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KW Project

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DMiller View Drop Down
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Joined: 14 Sep 2009
Location: Hermann, Mo
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 09 Mar 2021 at 4:53am
A kid I speak to on occasion asked how I know how to do all this stuff, Drive these, work on these, arrange parts for these machines.  Explained, Time In Field.  Been doing this first nearly 25 years as a profession, then a added 20 years in another profession as a side line.  Always working always learning.
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DMiller View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 11 Mar 2021 at 4:46am
By all counts should have this up and running about the time fuel hits $5/gal, so it will probably sit and await 2022 election where the Dems get thrown out.
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Michael V (NM) View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Michael V (NM) Quote  Post ReplyReply Direct Link To This Post Posted: 11 Mar 2021 at 10:35am
Originally posted by DMiller DMiller wrote:

By all counts should have this up and running about the time fuel hits $5/gal, so it will probably sit and await 2022 election where the Dems get thrown out.

I sure hope fuel don't get near $5.00/gallon,, but the way it goes up $0.10-0.12/ gal every other day around here, it will not take long....

dangit,, it took 4 years to get it(fuel cost) down to where I could actually keep some money,, only took 6 weeks to be back well over $3.00/gallon,,, CRAP....CryOuch


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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 19 Mar 2021 at 6:57pm
Received a roll of Fehr cab floormat so can recover the bunk compartment floors.  That and a roll of Engine Compartment Hood Insulation to use on the floor around the HVAC in the bunk.  Parts are dribbling in.
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Tim NH View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Tim NH Quote  Post ReplyReply Direct Link To This Post Posted: 19 Mar 2021 at 7:24pm
Dave the gear ratio in those rear ends must be high, like 3.70 or 3.90. Is it worth changing it to like 3.36 for what your going to use the truck for.  Anyway, your going to have a nice truck when your done. 
   Tim
  
1950 WD 1959 D14 1955 WD45 1976 7000 B 207
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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 19 Mar 2021 at 8:11pm
I believe them to be 3.70 Eaton axles, with the 24.5 tires and Overdrive in trans top speed would be close to 80 if pressed it, not intending to.  Will drive comfortably at 70, on secondary roads 60 will be quite quiet and low rpm, HP will not be challenged.  Heavy truck tires do not appreciate high speeds and high heat loads, this unit should see neither.

Sentimentally I almost traded my 1979 K100C KW in on a Aerodyne W900L in 1982, would have been a close twin other than bunk size to this with a 3406B and a 13 speed Double Over Drive.  This has an 18 speed, can split Every gear Low or High side, will not likely do that anymore either.  Truck is a hobby, will become a personal conveyance, may end up traded to a lesser T370, Pete 337(Or Similar) with a Crew Cab or Double sleeper and single axle with an automatic in it as I gain more age.

Trucks Used: Rv Toter Trucks Used
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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 22 Mar 2021 at 4:25am
Big day yesterday, door lamp switches and on connector repair, doors completed, did some research as to why nothing in bunk worked electrically, no ground.  Found my cable but no ends, added to list.  Moved on to WS Wiper transmission linkage, had to take pivot mounts loose and three firewall where one brkt to brkt bolt broke off, got two of firewall bolts drilled and threads cleaned up(m6 x 1.0 metric)feet were cramping trying to perch on narrow points like spring shackle blocks so stepped away there too, got the brackets started as to prep to repaint.  Fitted a test piece of Fehr Cab Interior floor mat into Right Compartment, looks and fits great, will order enough to fit the other side, the HVAC compartment and maybe a tote box bottom for rattle control.  Set the sleeves for protrusion check but bolts I had for retaining the sleeves not happy with, set paper across deck for now, made my order to McMaster Carr.  Finally crawled under and polished out #1 & 6 rod journals then cleaned sanding crap off crankshaft and replaced the mains.  They are torqued to 190# but need to mark the bolt heads and bearing caps, torque turn Two Flats yet.

One further inspection on wiper mount bolt found a rust hole in heater box(right side firewall), may have to find and order a used replacement.














Edited by DMiller - 22 Mar 2021 at 4:27am
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tadams(OH) View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote tadams(OH) Quote  Post ReplyReply Direct Link To This Post Posted: 25 Mar 2021 at 3:08pm
Slow and study progress, looking great
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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 06 Apr 2021 at 3:50am
Was working to use up small parts, getting WS Wiper mechanism back together, all but one bolt drilled out where the last would not go, had issues with cab HVAC box so ordered replacement and began that venture as dig deeper just more and more corruption.  As of last parts order and with the rust drippers all off the cab checked Liner Protrusion and will next weekend finish assembly of lower engine, should have head on in two weeks.  Managed to get done with Bunk HVAC and storage compartment insulation/matting.  As with most aftermarket the HVAC replacement leaves much to be desired but should still function, more parts ordered from KW/PACCAR.  



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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2021 at 4:02pm
Got brave today, been practice Aluminum Welding with my spool gun, took the rotted threaded holes for right tank back to threads using weld in bungs.  JEGS Racing Supply and yes I know, China Made, could not avoid it.   Saved from buying a $700 tank.






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PaulB View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PaulB Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2021 at 4:55pm
That's why I got a TIG welder, to make and repair aluminum tanks.
If it was fun to pull in LOW gear, I could have a John Deere.
If you can't make it GO... make it SHINY
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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2021 at 4:57pm
I tried my hand at TIG, not very good at it but decent with a MIG and does as I need.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote plummerscarin Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2021 at 7:00pm
Not too shabby considering how hard it is to weld dirty aluminium
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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2021 at 7:27pm
Cleaned where welded, SS Wire Brush, used ONLY on Aluminum, prepped with Acetone to remove residual Oils, then washed lightly with water and rag then repeat wire brush lightly.

Edited by DMiller - 17 Apr 2021 at 7:28pm
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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 29 Apr 2021 at 7:29pm
More engine progress, Sleeves are in, cyls 1&6 pistons/rods are set then ring compressor took a dump, was ONLY forty years young!!!  New compressor is coming.






Edited by DMiller - 29 Apr 2021 at 7:30pm
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shameless dude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote shameless dude Quote  Post ReplyReply Direct Link To This Post Posted: 30 Apr 2021 at 12:32am
lookin good!
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DMiller View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 02 May 2021 at 11:28am
All buckets are in, rods torqued and 60degree turn set, Oil pump is up where need to sort thru the o-ring sets and change the pickup and disch. tube rings then can set pan.

Next up, build head.


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tadams(OH) View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tadams(OH) Quote  Post ReplyReply Direct Link To This Post Posted: 02 May 2021 at 3:15pm
Yes, Looking Good
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mactractor Quote  Post ReplyReply Direct Link To This Post Posted: 02 May 2021 at 6:13pm
She'll be ready for a million mile Dave.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 02 May 2021 at 6:40pm
Can only hope!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 2021 at 4:04pm
Pistons and rods all back in, oil pump and pan back up, got started on the head parts cross over.  Had one lifting eye to repair while off.  Have a fuel line fitting to get and a rear cam access cover as screws on old head will NOT budge.  Currently polishing the cam by hand with 1000 grit w/d sand paper, once where I like it will be cleaned and placed in head.

Next weekend is out as will be hauling the old Chevy rust bucket as far as Lebanon MO for the new owner to pick up.  I also this morning ordered the Turbo Charger conversion kit from Momentum Worx.








Edited by DMiller - 09 May 2021 at 4:05pm
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plummerscarin View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote plummerscarin Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 2021 at 5:34pm
Question on the cam polishing. After you are done with that, what happens with the lifters? Reface and break in? Break in as is? Would break in be necessary? Or are they roller lifters. Sorry if too many questions.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 2021 at 7:27pm
Has no lifters
This is a roller rocker overhead cam engine
When the cam is too ‘slick’ or oil too dirty the rollers no longer roll but scoot on the cam
There is a tolerance level established by Cat in tech manuals as to quantity in area of scuff marks and how to ‘buff’ them

The rollers show little indications of the scuffing, where inspecting them you look for flat spots(not rolling)
The cam also has indications where sat in the old head stored inside a building for six years immobile
Those clean up readily


Edited by DMiller - 10 May 2021 at 3:53am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 2021 at 7:33pm
What I find some amusing, after close to fifty years wrenching(even as worked at the nuke) the cam in this engine is a amalgam of Cummins and Detroit diesels technology
Unit injectors as a DD where the ‘rack’ is operating by solenoid but is cam actuated delivery
The lobe is backward large diameter with a reversed lobe where at rest is depressing the injector fully down as comes to injection point rocker follows into low spot of cam rising the rocker then returns the rocker to down to inject the fuel set by the solenoid timing. Cummins style.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Tracy Martin TN Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 2021 at 7:41pm
Nice looking work! Tracy
No greater gift than healthy grandkids!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 2021 at 7:46pm
Thanks

Wish could have pressure washed the entire engine at start of this
Was already partially disassembled so was a no go. Could have gone out of frame but time and tooling limited these days.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Sugarmaker Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 2021 at 8:51pm
Dave,
 Sure glad you know what your doing, because I am no help here at all, except for moral support! Good Job! Keep going!
Regards,
 Chris


Edited by Sugarmaker - 09 May 2021 at 8:51pm
D17 1958 (NFE), WD45 1954 (NFE), WD 1952 (NFE), WD 1950 (WFE), Allis F-40 forklift, Allis CA, Allis D14, Ford Jubilee, Many IH Cub Cadets, 32 Ford Dump, 65 Comet.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 10 May 2021 at 6:34am
Will get photos of the rocker assemblies, the long round machined line on the head is where the support shafts are bolted in.  They are not fixed in place hard enough to stop all movement so the shafts erode and in this case need be replaced.  Retainer bolts are a one time use as well as are most CAT large component fasteners.  They torque in place then are 'Turned' additional degrees to take to a 'Torque to Yield' value as the fasteners stretch.  Never understood the positive value of that.  Rod bolts and Head bolts same concern.

Edited by DMiller - 10 May 2021 at 6:37am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SteveM C/IL Quote  Post ReplyReply Direct Link To This Post Posted: 10 May 2021 at 11:03pm
Those shaft and rocker assemblies are HEAVY!!! Do you have the Cat tool for picking those off and on the head? Would be very handy.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DMiller Quote  Post ReplyReply Direct Link To This Post Posted: 11 May 2021 at 4:10am
Just two hands here!!  Can see the erosion 'wear' on the shaft end, and these are hard bolted down.  Have replacement shafts and bolts.



Unit Injectors


Cam, Gear end



Edited by DMiller - 11 May 2021 at 4:25am
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