tube cannot be rotated The differences in thread pitch provide a finer adjustment range for setting toe in A Thread end assembles into tube equally on both sides to the approximate overall length required B Torque clamp lock nuts to specification Assemble tie rod assembly into the tie rod arms on the axle assembly Torque the end assembly nuts to specification and install cotter key E If cotter pin hole does not align with the nut castellation advance to the next castellation and install pin D6 not exceed the maximum specified torque while doing this Do not back nut off to align the cotter hole NOTE If tie rod end assemblies tie rod tubes or tie rod arms have been removed or replaced toe in must be checked and readjusted 23 GENERAL WHEEL BEARING ADJUSTMENT ASSEMBLY A Assemble bearings and hub on the axle spindle B Install thrust washer if used Install the wheel bearing adjusting nut Thread the nut against the bearing or thrust washer Be sure there is sufficient clearance between the brake shoe and drum so brake shoe drag will not interfere with the bearing adjustment SEATING BEARINGS NOTE It is recomm
374. nt bearings It was found that an improved seal was required for this type of operation Synthetic rubber type seals were developed for these installations These seals have been in use for many years on military vehicles and are now used in most commercial installations The improved sealing shows increased life and a less critical re lubrication cycle The sliding splines between slip joint permanent joint must support the drive shaft and be capable of sliding under full torque loads To provide adequate strength and wear resistance hardened and ground splines are used These splines are phosphate coated to resist galling and to reduce sliding friction COMPONENTS SLIP JOINT PERMANENT JOINT Kit Journal amp Bearing Kit Journal amp Bearing Y 16 15 M OR e a s 3 40 30 FIGURE 2 TABLE OF NOMENCLATURE Symbol Part Name 2 FLANGE YOKE 3 SLEEVE YOKE ASSEMBLY 4 END YOKE JOURNAL ASSEMBLY 6 BEARING ASSEMBLY 7 SNAP RING 14 DUST CAP 15 STEEL WASHER 16 CORK WASHER Symbol Part Name 27 STUB YOKE amp TUBE ASSEMBLY 28 STUB YOKE 30 TUBING 40 SLIP STUB SHAFT Welded Tube 583 MIDSHIP STUB SHAFT Center Bearing 70 amp BOLT ASSEMBLY 02 YOKE SHAFT 94 U BOLT ASSEMBLY 5 PERMANENT JOINT KO v a 9 30 28 ii CENTER BEARING ASSEMBLY FIGURE 3 SLIP JOINT FIGURE 4 FIGURE 5 5 SHO
375. ntrol port Air entering the control port now moves past the inlet of valve A and is conducted through a passage in the body to the underside of piston B The added force of air pressure beneath piston B moves up opening the exhaust of valve B When the exhaust of valve B opens air pressure trapped in the emergency section of the spring brake actuator is allowed to escape resulting in a brake application by the emergency section The amount of air pressure released from the spring brake is Park application 2 Service reservoir 1 Service n reservoir ganas Park control in proportion to the amount of air pressure delivered to the control port of the SR 1 by the No 2 delivery of the dual brake valve OPERATION PARKING If both systems 1 and 2 are intact and the park control valve is placed in the park or exhaust position the SR 1 supply of air pressure and the air pressure in the spring brake actuator cavities is exhausted The single check valve in the SH 1 assists this exhaust of air pressure from the spring brake by allowing the air below piston B to flow back out the open exhaust of the park control valve When air pressure below piston B has dropped sufficiently piston B moves down opening the inlet of valve B thus providing an additional exhaust passage for air exhausting through the SR 1 from the spring brakes PREVENTIVE MAINTENANCE Every 3600 operating hours 100 000 miles or yearly disassemble valve clean
376. nts on the shaft with chalk and straighten if necessary Install with the Slip Joint nearest the source of power Tighten the Flange Bolts evenly after the Nuts and NEW Lock Washers are in place FIGURE 31 15 be understood to be the same as 0 on the horizontal plane Thus if a vertical reading is 85 the angle being measured is 5 angles should be read within 15 min and they should be measured with the protractor held plumb on a clean flat surface 4 Inflate all tires to the pressure at which they are normally operated Park the tractor on a surface which is as nearly level as possible both from front to rear and from side to side 5 tractor must be in its normal operating position Do not attempt to level the truck by jacking up the front or rear axles to obtain a level condition INSTALLATION FIGURE 32 6 Check and record the angle on the engine and main transmission This reading can be taken at the rear of the main transmission on the output yoke or flange Record this reading on a sketch similar to Fig 32 Example on Figure 32 1 down 7 Move protractor to the 07 reading and check drive shaft angle between transmission and forward axle Example 4 30 down 8 Check front axle input yoke angle with protractor Example angle up 22307 also check front axle output yoke Example angle down 2 20 9 Measure the angle of the tandem drive shaft between the front axle and fir
377. o extra pints 0 946 liters of same lubricant to axles employing inter axle differentials of the type that can be directly filled through a top filler hole Refer to capacities on pado 27 Drive the vehicle unloaded for one or two miles 1 6 to 3 2 km at speeds not to exceed 25 miles per hour 40 kph to thoroughly circulate the lubricant throughout the axle and carrier assemblies e Output bearing two tapered bearing design only INNER amp OUTER BEARINGS OIL AND 51 AND SX GREASE PACK BEARINGS HERE RC BEARINGS HERE TOL AM OUTPUT BEARING CAGE X SNAP RING SE m THROUGH SHAFT 22 LUBRICATION 1 Reassemble the output shaft and bearing cage assembly dry without coating the parts with lubricant 2 Adjust output bearings to the correct preload or end play specifications 3 After bearings are adjusted squirt oil through the inner and outer openings of the bearing cage to coat bearings Use the same recommended GL 5 lubricant used in the axle 4 After oiling pack both the inner and outer bearings with 0 622 grease Use a suitable grease gun with a flexible nozzle to pack the bearing cavities through the inner and outer openings of the bearing cage e TWO SPEED HYPOID PLANETARY GEARING 600 Series LUBRICANTS Because of the planetary design of Rockwell 600 Series hypoid planetary two speed drive units use only SAE 85 90 viscosity API GL 5 grade hypoid gear oil Standard 0 76 C Optional Unus
378. ocedures as they apply to your steering gear INDEX Pune ES ME o So Model Identification Parts Identification 2 W lelsleziilo MEM ERE S o T NER General Hydraulic Supply Diagnosis Oil Flow Requirements Disassembly Cleaning amp PICO m ETE Integral Relief Pitman Arm Bleeding System Relief Valve Plunger Adjustment 0121 Dual Integral Gear Torque Miter Gear Repair 2 Swivel Miter Gear T Box Miter Gear Repair 2 2 veter emm Page 1 SHEPPARD POWER STEERING SERVICE MANUAL DESIGN ADVANTAGES YOU GET WITH SHEPPARD INTEGRAL POWER STEERING NEUTRAL POSITION Service Dependable and trouble free ADJUSTABLE STOPS prevent damage and unnecessary wear When wheels are turned to a desirable extreme in either direction adjustable stops automatically unload the complete hydraulic system Thus all parts of the steering mechanism are protected from undue stress and damage Oil in the hydraulic system 15 prevented from overheating Service life of both pump and by pass valve are prolonged Fast responsive stee
379. of the steering system To avoid repeat problems each clue gained from parts inspection should be followed to conclusion Listed below are the more common observations you may make during steering gear inspection and their possible cause This information should be considered carefully when repairing low mileage vehicles Remember it is more important to repair the cause than to repair the results Parts discolored blue Operating temperatures too high Flow rate excessive System back pressure too high Steering column binding Actuating valve blocked Hydraulic supply pump malfunctioning Broken housing 1 Accident damaged 2 Uncontrolled operating pressure Actuating shaft bearing retaining nut stripped Impact or accident damaged 2 Air in system Housing or piston scoring Foreign material entry Bronze bushing wear Actuating shaft and actuating Incorrect lubricant used Excessive temperature Overloading Contaminated oil Overloading Also see following NOTE Roller Bearings Severe overloading Incorrect lubricant used Excessive temperature over 200 Pump damaged Air in system Operating pressure too high valve acme thread wear Insufficient operating pressure Insufficient oil flow Continued operation at high temperature Pitted rough Bearing cage broken Foreign material in system Excessive overloading Roller Bearings Needles flattened
380. oltage High DC output vol tage low AC out put voltage Improper or no char ging with inverter Off proper opera tion with inverter on Section XI 12 81 TROUBLESHOOTING AND SERVICE PROBABLE CAUSE Loose alternator belts Alternator RPM too slow K3 Relay inoperative Inverter voltage regulator out of adjustment Shorted or open diodes in the alternator Inverter voltage regulator inoperative or shorted Inverter voltage regulator inoperative K2 Relay points 3 and 9 not disengaging Blocking Diode D5 and or D6 shorted Diodes D3 and or D4 open PA en e mee qoc pamm a Faulty K3 Relay Faulty Vehicle Voltage Reg ulator PCB3 Faulty K2 Relay Faulty K4 Relay in installa Tnstallation Kit onlv SOLUTION Tighten belts by adjusting alternator bracket Run engine at faster speed and see if output voltage goes up DYNAMOTE makes small diameter alternator pulleys iFollow procedure to checkout Relay i Section 4 3 5 Adjust voltage regulator IFollow alternator diode test procedure Section 4 3 11 Replace inverter voltage regulatcr Follow procedure for voltage regulator checkout Section 4 3 7 Follow procedure for K2 Relay checkout Section 4 3 4 Follow procedure for Diode D5 and D6 checkout Section 4 3 10 Check Diodes D3 and D4 according to checkout procedure Section 4 3 10 Follow procedure to checkout K3 Relay
381. om the steering system in the following manner 1 Fill pump reservoir with recommended oil lt will be necessary to continue filling after starting the engine and during the bleeding operation until Adjusting relief valve plungers The relief valve plunger adjustment is provided to automatically reduce the steering pressure when the road wheels have reached their limits of turn This keeps the supply pump from operating at maximum relief pressure when the road wheels are at their steering limits System temperatures are therefore reduced and high stress loads on the mechanical components of the steering system are relieved High pressure oil at either end of the piston will push the relief ball valve off its seat and fill the relief passage with oil at high pressure At the opposite end of this passage the relief ball valve is held against its seat and holds the high pressure in the relief passage As the piston moves close to its limits of stroke the adjustable relief plungers push the relief ball valve off its seat and the pressure is relieved The distance the piston can move is dependent upon the total front axle steering system geometry and tire size The relief valve plungers are adjustable to allow for variations or changes in these areas Adjust the relief valve plungers as follows 1 Start the engine and allow it to operate at idle FINAL ADJUSTMENTS correct oil level is maintained 2 oet parking brake or block wheels
382. on 3 4 OPTION YO 1 2 3 4 OPTION STRADDLE MOUNTED PINION Shown with parallel sided splines 1 Part Number 2 Tooth Combination Number The Part Number and Tooth Combination Number are found on the shank or threaded end of all pinions On the ring gears the numbers are normally found on the front face of the gear However as an option they may be located at the gear O D For any given pinion and gear set the ring gear always has an even part number i 36786 and the matched pinion has the odd number i 36787 The tooth combination number i e 5 37 indicates the gear set has a 5 tooth pinion and a 37 tooth ring gear the equivalent of a 7 4101 gear ratio Always refer to the Part Number and Tooth Combination Number before starting the reassembly Check to be certain the pinion and gear match 3 Gear Set Matching Numbers All Rockwell drive pinion and gear sets are manufactured and sold only in matched sets Both pieces of the set have a matching number such as M29 or any combination of a letter and number On most pinions the number is usually marked on the head end However on pinions with parallel sided splines the number may be marked on the top flat of one of the splines CARE AND MAINTENANCE because pinion and gear sets for a specific series of axles cannot be manufactured exactly alike and there may be slight differences in the Mounting Distance of the individual gear sets This P
383. on bushings at both inner and outer ends Cam pressure is applied through roller cam followers A suitable punch for the removal of these locking pins may be made from a 5 rod 9132 in diameter by turning or grinding one end to 3 16c diameter 1 8 long This smaller end will pilot in the pin and prevent punch from slipping oee illustration of suitable punch below r ASSEMBLY A Install the spider outer nylon bushing felts and retainers first if outer nylon bushing has been replaced B Loosely assemble the camshaft inner nylon bushing retainers to the nylon bushing and then loosely attach the retainers and nylon bushing assembly to the housing bracket C Lubricate the inner surfaces of both the outer nylon and inner nylon bushing D Install camshaft with large flat washer into spider and nylon bushing assembly When end of camshaft clears bushing assembly install lock rng on camshaft and proceed with shaft into and through the inner nylon bushing E Slide lock ring over shaft and secure into groove next to spider F Align the parts and carefully tighten the retainers around the nylon bushing then tighten the retainer and bushing BRAKES F M M NO 4 G Position S cam at zero and install slack adjuster washer and lock ring H Attach roller cam follower to brake shoe web with retainer spring l Assemble brake shoe assembly to spider and tap anchor pin in place J Secure anchor pi
384. on gear is reinstalled on the output shaft the distance between the end of the shaft to the face of the retainer must be adjusted Place the gear on the shaft splines aligning the timing marks and thread the retainer onto the shaft against the pinion gear The distance between the end of the shaft and the face of the retainer should be adjusted by moving the gear on the shaft until the following dimension is obtained Model 39 1 10 32 Model 59 1 25 32 Model 491 1 13 32 Now the retainer is backed off until the drilled holes in the retainer align with the tapped holes in the pinion gear Install and tighten retaining screws drawing the gear tightly against the retainer It may be necessary to press the gear onto the shaft or back against the retainer 3 B5B Page 39 SHEPPARD POWER STEERING SERVICE MANUAL REPAIR SHORT SERIES HOUSING ASSEMBLY The bronze bearings are presized and boring or honing are not required 5 86 Remove the Quad ring oil seal from the gear housing and discard 5 87 Use a drift punch to drive the bronze bearing out of the housing Alternately tap one side of the bearing and then at an opposite side to keep it moving evenly Withdraw the bronze bearing from the cover with a suitable bushing remover Owatonna Tools puller illustrated Page 40 SHEPPARD POWER STEERING SERVICE MANUAL Install new bearings if removed in the gear housing and cover using a press and a stra
385. on shaft Then turn unit over and start large bearing Fig 1 420 Press or drive into place with a soft hammer or a hydraulic or arbor press Photos 5 6 amp 7 Photo 7 REASSEMBLY A22 26 Series cont 2 Bearing Cap Installation NOTE Recommended to begin with two 020 gaskets A Turn P T O over output shaft down Place on both sides Minimum on either side is 010 gasket s on closed bearing cap Fig 1 10 and The offset in the bearing caps for the 22 series install on unit using four capscrews Fig 1 17 always points in the direction of the shifter cover Photos 8 amp 9 whereas the offset is placed away from the input gear in the 26 series Both series use the same QU UM MP bearing caps Photo 10 Photo 10 B unit over and install open bearing cap Fig 1 49 using previous procedure Step A Shaft should turn freely with a minimum of end play less than 006 Photos 11 amp 12 Photo 11 Photo 9 10 REASSEMBLY 22 26 Series cont Photo 12 Photo 14 C Make sure bearings are seated by first D Check end play of shaft with indicator Shaft tapping the shaft then place the driver over 2 7 MID B m amount o the shaft and strike it with the hammer end play 006 or less Photo Photos 13 amp 14 Photo 15 Photo 13 11 REASSEMBLY 22 26 Series cont 3 Input Gear Assembly And Installation E Install oil seal Fig 1 12 using slide and
386. on to 1 provide a lubricating film between the moving parts to reduce friction 2 help cool the contacting sliding parts 3 keep dirt and wear particles away from the mating parts Proper lubrication depends upon using the right type of lubricant at the proper intervals and filling to the specified capacities Past experience has shown that many service problems can be traced to an improper lubricant or to incorrect lubrication procedures of the Rockwell recommended lubrication practices specifications and most of the product capacities are covered in this manual It is essential to follow these procedures for adequate and lubrication of Rockwell components RECOMMENDED LUBRICATION PRACTICES NEW AND RECONDITIONED AXLE SERVICE Drain and flush the factory fill axle lubricant of a new or reconditioned axle after the first 1 000 miles 1 600 km but never later than 3 000 miles 4 800 km Drain the lubricant while the unit is still warm from the carrier housing and if a drain plug is employed from the inter axle differential assembly of the forward carrier of tandem axles Flush axle with clean GL 5 axle lubricant of the same viscosity as used in service Do not flush axles with solvent such as kerosene INTER AXLE DIFF OIL FILL PLUG INTER AXLE DIFF OIL DRAIN PLUG CURRENT SLHD OR SQHD MODEL TYPE SHOWN IMPORTANT The design of certain Rockwell forward rear tandem axle carriers such as the
387. onnect the ohmmeter to each adjacent pair of terminals making four checks in all lf any one check is infinite replace the connector body To check the regulator remove from the end frame and use an approved regulator tester available from commercial test equipment manufacturers Follow the manufacturer s recommended test procedure DIODE TRIO CHECK diode trio is identified in Figures 14 and 15 To check the diode trio remove it from the end frame assembly Page 6 Three rectifier 10 285 Service Bulletin Figure 12 End frame view with stator removed bridge type with three terminal CONNECTOR BODY REMOVED FROM REGULATOR OHMMETER Figure 13 Checking connector body Figure 14 End frame view with stator removed Two rectifier bridge type by detaching the nuts attaching screw Note that the insulating washer on the screw is assembled over the top of the diode trio connector Connect an ohmmeter having a 11 2 volt cell and using the lowest range scale to the single connector and to one of the three connectors Fig 16 Observe the reading Then reverse the ohmmeter leads to the same two connectors If both readings are the same replace the diode trio good diode trio will give one high and one low reading Repeat this same test between the single connector and each of the other two connectors NOTE Diode trios differing in appearance may be specified for use in the same Inte
388. or CO EP cm EC un A A M A NSA A Install proper alternator IS Install automatic throttle if used Attach harness to alternator Checkout alternator connections N O Checkout inverter Wire AC output Complete sign and mail warranty registration card 3 0 2 RECOMMENDED TOOLS AND EQUIPMENT FOR INVERTER INSTALLATION Socket wrench set 1 4 or 3 8 drive with 1 4 3 8 7 16 1 2 and 3 4 socket rachet and 6 extension NO mechanic s screwdriver CO 1 2 and 7 16 open end wrenches VO M volt ohm milliamp meter 4 Fluke 8020A Simpson 463 or equivalent Dynamote 4 2600 amp ees ee Wire crimpers and lineman s pliers O Wire stripper N Electrical tape and electrical putty _ om MEE cn NS Co Dynamote4 2600 Installation Tester 3 0 3 HARDWARE KITS INCLUDED WITH INVERTERS Figure 3 0 3A on the following page lists all the hardware items included with the various A Series inverters Check and identify the various items as you unpack the shipping carton DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 Copyright 1981 DYNAMOTE CORP Figure 3 0 3A HARDWARE KIT LL UT 2283 00014 Harness Input Power 60 MPA MPA MPA 30 40 60 4283 00010 1 4200 06400 4200 06400 4200 02150 4282 0
389. or there is a 50 PSI or more difference in two of the corresponding readings in Part 3 Check circuit for correct installation b Check hoses and screens 2 for obstruction 28 CIRCUIT CHECK continued 4 Remove the B line from the P T O with the Solenoid Valve On no oil should appear from line Then turning the oolenoid Valve to Off should dump the oil from the P T O Clutch Pack through this line 5 Remove the C line from the P T O Idler shaft end except 800 P T O and confirm that oil is running to this shaft for lubrication Retain the findings of these tests for future comparison Re check oil level in tranmission after testing is complete 29 INDICATOR LIGHT INSTALLATION DASH DRILLING TEMPLATE For Indicator Light Installation of 220 260 812 100 300 321 322 340 350 370A 381 410 420 431 450 and 611 Series Wire and Lever Control CHELSEA P T O 68 P 18 CONTROL PLATE 7 378978 12 VOLT INDICATOR LIGHT INDICATOR SWITCHES 378969 White Nylon 379110 Black Nylon 378884 9 AMP FUSE HOLDER Special Indicator Switch for these models AUses Two Switches Two Lights and one fuse omm 3 468 203 DIA 2 PLACES 1 734 road 750 DIA 1 500 3 000 30 SHIFTING PROCEDURE amp PRECAUTIONS This vehicle is equipped with a Power Take off Consult operating instructions before using Se
390. or Broken Steering Arm Ballstud e Over tightened draglink e Inadequate or improper lubrication e Misadjusted power steering stops 6 Excessive Wear of Knuckle Pins and Bushings e Worn or missing seals and gaskets e Improper type of grease e Inadequate lubrication frequency e Improper lubrication technique e Inadequate lubrication frequency due to extreme operating conditions such as abrasive dust and sandy environments 7 Front Axle Shimmy or Vibration e Incorrect caster setting e Wheels and or tires not properly balanced e Worn shock absorbers TAPERED KING PIN MODELS KNUCKLE CAP SLOTTED SCREWS KNUCKLE PIN NUT 516 18 30 35 LB IN INITIAL MAX AFTER RANGE ASSEMBLY Se eer KHUCKLE HER SCREWS 7 14 180 215 LB FT 300 LB FT INITIAL MAX AFTER 5 16 18 15 20 LB 1 4 250 325 LB FT 450 LB FT RANGE ASSEMBLY 118 12 35475 LB FT 850 LB FT 52 16 60 80 LB FT 115 LB FT STEERING ARM NUT 59 18 60 80 LB FT 115 LB FT 3416 90 120 LB FT I70 LB FT INITIAL AFTER PE 14 180 215 LB FT 300 tB FT RANGE ASSEMBLY DE 250 325 LB FT 450 LB FT 1744 390 525 LB FT 725 LB FT 1 17 12 550 740 LB FT 1025 LB FT 1 42 18 775 1050 LB 1450 LB FT T1212 1350 1825 LB FT 525 LB FT CROSS TUBE ARM NUT INITIAL MAX AFTER RANGE ASSEMBLY 114 3580 525 LB FT 725 LB FT CROSS TUBE END NUT 1418 12 550 740 LB FT 1025 LB FT Auri seini zniB ET INITIAL AFTER 1 4 2 725 1050 LB FT 1450 LB
391. or light are also located on the front panel 2 2 3 AC Hardware A knock out plug is located in the back panel of the chassis for hardwiring AC output to an external electrical system A Romex cable clamp for attachment of a flexible metal BX cable housing which should shield and restrain the AC leads is provided in the hardware kit AC hardwiring instructions are set forth in Section 3 9 of the Instruction Manual 2 2 4 Hookup Harness All inverters come standard with Quick Disconnect 20 foot six wire harness Harness is separate from the inverter to provide for easy installation and checkout according to the official instructions Once properly installed to the vehicle electrical system harness MUST be checked out according to the procedure set forth in oec 3 6 and the results MUST be recorded on warranty initiation card The 4 2600 Dynamic Installation Test Module plugs into the test receptacle on the front of the inverter and provides the readings necessary to checkout the installation and to record the information on the warranty card 2 2 5 Chassis Configuration Shown on the following page in Figures 2 2 5A and 2 2 5B DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 2 2 5 Chassis Configuration COMMUTATION FUSES iE T OUTPUT FUSES CONVENIENCE ON OFF LIGH OUTPUT RECEPTACLES 5 amp STOP SWITCHES 222 AIR VENTS 22 CONTROL HEAD RECEPT
392. or maximum protection against wear particles it is desirable that magnetic plugs be employed at all oil drain hole locations Further magnetic plugs can be used at fill or level hole locations if clearance allows However the use of a magnetic drain plug in the axle housing is specifically recommended TEMPERATURE INDICATORS Many Rockwell axles have a tapped hole in the housing for the installation of a lubricant temperature indicator The installation and use of an indicator will aid in reducing the failure of critical axle parts as a result of overheated lubricant The indicator is particularly useful in through drive tandem units where severe operating conditions and mismatched or unequally inflated tires may cause a sudden and dangerously high change in lubricant temperature Rockwell axles may operate above 190 F 88 without damage However when the lubrication temperature reaches 250 F 121 C the vehicle should be immediately stopped and checked for the cause of overheating SEALS The purpose of seals and gaskets is to keep lubricant in and dirt out of the component Worn or damaged seals usually caused by improper installation or extreme hot or cold temperature will leak and result in low lubricant levels It is recommended that periodic inspections for seal leakage be made especially during cold weather Keep in mind that many lubricants are colorless or semi transparent and are difficult to see on the ex
393. ound cable b Connect an ammeter in the circuit at the BAT terminal of the Integral Charging System c Reconnect battery ground cable d Turn on accessories Connect a carbon pile across the battery Operate engine at moderate speed as required usually 4000 generator r p m or more and ad just carbon pile as required to obtain maximum current output IMPORTANT Initial voltage build up is by resid ual magnetism in the rotor Increase the speed as required to obtain maximum current output If ampere output is not within 10 If ampere output is within 10 per cent of rated output as stamped on frame Integral Charging Sys tem is not defective In this case an adjustment of the voltage setting may correct the under charged condition Raise the set ting by removing the voltage ad justing cap rotating in increments of 90 and then re inserting the cap in the connector body as il lustrated in Figure 8 percent of rated output as stamped on Integra Charging System frame remove the Integral Charging Sys tem for repair as covered in sec tion entitled INTEGRAL CHARG ING SYSTEM REPAIR Page 11 DELCOTRON INTEGRAL CHARGING SYSTEM 16 285 Service Bulletin NOTES REPRINTED 4 80 CO 1 2 1 WDS amp PS 1 2X 131 132 16 1 2 52 1FD PRINTED IN U S A Page 12 E SEN maintenance FORM 2826 instructions File Maintenance 6 64 DC MAGNETIC SWITCHES Old DC Manual
394. ovide necessary power according to the guidelines set forth in Section 2 4 2 Be properly wired to install with the inverter If the alternator has an external regulator no modification is necessary IT IS STRONGLY RECOMMENDED THAT ALTERNATORS WITH EXTERNAL REGULATORS BE USED THIS WILL SIMPLIFY INSTALLATION BY ELIMINATING ALTERNATOR MODIFICATION IF THE ALTERNATOR HAS AN INTERNAL REGULATOR IT MUST BE MODIFIED BEFORE IT IS A PROPER ALTERNATOR For modification instructions for specific alternators please refer to Figure 3 3 1A DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 Copyright 1981 DYNAMOTE CORP 11 8 1 3 3 INSTALL PROPER ALTERNATOR ON ENGINE continued Delco Remy 275 Series 200 Type See Section 3 5 5 1 Delco Remy 4051 Series 150 Type See Section 3 5 5 2 Leece Neville Series 2000JB See Section 3 5 5 3 Leece Neville Series 4000JA amp 7000JA See Section 3 5 5 4 Figure 3 3 14 INDEX TO MODIFICATION PROCEDURES FOR INTERNALLY REGULATED ALTERNATORS 3 3 2 The Proper Alternator must be installed correctly on the engine according to the following general guidelines 1 Alternator Pulley Alignment The requirements of the alternator mechanical installation are several 1 solid vibration free attachment of the mounting bracket to the engine and of the alternator to the mounting bracket 2 correct belt alignment and 3 protection from road spray or marine water spray and from engine exh
395. ovided to operate auxiliary equipment in some circuits Also some models have three a c terminals to which a transformer rectifier combination be connected for conversion to 110 volts d c The rotor bearing in the slip ring end frame contains a supply of lubricant sufficiently adequate to eliminate the need for periodic lubrication The drive end frame bearing is sealed on both sides and is serviced by complete replacement Two brushes carry current through the two slip rings Service Bulletin 16 285 Pages 12 Date 12 1 75 Supersedes Bulletins Dated 5 23 75 9 1 71 References 1B 115 1B 116 to the field coil mounted on the rotor and under normal conditions will provide long periods of attention free service IMPORTANT This bulletin covers generators with a two terminal regulator having two male blade terminals and also generators with a three terminal regulator having two male blade terminals plus a threaded stud terminal The procedures in this bulletin cover both types of generators namely the two terminal type and the three terminal type Remy DIVISION OF GENERAL MOTORS CORPORATION ANDERSON INDIANA DELCOTRON INTEGRAL CHARGING SYSTEM 16 285 Service Bulletin Figure 2 Cross sectional view typical integral charging system OPERATING PRINCIPLES TWO TERMINAL REGULATOR Typical wiring diagrams are illustrated in Figures 3 and 4 The basic operating principles are explai
396. ows locking or unlocking from inside or outside Provision is Left hana snown right opposite made for vertical or thumb rotary locking and dimenslons unlocking from the inside And the mechanism is 4 in length of case enclosed to minimize damage from foreign ob 5 in width of case jects The striker is designed for primary and 52 4 in width of case with striker secondary latching capability in depth of case 1 V4 in depth of case with striker Accessories for this lock are independent pillar 144 in mounting holes 4 locking cylinders single or double remote control on 3 x 354 HxV pattern levers and recessed paddle handles and L type 1332 oval mounting slots 2 handles both available key locking or non key on 3 centers on striker locking 4x1 in mounting face of striker A tabl for left okthssdanetatfati 54e in square hole for handle shank vailable for leit or rignt nand instalation Weight depends on system used Consult factory Left hand shown Specify when ordering No 206U and VARIATIONS Right hand shown left opposite Section 1 Page 14 TCP 6 77 No 206U with striker standard No 1 206U Same as No 206U ex cept with cut off lock button No 1 206 11 2 No 3 206U No 2 206U Same as No 206U ex Same as 2060 cept with stainless steel cept less locking fea non key locking inside ture handle No 24 5551 No 1 2070
397. p Line to P T O From 3 Way Valve 22 270 Series C Shifter Component Installation Sketch For Power Shifts DUMP LINE BACK 378884 9 AMP FUSE TO TRANSMISSION THRU P T O NOTE CAREFULLY ir ad CHECK VALVE FOR CORRECT NO GROUND INDICATOR LIGHT 378978 12V OR 379005 24V SOLENOID VALVE SEE CHART BELOW 378965 SCREEN ADAPTER 378977 FROM TRANS BRACKET TO VALVE A FROM VALVE 378301 4 PRESSURE SWITCH W 378307 TERMINAL 378966 SCREEN ADAPTER SOLENOID VALVE APPLICATION TRANSMISSION VOLTAGE SOLENOID VALVE NO COLOR CODE ALL ALLISON 12 V 3 8882 1 Black 260 P S I 24 V 378882 2 Blue 300 P S I 12V 3 9193 1 Green 300 P S I 24V 399193 2 Brown NOTE These two valves are being phased out and are being replaced by 379193 1 amp 2 23 OPENINGS For Automatic Transmissions Allison Models HT 740 HT 750D T FITTING 378897 78T 6P 4 2333m 20 MAIN PRESSURE 1 8 90 175 P S I 6 3 12 2 Kg cm LUBE 1 5 16 RING 35 45 P S I 2 4 3 2 Kg cm CLT 750 142 24mm 3 5 Le 88 PRESSURE T FITTING 378897 Um 16 NPT 90 270 P S I 1 5 16 RING 35 45 P S I 2 4 3 2 Kg cm HT 70 2 40T 6P 4 2333m 25 4 67 170 18mm 78T 6P 4 2333m 20 8 46 214 8mm VW E 6 2 LUBE TAP 157 48m
398. p damages or high pressure hoses to rupture Constantly observe the pressure gauge while closing the shutoff valve If pressure rises rapidly or appears to be uncontrolled do not completely close the valve before inspecting the pump and pressure relief valve If supply pump does not meet specifications repair pump 4 If the supply pump is okay place a 1 2 inch spacer between the axle stops on one side and turn the steering wheel hard in the direction necessary to pinch the spacer block Record the maximum pressure reading 5 Remove the spacer and repeat test in the opposite direction Record pressure 6 If pressure is equal on both sides but not within specifications remove and repair or replace the integral pressure relief valve Page 47 SHEPPARD POWER STEERING SERVICE MANUAL When the pitman arm is installed the timing arrows on the arm and the output shafts must be aligned If the pitman arm has two timing arrows marked L and R the same arm is used on both the master and the slave gear The L arrow is used on the left or master gear and the arrow is used on the right or slave gear The following charts detail the various pitman arm installation methods offered by The Sheppard Co Follow these procedures for the attachment method you are working with Correct torque values are very important Use the lubricant where indicated NOTE WHEN INSTALLED END OF PITMAN ARM BE 1 TO 3 FROM END OF
399. pecification aria on the front panel and a small toggle switch on the instrument panel of the inverter labeled Load Demand Auto Manual When the toggle is in the Manual position the inverter must be started and stopped with the Start Stop push button switch on the panel or the remote control When the toggle switch is in the Auto position the inverter will start automatically when a load is applied to the inverter and the engine is running If there is an Autothrottle installed on the vehicle it will be automatically activated when the inverter turns on as long as the vehicle is in park or neutral and the emergency brake is engaged In the Auto position when the load is removed from the inverter there is a waiting period of approximately 15 seconds after which the inverter turns off and the Autothrottle is disengaged This waiting period is to prevent constant increase and decrease of engine speed when short intermittent loads such as power tools are being run on the inverter The time period resets every time a load is applied Note During check out and troubleshooting procedures the AutoManual switch should be in the Manual position 2 2 2 Instrument Panel Momentary START and STOP buttons AC voltage indicator and remote control receptacle are provided Two 15 amp convenience receptacles are provided on the front panel Each receptacle is separately fused A control circuit fuse commutation input fuses and an on off indicat
400. periods of heavy steering usage 10 Aerated Oil Visually check for the presence of air mixed with the oil in the steering system The oil should be clear Any signs of frothing indicate air entry and steering performance will be affected Carefully check for leakage on the suction side of the steering pump Drain and refill the system and bleed for air following the procedure under final adjustments Before any steering gear repairs are attempted the above hydraulic supply evaluation must be completed and corrections made as required Many times steering gears have been repaired or replaced needlessly because a hydraulic supply system evaluation had not been made Additional references to pressure and flow testing will be made in the diagnosis charts in the General Diagnosis section of this manual Page 18 OPERATING PRESSURE amp OIL FLOW SPECIFICATIONS SHEPPARD POWER STEERING SERVICE MANUAL The R H Sheppard Co Inc manufactures two series of steering gears A low pressure series designed to operate in Each vehicle manufacturer specifies the maximum operating pressure at which their various steering installations are to be operated Refer to your vehicle manufacturer s specifications for correct relief settings for each of your vehicles Do not increase the maximum the range of 0 1300 PSI and high pressure series with design capabilities to 2000 PSI operating pressure without consulting the vehicle manufacturer or serious damag
401. plaint Talk to and question the driver 0 Drive the vehicle Il Visual Inspection Look for poor loading practices Check tires for mismatch and proper air pressure Check for dry fifth wheel or improper location Check suspension for sagging or shifting out of line rear axles will tend to steer the front end of the vehicle mm dcm cc a b C d Nr lt Ill Mechanical Components Inspection Check all front axle components for wear looseness or seizure Inspect front and rear suspension components Check steering gear mounting to be sure it is tight and not shifting on the chassis or axle Inspect steering column components a b C d IV Hydraulic Supply System Inspection Evaluate hydraulic supply system performance Follow procedures in Hydraulic Supply Diagnosis section of this manual Oil pressure and oil flow must be within the vehicle manufacturer s specifications The following diagnosis charts list possible symptoms causes and corrective action Careful and complete diagnosis will enable you to solve steering problems quickly Note Keep in mind that the same problems that upset manual steering will also affect power steering Page 10 SHEPPARD POWER STEERING SERVICE MANUAL Symptom Oil leaking at output shaft of steering gear Oil leaking at actuating shaft of steering gear Damaged actuating shaft seal surface Oil leaking at supply pump drive shaft Oil leakin
402. plunger exerts force on the spring seat graduating spring and No 1 piston The No 1 piston which contains the exhaust valve seat closes the No 1 exhaust valve As the exhaust valve closes the No 1 inlet valve is moved off its seat allowing No 1 air to flow out the No 1 delivery port APPLYING NORMAL OPERATION NO 2 CIRCUIT PORTION When the No 1 inlet valve is moved off its seat air is permitted to pass through the bleed passage and enters the relay piston cavity The air pressure moves the relay piston which contains the exhaust seat and closes the 2 exhaust valve As the No 2 exhaust valve closes the No 2 inlet valve is moved off its seat allowing the No 2 air to flow out the No 2 delivery port Because of the small volume of air required to move the relay piston action of the No 2 circuit portion of the valve is almost simultaneous with the No 1 circuit portion APPLYING LOSS OF AIR IN THE NO 2 CIRCUIT Should air be lost in the No 2 circuit the No 1 circuit portion will continue to function as described above under Normal Operation No 1 Circuit Portion APPLYING LOSS OF AIR IN THE NO 1 CIRCUIT Should air be lost in the No 1 circuit the function will be as follows As the brake treadle is depressed and no air pressure is present in the No 1 circuit supply and delivery poris the No 1 piston will mechanically move the relay piston allowing the piston to close the No 2 exhaust valve and open the
403. points above center line C 21 CARE AND MAINTENANCE Insert straight end of return spring in shoe web and hook rounded end into backing plate catch Install brake shoe levers formed pressure points contacting web pressure points Insert operating lever through top abutment slot Lubricate with specification 0 615 the wedge assembly side slots and install by spreading the shoe and lever assemblies Insert adjusting spoon through slotted hole to engage lugs on adjusting bolt Move handle up or down using slot end as a fulcrum To expand shoes move tool handle down when in the L H slot and move tool handle up when in the R H slot Shoe liners should be brought out tight against the brake drum Adjusting bolt should then be backed off until the drum can rotate freely Brake shoes should be adjusted individually Replace adjusting slot cover VEE BRAKES The VEE brake is a mechanical wedge shoe type brake The wedge shoe and liner assembly when actuated into the V of drum is equally effective in forward and reverse The drum mounts on the shaft to be controlled and pressure is applied through the lever The VEE brake is used both as a service brake and a parking brake he VEE brake can be completely assembled before mounting into its enclosure VEE BRAKE LAYOUT BRAKES F M M NO 4 HOUSING LEVER CAM SHOE RETURN SPRING SHOE AND LINER ASSEMBLY DRUM ee DISASSEMBLY A Unhook return spring
404. r design 4 Special spindle and 5 drop 5 Tubular center 5 Special spindle and wheel end 7 Center Point steer design TABLE OF CONTENTS SUBJECT DISASSEMBLY FRONT 8 Remove the Steering PREPARATION FOR ASSEMBLY MEUM MEME M FECONCITIONING of 5 e qe erent ge BY a a Corrosion Aluminum Beam Galvanic Corrosion nnn nn lise ee T Tie Rod and Tie Rod End nennen nennen nennen nnne nnne Rebuilding Tie Rod End nennen nennen nennen nnn nn nhan nna nnne nnne nna nnns Wheel Bearing Repair and Check Procedures for Aluminum Beam ASSEMBLE FRONT 222000 100000000000000 assises ss nsn Heplacement of Bronze or Steel Backed Bronze Steering Knuckle Bushings Bushing Removal and Installation 0 nennen nnne nnn nnns OM
405. r bushings are to be installed 135 to 165 from the inner knuckle yoke faces The grease hole in the bushing must line up with the grease hole in the knuckle BUSHING SIZING METHODS D ELRIN BUSHINGS No Sizing Required BRONZE BUSHINGS Recommended Method Reaming this is the only method of sizing bushings which gives accurate size and alignment of bores as good as a new factory finished part Single purpose piloting reamers per the illustration and charted dimensions are the best An acceptable but less accurate reamer is a multipurpose adjustable piloting reamer One reamer through trial and error can accurately be sized to fit several axle sizes This is not a preferred method since the cutter cannot be gaged for diameter and bushing bore alignment is not very accurate It is however a more universal and affordable tool Methods Not Recommended Burnishing burnishing bars and balls are seldom the correct size and do not provide alignment of the upper and lower bushing bores Honing although this is the most universal method of sizing bushings it is not recommended because it does not provide good bushing bore alignment Bushing bore size is good with this method EASY STEER BUSHINGS Reaming as with bronze bushing a new axle finish can only be accomplished with a reamer See details under Bronze Bushings Methods Not Recommended Burnishing the Easy Steer bushing material is too resilient to be sized wit
406. r harness behind the inverter front panel under the AC outlet 7 Connect the adapter harness to the vehicle voltage regulator circuit board with the BLUE wire closest to the edge of the board as shown on the label inside the housing __ 8 Connect the other end of the adapter harness to the vehicle end of the small inverter control harness 9 Mount the VVR housing and ground the GREEN wire from the adapter harness using one of the inverter tie down bracket mounting screws and the large spot faced mounting hole on the flange of the VVR housing 22210 Pull apart the RED and BLACK plastic connectors from the vehicle end of the inverter power harness and connect them together to connect alternator to battery Copyright 1981 DYNAMOTE CORP F2134E section XI 12 81 TROUBLESHOOTING AND SERVICE 4 3 0 TROUBLE SHOOTING GUIDE FOR DYNAMOTE SERIES A DYNAMIC INVERTERS Introduction This Troubleshooting Section takes the most common symptoms of inverter failure and suggests probable causes and solutions The objective is to provide relatively simple solutions for 90 of the problems that will be encountered Only the simplest of tools and instruments are required a Volt Ohm Meter which reads to 100VDC socket wrenches and a screw driver A 10 extension on the socket wrench will be helpful if the cathode leads to the SCRs must be removed The remaining 10 of the possible problems are often intermittent or less obvious and require more sophi
407. r one of the other two screws as a ground may result causing no output or uncontrolled output SLIP RING SERVICING If the slip rings are dirty they may be cleaned and finished with 400 grain or finer polishing cloth Spin the rotor and hold the polishing cloth against the slip rings until they are clean CAUTION The rotor must be rotated in order that the slip rings will be cleaned evenly Cleaning the slip rings by hand without spinning the rotor may result in flat spots on the slip rings causing brush noise Slip rings which are rough or out of round should be trued in a lathe to 002 inch maximum _ indicator reading Remove only enough material to make the rings smooth Figure 19 Checking rotor DELCOTRON INTEGRAL CHARGING SYSTEM and round Finish with 400 grain or finer polishing cloth and blow away all dust BEARING REPLACEMENT AND LUBRICATION The drive end frame bearing is sealed on both sides and cannot be lubricated To replace the bearing press the rotor from the end frame remove the retainer plate and press the bearing from the end frame Use a tube or collar that just fits over the outer race to press the new bearing into the end frame Figure 21 Only The bearing in the slip ring end frame should be replaced if its grease supply is exhausted No attempt should be made to relubricate and reuse the bear ing To remove the bearing from the slip ring end frame press out with a tube or colla
408. r s specifications 95 P S l was chosen only for the purpose of explanation PP 7 CONTROL VALVE T E c2 H 11471 E 9 Ww v t 2 p E TE mO 1 TF 1 SERVICE RESERVOIR x PIPING DIAGRAM Figure 4 Charging Below 55 p s i 2 Service Piston B reservoir 24 AE 1 Service reservow Check valve 4 4 Inlet amp Exhaust d Double MEM Park control check valve Figure 4 System fully charged 2 Service reservoir 1 Service a reservoir Park control Park contro OPERATION NORMAL SERVICE RESERVOIRS 1 amp 2 CHARGED When a service application is made by actuating the dual brake valve air from the No 2 delivery circuit is delivered from the brake valve to the control port and is stopped at the closed inlet of valve A movement of the internal components of the SR 1 takes place Air from the No 1 delivery circuit of the dual brake valve actuates the service section of the spring brake actuators Piston B Check valve Inlet amp Exhaust 8 Check valve Inter amp Exhaust 8 OPERATION SERVICE APPLICATION WITH LOSS OF NO 2 RESERVOIR PRESSURE In the event air pressure is lost in No 2 reservoir the No 1 reservoir as well as the parking control valve will be protected through the action of the double and single check valves in the air system A service application of
409. r that just fits inside the end frame housing Press from the out side of the housing towards the inside To install a new bearing use the tube or collar to press the bearing in from the outside of the housing towards the inside to the dimension shown in Figure 21 Fill the plug with Delco Remy 1948791 lubricant so that when pressed in flush with the end frame the grease reservoir will be half filled Insure that Page 9 Checking stator Service Bulletin 1G 285 some of the lubricant will be contacting the bearing when the plug is assembled Use a new seal and press in to the dimension shown in Coat the seal lip with the lubricant to facilitate assembly of the rotor shaft into the bear ing Note that the lip of the seal is toward the bearing Figure 22 Only The type bearing shown in Figure 22 5 a complete assembly and the bearing seal and grease reservoir cannot be separated To replace the bearing assembly push out from either end Push the new bearing in as directed in The bearing need not be relubricated REASSEMBLY Reassembly is the reverse of disassembly To install the slip ring frame assem bly to the rotor and drive end frame assembly remove the tape over the bearing and shaft and make sure the shaft is perfectly clean after removing the tape Insert a pin through the holes to hold up the brushes Carefully install the shaft into the slip ring end frame assembly to avoid damage to
410. rdened wear pads Rw Excessive lubricant should be avoided as grease soaked lining cannot be salvaged or cleaned The use of meter type fittings which have a maximum 40 lb pressure relief or shut off is recommended for all fittings on camshafts Wheel cylinders should be checked for leaks and damaged boots replaced It is recommended that ill new lock rings be installed where used Wheel bearings should be properly adjusted before making brake adjustments Linings should not be allowed to wear to the point where rivets or bolts may contact brake drums SERVICE INSTRUCTIONS DH SERIES BRAKES LV AI E ERE al Ex 24 rut 4 E z EU aon rog x i i k ik Te E A 5 EM E fd n puc n ou uH y eet Hu a 8 3 mr M RR yox d LL T E pals E F 5 Eri ES AM ds ho um 4 D A TF 1 oe Em pas hais TET TA i t ea T A TTA nu S fr I FETTE d AT Louie ME NM NU X Jh gd s pps RI trei d Bg b E Iu Ted is pL j F ors mI D si E PELA i a i Tet wa acd F i 39 F t I i nu dr j ni 1 i No 1 pd 2 E i cH i Fae T m h a I E d 1 1 amp hn E E LF 1 4 2 Fi
411. re 3 5 1A Figure 3 5 1B 3 High Amperage Bypass Installation a Securely mount relay as close to the alternator as is practical with large 5 16 studs down Mounting of this relay with the studs up or horizontal would result in improper operation of the relay Use the large 4x3 4self tap screws the hardware kit for this purpose Connect the wires removed from the alternator positive output terminal in Step 2 above along with the BLACK wire from the Dynamote harness to one of the large 5 16 studs of Relay K3 This connection provides charging current to the vehicle battery system Connect a length of 4 AWG wire from the other large 5 16 stud to the positive output terminal of the alternator Connect a 16 or 18 AWG wire from the chassis of Relay to ground Connect the BROWN wire from the Dynamote harness to the small 10 stud of Relay This may have to be done through a jumper wire to the BROWN wire connected to the autothrottle solenoid valve if used 4 This step is required only if relay is not installed Connect the wires removed in Step 2 above to the BLACK wire from the Dynamote harness using the small bolt and nut provided in the hardware package Items 3 4 5 Tape this connection to prevent an electrical short This connection provides charging current to the vehicle battery system Copyright 1981 DYNAMOTE CORP 12 8 1 3 5 1 BASIC INSTALLATION STEPS continued 5 10
412. re delivered with steering stop screws preset Adjustments are often made by the vehicle manufacturer to accommodate various chassis designs and tire sizes steering stop adjustments on new vehicles are therefore not required These adjustments of both axle steering stops and power steering unit should be periodically checked and corrected if necessary The stop adjustment should be checked and corrected any time any part of the steering system is disassembled replaced added or adjusted Adjust the left and right knuckle steering stops to contact when the maximum turning angle of the specific axle is reached and lock with jam nut Figure 37 Refer to torque chart on page 24 STOP SCREW Figure 37 24 NOTE Do not adjust the turn angle beyond that specified by the vehicle manufacturer POWER STEERING GEAR CYLINDER ADJUSTMENT NOTE Rockwell does not approve any power steering system without provision for pressure relief or positive mechanical stop to be set BEFORE maximum turn angle Is reached The power must be cut off or reduced substantially ahead of the axle stop to prevent unnecessary stressing of the axle components MECHANICAL RELIEF Vehicles with mechanical Pitman arm stops or assist cylinder stops should be adjusted to end the travel of the Pitman arm or cylinder 1 8 before the steering stop screw would contact the axle bosd Figure 38 KNUCKLE POSITION AFTER PITMAN ARM CYLINDER STOPS RESET _
413. reassembling Cut lock wire if used remove bolts and separate case halves Remove spider pinions side gears and thrust washers If necessary remove rivets and separate gear and Case REMOVE GEAR RIVETS 1 Carefully center punch rivets in center of head 2 Use drill 1 32 smaller than body of rivet to drill through head 3 Press out rivets EXAMPLE OF HOW HOLES IN FLANGE WERE ELONGATED WHEN RIVETS WERE CHISELED OUT anA La PETERE Tes Bo o ug i TEL URN E Te E If necessary to replace differential bearings remove with a suitable puller and or press REMOVE PINION AND CAGE ASSEMBLY A Hold flange or yoke with suitable tool and remove pinion shaft nut and washer CARE AND MAINTENANCE B Remove flange or yoke with a suitable puller Driving the flange off will cause runout C Remove pinion cage stud nuts or capscrews D Remove bearing cover and oil seal assembly 1 d i x Mg dst ita T E Remove bearing cage Original may have puller holes The use of a pinch bar will damage the shims Driving pinion from inner end with a drift will damage the bearing lock ring groove F Wire shim pack together to facilitate adjustment on reassembling DISASSEMBLE PINION AND CAGE ASSEMBLY A Tap shaft out of cage with soft mallet or press s
414. red unserviceable OPERATING AND LEAKAGE TEST FOR TWO COMPARTMENT RESERVOIR CHECK VALVE 1 Determine the direction of the air flow 2 Build up system air pressure to governor cut out and turn off engine 3 Completely drain compartment 1 Figure 1 NOTE It may be necessary to remove automatic drain device if so equipped 4 To determine pressure retention in 2 compartment perform one of the following tests a Check dash gauge if connected to 2 compartment b Apply service brake if supplied from 2 compartment Momentarily open drain device on 2 compartment DO NOT COMPLETELY DRAIN 2 COMPARTMENT 5 Apply a soap solution to the drain ferrule 1 compartment A slight bubble leakage is permitted If 2 compartment fails to hold air pressure or if excessive leakage is evident at the drain ferrule of 1 compartment the check valve should be inspected for serviceability and its parts replaced if necessary SEHwWICE EACH MILES OR EVERY f MONTHS WITH FIELD MAINTENANCE KIT 282350 CONSISTING OF 1 245 CHECK VALVE 1 24528 CUIDE 1 246225 SPRING DHS O RING COMPARTMENT ee a DISASSEMBLY GENERAL There are two types of two compartment reservoir check valves and they are 1 The old ball style check with a removable seat and a seat sprind see Figure 2 2 he new flat style that has a non removable stainles
415. require Rockwell Material Specifications by writing to Rockwell an API GL 1 or 2 grade of lubricant Gear lube not International Heavy Vehicles Components Operations meeting these requirements will not provide adequate 2135 West Maple Road Troy Michigan 48084 service life and premature failures of the gears will occur It is important that the following lubrication specifications As a quick guide to Rockwell Material Specifications the be adhered to following are very brief descriptions of the various recommended lubricants specific cross references and IMPORTANT It is advisable to consider the outside climatic temperature ranges They are not reputation of the or vendor when meant to replace the complete specifications or to serve selecting a lubricant He is responsible for the in their place quality and correct application of his product In ROCKWELL A MINIMUM MAXIMUM LUBRICANT DESCRIPTION CROSS REFERENCE OUTSIDE _ OUTSIDE SPECIFICATIONS TEMPERATURE TEMPERATURE 6 1 1 GLLSAE90 06x ___ SAE AO pM GE Hypoid Gear PNE BERTI MENGE Hypoid Gear Oil MESS HieodGew OL GES SAE 5 Hypoid Gear GLSSAE EMO 15 F 26 1 C 40 F 40 0 616 Anchor Pin Grease Non Melting Grease with Bentone Thickeners Grade No
416. reservoir drain valve has a die cast aluminum body and cover and is normally mounted either in the bottom of the reservoir using the top port of the drain valve or in the end of an end drain available with a heater and thermostat cast into the cover for vehicles operated in subfreezing temperatures The heated DV 2 is supplied in either a 12 or 24 volt model and in bottom or end drain configuration A 1 4 male pipe adapter is supplied with all DV 2 drain valves end drain and bottom drain both standard and heated This adapter should be installed directly into the reservoir Early versions included a filter screen in the adapter The filter should be discarded Later versions may have a standard pipe nipple instead of the adapter NOTE If a vehicle equipped with a DV 2 Automatic Drain Valve s is operated in subfreezing temperatures it is recommended that an alcohol evaporator be installed and properly maintained regardless of the fact that a heated reservoir drain valve is installed alcohol evaporator provides complete system freeze up protection OPERATION Referring to Figure 1 with no air pressure in the system the inlet and exhaust valves are closed Upon charging the system a slight pressure opens the inlet valve Figure 2 which permits air and contaminants to collect in the sump The inlet valve remains open when pressure is ascending in the system until maximum governor cut out pressure is reached The spring actio
417. ries can be ordered from DYNAMOTE for use with the Dynamic Inverter Control Head 4 101 Provides remote Start Stop switches and voltmeter on 15 foot harness Plugs into receptacle on inverter instrument panel and mounts on top of or under a convenient surface where remote control is desired Autothrottle 4 306 Throttle control to automatically in crease engine to one preset speed when inverter energizes Energized by BROWN wire in inverter harness 2 OTHER DYNAMOTE PRODUCTS 2 7 1 2 7 2 2 7 3 2 7 4 2 7 5 2 7 6 2d otatic Inverters 500 to 6000 watts of dependable 120 240 VAC power from batteries at input voltage levels of 12 to 120 VDC Easy to install offering high surge capacity with quiet nonpolluting operation Battery Chargers From 10 to 40 amps precision charging capacity at 12 24 and 32 VDC You can rely on continuous charging at rated capacity automatic equalization between battery cells a constant float voltage and input voltage compensation Alternator Boosters Boosts alternator capacity to 200 amps from 130 amps to handle heavy DC loads Power Switch Automatically changes power source from inverter power to utility shore power 15 to 30 amps capacity Voltage Guard Digital battery voltage monitor with visual and audible alarm when charging system voltage falls below safe level Useful in vehicles with heavily loaded DC systems such as emergency and utility vehicles Available for 12 24 32
418. ring cap until flush with top Turn bearing cap over and evenly install the high pressure oil seal until it rests against the backup washer Lubricate all three seals with grease before installing actuating shaft assembly Caution If the backup washer is not installed properly the oil leak will return on the first application of pressure Page 36 SHEPPARD POWER STEERING SERVICE MANUAL Press the actuating shaft into the bearing cap Reinstall the bearing retainer Tighten retainer securely to keep the bearing from having end play Install a new lock pin VARIATION VERY EARLY PRODUCTION BEARING CAPS Some early production steering gears used two seals in the bearing cap and the back up washer was machined in the bearing cap housing Use a screwdriver to pry out the dirt seal S 77 With the dirt seal removed two access holes to the high pressure seal are uncovered Use a punch to tap the high pressure seal out of the housing Care must be taken to avoid damage to the housing or oil leakage will 5 78 Page 37 SHEPPARD POWER STEERING SERVICE MANUAL REPAIR SHORT SERIES OUTPUT SHAFT AND PINION The pinion gear is located and held in place on the output shaft with a retaining pin A roll pin through the pinion gear will keep the retaining pin from backing out of place To remove the pinion gear punch out the roll pin and drill out the retaining pin Press the pinion gear off the output
419. ring control With Sheppard integral design there is only ONE HIGH PRESSURE LINE from pump to gear This eliminates drift and mushy steering caused by the swelling and breathing of a complex of external pressure lines between separate valve pump cylinder and gear The Sheppard unit is mounted similar to the mechanical steering gear Accidental snagging and damage over rough terrain is avoided because GEAR DOES NOT PROTRUDE below frame Page 2 Parts wear is negligible because there are ONLY 4 MOVING PARTS With Sheppard integral design steering response is immediate and precise because the CONTROL VALVE IS LOCATED WITHIN THE PISTON This eliminates springy hydraulic pressure lines that can cause lag and hesitation In event of hydraulic malfunction BUILT IN MECHANICAL STEERING allows for safe control of the vehicle Integral Pressure Relief Valve optional pressure relief valve is available which limits the maximum pressure in the steering system This feature will avoid rapid temperature build up caused by normal pressure relief and recirculation within the pumping chamber or pump body SHEPPARD POWER STEERING SERVICE MANUAL 4 BASIC OPERATING PARTS ACTUATING SHAFT is connected to the steering column assembly with a heavy Acme thread having mulitiple starts ACTUATING VALVE is contained within the piston and threaded to accommodate the input shaft When the input shaft is turned the valve
420. rioration Replace all parts particularly rubber parts not considered serviceable during these inspections ASSEMBLY GENERAL Before assembly the O rings should be coated with sili cone lubricant BW 650 M Bendix pc number 291126 ASSEMBLY OF THE BALL STYLE CHECK VALVE Replace seat O ring and press seat into shelf Replace seat spring Install check valve and valve spring Replace O ring on cap nut and install and tighten nut ASSEMBLY OF THE FLAT STYLE CHECK VALVE Replace valve guide on valve and install valve Install valve spring Replace O ring on cap nut and install and tighten nut TEST Perform tests as outlined in Operation and Leakage Test section INSTALLATION Reservoirs should be securely mounted where they will be protected against outside damage and so they will not vibrate or move during normal operation of the vehicle vibrating reservoir usually causes broken tubing lines They should be the low point in the air brake system and all lines connected to them should drain toward the re Servoir The pipe tapped openings in the reservoir should not under any circumstances be reduced in size from original installation A drain cock or draining device must be installed in the bottom connection of every reservoir and in the case of the two compartment reservoir in each compartment first reservoir or first compartment must be protected by installing a safety valve MINOR
421. rises rapidly or appears to be uncontrolled do not completely close the valve before inspecting the pump and pressure relief valve Flow Test Minimum Recommended Flow With the engine running at a specified idle speed vehicle stationary on the shop floor and with a normal load on the front axle steer the wheels from full right to full left turn and observe the flow meter The flow must not fall below the minimum GPM flow specification Note It is important that flow be checked at normal operating temperature and with a load on the front axle or steering response complaints may not be found Inadequate flow will cause binding uneven or intermittently hard steering Flow Test Recommended Maximum Increase the engine speed to approximately 1500 RPM and note the flow rate with the steering wheel stationary Check this reading against the maximum flow rate specifications Excessive oil flow can cause high operating temperature and sluggish heavy steering response Back Pressure Normal system back pressure will be 50 to 75 PSI with the engine idling and the steering wheel stationary Back pressure is checked with the system at normal operating temperature Operating Temperatures Steering system oil temperature is best checked after two hours of normal operation Ideal operating temperature should range between 140 to 160 degrees Fahrenheit Normal operation in this range will allow for intermittently higher temperatures which will be encountered during
422. rn inverter OFF and refer to Troubleshooting Section 4 FOR MPA SERIES ONLY This unit is equipped with a Low Voltage Cutout Circuit Its function is to disconnect the inverter output from the AC loads in case of low AC output voltage e g throttle slowdown or overload When output voltage falls below 95 VAC for a sustained period of time approximately 20 seconds the unit output is turned off The inverter AC supply will not turn back on until unit is either 1 turned off and restarted or 2 engine speed is accelerated to normal operating speed for the inverter unit Adjust Automatic Throttle If optional automatic throttle is being used reconnect autothrottle linkage to carburetor Adjust chain initially so that there is about 1 2 droop in the chain at idle with the servo plunger fully retracted Now START the inverter The autothrottle should energize when the inverter starts Adjust turnbuckle on the autothrottle linkage to minimum engine speed that will maintain usable AC voltage when inverter is operating under normally expected AC load WIRE AC OUTPUT CAUTION NOTE The AC output hard wiring for Series A Inverter A60 120C is different than for A30 70D 40 120D and A60 120D and the MPA Series Inverters Be sure to follow the appropriate instructions for your specific inverter Copyright 1981 DYNAMOTE CORP 8118 Section X INSTALLATION INSTRUCTIONS 8 84 3 8 0 WIRE AC OUTPUT continued 3 8 1 Model A60 120C A In
423. rning the armature by hand Failure to operate with no current draw indicates Open field circuit This can be checked after disassembly by inspecting internal connections and tracing circuit with a test lamp COMMUTATOR SERIES COIL 4 COMMUTATOR BRUSH SERIES COIL 4 b Open armature coils the commutator for burned bars disassembly c Broken brush springs worn brushes high insulation between the commutator bars or other causes which would prevent good contact between the brushes and commutator 5 Low no load speed and low current draw indicate a High internal resistance due to poor connections defective leads dirty commutator and causes listed under Number 4 6 High free speed high current draw indicate shorted fields If shorted fields are suspected replace the field coil assembly and check for improved performance Inspect badly after COMMUTATOR BRUSH SERIES 4 SHUNT COMMUTATOR COIL 2 SERIES COIL 2 Figure 11 Typical motor circuits Page 6 CRANKING MOTORS 1 M 153 Service Bulletin DISASSEMBLY Normally the cranking motor should be disassembled only so far as is necessary to make repair or replacement of the defective parts As a precaution it is suggested that safety glasses be worn when disassembling or assembling the cranking motor Intermediate Duty Clutch Motor 1 Note the relative position of the solenoid lever housing and
424. rrosion protection high and low temperature characteristics oxidation stability shear stability etc All substitute products are subject to Rockwell approval Universal Joint Grease 0 637 Special Rust Preventing Brake Grease 6 OIL VISCOSITIES For service purposes and the convenience of description in this Field Maintenance Manual the term Standard indicates a lubricant of proper viscosity for average temperature conditions during the spring summer and fall in the continental United States except for Alaska and a part of the continental United States during winter Optional viscosity lubricants should be used whenever vehicles are parked at outside temperature lower than the minimum given for the Standard lubricant The proper viscosity of oil for the specific component shall be selected from the Outside Temperature columns on the Recommended Lubricants chart Where more than one lubricant can be selected from this table the higher viscosity oil should be used Experience has shown that the use of an S A E 140 viscosity grade lubricant Rockwell specifications 0 63 O 73 0 76 0 76 A and 0 76 will result in longer gear life Unusual temperature or operating conditions may require other or more specific lubricant recommendations Rockwell will review these circumstances upon request and make optional gear oil or grease recommendations It is essential that all details
425. rter with a bolt and 7 16 nut The SCR does not have to be removed from heat sink for this test The heat sink and anode are at the same potential 6 Check resistance across 5CR with positive lead from Ohm Meter on heat sink and negative lead on the cathode which was removed from ground stud See illustration If resistance reading is less than 1000 Ohms the SCR is shorted and should be replaced A resistance reading of 100 000 Ohms to infinity 03 indicates that the SCR is not shorted GROUND ANODE TO CATHODE READING 100K TOc IS OK 4 STUD CASE NOTE BE SURE EITHER STUD OR GROUND WIRE OF SCR IS REMOVED BEFORE CHECKING SCR 7 To replace the SCR do the following a If the inverter has one inch holes in the slotted area behind the heat sink pop the plastic plugs out of these holes from the inside with a screwdriver If the inverter does not have holes in the slotted or louvered area behind the heat sink then the heat sink must be removed by removing the four screws at the corners b Disconnect the small connector in the SCR gate lead Remove the SCR using the 7 16 socket if it is an A30 or the 3 4 socket for an A40 or A60 leaving as much of the white thermal compound on the heat sink as possible Copyright 1981 DYNAMOTE CORP Section XI F2143E TROUBLESHOOTING AND SERVICE 12 81 4 3 9 SCR CHECKOUT PROCEDURE continued d Install the new SCR making sure that the nut is on v
426. rviced the same as the fixed miter cap and the swivel miter cap Follow repair instructions previously outlined 5 16 When the miter housing is reassembled to the steering gear the backlash must be adjusted to zero Remove or install housing to bearing cap gaskets shims to obtain zero backlash Once the miter housing is in place and the gear clearance has been checked and adjusted the second input shaft and miter cap is installed Again the gear clearance must be adjusted by removal or addition of gaskets shims to obtain zero backlash Fill the miter housing with Fiske Multi Purpose Grease or an equivalent waterproof lubricant until a small quantity comes out the relief valve opposite the lube fitting 5 168 Page 66 SEA Aen The Sheppard T box miter has two input shafts and is used where dual steering controls are desirable The box housing can be swiveled a full 360 degrees to place it in its optimum design position Note The miter housing in most cases will be indexed to the bearing cap with a roll pin which passes through the clamping bar and enters a drilled hole in the miter housing This ensures that the miter housing is placed in its optimum position The locating pin will also keep the housing from turning in service During re assembly make sure that the locating pin is properly installed Page 65 SHEPPARD POWER STEERING SERVICE MANUAL The steering gear bearing cap and high pressure oil se
427. ry condition and the engine is known to be functioning properly remove the motor and follow the test procedures outlined below CRANKING MOTOR TESTS Regardless of the construction never operate the cranking motor more than 30 seconds at a time without pausing to allow it to cool at least two minutes On some applications 30 seconds may be excessive Overheating caused by excessive cranking will seriously damage the cranking motor without thermostat With the cranking motor removed from the engine the armature should be checked for freedom of rotation by prying the pinion with screwdriver Tight bearings a bent armature shaft or a loose pole shoe screw will cause the armature to not turn freely If the armature does not turn freely the motor should be disassembled immediately However if the armature does rotate freely the motor should be given a no load test before disassembly No Load Test Fig 9 Connect a voltmeter from the motor terminal to the motor frame and use an r p m indicator to measure armature speed Connect the motor and an ammeter in series with a fully charged battery of the specified voltage and a switch in the open position from the solenoid battery terminal to the solenoid switch terminal Close the switch and compare the r p m current and Page 5 CRANKING MOTORS Service Bulletin 1M 153 voltage reading with the specifications in Service Bulletins 1M 186 1 187 or 1M 18
428. s steel seal see Figure 3 Both types of check valves are located in a housing large ferrule with a cap nut cover They are generally located on top of the reservoir shell DISASSEMBLY OF THE BALL STYLE CHECK VALVE Figure 2 Block and hold vehicle by means other than air brakes Completely drain compartments 1 and 2 Hemove cap nut and cap nut O ring Remove check valve and check valve spring Remove seat spring With a hook or similar device carefully remove the check valve seat and its O ring so as not to mar or scratch it VALVE SEAT SPRING CHECK VALWE TWO COMPARTMENT RESERVOIR WITH CHECK VALVE Figure 1 CAP NUT O RING FIELD MAINTENANCE KIT 281553 CONSISTING 12952954 VAL WE SPRING 1 241083 CHECK 1 234045 O RING 1 239949 O RIMG 3 243835 SEAT PRING VALVE SEAT COMPARTMENT 2 DISASSEMBLY OF THE FLAT STYLE CHECK VALVE Figure 3 Block and hold vehicle by means other than air brakes Completely drain compartments 1 and 2 Hemove cap nut and cap nut O ring Remove valve spring Remove valve and valve guide CLEANING AND INSPECTION Wash all metal parts in a good cleaning solvent and dry them thoroughly All rubber parts should be wiped clean Inspect springs for distortion corrosion and cracks Inspect valves and valve seats for nicks cuts and burrs Inspect all rubber parts for swelling and dete
429. s shorted if above the specified value the winding has excessive resistance The specified resistance value can be determined by dividing the voltage by the current given in Bulletin 1G 187 Remember that the winding resistance and ammeter reading Page 8 1G 285 Service Bulletin Figure 18 Parts stack up and ohmmeter checks Stator and diode trio removed will vary slightly with winding temperature changes STATOR CHECKS Omit for overcharged battery The stator windings may be checked for grounds with a 110 volt test lamp or an ohmmeter If the lamp lights or if the meter reading is low when connected from any stator lead to a clean me part of the frame the windings grounded Fig 20 The delta windings cannot be checked for opens or for short circuits without laboratory test equipment However if all other electrical checks are normal and the generator fails to supply rated output butt will supply at least 10 amperes output shorted stator windings are indicated BRUSH HOLDER AND REGULATOR REPLACEMENT After removing the stator and diode trio the brush holder and regulator may be replaced by removing the two remaining screws Note the two insulators located over the top of the brush clips and that these two screws have special insulating sleeves over the screw body above the threads The third mounting screw may or may not have an insulating sleeve If not this screw must not be interchanged with eithe
430. s and machine screws C 45 are provided with foot plate For 30 45 and 50 min rated air cylinders SCUBA 72 cyhnd Model F For SCUBA cylinders Foot Plate only SPECIFY SIZE REQUIRED gig a RPE Ue wage cee el Le BOR Gad Ope BERS Re be oh SN E X PN T 6 A i ere bk t b a LET c Ed EARS servi Section VIII MISCELLANEOUS RTLAND OREGON 97207 4 TRL a ruck hood battery box hatch cover fasteners to plus 350 F Flexible quiet Huntington Hood Hooks rust never corrode Require no lubrication yet provide i positive fastening and unfastening with smooth effortless with a temperature range from 65 F to 250 F Normal WV ed length 115 of overall as manufactured length PEEWEE MODEL HRC No 71D1376 our smallest v 0 10 model Ideal size for small hoods and access panels T Pd Bc STEM DOWN STEM UP HOOD BRACKET HOOD BRAGKET 28A382 028 112 028 561 028 750 NOTE Determine stretch or holding force required from load dellection chart and add zero stretch dimension A or B to locate hood bracket in relation to anchor bracket 20 30 Section VIII MISCELLANEOUS ULTIMATE BREAKING LOAD IN EXCESS OF 350 POUNDS 40 50 60 170 PULL IN POUNDS EASY POSITIVE FASTENING ACTION Bis M s 4 MES 2 0 0 5
431. s for recommending lubricant changes Fluid lubricants serve more than one purpose They not only lubricate but they transport chemically reactive additives they wash away minute wear particles serve as a corrosion inhibitor and also act as a heat transfer medium Draining and refilling with a fresh supply assists in eliminating both magnetic and non magnetic wear particles which may not have been trapped by a magnetic plug Exposure to heat and use may also alter the desirable performance properties which are reassured through a lubricant change A regular schedule for changing the axle lubricant in a particular vehicle and operation can be accurately determined by analysis of samples taken from the assembly at specified intervals or mileages The lubricant supplier frequently makes available his laboratory facilities for determining the useful life of his product under actual service conditions The finally recommended schedule may be correlated for economic reasons with lubricant changes governed by climatic conditions magnetic drain plug maintenance Lubricant changes should be made as climatic temperatures demand regardless of vehicle mileage or established change schedule Refer to pages 8 through 24 for recommended lubricants and change intervals of specific equipment being serviced IMPORTANT The normal operating temperature of compounded lubricants during the summer season is approximately 160 F to 220 F 71 C 104 C
432. s or damage Replace all parts not considered serviceable during these inspections ASSEMBLY Position parts in proper order in body Install O Ring or gasket on cap nut A new gasket should always be used Screw cap nut in body and tighten securely Care should be taken that disc valve is not lodged between cap nut and body when assembling TESTING OF REBUILT SINGLE CHECK VALVE Perform Operating and Leakage Checks IMPORTANT PLEASE READ When working on or around brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended pressure and always wear safety glasses when working 4 Never attempt to disassemble a component until you have read and understand recommended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools 9 Use only genuine Bendix replacement parts and components A Only components devices and mounting and attaching hardware specifically designed for use in hydraulic brak
433. s shown in Figure 2 1 A below for each model 11 Miscellaneous See following page 2 1 1 INVERTER SPECIFICATIONS Watts Amps Surge Max Ship Required 120VAC 120 ping Intake Model Out Out AC Char Dimensions Wt Cooling Number put put Amps ging HxWxD Lbs Air CFM 0 70 3600 30 60 70 9 3 4 x 14 1 4 x15 70 120 40 120 4800 40 60 120 9 3 A x 17 x 14 105 200 60 120 6000 50 75 120 9 3 4 x 17 1412 105 200 A60 120A 7200 60 80 120 9 3 4 x 17 147 90 200 MPA30A 3600 30 60 70 9 3 4 x 14 1 4 x15 72 120 MPA40A 4800 40 75 120 9 3 4 x 17 x 14 1 2 105 200 MPA60A 6000 50 75 120 9 3 4 x 17 141 92 200 A60 120A has non isolated transformer all other models have isolated output transformer Figure 2 1 1A Inverter Specifications 2 2 PRODUCT CONFIGURATION 2 2 1 Chassis Dynamic Inverters are housed in a durable aluminum chassis with four shock absorbing rubber feet Cooling air is drawn in through louvers in each side wall and exhausted out through the back panel Tie down brackets are provided with the hardware kit they attach to the four heavy bolts at the bottom of the front and rear panels of the chassis Section IX F2102F GENERAL INFORMATION 10 83 Sec 2 3 2 2 2 1 Load Demand start Stop Feature Dynamic A series Inverter Your dynamic inverter may be equipped with the optional Load Demand Start Stop feature If the feature is installed there will be a LD after the model number in the s
434. s the jaws are not tightened to the point where the case mushrooms f a vise is not accessible a pair of vise grips will do the job Push the wire back through and install the cable using the hardware from the previously mentioned wire control parts bag Step 7 Fig 12 See exploded drawing 18 WIRE SHIFT P T s continued 12 13 14 15 Cut the excess wire after the cable casing and wire have been installed and tightened Fig 13 Shift the P T O to insure enough casing has been removed to allow full gear engagement Install the wiring for the indicator light using the schematic from page 30 Fig 14 NOTE Check both the cable and indicator light wires to be certain that they are not near the exhaust system or any moving parts Carefully fasten to stationary parts of the vehicle if necessary Shift the P T O The following should be adhered to CABLE IN P T O DISENGAGED LIGHT OUT Fig 14 amp 15 CABLE OUT P T O ENGAGED LIGHT ON Fig 16 amp 17 NOTE The P T O should be checked for continuity as per the instructions in this manual 19 WIRE SHIFT INSTALLATION INSTRUCTIONS Reversibles dual shift units and some gear boxes Use step 1 5 from previous instructions In step 6 the cable can come from either direction since the P T O will always be engaged when all the way in or out Follow step 7 and 8 In step 9 shift the P T O from forward to reverse or
435. s wear safety glasses when working Never attempt to disassemble a component until you have read and understand recommended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools 5 Use only genuine Bendix replacement parts and components A Only components devices and mounting and attaching hardware specifically designed for use in hydraulic brake systems should be used B Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as the original equipment 6 Devices with stripped threads or damaged parts should be replaced Repairs requiring machining should not be attempted Section VI BRAKE SYSTEM Service Data E 6 E 10 DUAL BRAKE VALVE Heavy Vehicle Systems Group uw E oa Es nt DN XE 5 6 DUAL TREAD ER 10 DUAL TREADLE BRAKE VALVE 5S BRAKE VALVE MQUITING lf PLATE aay A E Yr Figure 1 Figure 3 D mi EP LS f lit DUAL BRAKE VALVE BASIC Figure 4 DUAL BRAKE 4 2 VALVE BASIC LACAN 410 Figure 2 DESCRIPTION The E 6 Fig 1 and E 10 Fig 3 Dual Brake Valves are The circuits in the E 6 E 10 Dual Brake Valves are identified floor mounted treadle operated type brake valve
436. s winding REASSEMBLY The reassembly procedure for each type of motor is the reverse of disassembly On motors using a snap ring and re tainer on the shaft as a pinion stop the ring and retainer can be assembled in the manner shown in Figures 20 and 21 With the retainer placed over the shaft with the cupped surface facing the end of the shaft force the ring over the shaft with a light hammer blow and then slide the ring down into the groove Fig 20 To force the re tainer over the snap ring place a suit able washer over the shaft and squeeze with pliers Fig 21 REMOVE THE WASHER To reassemble the end frame having eight brushes onto the field frame pull the armature out of the field frame just far enough to permit the brushes to be placed over the commutator Then push the commutator end frame and the armature back against the field frame On intermediate duty clutch motors be sure to assemble all brushes to the brush arms so the long side of the brush is toward the riser bars See Figure 22 LUBRICATION Al bearings wicks reservoirs should be saturated with SAE No 20 oil Place a light coat of lubricant Delco Remy No 1960954 on the washer located on the shaft between the armature and shift lever housing Washer is identified in Figure 2 Sintered bronze bearings used in these motors have a dull finish as compared to the early type machined cast bronze bearings which had a shiny fin
437. s with elements having a minimum pick up capacity of 2 pounds of low carbon steel in plate or flat bar form See Plug section in Field Maintenance Manual No 1 opare clean plugs should be kept on hand for replacement at regular intervals The change schedule can easily be established by periodic plug examination FASTENER TORQUES Rockwell employs two methods of fastener retention Original design single reduction carriers employ a lock wire Current design models employ Dri Loc bolts or Loctite 277 Rockwell Part No 2297 C 3747 Liquid Adhesive When service is required rebuild these assemblies with new Dri Loc bolts or reuse the old bolts by applying liquid adhesive to the threaded holes in the cases NOTE Dri Loc bolts or liquid adhesive is not used in nut and bolt constructed cases 21 When new Dri Loc bolts are used identified by a visible patch of adhesive on threads the locking feature is usable only once When the same bolt is reused liquid adhesive must be applied to the threaded hole in the case to achieve the locking feature Use the following procedures New Dri Loc Bolts 1 Wipe excess oil and any residue from the threaded holes in the case The holes should be relatively oil free however no special cleaning is required 2 Assemble the differential case components using the new Dri Loc bolts DO NOT APPLY LIQUID ADHESIVE OR ANY OTHER OF FASTENER RETAINER MATERIAL SEAL ANT OR ADHESIVE ON NEW
438. screws a self locking nut or by a split nut and cap screw arrangement Caution Do not pound on the pitman arm or apply excessive heat as damages to the pitman arm or output shaft could cause a serious accident at a later date Welding of the pitman arm and shaft must be avoided at all times Page 20 SHEPPARD POWER STEERING SERVICE MANUAL The pitman arm may also be drawn onto the tapered spline of the output shaft with a one piece installation and safety retainer The 592 steering gear may also use a similar installation and safety retainer However it may be of a two piece design See below S 23 S 24 To remove the retainer a short piece of 5 8 or 3 4 inch hard steel hexagon stock is inserted into the retainer The retainer is now screwed out of the output shaft The two piece retainer used on the 592 steering gear is 5 18 removed with a standard socket arrangement 5 23 5 24 Page 21 SHEPPARD POWER STEERING SERVICE MANUAL Separate the mounting bracket from the steering gear if used Seo Make reference marks on the bearing cap cylinder head and housing so that the steering gear can be reassembled in the same configuration Note The cylinder head and bearing cap will fit either end of the housing 2b Remove the relief valve plungers from the cylinder head and the bearing cap This will protect them from damage during repairs ea Mii 27 Clean the exposed portion of the o
439. scription AIR O MATIC Wire to aas oua dex wm Nn Red de t dose ace aa dulce te AR AIT TA ae qt 328390 72X LEVER CO IE Peso IN E BERN OE UI se Oo ARA bn e arco n 328390 73X WIRE amp LEVER CONTROL INDICATOR LIGHT INSTALLATION KIT 328751X HELSEA PTO U T iON pem 68 18 378978 12 VOLT INDICATOR LIGHT 3 8969 White Nylon INDICATOR SWITCH BATTERY 378884 This kit does not contain Indicator Switch 378969 eee 11 HAYES DANA INC Mobile Power Division P O Box 6000 Beamsville Ontario LOR 1BO Telephone 416 563 4991 Telex 061 5242 WALK AWAY brackets MISCELLANEOUS COE kt PEt OPS a SCY MCAS NEW NASA There is a ZICO WALKAWAY bracket thal is ideal for all uses and any self contained breathing apparatus manufactured in the United States You can selec spring tension clips to hold the cylinder firmly in place or you may prefer the spring instead Cheose a foot plate or a yoke support For additional Safety you can specify the Newark Hold down a high tensile nylon webbing with a quick release hook and lever fastener recommended when no protective cover is to be used The new NASA 40 WALKAWAY bracket was designed spe cifically for the Scott Air Pak 4 5 SCBA unit The black nylon coated clips will not mar the finish on the cylinder which can be easily and smoothly releas
440. sed in towing or moving a vehicle where the engine or hydraulic supply pump are inoperative In this instance the ability of the steering gear to protect itself is reduced and mechanical damages can be encountered An optional pressure relief valve integral with the steering gear is available on the Series 5 Steering Gears This valve limits maximum steering system relief pressure at the steering gear a point in the steering system which is farthest from the supply pump pumping chamber This effectively reduces system temperature by avoiding high pressure by pass and recirculation within the pump The Sheppard Integral Power Steering Gears have been designed to provide long service life and simple service and repair The rack and pinion gear set does not require adjustment There is no center point adjustment The high pressure seal at the input actuating shaft is the only seal which is exposed to high pressure and motion This seal is protected by a dirt seal and a salt seal which are separated by a grease pack that is flushed during lubrication The clearance between the cylinder bore and the piston is closely controlled to eliminate the need for seals on the piston With reasonable care and limited maintenance the Sheppard Steering Gear will provide many miles of trouble free and effortless performance Page 4 SHEPPARD POWER STEERING SERVICE MANUAL 5 5 SHORT SERIES 5 STEERING GEAR WITH OPTIONAL INTEGRATED RELIEF VALVE 5 2 AXLE MOUNT
441. sh to the unmounted backlash found in Step 3 on page 7 Use Gaskets to get backlash feel as close to unmounted condition as possible ADAPTER PLATES Adapter plates are used to permit mounting a 6 bolt P T O ona transmission that has an 8 bolt aperture NOTE A wire locking stud kit is recommended when mounting a 6 Bolt P T O to an adapter plate on a bottom opening FILLER BLOCKS Filler blocks may be required where it is necessary to use a spacer to mount the power take off to a particular transmission P T O APPLICATION AND ADAPTER ASSEMBLY Figure 13 illustrates typical adapter assembly configurations Some P T O applications require adapter assemblies because it is impossible to reach the P T O driver gear in the transmission without this assembly An adapter assembly will change the rotation of the P T O and this may be necessary for driving pumps or other accessory equipment Obstructions such as a bulge in the transmission exhaust pipes or motor mounts can sometimes be compensated for through the use of an adapter 12 MOUNTING ADAPTER ASSEMBLY How to mount an adapter assembly to the transmission and P T O 1 Use same procedure for mounting the adapter and checking backlash as was used when mounting the P T O to transmission See Fig 14 2 After checking for proper backlash remove the adapter gaskets and filler block if required from the transmission Keep the gaskets and filler block
442. shaft Note If the retaining pin cannot be drilled out it can be sheared off with approximately 10 tons of pressure on a press Drive half the pin out of the pinion gear and now drill the remaining half out of the shaft Caution Use safety precautions when shearing the pin under pressure To reassemble the pinion gear to the output shaft align the timing arrows on the output shaft to the arrow on the pinion gear Press the gear on to the shaft splines until the locating pin can be driven through the gear and into the locating hole in the shaft Install the roll pin through the gear To provide 100 degrees of pitman arm travel some series 5 steering gears use a one piece forged output shaft and pinion gear assembly Service of this assembly is by replacement only The 372 382 series output shaft and pinion gear are different in appearance but are serviced in the same manner as the high pressure or short series gears 5 81 372 382 SERIES 38 SHEPPARD POWER STEERING SERVICE MANUAL VARIATION LOW PRESSURE SERIES OUTPUT SHAFT amp PINION Use an allen wrench to remove the cap screws The retaining nut is now removed by turning it counter clockwise off the output shaft Press the gear off the shaft 5 83 The gear on low pressure steering gears is held to the output shaft with a retaining nut threaded to the output shaft and locked to the pinion gear with two cap screws When the pini
443. ssembly or adjusting practice 5 Spalling or flaking on bearing cup and or cone surfaces Figure 17 E 1 UN he 1 Y 15 i 1 ji 3 I aps Bo gore 1 A re qi A 1 i v l ey Figure 17 PROCEDURES FOR ALUMINUM BEAM AXLES Rockwell disapproves of heating welding altering or drilling the aluminum axle center bending Repair of the spring seat howl hole is permitted if necessary Our recommendation is to drill out the dowel hole so that the new diameter is no more than 5 larger than the original diameter Install an aluminum bushing aluminum alloy 7075 173 or 7075 176 with interference fit of 000 to 003 The bushing should be shrunk by freezing prior to installation in the enlarged hole Pressing the bushing into place at ambient temperature is not recommended Under no circumstances should the axle center dowel hole be expanded by heating during installation of the bushing NOTE If brakes require service refer to RKc6kwell Field Maintenance Manual No 4 for CamMaster Brakes Also Disc ASSEMBLE FRONT AXLE REPLACEMENT OF BRONZE OR STEEL BACKED BRONZE STEERING KNUCKLE BUSHINGS A tool used for removal of old and the installation of new steering knuckle bushings is shown below The tool can be made from a piece of round bar stock which is machined with a step to serve
444. ssure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone 4 Never attempt to disassemble a component until you have read understand recommended procedures Use only proper tools and observe all precautions pertaining to use of those tools Some components contain powerful springs and injury can result if not properly disassembled SD 03 72 4 83 m Heavy Vehicle Systems Group WORM GEAR LOCK SLEEVE ADJUST ING SCREW MOAM SHAFT ADJUSTING GEAR GREASE HOLE SPLINE POSITIVE LOCK TYPE SLACK ADJUSTER Fiqura 1 DESCRIPTION In an S cam type foundation brake the final link between the pneumatic system and the foundation brake is the slack adjuster The arm of the slack adjuster is fastened to the push rod of the chamber with a yoke and the slack agjuster spline is installed on the brake cam shaft Primarily the slack adjuster is a lever converting the linear force of the air chamber push rod into a torque which turns the brake cam shaft and applies the brakes Standard slack ad
445. st rear axle Example 5 down 10 Measure the Example 12 rear axle input yoke angle 11 With all the above angles recorded these values are checked to obtain the journal cross operating angles of each drive shaft set to determine if they are operating to within a 3 maximum of each other If the operating angles or journals exceed 3 it will cause early wear and possible seizure of the journal to the needle bearing in the journal cap TRANSMISSION OUTPUT YOKE 4 1 FRONT DRIVE SHAFT 4 30 230 5 i430 FORWARD AXLE INPUT YOKE FRONT DRIVE SHAFT GOOD CANCELLATION OF JOURNAL OPERATING ANGLES FORWARD AXLE OUTPUT YOKE 2 30 INTERAXLE DRIVE SHAFT 4 5 OF TT 45 REAR AXLE YOKE INTERAXLE DRIVE SHAFT IMPROPER CANCELLATION OF JOURNAL OPERATING ANGLES FIGURE 33 TORQUE ARM SHIMMING The adding or removing of shims from the rear axle torque arm will change the angle of the interaxle drive shaft Therefore it is necessary to take the drive shaft angle and the rear axle yoke angle after each adjustment is made to determine the journal operating angle SHORT COUPLED JOINTS Short coupled joints must be installed so that the front and rear joints will have equal angles which should not exceed 3 BULLETIN 3304 1 For further information write to Universal Joint Division Dana Corporation P O Box 374 Toledo Ohio 43601 Section DRIVE LINE
446. stalled The relay provides for proper reading of the tachometer s both when the inverter is OFF and when it is ON Refer to Section 3 5 3 2 Disconnect all wiring from the positive output B terminal of the alternator NOTE 3 If the wires disconnected in step 2 above are 10 AWG or smaller attach a 4 AWG wire to the positive terminal of the battery Route and connect this lead to the alternator wires disconnected in Step 2 This will bypass the vehicle ameter if there is one to avoid burning out with the larger alternator It is recommended that a voltmeter be installed to monitor the battery condition and inverter operation NOTE 4 A High Amperage Bypass Relay Dynamote sales part 4 7211 must be installed if your alternator output capacity exceeds the limits listed below for each inverter model POO RS 141 amps PAO FOO 141 amps If K3 is required install according to the instructions in Step 3 5 1 Step 3 below and Figure 3 5 1A If K3 is not required skip to Step 4 below and proceed following Figure 3 5 1B F2109 D 3 5 1 BASIC INSTALLATION STEPS continued 12 81 Section X INSTALLATION INSTRUCTIONS To Auto IGNITION IGNITION SWITCH throttle SWITCH RELAY 4 7211 K 3 gt ALTERNATOR J ALTERNATOR TO BATTERY AUTOTHROTTLE IF USED DYNAMOTE DYNAMOTE HARNESS HARNESS NOTE RELAY 4 7211 WITH RELAY 4 7211 K 3 WITHOUT RELAY 4 7211 K 3 Figu
447. sticated instruments and technical expertise to solve This kind of capability can be found at the DYNAMOTE factory and major warranty and repair centers about the country If the problem cannot be solved using this Troubleshooting Guide within approximately one hour then help should be sought from one of these facilities The Inverter Electrical Schematics included in Section 4 4 0 will be essential in understanding the checkout procedures and the Inverter Wiring Diagrams in Section 4 5 0 Will be useful in locating parts and terminal points The parts list is also located in Section 4 5 0 and gives Dynamote part numbers for all referenced components for use in ordering replacement parts Good luck and please drop us a line if you have ideas about how to improve this manual SPECIAL NOTE If there is a battery isolator in the electrical system in which the inverter is installed the inverter wire from the B terminal inside the back of the inverter to Pin 6 on terminal strip 1 at the front of the inverter will have been removed An additional wire directly from a battery positive source will have been connected by the installer to Pin 6 To perform the checkout procedures it will be necessary to short around the battery isolator or temporarily remove it from the system connecting the wire from the B inverter terminal directly to battery positive 4 3 1 USE OF THE TROUBLESHOOTING GUIDE If the symptom of failure is known proceed direc
448. strap for support bolted to engine or transmission There is no pump weight limit on 8 Bolt P T O s TRANSMISSION TAG LOCATIONS SPICER S HORSEPOWER TORQUE RPM CONVERSION CHART TO FIND THE TORQUE Given 100 HP at 1750 RPM TO FIND THE HP 3 foot pounds torque at Then with a straight edge on HP scale at 100 Left 1750 RPM Side and on RPM scale at 1750 Then with a straight edge on the T scale at 3 Middle and on the RPM scale at 1750 Find Answer on T scale 300 foot pounds torque Middle Find Answer on the HP scale 1 Horsepower Left Formula Side HP x 5252 T Foot Formula RPM Pounds Torque TxRPM HP 5252 Horsepower 1000 l 0 2999 30 9 8 1000 40 6 50 500 300 70 400 4 Wa 200 90 3 100 250 2 5 100 200 12 150 50 1504 15 40 200 30 100 zt 20 300 9 Bo 7 70 7 ul ce 400 6 500 50 l 5 600 700 40 4 3 8 800 35 35 277 350 30 4 3 TS IC 1000 25 1 25 204 2 ss 1500 5 15 4 2000 3 bw 3000 HP Torque Revolutions Scale Pounds Foot Scale Ber Minute Scale P T O RATINGS Horsepower Basic P T 0 Models Ai Weight Torque Approximate Rating Pounds New Old SAE Model No Model No Aperture 100 A1 2 3N 6 Boilt 125 Ibs 10 Ibs 220L amp P A22C amp D 6 Bolt 30 Ibs 220 amp A22L amp LL 6 Bolt 30 Ibs 260 26 6
449. t grease or moisture from both mating surfaces 2 Dry both surfaces 3 Apply thin bead approximately 1 8 diameter completely around one mating surface and all fastener holes to assure complete sealing and prevent leakage CAUTION Minor concentrations of acetic acid vapor may be produced during application Adequate ventilation should be provided when silicone R TV is applied confined areas Further eye contact with these silicone RTV gasket materials may cause irritation if eye contact takes place flush eyes with water for 15 minutes and have eyes examined by a doctor 4 Assemble the components immediately to permit silicone RTV gasket material to spread evenly When rebuilding any assembly always use torque values on fasteners as specified by either Rockwell or the vehicle manufacturer SINGLE REDUCTION DRIVE UNIT CAUTION Failure to use appropriate gasket material will cause axle to leak REASSEMBLE CARRIER IMPORTANT If a new gear set drive pinion and ring gear is being installed into the carrier refer to the following gear set information before starting reassembly However if the original gear set is to be installed start with Reassemble Pinion and Cage Assembly on page 11 GEAR SET IDENTIFICATION The following information is marked on current drive pinion and gear sets and will be used for identifying matching and adjusting procedures The items listed are keyed to the following illustrati
450. t the desired pressure setting of the Safety Valve is determined by the governor cut out pressure The opening and closing pressures of the Safety Valve should always be in excess of Governor cut out pressure setting The pressure setting is stamped on the lower wrench flat of the valve Normally the Safety Valve remains inoperative and only functions if for any reason reservoir pressure rises above the setting of the valve Constant popping off or exhausting of the Safety Valve can be caused by a faulty Safety Valve faulty governor faulty compressor unloading mechanism or a combination of any of the preceding PREVENTIVE MAINTENANCE Every 100 000 miles 3600 operating hours or yearly the Safety Valve should be removed disassembled cleaned and checked for proper operation See Operating and Leakage Checks OPERATING AND LEAKAGE CHECKS OPERATING TEST With air pressure in the system pull the exposed end of the valve stem removing the spring load from the ball check valve Air should exhaust from the valve s exhaust port Release the stem the air flow should stop Failure of valve to pass operating test would indicate the valve should be disassembled cleaned and rebuilt See Disassembly and Assembly section If adjustment is necessary see Adjustment section LEAKAGE CHECK Coat the exhaust port with soap solution leakage of a one 1 inch bubble in 5 seconds is permitted Excessive leakage indicates dirt in val
451. t Axle Rear Axle Steering System Fuel System Brake System Electrical System Miscellaneous Publication TM 5 4210 227 24 amp P 5 continued TM 5 4210 227 24 amp P 7 TM 5 4210 227 24 amp P 8 TM 5 4210 227 10 Section alo cO CO NOOR WD COMPLETE MANUAL TABLE OF CONTENTS Continued Section Title General Information Installation Instructions Troubleshooting and Service General Information Engine less major assemblies Fuel System and Governors Air Intake System Lubricator System Cooling System Exhaust System Electrical Equipment Instruments and Protective Systems Power Take off and Torque Converter Transmissions Sections 10 and 11 not included Special Equipment Operation Tune up Preventive Maintenance Troubleshooting and Storage Parts List and Foldouts Tools and Equipment Introduction Tabulated Data Operator s Instructions Operator Maintenance Illustrations Operator s Manual Series 92 Engines Operator s Manual Series V 71 Engines Built in Parts Book for Detroit Diesel Engines Operator s Manual Fire Apparatus Chassis FOREWORD Descriptions instructions and parts listing pertaining to the Model QWT 85 are discussed throughout this manual under the general headings Chassis Pump and Ladder Foldout illustrations and schematics are located at the rear of this volume The foldout format is provided in order that illustrations and schema
452. t P ORE ME Tus OE EAS ee Sp AUI MIN a ae Meu di EAE ye gt HANDLES Flush Type Play eG FS PEOR UT nine atc 57 X EC ND Cr LE S PE RP BADEN S DEA TL te oa E LIE E NEIDE PERGIT gt TAS P y E KEHON e gg NE de pd P r h f gt 4 as z A Sp EO ELS REM RD exeo ER Pel e VPE In Ru es e RANT ITE Y tta ER aree frr Ma Re ay Doe ERR ec a on 32 cta n S YA T tel ed ar A L7 0 AD Mtn cas te oy Pe Md 27 um m s s square Flange zinc or chrom ee square Flange 1 27 Plain finish standard zinc or chrom Recess 1 2 deep ium finish also available Wt 13 oz is standard zinc or 5 16 Recess d d dia long 5 16 long 15 16 5 32 Plain finish standard Plain finish chromium finish also available Weight 1 Ib 3 02 M FLUSH HANDLE dia 1 8 Se amp ddgen Wii MISGEEULANEQOOS Shank 3 1 8 long 5 16 square Flange 79 5 FLUSH HANDLE Special length shanks available on special No 79 L FLUSH HANDLE ium finish also available Wt 1 Ib Handle 6 1 8 3 4 order No 79 Handie 4 Shank 3 1 8 E a N M Re E
453. t after the first 1000 miles 1600 km but never later than 3000 miles 4800 km Drain the lubricant while the unit is still warm from the carrier housing and if a drain plug is employed from the inter axle differential of the forward carrier of tandem axles e Heavy duty on highway on off highway and off highway service Check levels every 1000 miles 1600 km Drain and refill to bottom of filler hole or top of filler neck every 25 000 to 30 000 miles 40 000 to 48 000 km when yearly mileage is in excess of 60 000 miles 96 000 km If yearly mileage is less than 60 000 miles 96 000 km change twice a year spring and fall e Regular common carrier type duty on highway service Change every 100 000 miles 160 000 or once a year if yearly mileage is less than 100 000 miles 160 000 km e Output bearings two tapered bearing design only at overhaul time only the output bearings must first be coated with oil then packed with 0 622 grease Refer to following lube procedures e Oil filter Replace the oil filter of units employing a pump forced lubrication system every time the oil is changed e Oil pump SQHP only on and off highway models New units Pre lubricate oil pump gears with 2 oz 56 gr of recommended axle lubricant through the oil pump to filter passage Reconditioned units Pack the pump cavity with grease 0 622 before installing pump cover LUBE PROCEDURES e After filling drive unit and or housing with lubricant add tw
454. t change intervals The Series 5 steering gears be operated with hydraulic fluid or Dexron Motor oil is preferred See Vehicle Manufacturer s Recommendations The power steering pump reservoir must be kept filled to the proper indicator level and free of air When filling the reservoir start the engine and turn the steering wheel from left to right and continue filling until proper level is maintained See final adjustments section for system bleeding procedures A replaceable type filter element is located in the pump reservoir Carefully clean any build up of dirt and grease from the reservoir cover Remove the reservoir cover and filter element Clean inside of reservoir with a lint free cloth Install a new filter element refill with oil and replace cover The filter element should be changed when the oil in the steering system is changed LUBRICATION BEARING CAP To lubricate the dirt and salt seals in the bearing cap and flush out any contaminants that have passed these seals chassis grease should be added with low pressure when the vehicle is serviced The grease between the dirt and salt seals protects the actuating shaft from rust and corrosion and in addition keeps foreign materials from getting into the high pressure seal area The bearing cap should be serviced at least four times a year more frequently where the truck is operating in an atmosphere where dust and abrasive or corrosive materials are present ADJ
455. t frame to bracket or bracket to gear Rack on piston damaged Damaged pinion gear on output shaft Damaged output shaft splines Worn output shaft bushings Worn actuating shaft and valve threads Free play in miter gears of angle drive Damaged reversing springs Universal joint yoke loose on No positive caster Steering column bind Steering gear mounting distorted bore interference Linkage ball sockets seized or binding Page 15 SHEPPARD POWER STEERING SERVICE MANUAL Remedy Replace universal joint Replace pins and keys Check flow divider and pump drive belts Replace pitman arm assembly where riveted ball is used or only where bolted ball is used vertical socket Adjust drag link drag link to pitman arm and drag link to steering arm Remove bracket clean frame and bracket check radius of frame making sure bracket is not bearing on radius surface Check bracket for wear from working Replace bracket and tighten to recommended torque rating according to size and grade of bolts If necessary replace bracket with new one Replace parts as required Replace pinion gear Replace output shaft Replace bushings and polish shaft to remove bronze deposits Replace worn parts as required Follow Hydraulic Supply Diagnosis procedures to locate cause of wear Remove miter gear housing shims to mesh gears Check and repair as required Repair or replace damaged parts actuating shaft Set to 4 to 6 positive cas
456. t is not necessary to remove the bearing Fig 1 20 on the output end of the shaft unless it has been damaged or is worn excessively If it has to be removed this can be done using the bearing Photo 13 pullers after the shaft has been removed from the housing DISASSEMBLY 22 26 Series cont 9 Remove snap ring Fig 1 15 on C3 and C5 10 After removing the shaft Fig 1 42 the gear Fig assemblies only using a chisel and hammer Photo 1 4 and spacer Fig 1 6 will simply fall out of 14 the housing Photo 15 Photo 15 11 Inspect all parts for excessive wear or other damage All gaskets and seals should be discarded and all milled surfaces on the housing should be cleaned of any excess gasket material Photo 14 REASSEMBLY A22 26 Series ASSEMBLY ARRANGEMENTS B Determine snap ring placement 1 C4 amp C6 snap ring is on shaft before putting through gear Photo 2 ASSEMBLY ARRANGEMENTS Figure 2 Assembly Arrangements 1 Output Shaft Assembly Photo 2 A Select proper assembly arrangement Fig 2 and place output gear Fig 1 4 in housing 2 Photo 1 amp C5 shaft is put through gear before snap ring is driven onto shaft Photos 3 amp 4 NOTE Snap ring Fig 1 15 is always located next to the spacer Fig 1 6 in the 22 amp 26 series Photo 1 Photo 3 REASSEMBLY 22 26 Series cont Photo 4 Photo 5 Start small bearing Fig 1 21
457. t may be used at the discretion of the repairer SAFETY NOTICE The repair procedures outlined in this manual are intended to be used as a guide for repairing the Sheppard Integral Power Steering Gear To ensure safe and reliable operation service and repair procedures should be carefully considered For each repair a limited number of special tools are required and should be used as recommended This manual contains a number of cautions and notes that should be read carefully in order to avoid personal injury or faulty repairs which could cause a vehicle accident at a later date It is not possible to know evaluate and advise the repairer of all possible ways in which repairs might be completed or of the possible hazardous consequences of each Way The repairer must ensure himself that the repair procedure he selects to use will not endanger his personal safety nor safe operation of the vehicle SHEPPARD POWER STEERING SERVICE MANUAL How to use this manual This service manual will contain information covering all current and past model Sheppard Power Steering Gears The Sheppard Short Series Steering Gear is used as the base line and earlier and later production models will be covered in this manual as variations Use the identification guide to determine which particular Sheppard Steering Gear you are working with Follow the disassembly cleaning and inspection and repair procedures in this manual using the variation s pr
458. t port Place body on cover and install cap screws and lockwashers Install adapter or pipe nipple in appropriate port Install drain valve in reservoir and reconnect heater wire if drain valve is so equipped NOTE Covers on the standard and heated drain valve scan be interchanged TESTING REBUILT AUTOMATIC RESERVOIR DRAIN VALVE Perform Operating and Leakage Checks as outlined in this section IMPORTANT PLEASE READ When working on or around air brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops Never connect or disconnect a hose or line containing air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone Never attempt to disassemble a component until you have read and understand recommended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools Heavy Vehicle Systems Group 50 03 63 1 81
459. t with Clear Lens Optional Mars 888 Light with Blue Lens Optional Mars 888 Light with Red Lens Optional RH Headlight Assembly Side Turn Signal Exterior Cab Lights Model D 350 ty NOTE Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when ordering replacement parts 19 Co ON OO Ff 10 11 12 13 14 15 16 17 18 19 Note Your chassis Vehicle Identification Number V I N or Serial Number on older chassis must be supplied when Ordering replacement parts 1 2 Section VIII MISCELLANEOUS u 5 22 in 7 Lf 8 AE Y i 10 11 EA Seances SEEN 18 17 16 15 14 13 12 Part No Description 7605 4105 Rear Partition Window 7605 5373 Partition Glass 7605 4102 Dome Light 7605 0275 Sunvisor 7605 0276 Sunvisor Clip 7611 6863 Door Glass Channel Top 23 L g 7611 6864 Door Seal Rubber Specify Length 7611 6865 Door Window Rubber 7611 6866 Door Grab Handle 7611 6902 Remote Assembly R H Shown 7611 6908 Remote Assembly L H 7611 6909 Door Lock Assembly R H Shown 7611 6910 Door Lock Assembly L H 7611 6867 Inside Door Handle 7611 6872 Handle Escutcheon 7611 6869 Male Dovetail 7611 6871 Door Glass Lift Handle 7611 6872 Handle Escutcheon 7611 6873 Door Glass Lift Assembly R H Shown 7611 6873 Door Glass Lift Assembly L H 7611 6870 Door Bottom Rubber 7605 4108 Door Check Strap 7
460. taching bolts so they can be removed with a box or open end wrench permitting relocation of the nose housing During reassembly torque the nose housing attaching bolts to 11 15 Ib ft OPERATION There are many different cranking motor circuits used on various applications The cranking circuit may contain a key start switch or push switch or both a relay magnetic switches solenoids oil pressure switch fuel pressure switch other protective devices such as an ALDO relay Figure 5 Cross sectional view of motor with intermediate duty clutch Note different attaching bolt construction than Figure 4 Page 3 THERMOSTAT LEADS 2 Cal CRANKING MOTOR MOTOR THERMOSTAT TOP VIEW START SWITCH PUSH BUTTON AND OR KEY START BATTERY CONNECT TO SAME GROUND POINT AS STANDARD CIRCUIT MAY BE DIRECT GROUND AS PS a ym p Sp NM S SHOWN OR THROUGH ADLO RELAY OIL PRESSURE SWITCH OR FUEL PRESSURE SWITCH Figure 6 Basic wiring circuit Reference should be made to the vehicle manufacturer s wiring diagram for the complete cranking circuit A typical circuit is shown in Figure The motor shown has a built in thermostat to protect against damage due to over cranking for excessively long periods of time Thermostat components separated from the field coils and motor frame are shown in Also a motor with harness disconnected from the thermostat is shown in When
461. te cage several revolutions to assure normal bearing contact H While in press under pressure check bearing preload torque Wrap soft wire around cage and pull on horizontal line with pound scale Use rotating torque not starting torque If a press is not available the pinion nut may be tightened to the correct torque and preload checked The correct pressures and torque for checking pinion C Press rear thrust and radial bearings firmly bearing preload are as follows against the pinion shoulders with a suitable sleeve that will bear only on bearing inner race PINION NUT TORQUE PRESS LOAD required to obtain required to obtain PINION SHAFT correct pinion correct pinion THREAD SIZE bearing preload bearing preload 200 275 Ib ft 22 000 Ibs 11 tons 300 4001 b ft 30 000 Ibs 15 tons 700 90018 54 000 Ibs 27 tons 700 901 00 54 000 Ibs 27 tons 800 1100 Ib ft 54 000 Ibs 27 tons 800 1100 Ib ft 54 000 Ibs 27 tons 900 1200 Ib ft 22 50 000 Ibs 25 tons 1200 1500 Ib ft 50 000 Ibs 25 tons CARE AND MAINTENANCE L Hold flange and remove pinion shaft nut and flange If rotating torque is not within 5 to 15 pound inches use thinner spacer to increase or thicker spacer to decrease preload Example Assuming pinion cage diameter to be 6 inches the radius would be 3 inches and with 5 pounds pull would equal 15 pound inches preload torque
462. ted terminal posts 1 If automatic throttle is being used disconnect the auto throttle linkage from carburetor linkage 2 Remove warranty initiation card from Section 1 of the Instruction Manual Record in pencil the readings from all the following steps Turn ignition OFF Connect harness to inverter at this time 4 Connect battery negative ground cable 5 With ignition OFF and Dynamote Start Button ON readings should be as follows Ground GREEN post to Battery BLACK post 12 12 8V Ground GREEN post to Alternator B RED post OV Ground GREEN post to F Out BLUE post 12 12 8V Ground GREEN post to Ignition ORANGE post Ov Ground GREEN post to Accessory BROWN post 12 12 8V B With ignition ON engine OFF and inverter Start Button NOT depressed readings should be as follows Ground GREEN post to F Out BLUE post 10 12 8V Ground GREIEN post to Ignition ORANGE post 10 12 8V Copyright 1981 DYNAMOTE CORP 2111 Section X 11 82 INSTALLATION INSTRUCTIONS 3 6 2 HARNESS amp ALTERNATOR CHECKOUT WITHOUT 4 2600 continued Trouble Shooting Steps for Step 5 1 If GREEN to BLACK is less than 12 volts DC there could be a faulty ground condition GREEN wire or battery ground strap lf properly grounded the battery may be dead or defective Return battery to a charged state before continuing battery is acceptable the BLACK wire could have faulty connections If GREEN
463. ted by jacks only NOTE The aluminum beam axle FF 931 A is designed to allow jacking on the bottom surface of the beam UNDER NO CIRCUMSTANCES SHOULD IT BE JACKED UNDER THE SPRING Be sure to jack up the aluminum beam with care to prevent grooving or notching the lower surface of the beam Rockwell recommends the following procedures 1 Use a jack with a minimum of 10 tons 20 000 los capacity 2 A jack with a low pick up height of 8 should be used with a minimum power raise of approximately 5 3 The Walker 93660 or 93662 jacks or equivalent are acceptable for use on the aluminum axle beam B Remove the hub cap from hub Then remove jam nut wheel bearing adjusting nut and lock washers from knuckle spindle Remove the outer wheel bearing cone Remove wheel and hub assembly Disconnect brake air chamber lines on units equipped with air brakes or hydraulic lines on units equipped with hydraulic brakes Remove brake assembly from steering knuckle if knuckles are to be rebuilt If knuckles are to be rebuilt or tie rod to be serviced remove cross tube end nut and disassemble cross tube assembly from cross tube Figure 1 e Lb Figure 1 Remove steering Knuckle capscrews caps and gaskets from top and bottom of knuckle Some models may have a welsh plug in place of the lower king pin cap assembly Remove snap ring and plug Depending upon type of axle being servi
464. teering wheel diameters could effectively reduce these maximum allowances Unresponsive motion is measured at the rim of the steering wheel It must therefore be noted that any freeplay in the steering column and related components will affect your measurement The steering gear mounting must be tight and steering linkage wear adjusted out or worn parts replaced The vehicle should be standing on a smooth shop floor with the engine idling when unresponsive motion is checked Measurement is made at the rim of the steering wheel from initial tire and wheel movement left steer to initial tire and wheel movement right steer Page 16 SHEPPARD POWER STEERING SERVICE MANUAL HYDRAULIC SUPPLY DIAGNOSIS The Sheppard Integral Power Steering Gear is dependent upon adequate supplies of oil pressure and volume of oil flow to enable the steering gear to operate as designed Oil pressure reacting on a piston creates the force to cause the piston to move and assist steering effort As the piston moves it is displaced in the cylinder bore by a volume of oil under pressure How fast the piston can be displaced is dependent upon adequate oil flow and volume Oil pressure and oil flow requirements are engineering considerations that are established during the design of a total power steering installation When diagnosing power steering problems you must be able to determine that oil pressure and oil flow meet design specifications Pressure and flow specific
465. tending from the commutator end frame to threaded holes in the lever housing The nose housing is held to the lever housing by internal attaching bolts extending from the lever housing to threaded hole in Figure 3 Cross sectional view of motor with spline drive 50 MT Page 2 CLEARANCE LIGHTS SIDE RIGHT TURN TURN SIGNAL SIGNAL et i REAR AIR Low Beam 1 ee ji WARNING LIGHT HI BEAM 1 RIGHT TURN SIGNAL p 63 FUEL GAUGE SPOTLIGHT OPTION D 3 TRANS TEMP GAUGE WARNING LIGHT 1 i FRONT AIR GAUGE WARNING SPEEDOMETER H BEAM LIGHT PARKING BRAKE LIGHT ELECTRIC 7 HORNS i 29 TACHOMETER SPOTLIGHT OIL PRESSURE eno 5 ced LIGHT NE LEFT TURN SIGNAL AMMFTER BEAM LOW SEAM ig WATER TEMP 5 GAUGE WARNING LIGHT SIDE TURN SIGNAL DIMMER 142 SWATCH an 0 LEFT TURN SIGNAL lt EE i 4 4 P WIPER CHL N iJ I o md Fi i d iii E r m aes WIPER MOTOR e aie 4 MOTOR 45 6 cov cg Lg e 218 BED _ 54 9 3 Mn gt BLACK E RED E HEATER PANEL a 1 ENGINE STOP OR
466. ter Check and repair U joints and support bearings Shim mounting pads to correct piston to Check and repair or replace SHEPPARD POWER STEERING SERVICE MANUAL Symptom Possible cause Remedy No attempt to return straight ahead King pins seized or binding Repair or replace from turns cont d Knuckle clearance misadjust Adjust clearance to specifications Oil flow rate incorrect Check and correct supply pump or controls Note Acme thread wear generally comes from inadequate lubrication or excessive manual steering of the vehicle Manual steering results from inadequate pump pressure or flow or an overloaded front axle where you need steering forces in excess of the hydraulic design of the steering gear Note Freeplay The movement of the shuttle type actuating valve within the piston along with the normal clearances required between operating parts in the steering gear will produce a certain amount of unresponsive motion at the rim of the steering wheel This unresponsive motion is inherent to the design and must be considered normal With recent advances in technology and manufacturing methods it has been possible to considerably reduce the amount of this unresponsive motion Steering gears in service prior to July 1978 could be expected to have 31 2 to 4 inches unresponsive motion Current production Sheppard steering gears in service will have 1 1 2 to 21 2 inches of unresponsive motion Various combinations of steering gear ratios and s
467. ter ON Series A 60 volts As shown in Figure 2 0 2A when the inverter is OFF the alternator and battery function as in normal 12 volt operation The only differences are 1 that Dynamote Regulator CB3 controls the output of the alternator and 2 that alternator output travels through the Dynamote harness on its way to the battery As shown in Figure 2 0 2B when the inverter is ON the system operates as follows a b NOTES 1 output of the alternator is switched away from the battery and into the inverter The alternator field is regulated by Dynamote Voltage Regulator CB1 inside the inverter See Note 1 below Dynamote regulator controls alternator output at 45 volts A40 or 60 volts A30 60 rather than the standard 14 2 volts The high voltage output enters the inverter transformer the inverter produces 120 volt 60 Hz power and at the same time charges the vehicle battery and services the vehicle DC system at 14 2 volts See Note 2 below When the inverter is energized the Dynamic Voltage Regulator CB1 senses voltage at the secondary output of the inverter and regulates the alternator field with battery power to maintain 14 2 volts DC rectified AC at the BLACK wire of the inverter harness which charges the battery The inverter transformer is wound so that at an average AC output of 120 volts the vehicle battery is charged at 14 2 DYNAMOTE CORPORATION 1200 W Nickerson Seattle
468. terior of the axle Always replace faulty seals with proper tools and installation techniques TRACTION EQUALIZERID ADDITIVES Traction equalizers are employed by many drive units to maintain an appreciable amount of wheel end traction in all operating conditions while still allowing the vehicle to negotiate turns smoothly This is accomplished with the ability of the traction equalizer to slip above a certain torque value and remain rigid below this torque value Rockwell Traction Equalizers will normally operate with oils not having special additives Occasionally it is found however that the traction equalizer will tend to slip and produce irregular intervals of sharp noises This generally occurs when the vehicle is operating at low speeds on fairly sharp turns This slip stick condition can often be corrected by the addition of certain friction modifiers which reduce the static coefficient of friction to a value equal to or lower than the sliding coefficient These friction modifiers generally deteriorate faster than the conventional E P additives and the lubricant change schedule should be shortened when these are used For axles equipped with Rockwell Traction Equalizers the following are approved additives quantities and lube change intervals e Additives typically referred to as Limited Slip Friction Modifiers by lubricant suppliers 1 For all GL 5 gear oils mineral oil or synthetic other than Mobil add an
469. the alternator while providing proper length for bends and obstructions 3 1 2 the inverter is in as cool a place as possible and that there is adequate cooling air available lf in a closed cabinet provide louvers or screened openings in the cabinet surfaces to supply cool intake air to the chassis end panels and duct the inverter exhaust air to the outside of the cabinet A flange Part 41230000 is available from Dynamote for attaching dryer hose to the inverter exhaust 3 1 8 it is protected from weather inside the vehicle or in a service compartment or special cabinet 3 2 0 ROUTE HARNESS TO ALTERNATOR BURNING OR CHAFING THROUGH HARNESS INSULATION WILL DAMAGE THE INVERTER AND THE VEHICLE ELECTRICAL SYSTEMS YOU SHOULD BE AWARE THAT THIS IS A COMMON INSTALLATION PROBLEM Route the wiring harness to the alternator using existing holes where possible Use tie wraps and tape liberally to secure the harness wires so they cannot come in contact with the hot engine exhaust or other heat producing components Grommets should be used to protect the wiring harness where it comes in contact with hard or sharp edges NOTE Do not attach any wires to the inverter at this time 3 3 0 INSTALL PROPER ALTERNATOR ON ENGINE This step requires two things as explained below First is selection and preparation of a proper alternator Second is proper installation on the engine 3 3 1 To be a proper alternator the alternator being installed must 1 Pr
470. the dual air brake valve in this situation results in little or no air being delivered from the No 2 delivery circuit to the control port of the SR 1 No movement of the SR 1 internal components takes place Service application loss of 2 reservoir 2 Service reservoir 1 Service reser votr Double check valve 2 Service reservoir D Service reservoir Double check valve uM Park control Braking is assured because the No 1 service reservoir is protected by a check valve and the No 1 delivery circuit of the dual brake valve will apply the ser vice section of the spring brake actuators OPERATION SERVICE APPLICATION WITH LOSS OF NO 1 RESERVOIR PRESSURE If air pressure in the No 1 service reservoir falls below approximately 55 P S I the pressure beneath piston A is insufficient to resist the spring force above and piston A moves into contact with valve A Initial contact between piston A and valve A closes the hollow exhaust passage of piston A Continued movement of the piston opens the inlet of valve A Piston Figure 8 Piston B Check valve Check valve The No 2 service reservoir and the park control valve are protected from pressure loss by the action of the Double Check Valve When a service application of the dual brake valve is made air delivered from the No 2 delivery circuit of the dual brake valve enters the SR 1 co
471. the start switch is closed battery current flows through the through a thermostat magnetic switch winding and the thermostat to ground as shown in The magnetic switch closes connecting the motor solenoid S terminal to the battery The solenoid windings are energized and the resulting plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear and the solenoid main contacts to close and cranking takes place When the engine starts overrun protects the armature from excessive speed until the switch is opened at which time the return spring causes the pinion to disengage To prevent excessive overrun and damage to the drive and armature windings the switch CRANKING MOTORS 1M 153 Service Bulletin Figure 7 Typical thermostat must be opened immediately when the engine starts A cranking period for all types of motors should never exceed 30 seconds without stopping to allow the motor to cool If over cranking should occur the thermostat will open and the cranking cycle will stop to protect the motor After the cranking motor cools usually 1 6 minutes the thermostat will close and then a new starting attempt can be made A circuit without the motor thermostat would be the same as Figure 6 except the magnetic switch winding terminal would be grounded directly to the point noted in d without passing Figure 8 Typical motor snowing thermostat conn
472. the steering gear is installed on the vehicle Note Variation Later production steering gears may have slotted and recessed relief plunger The later style plungers are removed or adjusted with a straight bladed screwdriver These plungers can be turned out until they are flush with the plunger boss Turning them out beyond this point could cause an oil leak Reinstall the bracket on the steering gear and torque the bolts to specification Page 45 SHEPPARD POWER STEERING SERVICE MANUAL S 113 OPTIONAL INTEGRAL RELIEF VALVE SERVICING An optional integral pressure relief valve is offered with the Sheppard Series 5 Steering Gear This valve is mounted externally on the Steering Gear and limits the maximum operating pressure in the steering system In most cases the hydraulic supply pump will have a maximum relief pressure setting several hundred pounds higher than the relief valve integral with the steering gear Therefore when maximum relief pressures are reached in the steering system the excess pressure is relieved at the steering gear and the supply pump is not subjected to high temperatures caused by normal pressure relief and recirculation within the supply pump The optional pressure relief valve offered with the Sheppard Series 5 Steering Gear bolts externally to the steering gear housing and connects the high pressure supply circuit to the low pressure pinion gear area of the steering gear When oil pressure
473. the valve from the piston bore The actuating valve and piston are serviced only as an assembly due to the critical tolerances in this area 5 61 Remove the actuating valve positioning pin from the piston Note positioning pin on later production steering gears will have an O ring oil seal 5 62 32 SHEPPARD POWER STEERING SERVICE MANUAL The reversing springs are the only serviceable parts in the piston assembly Use an allen wrench to remove the relief ball seats gay E n relief balls and spring Caution The balls are under slight spring pressure Handle carefully to avoid loss or personal injury dod Position the relief valve spring and one relief valve ball REASSEMBLY EARLY PRODUCTION into the valve bore Then using a 3116 allen wrench PISTONS install one of the valve seats The valve seats must be tight and flush with or slightly below the end surface of the piston Install the second relief valve ball seat in the same manner Position one of the reversing springs in bottom of valve bore Be sure spring is centered The end of the valve must enter the inside diameter of the spring Install the valve positioning pin in the piston Turn pin inward with a screwdriver until it is below the outside surface of the piston The flats must enter into the piston 1 4 to engage the mating slot in the valve Carefully slide the actuating valve into the piston so that the slot o
474. this unit both AC 1 and AC 2 wires are hot relative to chassis ground Therefore neither AC 1 or AC 2 be grounded either wire is grounded the inverter will not operate The AC receptacles may be used up to the fused limit of 15 amps per AC receptacle on all models If permanent connection inverter output to external AC circuit breakers and receptacles is desired follow these directions Connect BLACK AC leads from rear of unit to the external junction box using circuit breaker of fuses for each separate circuit Be sure that neither hot wire is grounded at this connection 3 8 2 Models A30 70D A40 120D A60 120D and MPA Models A In these units AC output is a standard two wire output with a hot and neutral lead Only the hot lead AC 1 cannot be grounded The AC receptacles can be used up to their fused capacity of 15 amps per receptacle for all models If permanent connection of inverter is desired follow these directions Connect AC leads to external AC junction box using circuit breaker or fuses for each separate circuit Only the hot BLACK wire should not be grounded 3 9 COMPLETE SIGN AND MAIL WARRANTY INITIATION CARD The final step is to initiate the inverter warranty Proper installation is not complete until warranty is properly initiated as follows A B Fill in the final customer s name and address and vehicle data Enter all checkout data from the harness and alternator ch
475. thorized Bendix Distributor REMOVING AND INSTALLING REMOVING 1 Block or hold the vehicle by means other than air brakes 2 Drain all system reservoirs individually to O psi 3 Disconnect and identify supply and delivery the air lines leading to and from the pressure protection valve 4 Remove the mounting bolts if any that secure the valve INSTALLING 1 Re install the mounting bolts and secure the replacem ent valve to the vehicle 2 Reconnect the supply delivery air lines to the proper ports of the replacement valve GENERAL After installing a replacement valve it is recommended that the operating and leakage checks be performed as outlined in this manual If the closing pressure does not conform to that shown on the valve label or in the vehicle or a different setting is desired the PR 2 may be adjusted by loosening the locknut and tightening or loosening the adjusting cap as required however if the proper setting cannot be attained by moderate adjustment of the cap the valve may have the wrong spring and will have to be exchanged for the correct valve The PR 3 and PR 4 are not adjustable IMPORTANT PLEASE READ When working on or around air brake systems and components the following precautions should be observed i Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack a
476. tics may be referred to while the supporting text is being examined and studied A detailed description is given in the Introduction of each volume to assist the user in finding the information required to maintain the equipment e Operator s Manual TM 5 4210 227 10 This manual is designed to provide the information necessary for a fire fighter or mechanic to properly operate the truck the pump and the ladder e Maintenance Manual TM 5 4210 227 24 amp P This manual is divided into 8 volumes and contains the information necessary for an experienced mechanic to maintain and repair all facets of the apparatus Each volume is individually indexed for ease of reference This manual contains all the information necessary to obtain assemblies and subassemblies or individual parts required to repair and maintain the fire truck i ii blank TABULATED DATA a Fire Truck Federal Stock Number Manufacturer s Serial No Registration Nos Manufacturer Model Contract Number Truck Length Truck Wiath Truck Height Capacity or Payload Shipping Weight Ground Clearance Weight Loaded Front Axle Hear Axle Chassis Manufacturer I D Number Model Wheel Base Engine Manufacturer Model Serial Number Fuel 4210 00 965 1254 CM3653 through CM3664 Pierre Thibault Inc QWT 85 DAAJ10 84 A218 459 108 138 51 000 GVWR 43 880 10 25 45 940 19 740 26 200 Duplex
477. tion If the 4 2600 is not available see Section 3 6 2 1 Follow the instructions in Section 3 to install the inverter harness 2 Put the test module sequence switch in the OFF position before connecting the module to the Dynamic Inverter The vehicle ignition should also be in the OFF position 3 Plug the six pin test module into the Test Module Receptacle on the inverter front panel NOTE 1 Do not plug the test module into the control head receptacle on the inverter Do not plug the inverter Remote Control head plug into the Test Module Receptacle NOTE 2 If the BLACK B lead is connected to a battery selector switch the switch should be in the ON that is the B1 B2 or both position 4 Follow the steps on the chart on the following pages Figure 3 6 14 DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 Figure 3 6 1A INSTALLATION AND INVERTER CHECKOUT USING 4 2600 DYNAMIC INVERTER TEST MODULE Figure 3 6 1A INSTALLATION AND INVERTER CHECKOUT USING 4 2600 DYNAMIC INVERTER TEST MODULE 1 Switch Terminal or Wire Being Read Inverter Start Button Depressed Red If voltage reading is outside proper limits recheck installation of inverter harness RED and BLACK wires Also check at Kl relay Section 4 3 3 K3 relay Sec 4 3 5 then the OR Igni tion Orange If meter reads battery voltage ANGE wire is connected to
478. tion Capac Contactor Suppression Capacitor Circuit Board Filter AC Output Capacitor AC Output Capacitor Boosted Field Capacitor DC Input Capacitor Unit Isolation Diode K2 Relay Hold in Diode Battery Charging Diode Battery Charging Diode AC Blocking Diode AC Blocking Diode Spike Suppression Diode Reverse Parallel Diode Battery Isolation Diode Isolation Diode Rectification Diode Stabilizing Resistors Current Limit Resistor VR Stabilizing Resis Field Cur Limit Resis Current Limit Resistor Meter Adjustment Potentiometer Fuses ABU40 Fuses ABU40 Fuses AGC15 Fuses AGC15 Fuses AGC15 Fuse Holders Large HPC Fuse Holders Large HPC Fuse Holders Small HKP Fuse Holders Small HKP Fuse Holders Small HKP Power Relay Control Relay VVR Relay LVCO Relay LVCO Relay Power LVCO Relay Control High Amperage Bypass Rela 40 2 84 MPA 60 Fig 4 5 0 DYNAMIC INVERTER PARTS LIST continued Circuit Designation SCR1 SCR2 SCR1 SCR2 X1 X2 X3 Dynamote Part 4721 08411 4721 00256 4046 12337 4481 20123 2081 00005 2081 00930 2081 00005 2081 00200 2081 02407 2 64 02007 2 64 01415 2 64 01412 2 64 02022 2 20 40125 2720 70100 4080 03080 4683 25320 4080 30160 4080 04014 4080 04013 4080 04015 4442 90000 LD Units Only Description otart Stop Switch Field Selection Switch Fan Motor Voltmeter Regulator Unit Oscillator Regulator Vehicle Load Demand Low Voltag
479. tly to that symptom in the Troubleshooting Chart Section 4 3 2 If the symptom is not known begin the troubleshooting process by going to Symptom 1 in the Troubleshooting Chart pushing the START Button and progressing through the chart steps until the applicable symptom is found 4 3 2 TROUBLESHOOTING CHART Put the Auto Manual Switch in Manual position See 2 2 2 1 The alternator should be turning approximately 4000 RPM or about 1500 engine RPM for performing tests to determine the applicable symptom If the inverter is connected only to a battery and not an alternator the test at Symptom 1 can be performed as well as the checkout procedures for the Voltage Regulators Oscillator Board Diodes SCRs and Relays K1 K2 and DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 No SYMPTOM otart button pushed no response Put Auto Manual Switch in Manual position See 2 2 2 Start button pushed relays will not remain energized but chatter on and off Start button pushed relays energize with an audible click but inverter will not start Fan does not turn ENGINE MUST BE RUNNING APPROXIMATELY 1500 RPM FOR THIS AND REMAINING TROUBLESHOOTING STEPS Start button pushed inverter turns on fan turns but stops when start button is released section 4 3 2 TROUBLESHOOTING CHART PROBABLE CAUSE Blown control fuse Inoperative K2 Relay If new installation battery isolator i
480. to RED is greater than zero without K3 Relay the alternator is still connected directly to the battery Check to be sure the Dynamote RED harness wire is the only one attached to the output terminal of the alternator If GREEN to RED is greater than zero with K3 Relay the K3 Relay is incorrectly installed or not energizing Refer to Section 3 5 1 Step 3 If GREEN to ORANGE is larger than zero ORANGE wire is incorrectly connected to the ignition switch 6 Start engine and increase engine speed to about 1000 RPM equivalent to engine speed at about 20 MPH Voltages should read as follows Ground GREEN post to Battery BLACK post 13 5 14 2V Ground GREEN post to Alternator B RED post 13 5 14 2V Ground GREEN post to F Out BLUE post variable up to 14 2V Ground GREEN post to Ignition ORANGE post 12 0 14 2V Ground GREEN post to Accessory BROWN post OV Trouble Shooting Tips for Step 6 1 If BLACK and RED are greater than 14 2VDC or less than 13 5VDC adjust the vehicle voltage regulator If adjusting the does not correct the DC voltage at BLACK proceed to the applicable step following a If BLACK and RED are less than 13 5VDC and BLUE is greater than 11VDC check if BLACK voltage varies with the engine speed If it does either the pulley ratio is too low or the alternator is overloaded Verify that BLUE is the only wire on the alternator positive FIELD terminal and that the alternator negative FIEL
481. to check out all inverter functions Another alternative is a test bench which includes alternator and battery and simulates a vehicle or boat electrical system If neither of these is available many of the troubleshooting tests can be performed by connecting the inverter harness to a 12 volt battery as follows GREEN to Battery Negative BLACK to Battery Positive 4 ORANGE to Battery Positive Other wires not connected The Trouble Shooting Guide is to be found in Section 4 3 0 4 2 0 INVERTER REMOVAL FROM VEHICLE SYSTEM FOR SERVICING AND TEMPORARY OPERATION OF VEHICLE WITHOUT INVERTER NOTE DO NOT REMOVE INVERTER UNTIL AFTER THE TROUBLESHOOTING PROCEDURE HAS BEEN COMPLETED AND IT IS DETERMINED THAT THE INVERTER MUST BE REMOVED FOR SERVICE 1 Remove inverter mounting screws 2222 Pull inverter out to gain access to the Quick Disconnect plugs Separate both connectors control and power harness 3 Remove inverter from vehicle 4 Remove vehicle voltage regulator housing from behind the inverter front panel under the AC outlet by removing the screws at the four corners of the housing DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 12 81 4 2 0 INVERTER REMOVAL FROM VEHICLE SYSTEM FOR SERVICING AND TEMPORARY OPERATION VEHICLE WITHOUT INVERTER continued 9 Disconnect the wiring harness from vehicle voltage regulator in the housing ___6 Locate vehicle voltage regulator adapte
482. tom of Case d 2 875 2 875 2 875 2 875 CX Face of Case to Pitch Line 1 110 1 295 1 330 1 110 P T O Output Shaft Dimensions SD Outside Diameter of Standard Shaft For U Joint 1 1 4 Rd 1 1 4 Rd 1 1 4 Rd 1 1 4 Rd 5 16 Key 5 16 Key 5 16 Key 5 16 Key SE Center Line of P T O to End of Output Shaft 4 1 4 4 1 4 4 1 4 4 1 4 d Approximate Dimension for estimating clearance in installations 10 CHELSEA 220 SERIES PARTS LIST amp SPECIFICATIONS P410 220 CHELSEA MODEL NUMBER CONSTRUCTION 220 SERIES EXTRA HEAVY DUTY P T O 20 X AB 3 H D BASIC MODEL __ L OUTPUT TYPE D 1 250 Rd M 130 Pump Mtg 75 Pump Mtg 159 Pump Mtg G 96A Pump Mtg O New Pump Mtg J 102 Pump Mtg P 220 Pump Mtg K 113 Pump Mtg Q 222 Pump Mtg L 114 Pump Mtg R 225 Pump Mtg HOLLEY GOVERNOR DRIVE X No Governor Drive H Holley Governor Drive Available on D G J K M N O P Q amp R Outputs Only ASSEMBLY ARRANGEMENT Z Deep Mount GEAR RATIO C 2 445 A22LL 514 A22L L 691 A23 P 835 22 amp D INPUT GEAR DESIGNATOR LUBRICATION No Lubrication P Pressure Lube 220 Old 22 Series 3 4 5 6 MOUNTING TYPE Q Extra Deep Mount SHIFTER TYPE A Air Y Lever R Special Clearance Housing X Standard Mounting W Wire M Constant Mesh No Shifter AIR SHIFT CONVERSION KITS De
483. torted and cause severe oil leakage 20 Install lock washers and stud nuts on any studs under carrier housing offsets It is impossible to start these nuts after carrier is drawn into housing D Tighten the four nuts over flat washers alternately to draw carrier squarely into axle housing E If necessary remove nuts and flat washers and install taper dowels lock washers and stud nuts Tighten to the correct torque F Connect universal at pinion shaft G Install axle shafts PREPARATION FOR STORAGE In the event the carrier is a spare and may not be immediately installed all gears and bearings should be thoroughly oiled and the carrier placed in a dustproof container SINGLE REDUCTION DRIVE UNIT LUBRICATION Proper lubrication of the drive units is extremely important Standard recommended lubricant is Rockwell Standard Specification 0 76 0 76 A 0 76 B or 0 76 D SAE 140 viscosity multipurpose gear lubricant Unusual operating conditions such as extremes climatic temperatures may require lubricants of Optional viscosities However experience has shown that the use of an SAE 140 viscosity grade lubricant will result in longer gear life Refer to Field Maintenance Manual No 1 Lubrication for detailed information Since Rockwell lubricant specifications periodically revised always refer to Field Maintenance Manual 1 for current complete lubricant specifications and applications
484. toward the gasket and knuckle The flat sealing side contains no numbering or lettering B Torque fasteners to specification WELSH PLUGS A Place welsh plug into the lower knuckle bore with the rounded convex side toward the king pin B Install lock ring C models not grooved for lock rings secure the plugs in place by staking in four equally spaced places KING PIN RETAINERS A On units employing grooved knuckle pins that protrude below the knuckle lower yoke install lock ring in groove The upper ends of steering knuckle are protected with covers Caps or retainers and felts B Install the cover or cap and gasket with capscrews 22 where used C Install the felt retainer and lock ring on the protruding straight pins that are not provided with covers or caps GREASING PROCEDURE A Grease upper bushing first then lower Grease specification 617 A or B If grease does not flow through the thrust bearing it will be necessary to raise the knuckle with a jack to close off passage of grease around the thrust bearing Regrease the lower bushing and thrust bearing then remove jack B Rotate knuckle lock to lock to help distribute the grease Note the knuckle will now be noticeably harder to rotate than during the play measurement This is normal Repeat step 1 On models using drawkeys fill the voids in the drawkey holes with grease to prevent corrosion and ease future disassembly INSTAL
485. ts Be sure bolts are tight B Rotate both anchor pins to the full release position Punch marks together wrench flats in line C Adjust cam to bring liners in contact with drum and rotate anchor pins sufficiently to relieve drag Repeat until additional rotation of anchor pins will no longer free drag D Tighten anchor pin lock nuts and back off cam to minimum running clearance To compensate for liner wear on both the T Fabricated Steel and the T Cast assemblies adjust cam at cam lever adjusting bolt to bring liners in contact with drum and back off to minimum running clearance THE CAM MASTER P SERIES BRAKES The Automotive P series brake is an air actuated two shoe brake each shoe employing two 3 4 tapered block liners These shoes are of fabricated steel mounted on individual anchor pins and supported by open type spiders The air chamber mounts on a bracket that bolts directly to the spider thus making the brake completely unit mounted Automotive P series brakes may also be equipped with inboard cam supports where operation or axle design requires mounting the air chambers toward the axle centers Dust shields are available for use when protection becomes desirable The P series brakes are actuated by the S type constant lift cams which are forged integrally with shaft and supported in nylon bushings Cam pressure is applied through roller cam followers 12 CARE AND MAINTENANCE P BRAKE LA
486. tside proper limits per Black form alternator check given for Switch Pos 11 below reading IMPORTANT NOTE first Follow checkout procedure and adjust inverter Voltage Regulator CBl NOTE Be sure engine is running at or above the speed at which the voltage reading is at its maximum This could be higher or lower than 1500 RPM but will be the point at which increasing the RPM will no long er increase the voltage reading 10 Yes This reading shows alternator output with in Red verter ON divided by 5 that is the actual voltage is 5 times the reading If alternator voltage fails to come up to this level perform alternator check in the next step IMPORTANT NOTE The test at Switch Position ll is to check for a faulty alternator Before moving the switch to Position ll return the engine to an idle turn the inverter OFF and remove the com mutation fuses on the inverter front panel When the switch is in Position 11 the voltage regula tor is taken out of the circuit and battery voltage is applied directly to the field of the alterna tor This causes the voltage output of the alternator to increase directly with engine RPM Rotate switch to Position 11 and slowly increase engine RPM until the voltmeter reads 20VDC At this point the actual alternator voltage is 100VDC 5 times the meter reading If the alternator will not comej up to this voltage then either the alternator or the installation is
487. ual temperature or operating conditions may require other or specific lubricant recommendations Rockwell will review these circumstances upon request and make optional gear oil or grease recommendations Refer to Recommended Lubricants orj pages and 7 LUBE INTERVALS e All new and reconditioned units Drain and refill initial fill lubricant after the first 1000 miles 1600 km but never later than 3000 miles 4800 km Drain the lubricant while the unit is still warm from the carrier and housing e Check every 1000 miles 1600 km Drain and refill every 25 000 to 30 000 miles 40 000 to 48 000 km when yearly mileage is in excess of 60 000 miles 96 000 km yearly mileage is less than 60 000 miles 96 000 km change twice a year spring and fall LUBE PROCEDURES E for Inter axle Differential information use same procedures as for Hypoid Amboid and Spiral Bevel Gears on 23 LUBRICATION 9 DRIVE LINE UNIVERSAL JOINTS SLIP YOKES SPLINES DRIVE LINE U JOINT AND SLIP YOKE LUBRICANTS otandard 0 634 B Refer to Recommended Lubricants or pages and 7 LUBE INTERVALS The frequency of lubricant change depends upon individual operating conditions speeds and loads e On highway X TRA LIFE universal joints and shafts 50 000 miles 80 000 km maximum Non X TRA LIFE universal joints and shafts 1 6 000 miles 25 600 km maximum e Off highway Change intervals will differ greatly and be determ
488. ube end assemblies should be replaced if found below specifications Serviceable models should be rebuilt C Any tie rod tubes found to be cracked bent dented or severely gouged should be replaced REBUILDING TIE ROD END ASSEMBLIES Some older models contain tie rod assemblies which are rebuildable These are however limited in the number of rebuilds determination must first be made of the condition of the socket forging Those excessively worn must not be used again but replaced These can be replaced with new rebuildable or non rebuildable end assemblies WHEEL BEARING INSPECTION Wheel bearings should be very closely inspected at the time of knuckle inspection or when knuckle repair is being made Inspect wheel bearing cones and cups if rollers or cups are worn pitted or damaged any way If wheel bearing cups are to be replaced remove from hubs with a suitable puller To avoid hub damage don t use drifts and hammers Remove all the old grease from the wheel bearings spindle hub cavity and hub cap The old grease may contain moisture which would lead to an early bearing failure if not removed Use kerosene or diesel fuel and a stiff brush Gasoline and heated solvents should be avoided Allow the cleaned parts to dry or dry them with a clean absorbent cloth or paper Clean and dry hands and all tools used in the service operation Grease will not adhere to a surface which is wet with solve
489. uing assembly Then proceed in the following manner 1 Fill pump reservoir with recommended engine oil Continue filling after starting engine and during the bleeding operation until correct oil level is maintained 2 oet parking brake Start engine and allow it to operate at fast idle speed 3 See Figs amp 2 With engine running drag links disconnected turn steering wheel to the left and hold until the secondary slave gear pitman arm moves the full travel Then turn to the right and hold until the secondary slave gear pitman arm again moves the full travel repeat this process three or more times 4 See Figs amp 2 Connect the drag link to the master gear Do not connect the secondary slave gear drag link at this time Turn steering wheel to the left and hold until the secondary slave gear pitman arm moves the full travel Then turn to the right and hold until the secondary slave gear pitman arm again moves the full travel Repeat this process three or more times Turn the steering wheel until the secondary slave gear pitman arm lines up with the drag link Then install the pitman arm DO NOT move the pitman arm by hand or air will be pulled back into the system Page 52 SHEPPARD POWER STEERING SERVICE MANUAL DUAL SYSTEMS SECONDARY uw SLAVE GEAR 6 ELSE RETURN FROM SLAVE TO RESERVOIR ES A LLL LI l RESERVOIR FOR PUMP zou FIG 1 RETURN LINE T
490. um Cleaners Inductive loads require intermittent starting surge amperage up to four times running amperage Figure 2 3A Average Amps for Appliances and Tools DYNAMOTE CORPORATION 1200 W Nickerson Seattle WA 98119 206 282 1000 2 3 1 83 2 3 SELECTION OF ALTERNATOR AND INVERTER AMPERAGE REQUIREMENTS OF VARIOUS LOADS continued The approximate amps required to start and run various sizes of electric motors is shown in Diagram 2 3B below Motor Loads Approximate Amps Required to Start Running Repul Or Capac Induc Type 8 9 11 15 22 28 39 51 76 For hard starting loads increase motor starting requirement by 25 NOTE Motor load running amperage taken from Table 430 148 page 388 NFPA Handbook of the National Electrical Code 3rd Edition 1972 Figure 2 3B Average Motor Loads Starting and Running Copyright 1983 DYNAMOTE CORP Section IX F2103D GENERAL INFORMATION 10 81 Sec 2 4 2 4 SELECTION OF ALTERNATOR AND INVERTER continued ALTERNATOR PERFORMANCE DATA The alternator is the basic power source for the inverter so the inverter output is dependent on the size and type of alternator and the speed at which the alternator is turning The following power curves plot the total output of the inverter on the vertical axis vs the alternator RPM on the horizontal axis The most convenient way to use these curves is as follows Find the required power level on the vertical axis
491. unctions having been designated let s look at conventional universal joint and drive shaft construction To transmit required loads the drive shaft must possess high strength Forged steel or high strength cast yokes are generally used to provide necessary strength and the rigidity required to maintain bearing alignment under torque loads and during high speed operation Special high strength tubing is used to provide maximum torque carrying capacity at minimum practical weight This tubing must be securely welded to its end members to provide the necessary torque capacity High quality anti friction bearings are used to withstand required loads while oscillating at high speeds These bearings on the journal cross carry very high loads for their size The full complement roller type needle bearings are generally used because of their high capacity in a limited space Bearings are individually sealed to provide retention of required lubricants as well as to prevent the entry of foreign material If lubricants become contaminated with water or abrasive material needle bearing life is seriously affected Abrasive material is a major problem where a vehicle operates under conditions of extreme moisture and dirt Off highway installations are especially critical in this respect Military trucks represent the extreme in this direction and were the first to show the shortcomings in the conventional cork seals used in universal joi
492. ury can result if not properly disassembled Use only pro per tools and observe all precautions pertaining to use of those tools 5 Use only genuine Bendix replacement parts and components A Only components devices and mounting and attaching hardware specifically designed for use in hydraulic brake systems should be used B Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as the original equipment 6 Devices with stripped threads or damaged parts should be replaced Repairs requiring machining should not be attempted i Heavy Vehicle Systems Group 5 04 1 5 81 Section VI Bendix f Heavy Vehicle Systems Group BRAKE SYSTEM Service Data Formerly SD 29 QR AND QR 1 QUICK RELEASE VALVES QR VALVE BRAKE VALVE PORT BRAKE CHAMBER PORT EXHAUST PORT SPRING OR VALVE DESCRIPTION The function of the Quick Release Valve is to speed up the exhaust of air from the air chambers It is mounted close to the chambers it serves In its standard configuration the valve is designed to deliver within one 1 psi of control pressure to the controlled device however for special applications the valve is available with greater differential pressure designed into the valve Reference Figure 1 two styles of Quick Release Valves are available and are functionally the same the QR valve which is of older design and utilizes a spr
493. ury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools 5 Use only genuine Bendix replacement parts and components A Only components devices and mounting and attaching hardware specifically designed for use in hydraulic brake systems should be used B Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as the original equipment 6 Devices with stripped threads or damaged parts should be replaced Repairs requiring machining should not be attempted SD 03 69 4 81 Section VI Bendix Heavy Vehicle Systems Group BRAKE SYSTEM Service Data Formerly SD 29 SL 5 STOP LIGHT SWITCH amp DS 2 COMBINED STOP LIGHT SWITCH amp DOUBLE CHECK VALVE DS 2 x SL5 SPRING TERMINAL na RIVET FULCRUM 1 CONTACT STRIP DIAPHRAGM SHORTING Ma re VALVE BAR CHECK VALVE I INLET PORT 05 2 DESCHIPTION The stop light switch SL 5 is an electro pneumatic 5 psi non grounded switch that operates in conjunction with the brake valve and stop lights by completing the electrical circuit and lighting the stop lights when a brake application is made The combined stop light switch and double check valve DS 2 as the name implies combines a stop light switch ji pap oat INLET PORT 78 miti
494. ush holder Slide the brushes all the way into the brush guides making sure that the WHITE wire does not interfere with the positive brush spring B retract brushes into the guides insert a pin or paper clip into the small hole in the brush holder Using a bent wooden match or the flat end of an allen wrench push the first brush back into the brush guide holding it back in the guide with the pin or clip Do the same thing with the second brush C Referring to Fig 3 5 5 4A replace the NEGATIVE terminal tab to negative regulator housing bolt on the bottom of the brush holder housing and secure with the original lock washer and nut DO NOT replace the positive connecting terminal tab as it will no longer be used Replace the lock washer and nut only contacts 7 Remove the or paper clip releasing the brushes so they make contact with regulator 8 alternator should now have a WHITE wire from bottom of regulator housing Attach WHITE wire to ground or negative output terminal of alternator Positive brush terminal should be used as Dynamote BLUE wire connection terminal Reinstall the alternator and proceed to Section 3 5 1 ALTERNATOR TERMINAL INSIDE NUT NEG REG HOUSING BOLT 5 DIODE TRIO TERMINAL REG HOUSING POSITIVE OUTPUT 4 No 8 32x 7 16 SCREWS HOLDER ASSEMBLY Figure 3 5 5 4A Copyright 1981 DYNAMOTE CORP REGULATOR amp BRUSH NE
495. ust be supplied when ordering replacement parts gi Auxiliary Electric Section V FuUSectosr ym FUEL SYSTEM Fuel Pump All Models CROSSMEMBER e 2V 25 Part No Description Qty 8874 3018 Adaptor 3 2 7604 6803 Hose Assembly 1 3 7604 6286 Tee 2 4 8870 1063 1 5 7604 4513 Swivel 2 6 8870 1053 1 7 8820 1005 Hex Head Capscrew 2 8 8855 1009 Lockwasher 4 9 8850 1004 Hex Nut 4 10 7604 6807 Hose Assembly 1 11 7604 3252 Check Valve 1 12 7604 5712 Fuel Pump 1 13 7604 6809 Hose Assembly 1 14 8871 1102 Elbow 1 15 8874 3074 Elbow 1 16 7604 6811 Spacer 2 17 7603 5121 Clamp 2 18 8820 1007 Head Capscrew 2 NOTE Your chassis Vehicle Identification Number V 1 N or Serial Number on older chassis must be supplied when ordering replacement parts NX NS 36 BRAKE CHAMBER X 24 BRAKE CHAMBER d 120 5 1 GOVERNOR SER LUN DET AIR COMPRESSOR B D s a QUICK REL A DOUBLE 3 8 Section VI BRAKE SYSTEM y CHK VLV D PARKING BRAKE CONTROL VALVE EM SER Q5 abc 36 BRAKE CHAMBER o EN Y BI di RU NM Fiy SS i Bx TN DUI LEX Model D 350 Air System Schematic 4 x 2 Isolated enan aj 3 Part No 811 3418 7604 7269 7604 7305 7810 3453 7604 4297 7604 2398 7811 3648 7604 7257 7604 2413 7605 3637
496. utput shaft to prevent damaging the bearing 5 28 Page 22 SHEPPARD POWER STEERING SERVICE MANUAL Remove the eight bolts attaching the pinion gear cover to the housing Using a soft hammer tap on the end of the output shaft to Loosen the cover 5 30 Carefully slide the output shaft pinion gear and cover through the housing Pull the output shaft out of the cover Remove and discard the cover O ring seal Note The Series 5 steering gear may use loose needle roller bearings in the cover and housing to support the output shaft On disassembly the needle rollers for the two bearings must be kept separate See Series 5 variation Hemove the cylinder head and discard the seal ring 5 32 23 SHEPPARD POWER STEERING SERVICE MANUAL Remove the bolts from the bearing cap and turn the actuating shaft to free the bearing cap from the piston and housing Support the bearing cap and turn the actuating shaft until it is free of the piston Remove and discard the seal ring Carefully slide the piston assembly from the bore of the housing he steering gear has now been disassembled into subassemblies which can be further disassembled and repaired as required 5 36 24 SHEPPARD POWER STEERING SERVICE MANUAL CLEANING amp INSPECTION Cleaning Cleanliness is of utmost importance Dirt and foreign material introduced into the steering system during repair operations can cause dam
497. ve faulty ball valve or seat Valve should be disassembled cleaned and rebuilt See Disassembly and Assembly section REMOVING AND INSTALLING REMOVING 1 Block wheels or otherwise secure vehicle and drain reservoirs 2 Using wrench flat closest to reservoir unscrew valve from reservoir INSTALLING oafety valve should be installed in same reservoir that Compressor discharge line is connected to Install in a convenient location in a top port of the reservoir If oafety Valve is installed horizontally exhaust port should point down stem of the valve should face rear of vehicle DISASSEMBLY ST 1 ADJUSTABLE VALVE 1 Clamp lower wrench flat in vise flat nearest pipe thread 2 Using upper wrench flat unscrew lock nut Unscrew and remove spring cage from body of valve 3 Remove ball valve spring and release pin from spring cage DISASSEMBLY ST 3 NON ADJUSTABLE VALVE 1 Clamp spring cage in soft jawed vise 2 Using wrench flat unscrew body from spring cage 3 Remove ball valve spring and release pin from spring cage ee RELEASE PIN ADJUSTING e 7 NUT PIPES THREAD CLEANING AND INSPECTION Clean all parts in mineral spirits Inspect all parts All parts not considered serviceable should be replaced with genuine Bendix replacement parts ASSEMBLY ST 1 ADJUSTABLE VALVE 1 Place the ball valve in body 2 Install spring and release pin in spring cage with adjusting scr
498. ve applications and note each time an application is made an exhaust of air occurs at the exhaust port of the drain valve If no air comes out push the wire stem If no air comes out there may be a plugged filter in the adapter which should be removed and discarded LEAKAGE TEST With system charged and pressure stabilized in system there should be no leaks at the drain valve exhaust A constant slight exhaust of air at the drain valve exhaust could be caused by excessive leakage in the air brake system If the DV 2 Automatic Drain Valve does not function as described or if leakage is excessive it is recommended that it be replaced with a new or remanufactured unit or repaired with genuine Bendix parts available at Bendix outlets INSTALLING AND REMOVING REMOVING Block and hold vehicle by means other than air brakes Drain air system Disconnect heater wire if valve is so equipped Remove automatic reservoir drain valve DISASSEMBLY Remove 4 cap screws and lock washers Remove cover and sealing ring NOTE The heater and thermostat of the DV 2 s so equipped are not serviceable If the heater or thermostat has failed the entire cover must be replaced Do not remove the thermostat cover plate It is moisture sealed and removal could result in early thermostat failure Remove valve guide Remove inlet and exhaust valve Remove adapter and filter assembly if filter present Remove filter retainer if any Remove filter if
499. ver 55 1727724 68 P 29 Name Plate 328865X Valve Assembly 379130 Bracket 2 500376 6 Hex Nut 4 500357 7 Lockwasher 4 500448 9 Slotted Screw 4 328388 31X Installation Kit 378978 Indicator Light 378884 Fuse Holder gt Battery or ignition AIR SHIFT Installation Sketch for 370 Series Using New Williams Valve 378416 Hex 379131 1 Reducer Nipple Bushing 2 Places Air Supply 37841 4 Pressure Protection Valve Opens at 60 70 PSI 378360 Male Connector 6 Places To Ports on Shifter Cover Ass y Note Tubenutis reusable as long as nylon tubing is not removed from the tube nut Caution When installing nylon tubing avoid sharp angles exhaust and manifold systems Template for control plate on page 30 and 38 378356 Tube Nut 6 Places 379110 Indicator Switch Nylon Tubing CHELSEA CAUTION T MC Shifter Cover Ass y 68 P 18 Name Plate 378884 lil Fuse Holder Battery or Ignition Connect directly to air supply Do not use tubing between air supply and press yrotection valve 33 L 378978 Indicator Light 68 P 29 Name Plate wy 57 v 328865X Valve Assembly 379130 Bracket 2 500376 6 Hex Nut 4
500. ver the stem 14 Install the lock nut 16 on the stem and torque to 20 30 inch pounds 15 Install the primary piston retainer 15 over the piston making certain all three lock tabs have engaged the outer lip of the body IMPORTANT PLEASE READ When working on or around air brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 2 Never connect or disconnect a hose or line containing air pressure t may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted 3 Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone 4 Never attempt to disassemble a component until you have read and understand recommended procedures Use only proper tools and observe all precautions pertaining to use of those tools Some components contain powerful springs and injury can result if not properly disassembled SD 03 5 1 81 Section VI BRAKE SYSTEM Service Data Heavy Vehicle Systems Group Formerly SD 46 PRESSURE PROTECTION VALVES DESCRIPTION filling of auxiliary reservoirs to insure a quick build up of brake Th
501. vice versa to determine the amount of travel needed and the length of casing to be cut Follow step 10 14 Step 15 will show the following CABLE IN P T O ENGAGED LIGHT ON CABLE OUT 1st position P T O DISENGAGED LIGHT OUT CABLE OUT 2nd position P T O ENGAGED LIGHT ON 20 AUTOMATIC TRANSMISSIONS Pressure Lube H6se Connection HOSE FURNISHED WITH P T O TEE FITTING 3 8840 378880 378970 378897 D 750 16 U N F 2A 875 14 U N F 2A 1 062 16 U N F 2A 1 312 12 U N 2A 250 18 N P T F 250 18 N P T F 250 18 N P T F 250 18 N P T F 750 16 U N F 2B 875 14 U N F 2B 1 062 16 U N F 2B 1 312 12 U N 2B The specific Fitting for each Automatic Transmission is called out at the bottom of each transmission s application sheet If a T fitting is not called out then a standard pipe tee will adapt ANOTE The 032 orifice is built into all pressure Tubed idler shafts No additional orifices are required when using these pressure lubed shafts 21 POWER SHIFTS P T O Hose Connection Illustration A High Pressure Line From Valve B Dump Line to P T O From 3 Way Valve C Lubrication Line From Transmission A High Pressure Line From Valve 00 C Lubrication Line From Transmission Attach to either End of IDLER Shaft A High Pressure Line From Valve 00 C Lubrication Line From Transmission Attach to either End of IDLER Shaft Dump Line to P T O From 3 Way Valve Dum
502. vide a passage for grease to purge during bushing lubrication Excessive end play can cause interference between the king pin and end caps or retainers A With king pin caps off turn the knuckle to the straight ahead position Take a rubber mallet and repeatedly strike the top draft of the knuckle as shown This will shift all of the components down and remove grease layers so an accurate reading may be ake TENTE Figure 32 20 B Attach the dial indicator with a C clamp or magnetic base to the knuckle spindle such that the knuckle can be turned freely as show C Place the dial indicator plunger on the exposed end of the king pin so that its line of action is approximately parallel to the king pin center line Figure 33 ee n o EL lt V Figure 33 D Zero the dial indicator E Measure the knuckle clearance end play by using a suitable lever to lift the knuckle while observing the dial indicator Make a note of the measurement NOTE protective pad such as a piece of cardboard or heavy tape should be placed between pry bar and aluminum axle center to prevent grooves ES ac 3 RO Pisa kite abe ROOTS T nn 52 F vy E ui odia HO j
503. w key NOTE Failure to strike the draw key square may result in a damaged key causing removal difficulties C Remove the nut and key from the axle center NOTE Aluminum beam axles do not have machined draw key flat on the king pin Figure 5 PRYING SLOTS DRAW KEY AXLE CENTER KNUCKLE PIN 22 THRUST BEARING AND SEAL ASSEMBLY Figure 5 C Disassembly of Draw Key Wedges Aluminum Beam Axles 1 Remove the locking nut washers and capscrew from the draw key wedges 2 Wedges can then be removed using a wooden or rawhide mallet or by using the prying slots provided on the wedges D _Tap out the knuckle pin by use of a bronze drift __ Figure 6 NOTE If bushings are not to replaced precautions must be taken not to damage the bushings while removing the king pin Grind off any flaring on the end of the drift which will contact the pin Wrap tape around the drift 1 16 thick for the first inch from the end of the drift This step is especially important for Delrin and easy steer bushings CAUTION Do not strike these hardened steel pieces directly with a steel hammer Personal injury from chips or splinters may result E Lift off the knuckle assembly thrust bearing and shims Retain shims thrust bearing and seal for assembly NOTE Aluminum beam axles employ an integral thrust bearing and lower seal assembly DO NOT SEPARATE THE SEAL FROM THE THRUST B
504. well Parts Rockwell International Where science gets down to business ROCKWELL BRAKES CARE AND MAINTENANCE IMPORTANT Brake lining contains asbestos fibers Caution should be exercised handling maintenance as described OSHA Regulation 29 PART 1910 1001 Different types of brake actuating systems are used This equipment is applied by the vehicle manufacturer The following outputs must be maintained for satisfactory brake operation OPERATING PRESSURES Vacuum 18 inches a 85 PSI minimum reservoir 60 PSI minimum wheels Hydraulic 1500 PSI maximum Rockwell does not encourage the reboring of brake drums due to the reduced strength of refaced drums As an economy measure in order to salvage drums some operators do follow this practice On the Cam Master P Automotive and CamMaster amp P Trailer series brakes under circumstances where refaced drums and oversize linings are used precautions regarding cam travel should be observed to prevent sticking cams or cam roll over This condition prevails when the linings become worn The service instructions relative to the use of oversize roller cam followers should be carefully followed Drums which have been refaced should be installed on vehicles operating under the least severe conditions SLACK ADJUSTERS BENDIX WESTINGHOUSE AND MIDLAND ni ed Bendix Westinghouse and Midland l
505. witch 58 Oil Pressure Gauge to Engine Oil Pressure Sender Section VII ELECTRICAL SYSTEM Electrical Circuit Schematic All Models Wire No Circuit 59 Water Temperature Gauge to Engine Water Temperature Sender 62 Circuit Breaker to Turn Signal Flasher 62A Turn Signal Flasher to Steering Column 62B Turn Signal Flasher to Steering Column 63 Steering Column to Right Front Turn Signal amp Side Turn Signal 63A Steering Column to Right Turn Dash Indicator 64 Steering Column to Left Front Turn Signal amp Side Turn Signal 64A Steering Column to Left Turn Dash Indicator 65 Steering Column to Right Rear Turn Signal 66 Steering Column to Left Rear Turn Signal 70 Warning Alarm to Oil Pressure Warning Light 70A Warning Alarm to Water Temperature Warning Light 71 Transmission Temperature Warning Light to Transmission Temperature Switch 71A Warning Alarm to Transmission Temperature Warning Light 72 Transmission Temperature Gauge to Transmission Temperature Sender 80 Circuit Breaker to Back Up Light Switch 81 Back Up Light Switch to Back Up Lights amp Back Up Alarm 86 Water Temperature Warning Light to Water Temperature Switch 87 Oil Pressure Warning Light to Oil Pressure Switch 88 Circuit Breaker to Parking Brake Switch 90 Parking Brake Switch to Dash Indicator Light 92 Circuit Breaker to Auxiliary Power Optional Accessory 96 Headlight Relay to Dimmer Switch 97 Clearance amp Parking Light Relay to Cab Clearance Lights and Right amp Left
506. y give an approximation of lining wear However this is accurate enough to tell when lining replacement is necessary For further information installing lining wear indicators refer to Rockwell Technic Aid Section 6 Aid 42 ROCKWELL AUTOMATIC For information on Rockwell automatic slack adjusters refer to advance manual Automatic Slack Adjusters BRAKE LINERS IMPORTANT Brake lining contains asbestos fiber Caution should be exercised handling maintenance as described in OSHA Hegulation 29 CFH PART 1910 1001 Brake liners vary considerably in both size and content This is determined by the joint engineering departments of Rockwell and the vehicle manufacturer depending on the vehicle and its prospective application Consequently liners should be replaced in accordance with the manufacturer s recommendations CARE AND MAINTENANCE Combination liners with a different coefficient of friction for the forward primary and reverse secondary shoes arc frequently used this type installation RIGHT WHEEL ROTATION RIGHT WHEEL ROTATION RIGHT WHEEL ROTATION the forward blocks must be installed on the forward shoe It should be remembered that following the rotation of the drum the first shoe after passing the cam or wheel cylinder is the forward shoe Primary lining will be painted blue on the edge and the secondary yellow If the cam is behind the axle the top shoe is the primary a
507. y one of the following materials Elco 2 The Elco Corporation Lubrizol 46178 Lubrizol Corporation Hi Tec 336 Edwin Cooper Inc The R 170 series axle requires 43 pints 20 3 litres of lubricant With a Rockwell Traction Equalizer this same axle requires 40 pints 18 9 litres of lubricant and 3 pints 1 4 litres of one of the above additives 2 For Mobilube HD mineral oil and Mobilube SHC synthetic use Mobil 204 Mobil Oil Corporation When using Mobilubes in the R 170 series axle with a Rockwell Traction Equalizer use 41 pints 19 3 litres of lubricant and 2 pints 9 litres of Mobil 204 additive e Lubrication change interval The original factory installed drive axle lubricant should be replaced with approved lubricants and the above recommended additives Thereafter the recommended lubrication change interval including additive on axles equipped with Rockwell Traction Equalizers should be no more than 50 000 miles 80 000 km LUBRICATION ROCKWELL RECOMMENDED LUBRICANTS PROPER LUBRICANTS all cases the lubricant supplier assumes all responsibility for the performance of his product Improper lubricants or lubricants with the wrong additives and for product and patent liability are a major cause of gear set failures Rockwell hypoid or amboid gear sets require lubricants that have an API GL Lubricant suppliers may obtain copies of any referenced 9 grade Transfer case gearing and worm gearing
508. y plain or zinc finish NOTE Available with new 093 case matl by ordering 55 HD No 55 B CAB LOCK right hand shown Inside Handle No mortising required Built in Push Handle integral with lock bushing Die formed steel bushing 1 striker bolt Size 3 3 8 high 2 wide 1 1 4 handle Weight 1 Ib 453 6 grams Both left and right hand models Available with reverse bolt when specified Also specify plain or zinc finish No 56 CAB LOCK left hand shown Inside handle mortising required Locking device inside lock and unlocks by easy thumb pressure Size 3 3 8 high 2 wide 3 1 4 handle 1 striker bolt Weight 3 4 Ib 340 2 grams Both left and right hand models Available with reverse bolt when specified Also specify plain or zinc finish All locks marked with asterisk are avail able with flanged back plate if desired order by adding F to lock number a 8 NT Mb P rt n MESE n d E e T tom 420 E AE ER 1 Ri te y f A Ex j Sos 4 1 M DU WOOL AONO v gt um vor de us nal MR 7 i M a i 4 22 dh ve nr 2 w DISTRIBUTION CENTER 00 Suacti onV Ulr I T MASCELILAANG GUS PART DESCRIPTION DIM OF COMP T 305 152 133 PROT RUDE COMP T THE DISJONCTOR
509. you how to get additional and more profitable miles from truck tractor and trailer components we want to provide you with information on the installation of 6 and 8 Bolt Chelsea Power Take Offs We all realize that an inadequate transmission will overwork any power take off in a very short period of time In addition a mismatched transmission P T O combination result satisfactory performance of equipment right from the start Before you order new trucks be sure that you re getting the right transmission P T O combination It is of vital importance for efficient performance to have adequate power To help you select the proper type size and design of P T O it is advisable to discuss your specific requirements with a Chelsea P T O specialist knows his products and has easy access to manufacturers of equipment transmissions and power takeoffs He can inform you about everything you need to know about power at the right time before you specify components EXPLODED VIEW OF A TYPICAL TRANSMISSION MOUNTED P T O e P T O Case e Shifter Cover Sub assembly Components for Wire Control Output Shaft Gear Components Mounting Gaskets Input Gear Shaft Components CAUTION When a P T O has the pump flange direct mount option the pump being bolted to the 6 Bolt or Counter Shaft P T O should weight no more than forty 40 pounds If the pump is heavier we suggest the use of a bracket or

TM 5-4210-227-24&P-5

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TM 5-4210-227-24&amp;P-5

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TM 5-4210-227-24&P-5