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Hino 600, Workshop Manual, Page: 161 / 451

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Page 1: ...al All information and specifications in this manual are based upon the latest product information available at the time of printing Hino Motors Sales U S A Inc reserves the right to make changes at any time without prior notice Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys tems in these vehicles Manual Name Pub No Chassis W...

Page 2: ...OMATIC TRANSMISSION TR04 001 TR04 002 TRANSMISSION TRANSFER CONTROL TR06 001 TR06 002 PROPELLER SHAFT PP02 001 DIFFERENTIAL CARRIER DF02 001 BRAKE EQUIPMENT BR01 001 BR01 002 SERVICE BRAKE BR02 001 BR02 002 ABS ANTI LOCK BRAKE SYSTEM BR03 001 BR03 002 EXHAUST BRAKE BR05 001 PARKING BRAKE BR07 001 STEERING EQUIPMENT SR01 001 STEERING UNIT SR02 001 POWER STEERING SR03 001 FRONT AXLE AX02 001 REAR AX...

Page 3: ...ON MAIN UNIT TRANSFER MAIN UNIT AUTOMATIC TRANSMISSION PTO POWER TAKE OFF TRANSMISSION TRANSFER CONTROL PROPELLER SHAFT DIFFERENTIAL EQUIPMENT DIFFERENTIAL CARRIER INDEX CHASSIS GROUP 1 4 PROPELLER SHAFT EQUIPMENT BRAKE EQUIPMENT SERVICE BRAKE ABS GENERAL INTRODUCTION WORKSHOP MANUAL ...

Page 4: ...AKE RETARDER BRAKE PARKING BRAKE STEERING EQUIPMENT STEERING UNIT INDEX CHASSIS GROUP 2 4 POWER STEERING AXLE EQUIPMENT FRONT AXLE REAR AXLE WHEEL TIRE SUSPENSION EQUIPMENT SUSPENSION CHASSIS EQUIPMENT CHASSIS FRAME COUPLER 5TH WHEEL PINTLE HOOK ...

Page 5: ...CAB EQUIPMENT CAB INDEX CHASSIS GROUP 3 4 ELECTRICAL EQUIPMENT ELECTRIC WIRE HYBRID SYSTEM ...

Page 6: ...ENGINE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS INDEX CHASSIS GROUP 4 4 ...

Page 7: ...TIONS GN02 15 SEALANT ON THE TAPERED SCREW FOR PIPING GN02 18 NYLON TUBE REPLACEMENT METHOD GN02 19 METRIC INFORMATION GN02 21 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS GN02 23 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS GN02 23 RECOMMENDED LUBRICANTS GN02 25 VEHICLE LIFT AND SUPPORT LOCATIONS GN02 27 INFORMATION DISPLAY GN02 29 SYMPTOM SIMULATION GN02 34 GLOSSARY GN02 36 GLOSSARY OF SAE AND HIN...

Page 8: ...en working on the battery It contains corrosive sulfuric acid Large electric current flows through the battery cable and starter cable Be careful not to cause a short which can result in personal injury and or property damage Read carefully and observe the instructions specified on the jack before using it Use safety stands to support the vehicle whenever you need to work under it It is dangerous ...

Page 9: ...ant or the entry of dirt or foreign matter The above mentioned precautions should be observed for vehicles equipped with either manual or automatic transmission and for even short distance towing After being towed check and refill the rear axle housing with lubricant if necessary 2 Rear end towing When being towed with the rear wheels raised off the ground fasten and secure the steering wheel in a...

Page 10: ...ns related control components including a listing of parts and components used engine parameter adjustments emis sions related codes or signals responded to and reset and work performed under paragraph 4 of this section a Parties may keep records in whatever format or system they choose as long as the records are understandable to an EPA enforcement officer or can be otherwise provided to an EPA e...

Page 11: ... and letters The VIN label is affixed to the left pillar of the cab These numbers are used for identification purposes when you have a vehicle registered or inspected Please quote these numbers when ordering spare parts or reporting technical matter to receive prompt service attention The following is an explanation of the items that are listed on the VIN label VIN label ...

Page 12: ... 22 2 04 1 36 1 00 8 63 RS17 145 H D L or A RS19 145 HBC 2200HS 3 10 1 81 1 41 1 00 0 71 0 61 4 49 RS17 145 RS19 145 2200RDS 3 10 1 81 1 41 1 00 0 71 0 61 4 49 RS17 145 RS19 145 2500RDS 3 51 1 90 1 44 1 00 0 74 0 64 5 09 RS17 145 RS19 145 NJ8J JBC 350mm FS5406 9 01 5 27 3 22 2 04 1 36 1 00 8 63 RS17 145 F W A RS19 145 KBC 2200HS 3 10 1 81 1 41 1 00 0 71 0 61 4 49 RS17 145 F W L or A RS19 145 2200R...

Page 13: ... RS23 160 3500RDS 4 59 2 25 1 54 1 00 0 75 0 65 5 00 RS21 145 RS23 160 TBC 350mm FS6406 9 01 5 27 3 22 2 04 1 36 1 00 8 63 RS21 145 RS23 160 SBC 2500RDS 3 51 1 90 1 44 1 00 0 74 0 64 5 09 RS21 145 RS23 160 3000RDS 3 49 1 86 1 41 1 00 0 75 0 65 5 03 RS21 145 RS23 160 3500RDS 4 59 2 25 1 54 1 00 0 75 0 65 5 00 RS21 145 RS23 160 HINO338 7 NF8J DBC 350mm FS6406 9 01 5 27 3 22 2 04 1 36 1 00 8 63 RS21 ...

Page 14: ... 160 HINO358 8 NH8J NBC 350mm FS6406 9 01 5 27 3 22 2 04 1 36 1 00 8 63 RS23 160 F W L or A PBC 3000RDS 3 49 1 86 1 41 1 00 0 75 0 65 5 03 RS23 160 3500RDS 4 59 2 25 1 54 1 00 0 75 0 65 5 00 RS23 160 TBC 350mm FS6406 9 01 5 27 3 22 2 04 1 36 1 00 8 63 RS23 160 SBC 3000RDS 3 49 1 86 1 41 1 00 0 75 0 65 5 03 RS23 160 F W L or A 3500RDS 4 59 2 25 1 54 1 00 0 75 0 65 5 00 RS23 160 CODE SERVICE BRAKE H...

Page 15: ...B 7 6 LITERS DIESEL 260HP DESCRIPTION MANUFACTURER HINO MOTORS LTD CODE G 3 861 LENGTH NE NV mm in J 4 445 L 4 750 M 5 207 N 5 385 P 5 512 R 5 969 T 6 426 V 6 883 152 175 187 205 212 217 235 253 271 CODE S DESCRIPTION A NEW LETTER T WILL BE ALLOTTED U AT EVERY MAJOR MODIFICATION Z CODE 1 ASSEMBLY PLANT HINO MOTORS LTD HINO PLANT IN JAPAN 3 Canada Plant 4 W V Plant MODEL CODE MAKE NF HYDRAULIC LINE...

Page 16: ...the CARB below the label must be affixed there to prove that the new vehicle with diesel engine manufactured from Jan 2008 con forms to this low VEHICLE NOISE EMISSION CONTROL INFORMATION THIS VEHICLE CONFORMS TO U S EPA REGULATIONS FOR NOISE EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUCKS THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT OF 1972 A THE ...

Page 17: ... Control Information is affixed to the side of the left door The name of manufacturer production year and month and emission applicable to medium and heavy trucks in conformity with U S EPA Regulations are displayed VIN label Vehicle emission control information GN02 13 1 0 For example GN02 13 1 1 ...

Page 18: ... TROUBLESHOOTING section for a guide to appropriate diagnosis SPECIAL TOOL is dealt with in each chapter When ordering a special tool confirm the part number with the applicable parts catalog RERAIR PROCEDURES Repair procedures when self explanatory such as simple installation and removal of parts have been omitted Illustrations such as the one below have been provided to make such simple procedur...

Page 19: ...ocedure being illustrated applies regardless of such nones sential differences DEFINITION OF TERMS Definition of vehicle right and left Right and left refers to the left and right sides of the vehicle as seen while looking down the center line from the rear towards the front SHTS00Z000200014 1 Clevis 8 Return spring 2 Lock nut 9 Body 3 Push rod 10 Hose joint 4 Boot 11 O ring 5 Retainer ring 12 Sof...

Page 20: ...GENERAL INTRODUCTION CHASSIS GN02 14 SHTS00Z000200015C ...

Page 21: ...e cable from the minus termi nal of the battery in order to avoid burning caused by short circuiting 2 To remove the battery cable fully release the nut to avoid damage to the battery terminal Never twist the terminal 2 HANDLING OF ELECTRONIC PARTS 1 Never give an impact to electronic parts of a computer or relay 2 Keep electronic parts away from high temperatures and humidity 3 Never splash water...

Page 22: ...inspection 5 INSTALLATION OF BATTERY DISCONNECT SWITCH WARNING Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF SCR DCU may dam age or result in the malfunction of DEF SCR system Be sure to read and follow the procedures and instructions on the service bulletin before the installation of the battery discon nect switch 6 HANDLING OF BATTER...

Page 23: ...s brake pipes or fuel pipes and leaf spring etc a Turn the starter switch off b Disconnect the negative terminal of the battery c Earth welding equipment securely near to the area to be welded d Put back battery negative ground as original condition e Finally check the functioning of all instruments 2 In order to prevent damage to ancillary equipment components from sparks during welding take step...

Page 24: ... turn three ridges starting from the second ridge from the tip then assem ble in accordance with the tightening torque table below Wipe dirt off the mating part female screw before tightening it WARNING In case the sealant has entered your eye or attached to your skin wash it away in running water Tightening torque of tapered joint Unit N m kgf cm lbf ft 2 To replace vulcanized tape with sealant r...

Page 25: ...tube to push the connec tor end pull off the nylon tube with your hand in one stroke without stopping partway pulling the tube in the connector axial direction SST Puller S0942 11490 INSTALLATION OF A ONE TOUCH JOINT AND CAULK ING JOINT Make sure the joint interior is free of dirt grease If the interior is dirty clean it thoroughly by air blowing or other means Cut off the tube end where the tube ...

Page 26: ...ore 3 Always check air leakage after assembling the joint If air is leaking from the joint continue tightening the sleeve nut until the leak stops 4 If the air leak does not stop replace the tube sleeve and insert with new parts If the air leak still continues replace the nut and connector union NOTICE During repair or other work make sure the temperature limit of the nylon tube is within 40 90 C ...

Page 27: ...that are equivalent to the original parts in dimensions strength and thread pitch must be selected 3 Most original bolts are marked with identification numbers indi cating the strength of the bolts The markings are shown below 4 When replacing bolts be careful to use bolts with the same markings as the original bolts Metric system M12 1 75 25 D T L P 7 T L D 7 9 D Nominal Diameter P Property Class...

Page 28: ...463 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 250 6 35 3 4 0 750 19 05 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 54 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375...

Page 29: ...0 6 105 8 128 0 192 0 1 304 1 956 94 3 141 4 M16 96 0 144 0 976 1 464 70 6 105 8 152 0 228 0 1 552 2 328 112 3 168 3 200 0 300 0 2 040 3 060 147 5 221 2 M18 132 0 198 0 1 344 2 016 97 2 145 7 208 0 312 0 2 120 3 180 153 3 229 9 276 0 414 0 2 816 4 224 203 6 305 4 M20 188 0 282 0 1 920 2 880 138 8 208 2 296 0 444 0 3 024 4 536 218 7 327 9 392 0 588 0 4 000 6 000 289 3 433 8 M22 256 0 384 0 2 616 3 ...

Page 30: ...m lbf ft Class 8 8T 10 9T Shape Diameter M8 21 7 40 3 221 411 16 0 29 7 27 3 50 7 278 517 20 1 37 4 M10 24 5 45 5 250 464 18 1 33 6 32 7 60 3 333 615 24 1 44 5 M12 44 1 81 9 450 835 32 5 60 4 57 4 106 6 585 1087 42 3 78 6 M14 91 169 928 1723 67 1 124 6 104 156 106 1590 76 7 115 1 ...

Page 31: ...nsmission oil or equivalent See Eaton Lubrication Manual for detail EATON Fuller FS 5406A FS 6406A All 50 4 Automatic transmission fluid TES 389 approved fluid Allison 2200HS 2200RDS 2500RDS 3000RDS 3500RDS Automatic transmission fluid TES 295 approved fluid Allison 2200HS 2200RDS 2500RDS 3000RDS 3500RDS 5 Axle lubricant Non Extended Drain Lubri cants Petroleum with EP Additives A P I GL 5 MIL PRF...

Page 32: ...r Clevis Pin Parking Brake Camshaft Anchor Pin Shoe web 10 SPECIAL GREASE KLUBER GLKO B Frame Disc Brake Guide buss Caliper body Piston 11 STARTER GREASE N L G I s No 2 LITHIUM SOAP Bushing Clutch Drive Shaft Pinion Shaft Lever Reduction Gear 12 BEARING GREASE N L G I s No 2 LITHIUM SOAP Clutch Release Sleeve Clutch Release Shaft Alternator Bearing Starter Bearing 13 CHASSIS GREASE MIL G 17740 N L...

Page 33: ... the specified location with a jack and safety stand accurately 3 Do not work or leave the vehicle supported only by a jack Be sure to support the vehicle together with a safety stand 4 Be careful and accurate in jacking up and down the vehicle 5 Care must be taken when jacking up and supporting the vehicle Be sure to lift and support the vehicle at the proper locations Cancel the parking brake on...

Page 34: ...ront Rear Leaf suspension Air suspension Air spring Front Rear Center of front axle beam Center of rear axle housing Garage jack position Safety stand If necessary remove the front bumper Support position Oil jack position SHTS00Z000200034 ...

Page 35: ...ast message But in case of device operating the warning display is prior to ordinary display 2 INFORMATION DISPLAY CONTROL SWITCH The following information is shown with the key turned on Each time you push the MODE button the displayed information is changed NOTICE Diagram on the next page shows the operation method of the information display If you push and hold SET RESET button as the display c...

Page 36: ...n menu Control menu Secondary Setting Maintenance Returns to last display automatically Fuel consumption monitor Trip data Operation time DPR Water temperature Voltage meter Setting cannot be made while driving Push and hold for at least 1sec Starter key ON Interruption display Water temp Voltage DPR Current Average Main menu Clock Language Units Display Conversion rate Engine oil T M oil Diff oil...

Page 37: ...ion of soot and keeps the DPR cleaner in good condition Use of high performance catalyst and an electronically controlled common rail fuel injection sys tem has made it possible to burn regenerate the soot while driving Display Warning Display remarks Engine control system has malfunction This is important and must be addressed immediately DPR cleaner needs to be manually regenerated Display Displ...

Page 38: ...SELECT button for longer than 1 sec to display the Inactive 6 Trouble code display 5 RESETTING PROCEDURE EX Differential oil change period 1 Scroll up and select Maintenance and push SET RESET button 2 Scroll up and select the preferred setting item and push SET RESET button 3 Push and hold SET RESET button for longer than 1 sec NOTICE In the case of the other item on trouble code data may be rese...

Page 39: ...ENERAL INTRODUCTION CHASSIS GN02 33 6 AVAILABLE SETTING ITEMS Engine oil T M oil Diff oil Coolant Fuel filter Belt DPR Turbo Starter Alternator Radiator Battery Air dryer Customize1 Customize2 Customize3 ...

Page 40: ... be confirmed First narrow down the possible problem circuits according to the symp toms Then connect the tester and carry out the symptom simulation test judging whether the circuit being tested is defective or normal Also confirm the problem symptoms at the same time Refer to the problem symptoms table for each system to narrow down the possi ble causes 1 VIBRATION METHOD When malfunction seems ...

Page 41: ...ater onto the front of the radiator Never apply water directly onto the electronic components HINT If the vehicle has or had a water leakage problem the leakage may have damaged the ECU or connections Look for evidence of corro sion or short circuits Proceed with caution during water tests 4 HIGH ELECTRICAL LOAD METHOD When a malfunction seems to occur when electrical load is excessive 1 Turn on t...

Page 42: ...B Decibel DC Direct Current D CAT Diesel Clean Advanced Technology System DC motor Direct Current Motor DCU Dosing Control Unit DEF Diesel Exhaust Fluid DPR Diesel Particulate active Reduction System DSS Driving Support System ECU Electronic Control Unit EEPROM Electronically Erasable and Programmable Read Only Memory EGR Exhaust Gas Recirculation ELR Emergency Locking Retractor ENG Engine ES STAR...

Page 43: ...anese Industrial Standards LED Light Emitting Diode LEV Low Emission Vehicle LH Left Hand LLC Long Life Coolant Lo Low MAX Maximum MIN Minimum MS evaporator Multi rank and Super slim structure evaporator No Number NOx Nitrogen Oxide NMR No load Maximum Revolution OHC Over Head Camshaft PC Personal Computer PCD Pitch Circle Diameter PCS Pre Crash Safety PCV Pump Control Valve PCV valve Positive Cra...

Page 44: ...INTRODUCTION CHASSIS GN02 38 PVD Physical Vapor Deposit PWR Power QE code Quick Response Code R A Rear axle RH Right Hand SCR Selective Catalytic Reduction SW Switch T M Transmission SAE ABBREVIATIONS SAE TERMS ...

Page 45: ...TREATMENT DIESEL OXIDATION CATALYST DOC Diesel Oxidation Catalyst AFTDOS AFTERTREATMENT DOSER AFTDOS DEF injector AFTDPF AFTERTREATMENT DIESEL PARTICULATE FILTER DPR filter AFTDPFDP Aftertreatment Diesel Particulate Filter Differ ential Pressure DPR differential pressure AFTEGT AFTERTREATMENT EXHAUST GAS TEM PERATURE Exhaust gas temperature AP ACCELERATOR PEDAL Accelerator pedal AP Sensor ACCELERA...

Page 46: ... Fuel pump FUEL PRESSURE Sensor FUEL PRESSURE Sensor Fuel Pressure sensor GLOW PLUG GLOW PLUG Glow plug GND GROUND GROUND IA INTAKE AIR Air Intake IA System INTAKE AIR System Air Intake System IAT INTAKE AIR TEMPERATURE Intake temperature IAT Sensor INTAKE AIR TEMPERATURE Sensor Intake temperature sensor IDLE IDLE idle IMAT INTAKE MANIFOLD AIR TEMPERATURE Intake manifold Air temperature sensor IMA...

Page 47: ...Common rail pressure sensor SPARK PLUG SPARK PLUG Spark plug SRI SERVICE REMINDER INDICATOR Check engine ST SCAN TOOL Diagnostic tool TC TURBOCHARGER Turbocharger TCC TORQUE CONVERTER CLUTCH Torque Converter TP Sensor THROTTLE POSITION Sensor Throttle Sensor TSS Sensor TURBINE SHAFT SPEED Sensor Turbine Speed Sensor VAF Sensor VOLUME AIR FLOW Sensor Air flow sensor VLS VEHICLE LIMITING SPEED Speed...

Page 48: ...TON SAS1401 CL02 2 DATA AND SPECIFICATIONS CL02 2 DESCRIPTION CL02 2 TROUBLESHOOTING CL02 3 SPECIAL TOOL CL02 5 COMPONENT LOCATOR CL02 6 OVERHAUL CL02 7 CLUTCH ASSEMBLY EATON SOLO1401 CL02 14 DATA AND SPECIFICATIONS CL02 14 COMPONENT LOCATOR CL02 14 OVERHAUL CL02 15 INSPECTION AND REPAIR CL02 22 ...

Page 49: ...IFICATIONS EN02Z0202I200001 CLUTCH FACING Unit mm in DESCRIPTION EN02Z0202C100001 Material Sintered metal Ceramic metal Type Dry single plate with damper spring Inside diameter 222 8 8 Outside diameter 350 13 8 Thickness 11 5 0 45 1 2 SHTS02Z020200001 1 Clutch disc 2 Clutch cover ...

Page 50: ... Clutch pedal free play incorrectly adjusted Adjust free play Compression spring weak Replace cover assembly Clutch facing worn Replace disc assembly Failing to remove plate from the clutch pressure plate assembly Remove plate Driver riding clutch pedal Do not ride the clutch pedal Vehicle vibrates when starting Improper engine idling Adjust idling Clutch control incorrectly adjusted Adjust clutch...

Page 51: ...sufficient lubrication of pedal and its accessories Lubricate Insufficient lubrication of release shaft and release bearing hub Lubricate Transmission input shaft retainer rusted or soiled Clean or replace if rusted Clutch pedal free play incorrectly adjusted Adjust free Play Clutch pedal cannot be depressed Clutch control incorrectly adjusted Adjust clutch control Insufficient lubricant release s...

Page 52: ...2K100001 Prior to starting a clutch overhaul it is necessary to have these special tools Illustration Part number Tool name Remarks S0965 01970 CLUTCH PILOT BEARING PULLER S0942 01442 SLIDING HAMMER S0966 21410 CLUTCH ALIGNING ARBOR S0940 91200 CRANKING TOOL ...

Page 53: ...LUTCH MAIN UNIT EATON 1401 CL02 6 COMPONENT LOCATOR EN02Z0202D100001 Tightening torque Unit N m kgf cm lbf ft 1 Clutch cover 3 Adjusting screw 2 Clutch disc 4 Bolt A 50 64 510 655 37 47 SHTS02Z020200006 ...

Page 54: ...ve the pilot bearing SST Pilot Bearing Puller S0965 01970 Sliding Hammer S0942 01442 2 Using a suitable tapping rod install the pilot bearing NOTICE After installing the pilot bearing ensure that it rotates smoothly 2 CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY WORN COMPONENTS 1 Cross shafts and bushings NOTICE Excessive wear at these points can cause a side loading condition Also inspect the r...

Page 55: ...t a twisted input shaft Replace input shaft if disc does not freely slide 4 Smooth area of input shaft 5 Mating surfaces NOTICE Inspect the mating surfaces of both the transmission bell housing and the flywheel housing Any appreciable wear on either housing will cause misalignment Most wear will occur between the 3 and 8 o clock positions Replace housings if worn B Check release yoke fingers SHTS0...

Page 56: ...TIGHTEN 1 Remove the two 2 guide studs and replace with the remaining mounting bolts with lockwasher Using a torque wrench progressively tighten the eight 8 mounting bolts using the following crisis cross pattern Starting at lower left Remove the shipping blocks from between the release bearing and the cover assembly Tightening Torque 50 64 N m 510 665 kgf cm 37 47 lbf ft CAUTION Failure to tighte...

Page 57: ... THE TRANSMISSION INTO GEAR 7 POSITION THE TRANSMISSION SO THAT IT IS BOTH SQUARE TO AND ALIGNED WITH THE ENGINE 5 Remove aligning tool SHTS02Z020200017 6 Shift transmission into gear Shift into gear SHTS02Z020200018 7 Align the transmission to the engine SHTS02Z020200019 ...

Page 58: ...m and make any necessary changes If the input shaft will not slide into the discs they may need to be repositioned Do not let the transmission drop or hang unsup ported in the driven discs This can cause the discs to become distorted and the clutch will not release 9 INSTALL THE TRANSMISSION MOUNTING BOLTS AND TORQUE TO THE PROPER SPECIFICATION Tightening Torque 37 5 48 5 N m 382 494 kgf cm 28 35 ...

Page 59: ...sh rod only When the clutch disc or control linkage is replaced NOTICE The above adjusting should be made after adjusting the release bear ing position 3 Manual Adjust Kwik Adjust Depress adjusting bolt and rotate Kwik Adjust will re engage at 1 3 of a turn NOTICE Open end wrenches are not recommended Internal adjustments are performed with pedal down clutch released SST Crank pulley Torque wrench...

Page 60: ...is depress pedal down fully releasing clutch and check release travel to settings shown NOTICE It may be necessary to reduce the 1 75 44 mm settings to be able to achieve 0 500 0 562 13 14 mm travel on some models of transmis sions 5 ADJUST THE FREE TRAVEL 1 Remove the return spring 2 Loosen the lock nut and turn the push rod counterclockwise until the release bearing contacts the release lever pl...

Page 61: ...D100002 Tightening torque Unit N m kgf cm lbf ft Material Sintered metal Ceramic metal Type Dry single plate with damper spring Inside diameter 222 8 8 Outside diameter 350 13 8 Thickness 11 5 0 45 Adjustment Free 1 Clutch cover 3 Bolt 2 Clutch disc A 50 64 510 655 37 47 Shipping bolts 4 to be removed at installation Wear indicator Section B B SHTS02Z020200030 ...

Page 62: ...clutch 3 8 x 16 UNC x 1 1 4 2 LOCATE FOUR 4 3 8 x 16 UNC x 1 1 4 HEX HEAD MACHINE SCREWS INSTALL THEM IN THE 4 COVER HOLES TURNING THEM ONE COMPLETE TURN AFTER THEY CONTACT THE COVER 3 REMOVE THE CLUTCH FROM THE FLYWHEEL IMPORTANT POINT INSPECTION AND REPLACE MENT 1 REPLACE THE PILOT BEARING 1 Remove the pilot bearing SST Pilot Bearing Puller S0965 01970 Sliding Hammer S0942 01442 1 Remove the tra...

Page 63: ...of the linkage for excessive wear 2 Release yoke fingers 3 Splines on the input shaft NOTICE Any wear on the splines will prevent the newly installed driven discs from sliding freely thus causing poor release clutch drag Select a disc out of the new installation and slide it full length on the transmis sion splines This will detect a twisted input shaft Replace input shaft if disc does not freely ...

Page 64: ...HE ALIGNING TOOL AND THE TWO 2 GUIDE STUDS 4 INSTALL LOCKWASHER AND SIX 6 3 8 x 16 UNC MOUNTING BOLTS HAND TIGHTEN 1 Remove the two 2 guide studs and replace with the remaining mounting bolts with lockwasher Using a torque wrench progressively tighten the eight 8 mounting bolts using the following crisis cross pattern Starting at lower left Tightening Torque 50 64 N m 510 665 kgf cm 37 47 lbf ft C...

Page 65: ...case you need to remove then reinstall the SOLO Clutch 5 REMOVE THE ALIGNING TOOL 6 SHIFT THE TRANSMISSION INTO GEAR 7 POSITION THE TRANSMISSION SO THAT IT IS BOTH SQUARE TO AND ALIGNED WITH THE ENGINE 5 Remove aligning tool SHTS02Z020200042 6 Shift transmission into gear Shift into gear SHTS02Z020200043 7 Align the transmission to the engine SHTS02Z020200044 ...

Page 66: ... the REPLACE position Do not excessively force the transmission into the clutch assem bly or engine housing If it does not enter freely investigate the cause of the problem and make any necessary changes If the input shaft will not slide into the discs they may need to be repositioned If the clutch is to be unbolted from the flywheel re install the shipping bolts and tighten one turn past contact ...

Page 67: ...slightly closer to the transmission and gain free play in the cab 2 ADJUST THE FREE TRAVEL 1 Turn the push rod counterclockwise until the release bearing contacts the release lever plate or release lever 2 Turn the push rod clockwise about 3 1 3 turns 3 Tighten the lock nut Master cylinder Push rod 0 SHTS02Z020200046 Stroke pedal 5 times SHTS02Z020200047 Master cylinder Push rod 0 SHTS02Z020200046...

Page 68: ...OR 1 REMOVE THE COVER OF INSPECTION HOLE AT THE BOTTOM OF THE CLUTCH HOUSING 2 CHECK WEAR INDICATOR Reflects clutch wear and indicates when it is time to replace clutch When replacing clutch should change clutch disc together with clutch cover New Replace SAPH02Z080200007 ...

Page 69: ...place disc assembly if nec essary Visual check Clearance between clutch disc hub and transmission input shaft spline 0 05 0 15 0 0020 0 0059 0 5 0 020 Replace the clutch disc or the transmission input shaft Measure Pressure plate misalign ment 0 0 102 0 0 040 0 76 0 029 Replace the clutch cover assembly Measure Pressure plate friction sur face scoring or heat crack ing Replace the clutch cover ass...

Page 70: ...0 00157 Regrind the fric tion surface or replace if neces sary NOTICE Do not grind the flywheel over the limit Visual check Flywheel misalignment 0 15 0 0059 Regrind the fric tion surface or replace Measure Pilot bearing improper rotation Replace if neces sary Visual check Inspection item Standard Limit Remedy Inspection procedure ...

Page 71: ...RING 1 The pilot bearing inside the flywheel is a sealed for life bearing and requires no lubrication RECOMMENDED LUBRICATION Use a lithium soap base E P Extreme Pressure grease with a minimum of 325 degree F operating range It must meet the N L G I s Grade 2 or 3 specs CAUTION Incorrect grease and improper lube procedures will cause bearing failures bushing wearout yoke tip and bearing wear pad w...

Page 72: ...TON SAS1402 CL02 2 DATA AND SPECIFICATIONS CL02 2 DESCRIPTION CL02 2 TROUBLESHOOTING CL02 3 SPECIAL TOOL CL02 5 COMPONENT LOCATOR CL02 6 OVERHAUL CL02 7 CLUTCH ASSEMBLY EATON SOLO1402 CL02 16 DATA AND SPECIFICATIONS CL02 16 COMPONENT LOCATOR CL02 16 OVERHAUL CL02 17 INSPECTION AND REPAIR CL02 27 ...

Page 73: ...EN02Z0202I200001 CLUTCH FACING Unit mm in DESCRIPTION EN02Z0202C100001 Material Sintered metal Ceramic metal Type Dry two plate with damper spring Inside diameter 222 8 8 Outside diameter 350 13 8 Thickness 11 5 0 45 1 1 3 2 SHTS02Z020200001 1 Clutch disc 3 Clutch cover 2 Intermediate plate ...

Page 74: ... Clutch pedal free play incorrectly adjusted Adjust free play Compression spring weak Replace cover assembly Clutch facing worn Replace disc assembly Failing to remove plate from the clutch pressure plate assembly Remove plate Driver riding clutch pedal Do not ride the clutch pedal Vehicle vibrates when starting Improper engine idling Adjust idling Clutch control incorrectly adjusted Adjust clutch...

Page 75: ...sufficient lubrication of pedal and its accessories Lubricate Insufficient lubrication of release shaft and release bearing hub Lubricate Transmission input shaft retainer rusted or soiled Clean or replace if rusted Clutch pedal free play incorrectly adjusted Adjust free Play Clutch pedal cannot be depressed Clutch control incorrectly adjusted Adjust clutch control Insufficient lubricant release s...

Page 76: ...2K100001 Prior to starting a clutch overhaul it is necessary to have these special tools Illustration Part number Tool name Remarks S0965 01970 CLUTCH PILOT BEARING PULLER S0942 01442 SLIDING HAMMER S0966 21420 CLUTCH ALIGNING ARBOR S0940 91200 CRANKING TOOL ...

Page 77: ...EATON 1402 CL02 6 COMPONENT LOCATOR EN02Z0202D100001 Tightening torque Unit N m kgf cm lbf ft 1 Clutch cover 4 Adjusting screw 2 Clutch disc 5 Bolt 3 Intermediate plate A 50 64 510 655 37 47 5 A 1 4 2 3 SHTS02Z020200006 ...

Page 78: ...ve the pilot bearing SST Pilot Bearing Puller S0965 01970 Sliding Hammer S0942 01442 2 Using a suitable tapping rod install the pilot bearing NOTICE After installing the pilot bearing ensure that it rotates smoothly 2 CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY WORN COMPONENTS 1 Cross shafts and bushings NOTICE Excessive wear at these points can cause a side loading condition Also inspect the r...

Page 79: ...t a twisted input shaft Replace input shaft if disc does not freely slide 4 Smooth area of input shaft 5 Mating surfaces NOTICE Inspect the mating surfaces of both the transmission bell housing and the flywheel housing Any appreciable wear on either housing will cause misalignment Most wear will occur between the 3 and 8 o clock positions Replace housings if worn B Check release yoke fingers SAPH0...

Page 80: ...0 NOTICE Make sure the side marked Flywheel faces the flywheel 3 INSTALL THE INTERMEDIATE PLATE ASSEMBLY OVER THE TWO 2 GUIDE STUDS AND SLIDE IT FORWARD UNTIL IT TOUCHES THE FLYWHEEL NOTICE Make sure the side marked Pressure Plate Side is facing the pres sure plate the drive straps must face the pressure plate 1 Insert 2 guide studs Guide studs SHTS02Z020200014 2 Insert the aligning tool through r...

Page 81: ...re plate As you complete this step ensure that the ceramic buttons align with each other as closely as possible Doing so will aid the function of the positive separator pins roll pins 5 WITH THE ALIGNING TOOL STILL IN PLACE SLIDE THE COVER ASSEMBLY OVER BOTH THE ALIGNING TOOL AND THE TWO 2 GUIDE STUDS UNTIL IT RESTS AGAINST THE INTERMEDIATE PLATE ASSEMBLY 4 Remove aligning tool Buttons SHTS02Z0202...

Page 82: ...cracked or broken Cause the clutch assembly to be out of balance with the fly wheel 7 REMOVE THE ALIGNING TOOL 8 USING A 1 4 6 mm DIAMETER FLAT NOSE PUNCH LIGHTLY TAP EACH OF THE FOUR 4 POSITIVE SEPARATOR PINS TOWARD THE FLYWHEEL PERFORMING THIS STEP WILL VER IFY THAT ALL FOUR 4 PINS ARE FLUSH AGAINST THE FLY WHEEL CAUTION Failure to perform this step properly may cause the clutch to drag clutch d...

Page 83: ... SQUARE TO AND ALIGNED WITH THE ENGINE Top view Roll pin Clutch cover Access hole SHTS02Z020200022 Side view Gap 0 20 0 30 0 5 0 8mm Flywheel Clutch cover Roll pin Qty 4 Access hole SHTS02Z020200023 9 Shift transmission into gear Shift into gear SHTS02Z020200024 10 Align the transmission to the engine SHTS02Z020200025 ...

Page 84: ...m and make any necessary changes If the input shaft will not slide into the discs they may need to be repositioned Do not let the transmission drop or hang unsup ported in the driven discs This can cause the discs to become distorted and the clutch will not release 12 INSTALL THE TRANSMISSION MOUNTING BOLTS AND TORQUE TO THE PROPER SPECIFICATION Tightening Torque 37 5 48 5 N m 382 494 kgf cm 28 35...

Page 85: ...ush rod only When the clutch disc or control linkage is replaced NOTICE The above adjusting should be made after adjusting the release bear ing position 3 Manual Adjust Kwik Adjust Depress adjusting bolt and rotate Kwik Adjust will re engage at 1 3 of a turn NOTICE Open end wrenches are not recommended Internal adjustments are performed with pedal down clutch released SST Crank pulley Torque wrenc...

Page 86: ...eleasing clutch and check release travel to settings shown NOTICE It may be necessary to reduce the 0 75 19 mm settings to be able to achieve 0 500 0 562 13 14 mm travel on some models of transmis sions 5 ADJUST THE FREE TRAVEL 1 Remove the return spring 2 Loosen the lock nut and turn the push rod counterclockwise until the release bearing contacts the release lever plate or release lever 3 Turn t...

Page 87: ...0002 Tightening torque Unit N m kgf cm lbf ft Material Sintered metal Ceramic metal Type Dry two plate with damper spring Inside diameter 222 8 8 Outside diameter 350 13 8 Thickness 11 5 0 45 Adjustment Free 1 Clutch cover 3 Intermediate plate 2 Clutch disc 4 Bolt A 50 64 510 655 37 47 Wear indicator Shipping bolts 4 to be removed at installation SHTS02Z020200036 ...

Page 88: ...16 x 1 1 4 UNC HEX HEAD MACHINE SCREWS INSTALL THEM IN THE 4 COVER HOLES TURNING THEM ONE COMPLETE TURN AFTER THEY CONTACT THE COVER 3 REMOVE THE CLUTCH FROM THE FLYWHEEL NOTICE Mark the proper position of the discs and intermediate plate adapter ring for reinstallation IMPORTANT POINT INSPECTION AND REPLACE MENT 1 REPLACE THE PILOT BEARING 1 Remove the pilot bearing SST Pilot Bearing Puller S0965...

Page 89: ...s of the linkage for excessive wear 2 Release yoke fingers 3 Splines on the input shaft NOTICE Any wear on the splines will prevent the newly installed driven discs from sliding freely thus causing poor release clutch drag Select a disc out of the new installation and slide it full length on the transmis sion splines This will detect a twisted input shaft Replace input shaft if disc does not freel...

Page 90: ...INT MOUNTING 1 INSERT TWO 2 3 8 x 16 UNC x 3 76 MM LONG GUIDE STUDS INTO THE TWO UPPER MOUNTING HOLES OF THE FLYWHEEL 2 INSTALL THE FRONT DISC BY INSERTING THE ALIGNING TOOL THROUGH THE DISC SPLINES AND THEN INTO THE PILOT BEARING SST Clutch Aligning Arbor S0966 21420 NOTICE Make sure the side marked Flywheel faces the flywheel E Check smooth area of input shaft for wear roughness SAPH02Z080200009...

Page 91: ... AND INSTALL IT THROUGH THE SPLINES OF THE REAR DISC AND INSERT THE ALIGNING TOOL THROUGH THE FRONT DISC AND ALSO THE PILOT BEARING NOTICE Make sure the side of the disc marked Pressure Plate Side is facing the pressure plate As you complete this step ensure that the ceramic buttons align with each other as closely as possible Doing so will aid the function of the positive separator pins roll pins...

Page 92: ...progressively tighten the eight 8 mounting bolts using the following criss cross pat tern Starting at lower left Tightening Torque 50 64 N m 510 665 kgf cm 37 47 lbf ft CAUTION Failure to tighten these bolts in this manner can Prevent the clutch cover from centering into the pilot area of the flywheel Cause permanent damage to the clutch cover i e become cracked or broken Cause the clutch assembly...

Page 93: ...S TOWARD THE FLYWHEEL PERFORMING THIS STEP WILL VER IFY THAT ALL FOUR 4 PINS ARE FLUSH AGAINST THE FLY WHEEL CAUTION Failure to perform this step properly may cause the clutch to drag clutch does not release Excessive force can damage the pins and cause a release problem NOTICE The four 4 pins can also be set through the inspection opening of the transmission bell housing if they were not to set p...

Page 94: ... SQUARE TO AND ALIGNED WITH THE ENGINE Top view Roll pin Clutch cover Access hole SHTS02Z020200050 Side view Gap 0 20 0 30 0 5 0 8mm Flywheel Clutch cover Roll Pin Qty 4 Access hole SHTS02Z020200051 10 Shift transmission into gear Shift into gear SHTS02Z020200052 11 Align the transmission to the engine SHTS02Z020200053 ...

Page 95: ...d cause the wear indication tab to move to 1 3 1 2 the distance towards the REPLACE position Do not excessively force the transmission into the clutch assem bly or engine housing If it does not enter freely investigate the cause of the problem and make any necessary changes If the input shaft will not slide into the discs they may need to be repositioned If the clutch is to be unbolted from the fl...

Page 96: ...earing contacts the release lever plate or release lever 3 Fully press the pedal up to 5 times to move the release bearing slightly closer to the transmission and gain free play in the cab 2 ADJUST THE FREE TRAVEL 1 Turn the push rod counterclockwise until the release bearing contacts the release lever plate or release lever 2 Turn the push rod clockwise about 3 1 3 turns 3 Tighten the lock nut SH...

Page 97: ...OR 1 REMOVE THE COVER OF INSPECTION HOLE AT THE BOTTOM OF THE CLUTCH HOUSING 2 CHECK WEAR INDICATOR Reflects clutch wear and indicates when it is time to replace clutch When replacing clutch should change clutch disc together with clutch cover New Replace SAPH02Z080200010 ...

Page 98: ...place disc assembly if nec essary Visual check Clearance between clutch disc hub and transmission input shaft spline 0 05 0 15 0 0020 0 0059 0 5 0 020 Replace the clutch disc or the transmission input shaft Measure Pressure plate misalign ment 0 0 102 0 0 040 0 76 0 029 Replace the clutch cover assembly Measure Pressure plate friction sur face scoring or heat crack ing Replace the clutch cover ass...

Page 99: ...0 00157 Regrind the fric tion surface or replace if neces sary NOTICE Do not grind the flywheel over the limit Visual check Flywheel misalignment 0 15 0 0059 Regrind the fric tion surface or replace Measure Pilot bearing improper rotation Replace if neces sary Visual check Inspection item Standard Limit Remedy Inspection procedure ...

Page 100: ...RING 1 The pilot bearing inside the flywheel is a sealed for life bearing and requires no lubrication RECOMMENDED LUBRICATION Use a lithium soap base E P Extreme Pressure grease with a minimum of 325 degree F operating range It must meet the N L G I s Grade 2 or 3 specs CAUTION Incorrect grease and improper lube procedures will cause bearing failures bushing wearout yoke tip and bearing wear pad w...

Page 101: ... CL03 2 DESCRIPTION CL03 2 INSPECTION AND ADJUSTMENT CL03 3 CLUTCH PEDAL AND RELEASE UNIT CL03 6 COMPONENT LOCATOR CL03 6 OVERHAUL CL03 7 INSPECTION AND REPAIR CL03 9 CLUTCH MASTER CYLINDER CL03 10 COMPONENT LOCATOR CL03 10 OVERHAUL CL03 11 INSPECTION AND REPAIR CL03 11 ...

Page 102: ...CLUTCH CONTROL CL03 2 CLUTCH CONTROL UNIT DESCRIPTION EN02Z0203C100001 CLUTCH RELEASE UNIT SHTS02Z020300001 1 Clutch master cylinder 3 Clutch pedal 2 Reservoir tank 4 Pedal bracket ...

Page 103: ... 3 Hold the funnel about 1 5 m 4 92 ft higher than the reservoir tank 4 Loosen the bleeder screw and pour the clutch fluid into the funnel 5 Observe the flow of clutch fluid into the reservoir tank 6 When the air bubbles cease close the bleeder screw 7 Check the fluid level If necessary add or remove clutch fluid in order to match the MAX level 3 MANUAL BLEEDING 1 Fill the reservoir with clutch fl...

Page 104: ...g will be necessary if the reservoir is emptied during bleeding operation 4 Check the fluid level If necessary add or remove clutch fluid in order to match the MAX level 4 AFTER BLEEDING MAKE SURE THE PUSH ROD STROKE IS AS SPECIFIED 1 Depress the clutch pedal fully and measure the push rod stroke If the stroke is less than standard re bleed the hydraulic system Standard SHTS02Z020300004 SHTS02Z020...

Page 105: ...Tighten the lock nut 2 Check the clutch pedal play a Push the pedal until the beginning of clutch resistance is felt Assembly Standard NOTICE For adjustment of clutch refer to the chapter CLUTCH MAIN UNIT 2 CHECK THE CLUTCH PEDAL HEIGHT AND STROKE 1 STEP Push rod play 2 STEP Clutch pedal play SHTS02Z020300007 SHTS02Z020300008 SHTS02Z020300009 Model Standard Limit HINO 238 NE 258 NE NJ 268 NE NF NJ...

Page 106: ...001 Tightening torque Unit N m kgf cm lbf ft 1 Reservoir tank 6 Pedal pad 2 Master cylinder 7 Switch For cruise control 3 Return spring 8 Switch For clutch on start 4 Clutch pedal 9 Pedal shaft 5 Bracket 10 Pedal bracket A 41 5 61 5 424 627 30 46 B 18 26 184 265 14 19 SHTS02Z020300011 ...

Page 107: ...shaft lightly to remove the clutch pedal using a brass bar and a hammer IMPORTANT POINT MOUNTING 1 INSTALL THE CLUTCH PEDAL 1 Apply lithium grease to the inner side and outer periphery of the bush ing and install the bushing to the inserting hole on the shaft part of the clutch pedal 2 Install the clutch pedal to the installing axle for pedal shaft and install the pedal shaft to the pedal bracket ...

Page 108: ...body does not contact the buffer and also that the switch rightly functions IMPORTANT POINTS ASSEMBLY 1 APPLY BEARING GREASE OR HEAT RESISTANCE GREASE 1 Apply bearing grease to the following parts a The release fork and the release bearing hub contact point b The release bearing hub inner groove 2 Apply heat resistance grease to the transmission input shaft spline NOTICE Apply a small amount of gr...

Page 109: ...e release bearing if necessary Visual check Release fork and release hub Wear and damage Replace the parts if necessary Visual check Release shaft bush Wear and damage Bush inner diameter 25 48 25 52 mm 1 003 1 005 in Replace the bush if necessary After pressing in a new bush grind inner diameter of the bush to be fit ted to standard specification Visual check ...

Page 110: ...g torque Unit N m kgf cm lbf ft 1 Clevis 9 Clamp 2 Lock nut 10 Reservoir cap 3 Push rod 11 Gasket 4 Boot 12 Oil reservoir strainer 5 Retainer ring 13 Reservoir tank 6 Piston 14 Stopper bolt 7 Return spring 15 O ring 8 Body A 11 5 16 9 118 172 8 5 12 4 B 2 4 4 4 24 45 1 8 3 2 SHTS02Z020300021 ...

Page 111: ...o not let the clutch fluid remain on a painted floor Wash it off immediately IMPORTANT POINT ASSEMBLY 1 INSTALL THE RETURN SPRING AND PISTON TO THE CYLINDER NOTICE Lubricate the cylinder bore and piston with clean clutch fluid INSPECTION AND REPAIR EN02Z0203H300003 Inspection item Standard Limit Remedy Inspection procedure Piston seal and cup Wear and damage Cylinder body bore Scoring and corrosio...

Page 112: ...TRANSMISSION MAIN UNIT EATON FS 5406 6406 TR02 1 TR02TRANSMISSION MAIN UNIT EATON FS 5406 6406 TR02 001 TRANSMISSION ASSEMBLY TR02 2 DATA AND SPECIFICATION TR02 2 DISMOUNTING AND MOUNTING TR02 3 ...

Page 113: ...Gear ratios 1st 9 01 2nd 5 27 3rd 3 22 4th 2 04 5th 1 36 6th 1 00 Reverse 8 63 Number of teeth input shaft 24 Number of teeth counter shaft 1st gear 10 2nd gear 16 3rd gear 25 4th gear 31 5th gear 38 6th gear 46 Reverse gear 10 Number of teeth main shaft 1st gear 47 2nd gear 44 3rd gear 42 4th gear 33 5th gear 27 6th gear 24 Reverse gear 45 Number or teeth reverse idle gear 21 Oil capacity gear bo...

Page 114: ...RNESS AND OTHER ATTACH MENTS 5 DISCONNECT THE TRANSMISSION CONTROL LEVER 6 DISCONNECT THE CLUTCH SLAVE CYLINDER NOTICE Do not remove the clutch control piping unless absolutely necessary Air bleeding is not required when reassembling 7 REMOVE THE TRANSMISSION 1 Remove the lower bolts around the clutch housing 2 Support the transmission using a transmission jack or lifting wires to prevent it from ...

Page 115: ...nd could cause poor clutch operation or clutch release problems 2 Install the upper nuts or bolts around the clutch housing 3 Lower the transmission jack and pull the jack out from under the vehi cle 4 Install the remaining nuts or bolts around the clutch housing Tightening Torque 37 5 48 5 N m 382 494 kgf cm 28 35 lbf ft 3 INSTALL THE CLUTCH SLAVE CYLINDER 4 CONNECT THE TRANSMISSION CONTROL LEVER...

Page 116: ...ON ALLISON 2200RDS 2500RDS 2200HS TR04 1 TR04AUTOMATIC TRANSMISSION ALLISON 2200RDS 2500RDS 2200HS TR04 001 AUTOMATIC TRANSMISSION ASSEMBLY TR04 2 TROUBLESHOOTING TR04 2 SPECIAL TOOL TR04 2 DISMOUNTING AND MOUNTING TR04 2 ...

Page 117: ...D MOUNTING EN03Z0304H100001 IMPORTANT POINTS DISMOUNTING NOTICE Allison transmission repairs are to be performed by an authorized Allison service dealer WARNING Do not work on the transmission while it is hot This can result in per sonal injury 1 BLOCK THE WHEELS 1 Park the vehicle on level ground 2 Block the wheels NOTICE Be sure to apply wheel stoppers at the front tires 2 DRAIN THE AUTOMATIC TR...

Page 118: ... the center bearing holder 2 Move the forward end of the propeller shaft out of the way 4 DISCONNECT THE ELECTRICAL HARNESS FROM THE REAR OF THE TRANSMISSION 5 DISCONNECT THE OIL COOLER LINES AT THE TRANSMISSION 6 DISCONNECT THE SHIFT CABLE FROM THE MANUAL LEVER AT THE TRANSMISSION SHTS03Z030400004 SHTS03Z030400005 SHTS03Z030400006 SHTS03Z030400007 ...

Page 119: ...F THE FLYWHEEL HOUSING 9 REMOVE THE SIX COUPLING BOLTS FROM THE FLYWHEEL 1 Turn the flywheel manually to match the attaching bolt to the slot on the inspection opening at the bottom front side of the flywheel hous ing 2 Remove the coupling bolts one by one 10 REMOVE THE CONVERTER HOUSING ATTACHING BOLTS Side view Rear view SHTS03Z030400008 SHTS03Z030400009 SHTS03Z030400010 SHTS03Z030400011 ...

Page 120: ...MISSION TO THE JACK WITH A SAFETY CHAIN OR WIRE CABLE 12 REMOVE THE REMAINING CONVERTER HOUSING FROM THE FLYWHEEL HOUSING ATTACHING BOLTS 13 PULL OUT THE TRANSMISSION BACKWARDS WARNING Do not lower the front end of the transmission If lowered the torque converter may slide out of the transmission and you may be injured SHTS03Z030400012 ...

Page 121: ...ission side 2 TIGHTEN THE TORQUE CONVERTER AND THE FLEX PLATE Tightening Torque 57 68 N m 582 693 kgf cm 42 50 lbf ft NOTICE Apply grease containing molybdenum disulfide to the boss at the end of the torque converter before assembling Without grease the flex plate will not slide well and abnormal force will be generated causing the flex plate to break 3 MOUNT THE TRANSMISSION ASSEMBLY ON A TRANSMI...

Page 122: ...RANSMISSION JACK SLOWLY AND INSERT THE GUIDE INTO THE FITTING HOLE OF THE FLYWHEEL WARNING Do not lower the front side of the transmission If lowered the torque converter may slide out of the transmission and you may be injured 7 MOVE THE TRANSMISSION JACK SLOWLY AND ADJUST BY BRINGING THE FITTING FACES OF THE TORQUE CONVERTER HOUSING AND THE FLYWHEEL HOUSING 8 TIGHTEN THE BOLTS TO JOIN THE TORQUE...

Page 123: ...hly with a screw driver remove the transmission and repeat the procedure again from 5 above because the hub ends of the flywheel and the spacer coupling do not fit well Tightening bolts in such a condition will cause damage to the bolts and jamming of the engine 12 TIGHTEN THE BOLTS PRETIGHTENED IN STEP 11 Tightening Torque 64 85 N m 653 867 kgf cm 48 62 lbf ft 13 CONNECT THE ELECTRICAL HARNESS TO...

Page 124: ...he joints before tightening NOTICE Apply automatic transmission fluid to the O rings when inserting them If the fluid is not applied the O rings will not be inserted smoothly and will thus be damaged causing oil to leak 19 REMOVE THE CAP OF THE OIL FILLER TUBE AND POUR AUTO MATIC TRANSMISSION FLUID INTO THE TUBE Automatic transmission fluid Refer to RECOMMENDED LUBRICANTS LIST in the chapter GENER...

Page 125: ...NSMISSION ALLISON 3000RDS 3500RDS TR04 1 TR04AUTOMATIC TRANSMISSION ALLISON 3000RDS 3500RDS TR04 002 AUTOMATIC TRANSMISSION ASSEMBLY TR04 2 TROUBLESHOOTING TR04 2 SPECIAL TOOL TR04 2 DISMOUNTING AND MOUNTING TR04 2 ...

Page 126: ...s are to be performed by an authorized Allison service dealer WARNING Do not work on the transmission while it is hot This can result in per sonal injury 1 BLOCK THE WHEELS 1 Park the vehicle on level ground 2 Block the wheels NOTICE Be sure to apply wheel stoppers at the front tires 2 DRAIN THE AUTOMATIC TRANSMISSION FLUID 1 Place the drain pan under the transmission 2 Remove the drain plug from ...

Page 127: ...SCONNECT THE OIL COOLER LINES AT THE TRANSMISSION 6 REMOVE THE SUPPORT OF THE OIL LEVEL GAUGE FROM THE ENGINE CYLINDER BLOCK 7 REMOVE INSPECTION COVER FROM THE BOTTOM FRONT SIDE OF THE FLYWHEEL HOUSING Converter turbine sensor Main connector Speed sensor SHTS03Z030400004C SHTS03Z030400005 Side view Rear view SHTS03Z030400007 SHTS03Z030400008 ...

Page 128: ...ONVERTER HOUSING ATTACHING BOLTS LOWER THE TRANSMISSION 10 POSITION A TRANSMISSION JACK UNDER THE TRANSMISSION AND SECURE THE TRANSMISSION TO THE JACK WITH A SAFETY CHAIN OR WIRE CABLE 11 REMOVE THE REMAINING CONVERTER HOUSING FROM THE FLYWHEEL HOUSING ATTACHING BOLTS 12 PULL OUT THE TRANSMISSION BACKWARDS WARNING Do not lower the front end of the transmission If lowered the torque converter may s...

Page 129: ...g molybdenum disulfide to the boss at the end of the torque converter before assembling Without grease the flex plate will not slide well and abnormal force will be generated causing the flex plate to break 3 INSTALL THE FLEX PLATE SPACER COUPLING AND WEAR PLATE THEN TIGHTEN THE FLEX PLATE AND ADAPTER TOGETHER Tightening Torque 63 73 N m 643 744 kgf cm 47 53 lbf ft NOTICE Flex plate s hole A and s...

Page 130: ...MISSION JACK SLOWLY AND INSERT THE GUIDE INTO THE FITTING HOLE OF THE FLYWHEEL WARNING Do not lower the front side of the transmission If lowered the torque converter may slide out of the transmission and you can be injured 8 MOVE THE TRANSMISSION JACK SLOWLY AND ADJUST BY BRINGING THE FITTING FACES OF THE TORQUE CONVERTER HOUSING AND THE FLYWHEEL HOUSING 9 TIGHTEN THE BOLTS TO JOIN THE TORQUE CON...

Page 131: ...nd jamming of the engine 13 TIGHTEN THE BOLTS PRETIGHTENED IN STEP 12 Tightening Torque 64 85 N m 653 867 kgf cm 48 62 lbf ft 14 INSTALL THE SPEED SENSOR HARNESS TO THE REAR PART OF THE TRANSMISSION 15 CONNECT THE CONNECTORS OF WIRING 16 INSTALL THE PROPELLER SHAFT YOKE TO THE TRANSMIS SION YOKE 17 INSTALL THE CENTER BEARING HOLDER TO THE FRAME 18 CONNECT THE OIL COOLER LINE 1 For connecting the t...

Page 132: ... OIL FILLER TUBE AND POUR AUTO MATIC TRANSMISSION FLUID INTO THE TUBE Automatic transmission fluid Refer to RECOMMENDED LUBRICANTS LIST in the chapter GENERAL INTRODUCTION CHASSIS NOTICE For further details consult your nearest ALLISON representative or ALLISON service station Notice Cover over the plate Cover Plate Side view Rear view SHTS03Z030400023 ...

Page 133: ...TRANSFER CONTROL EATON MANUAL TRANSMISSION TR06 1 TR06TRANSMISSION TRANSFER CONTROL EATON MANUAL TRANSMISSION TR06 001 TRANSMISSION CONTROL UNIT TR06 2 TROUBLESHOOTING TR06 2 COMPONENT LOCATOR TR06 3 OVERHAUL TR06 4 ...

Page 134: ...is turned off Damaged shift lever assembly Replace shift lever Damaged or broken transmission upper cover lever spring etc Replace The looseness of tightening bolt and nut Inspect and tighten each bolt and nut Gear disengages when driving on bumpy roads Loose control lever joint Tighten or replace The play of the lever is excessive A joint is seriously worn Replace the joint The looseness of tight...

Page 135: ...EATON MANUAL TRANSMISSION TR06 3 COMPONENT LOCATOR EN03Z0306D100001 1 MANUAL TRANSMISSION CONTROL Tightening torque Unit N m kgf cm lbf ft 1 Knob 4 Isolator 2 Shift lever 5 Stub lever 3 Boot A 14 16 143 163 10 11 8 SHTS03Z030600001 ...

Page 136: ...ect the shift lever and the stub lever tighten the nut with the isolator steadily Tightening Torque 14 16 N m 143 163 kgf cm 10 11 8 lbf ft 2 Check the shift and select stroke Unit mm in 1 S1 FS5406 6406 S2 2 3 4 5 6 R S3 S4 S5 N SHTS03Z030600002 TM FS5406 6406 S1 70 90 2 76 3 54 S2 70 90 2 76 3 54 S3 70 90 2 76 3 54 S4 100 120 3 93 4 72 S5 100 120 3 93 4 72 ...

Page 137: ...FER CONTROL ALLISON AUTOMATIC TRANSMISSION TR06 1 TR06TRANSMISSION TRANSFER CONTROL ALLISON AUTOMATIC TRANSMISSION TR06 002 TRANSMISSION CONTROL UNIT TR06 2 TROUBLESHOOTING TR06 2 COMPONENT LOCATOR TR06 2 OVERHAUL TR06 4 ...

Page 138: ...on 2200RDS 2200HS 2500RDS 3000RDS 3500RDS auto transmission problem refer to the Allison shop manual or troubleshooting procedures for detailed information on items that could be causing the problem COMPONENT LOCATOR EN03Z0306D100001 1 AUTOMATIC TRANSMISSION CONTROL 1 Selector assembly 2 Shift cable assembly P D OD N R 2 L Side view Rear view SAPH03Z030600001 ...

Page 139: ...TRANSMISSION TRANSFER CONTROL ALLISON AUTOMATIC TRANSMISSION TR06 3 1 Selector assembly Allison 3000RDS 3500RDS button type SAPH03Z030600002 ...

Page 140: ...ATIC TRANSMISSION CONTROL Allison 2200RDS 2200HS 2500RDS MODEL 1 Before installation the cable check the shift cable for wear and dam age if necessary replace the parts 2 When you install the shift cable it should not bent sharply Any loop ing should have a radius of more than 150 mm 5 91 in SAPH03Z030600004 R SAPH03Z030600005 ...

Page 141: ...SHAFT SPL 100 140 PP02 1 PP02PROPELLER SHAFT SPL 100 140 PP02 001 PROPELLER SHAFT ASSEMBLY PP02 2 DATA AND SPECIFICATIONS PP02 2 DESCRIPTION PP02 2 TROUBLESHOOTING PP02 3 COMPONENT LOCATOR PP02 3 OVERHAUL PP02 5 ...

Page 142: ...ON EN04Z0402C100001 Manufacturer Spicer Type Tubular shaft type Universal joint All metal round bearing type with needle roller bearing SHTS04Z040200001 1 Bearing assembly 7 Washer 2 Cross assembly 8 Nut 3 Snap ring 9 Slip yoke assembly 4 Yoke shaft assembly 10 Clamp 5 Center bearing assembly 11 Boot 6 End yoke ...

Page 143: ...eath serious personal injury or property damage Symptom Possible cause Remedy Prevention Abnormal vibration when driving Looseness of universal joint yoke and flange tightening nuts Tighten the nuts Looseness of universal joint flange lock nut Replace the lock nut with new one then tighten the lock nut with specified torque and caulk the nut securely Excessively bent propeller shaft Replace the sh...

Page 144: ...r oil which adhere to the stamped retainer bolts stamped straps stamped strap bolts damaged bearing retainers or used inferior grade bolts can cause driveline failure which can result in separation of driveline from the vehicle A sepa rated driveline can result in death serious personal injury or property damage A 143 169 1 457 1 723 105 125 B 128 156 1 300 1 600 95 115 SHTS04Z040200003 ...

Page 145: ...all bearing positions spline positions shaft locations and all bearing retainers 3 Working from the rear end support the propeller shaft with support straps as illustrated in Figure Be sure to support the shaft assembly at the rear at the slip member behind the center bearing end fitting and in front of center bearing with support straps SHTS04Z040200004 SHTS04Z040200005 Four piece Front Coupling ...

Page 146: ... must be replaced Raised metal or fretting on open yoke cross holes can be removed with a fine toothed file and or emery cloth WARNING DO NOT deform yoke cross holes by removing excessive metal Raised metal or deformed yoke cross holes can be a cause of cross and bearing failure which can result in separation of driveline from vehicle A separated driveline can result in death serious personal inju...

Page 147: ...ty damage 2 Remove the outboard bearing cup assemblies 3 Make sure the universal joint cross assembly is not tilted in yoke 4 Place bearing cup spacer onto the base of the arbor press and under the yoke If the arbor is larger than the bearing cup diameter a smaller diameter push rod will be needed to avoid damage to the yoke or bearing Using the arbor press press down on the upper bearing cup asse...

Page 148: ...oothed file and or emery cloth WARNING DO NOT deform yoke cross holes by removing excessive metal Raised metal or deformed yoke cross holes can be a cause of cross and bearing problems and can result in separation of driveline from vehicle A separated driveline can result in death serious personal injury or property damage 9 Inspect the yoke for distorted cross holes using the appropriate Spicer a...

Page 149: ...amage 2 Remove the outboard bearing cup assemblies 3 Make sure universal joint cross assembly is not tilted in the yoke 4 Place bearing cup spacer onto the base of the arbor press and under the yoke If the arbor is larger than the bearing cup diameter a smaller diameter push rod will be needed to avoid damaging the yoke or bearing Using an arbor press press down on the upper bearing cup assembly u...

Page 150: ...file and or emery cloth WARNING DO NOT deform yoke cross holes by removing excessive metal Raised metal or deformed yoke cross holes can be a cause of cross and bearing problems and can result in separation of driveline from vehicle A separated driveline can result in death serious personal injury or property damage 10 Inspect the tube yoke or flange yoke if applicable for distorted cross holes us...

Page 151: ...pline sleeve areas clean 3 Mark spline sleeve and end of weld ring with a marking stick paint marker or other legible marking device This assures that the slip member can be reassembled in its original phased condition WARNING Reassembly of a driveline out of original phase can cause vibration and failure of the driveline and attaching components Failure of a driveline can result in separation of ...

Page 152: ...replaced Remove and discard slinger from the yoke WARNING Failure to replace damaged driveline components can cause driveline failure which can result in separation of driveline from vehicle A sep arated driveline can result in death serious personal injury or prop erty damage 4 Visually inspect the splines of the center bearing end yoke If the yoke splines are damaged missing or twisted the yoke ...

Page 153: ...icating Grease Institute WARNING Inadequate lubrication can cause driveline failure which can result in separation of the driveline from the vehicle A separated driveline can result in death serious personal injury or property damage CAUTION DO NOT Wipe the outside of bearing cup assemblies or yoke cross holes with grease oil or silicone based sprays This could cause bearing cup assembly rotation ...

Page 154: ...earing cup assembly over trunnion diameter and align it to the yoke cross hole Push the bearing cup assembly until both installation height tools are flush with the cross hole face Remove and discard both installation height tools 6 Install new spring tabs and 8 mm thread bolts Make sure that no grease or foreign material is present between the contact areas of the spring tabs bearing cups and yok...

Page 155: ...d yokes can result in separation of the drive line from the vehicle A separated driveline can result in death seri ous personal injury or property damage 2 Position the journal cross into the yoke cross holes with grease zerk nipple fitting inward toward tubing The double headed grease zerk nipple fitting should be perpendicular to the yoke cross holes Failure to properly position the universal jo...

Page 156: ...protruding trunnion diameter and align it to the flange yoke cross hole 11 Align the yoke in an arbor press with the bearing assembly resting on the base of the press Cover the yoke ear with a metal plate that has 0 25 inch 6 4 mm minimum thickness Push the yoke onto the bear ing cup assembly until it is flush with the cross hole face 12 Place a push rod that is smaller than the diameter of the be...

Page 157: ...ap ring style 3 INSTALL THE SLIP MEMBER BOOT 1 Clean ALL grease from yoke shaft and spline sleeve Make sure grease cutting solvent does not intrude into the tube through the vent hole in the spline sleeve plug Be sure the phasing marks made dur ing disassembly are not removed 2 After all traces of grease cutting solvent have been removed from yoke shaft and spline sleeve apply enough N L G I E P G...

Page 158: ...eshaft is completely installed in the vehicle slowly col lapse and extend the driveshaft to make sure the boot clamps are sta tionary If the clamps are not stationary recheck for proper clamp torque If clamps still are not stationary repeat disassembly and assembly procedure DO NOT reuse clamps WARNING Reuse of boot clamps or failure to properly tighten boot clamps to required specifications could...

Page 159: ...ubing to avoid damaging slinger 6 Using a soft faced hammer tap the yoke onto midship tube shaft making sure phasing marks from driveshaft removal procedure are in line Continue to tap the yoke until it is completely seated against the center bearing 7 Install a washer if required and new midship nut and torque nut to specifications See midship nut specifications Table WARNING Failure to torque mi...

Page 160: ...an result in separation of the driveline from the vehicle A separated driveline could result in death serious per sonal injury or property damage Failure to install new stamped straps and new bolts and to torque bolts to specification can cause driveline failure which can result in separation of the driveline from the vehicle A sepa rated driveline can result in death serious personal injury or pr...

Page 161: ... 001 DIFFERENTIAL CARRIER ASSEMBLY DF02 2 DATA AND SPECIFICATIONS DF02 2 DESCRIPTION DF02 4 TROUBLESHOOTING DF02 7 SPECIAL TOOL DF02 8 COMPONENT LOCATOR DF02 10 OVERHAUL DF02 14 INSPECTION AND REPAIR DF02 54 DRIVER CONTROLLED MAIN DIFFERENTIAL LOCK DF02 63 OVERHAUL DF02 63 INSPECTION AND REPAIR DF02 66 ...

Page 162: ...J NJ8J RS19 145 3 73 3 90 4 11 4 88 5 13 5 29 5 57 33 2 15 7 HINO 338 NF8J NV8J RS21 145 3 90 4 11 4 33 4 63 4 88 5 13 5 29 5 57 5 86 6 14 32 3 15 3 HINO 358 NH8J RS23 160 3 91 4 10 4 56 4 89 5 38 5 63 6 14 39 5 18 7 1 TAPERED ROLLER BEARINGS 5 BEVEL DIFFERENTIAL GEARS 2 CARRIER 6 HOUSING 3 STRAIGHT ROLLER BEARING 7 TAPERED ROLLER BEARING 4 TAPERED ROLLER BEARING 8 HYPOID DRIVE PINION AND RING GEA...

Page 163: ...OUSING 2 CARRIER 7 TAPERED ROLLER BEARING 3 STRAIGHT ROLLER BEARING 8 HYPOID DRIVE PINION AND RING GEAR 4 TAPERED ROLLER BEARING 9 DIFFERENTIAL LOCK ASSEMBLY 5 BEVEL DIFFERENTIAL GEARS 1 2 3 9 5 4 6 7 8 Single Reduction Differential carrier with Differential Lock SHTS05Z050200002 ...

Page 164: ...ing 7 Bearing Cup Inner 24 Drive Pinion 8 Capscrews Lock Plate 25 Bearing Cone Pinion Inner 9 Washers Lock Plate 26 Bearing Cup Pinion Inner 10 Lock Plate Adjusting Ring 27 Spacer Pinion Bearing 11 Capscrews Differential Bearing Cap 28 Shims 12 Washers 29 Bearing Cage Drive Pinion 13 Caps Differential Bearing 30 Capscrew Bearing Cage 14 Capscrews Differential Bearing Cap 31 Washer 15 Washers 32 Cl...

Page 165: ...ive Gear 4 Differential Side Gears 15 Case Half Flange 5 Thrust Washers Differential Side Gear 16 Washers Case Half 6 Cone Differential Bearing 17 Nuts Case Half 7 Cup Differential Bearing 18 Bearing Cone Differential L H 8 Thru Bolt 19 Bearing Cup Differential L H 9 Bolts Differential Case 20 Washer for Thru Bolt 10 Washers Differential Case 21 Nut for Thru Bolt 11 Case Assembly Main Differential...

Page 166: ...ENSOR SWITCH 7 AIR CYLINDER TUBE 2 SHIFT FORK 8 SCREW IN DIFFERENTIAL LOCK 3 SHIFT SHAFT SPRING 9 PISTON O RING 4 SHIFT SHAFT 10 PISTON 5 SPRING RETAINING PIN 11 SHIFT COLLAR 6 FLAT WASHER OR SILASTIC AS REQUIRED 12 SHIFT FORK ROLL PINS 1 2 3 4 5 6 7 8 9 11 12 10 12 Differential lock assembly SHTS05Z050200005 ...

Page 167: ...hrust washers Replace Worn differential spider Replace Worn or damaged ring gear and pinion Replace Worn or damaged differential side gear and pinion Replace Loose ring gear bolts Tighten bolts Inadequate tooth contact of ring gear and pinion gear Replace or adjust tooth contact Worn opinion spline Replace Abnormal noise rear axle system Worn rear axle shaft spline Replace Worn hub bearings Replac...

Page 168: ...REW 8 CHAMFER END OF PIPE FOR WELDING 3 BAR 2 DIAMETER X 9 LONG WITH ONE END SLOTTED TO FIT PLATE 9 4 DIAMETER PIPE 4 WELD ALL AROUND AFTER PRESSING PLUG IN PIPE 10 PLUG 4 DIAMETER X 7 LONG WITH ONE END TURNED 3 LONG TO FIT PIPE DRILL 2 HOLE AND MILL 3 16 WIDE SLOT 2 FROM TOP 5 WELD 11 SCREW 3 1 2 LONG X 5 8 DIAMETER WITH FLATS ON END TO FIT HANDLE AND 2 1 2 LENGTH OF THREAD ON OTHER END 6 SHAPE A...

Page 169: ... To make the box section cut and weld 1 0 inch x 2 0 inch mild steel square stock according to dimensions C and D 4 Cut a 4 0 foot x 1 25 inch piece of mild steel round stock to make the yoke bar handle Center weld this piece to the box section To increase yoke bar rigidity Weld two angle pieces onto the handle 2 HOW TO ORDER TOOLS AND SUPPLIES SPECIFIED IN THIS MANUAL Call ArvinMeritor s Commerci...

Page 170: ...DIFFERENTIAL CARRIER MERITOR RS17 19 21 23 DF02 10 COMPONENT LOCATOR EN05Z0502D100002 5 4 3 2 1 19 20 18 6 12 14 15 11 13 10 8 16 17 10 9 7 SHTS05Z050200009 ...

Page 171: ...12 62 11 M12 x 1 75 M12 x 1 75 M12 x 1 75 M16 x 2 M16 x 2 35 50 60 75 85 115 130 165 180 230 85 103 74 96 105 125 203 251 220 310 48 68 81 102 115 156 176 224 244 312 115 140 100 130 143 169 275 340 300 420 8 Nut Differential Case Bolt 50 13 50 20 62 11 62 18 M12 x 1 75 M16 x 2 75 100 85 115 150 190 180 230 74 96 220 310 102 136 115 156 203 258 244 312 100 130 300 420 9 Nut Ring Gear Bolt Flange H...

Page 172: ...pscrew Bearing Cage 38 16 44 14 50 13 56 12 62 11 M12 x 1 75 30 50 50 75 75 115 110 165 150 230 70 110 41 68 68 102 102 156 149 224 203 312 90 150 16 Plug Oil Fill Carrier 75 14 1 5 11 5 M24 x 1 5 25 minimum 34 minimum 120 minimum 163 minimum 35 minimum 47 minimum 17 Capscrew Lock Plate 31 18 M8 x 1 25 20 30 21 26 27 41 28 35 18 Lock Nut Sensor Switch M16 x 1 0 25 35 35 45 19 Air Cylinder M60 x 2 ...

Page 173: ...0 13 0 50 is the diameter of the fastener in inches or dimension X 13 is the amount of threads in 1 inch 3 METRIC FASTENERS a Measure the diameter of the threads in millimeters mm dimension X b Measure the distance of 10 threads point to point in millimeters mm dimension Y Make a note of dimension Y c Divide dimension Y by 10 The result will be the distance between two threads or pitch Example Met...

Page 174: ...elp avoid serious personal injury and damage to components 1 SAFETY ALERTS TORQUE SYMBOL AND NOTES 2 ACCESS PRODUCT AND SERVICE INFORMATION ON OUR WEB SITE Visit the DriveTrain PlusTM by ArvinMeritor Tech Library at arvinmeri tor com to access and order product and service information 3 TO ORDER INFORMATION BY PHONE Call ArvinMeritor s Customer Service Center at 800 535 5560 to order the following...

Page 175: ...ock the wheels to prevent the vehicle from moving 2 Use a jack or other lifting tool to raise the vehicle so that the wheels to be serviced are off the ground Support the vehicle with safety stands 3 Place a drain pan under the rear axle 4 Remove the plug from bottom of axle housing Drain lubricant from the assembly 5 Disconnect the driveline universal joint from the pinion input yoke or flange on...

Page 176: ...hammer When using power tools axle components can loosen and break off causing seri ous personal injury CAUTION Do not use a chisel or wedge to loosen the axle shaft and tapered dowels Using a chisel or wedge can result in damage to the axle shaft the gasket and seal and the axle hub a Use a round hammer bit and an air hammer to loosen tapered dowels and axle shaft b Place the round hammer bit aga...

Page 177: ...ier at several points 5 After the carrier is loosened remove the top two fasteners CAUTION When using a pry bar be careful not to damage the carrier or housing flange Damage to these surfaces will cause oil leaks 6 Use the hydraulic roller jack to remove the carrier from the axle hous ing Use a pry bar that has a round end to help remove the carrier from the housing NOTICE A carrier stand is avail...

Page 178: ... to page DF02 44 1 Loosen the jam nut on the thrust screw if equipped 2 Remove the thrust screw and jam nut if equipped from the differen tial carrier 3 Rotate the differential carrier in the repair stand until the ring gear is at the top of the assembly 4 Mark one carrier leg and bearing cap to correctly match the parts dur ing carrier assembly Mark the parts using a center punch and ham mer 1 DI...

Page 179: ...ews and washers that hold the two bearing caps on the carrier Each cap is held in position by two capscrews and washers 7 Remove the bearing caps and bearing adjusting rings from the carrier 8 Safely lift the main differential and ring gear assembly from the carrier Place the assembly on a work bench 1 REMOVING COTTER KEY 2 REMOVING LOCK PLATE 1 2 SHTS05Z050200023 1 BEARING CAP 1 SHTS05Z050200024 ...

Page 180: ... rivets or rivet heads with a chisel and hammer Using a flat edge tool can cause damage to the flange case 6 If rivets hold the ring gear to the flange case half remove the rivets as follows a Carefully center punch each rivet head in the center on the ring gear side of the assembly Do not use a chisel and hammer b Drill each rivet head on the ring gear side of the assembly to a depth equal to the...

Page 181: ...to loosen and remove the yoke or flange A hammer or mallet can damage the parts and cause driveline runout or driveline imbalance problems after carrier to driveline assembly 4 Remove the yoke or flange from the drive pinion Do not use a ham mer or mallet If the yoke or flange is tight on the pinion Use a puller for removal 5 Remove the capscrews and washers that hold the bearing cage in the carri...

Page 182: ...press The pinion shaft must be toward the top of the assembly 2 Support the bearing cage under the flange area with metal or wood blocks 3 Press the drive pinion through the bearing cage The inner bearing cone and bearing spacer will remain on the pinion shaft If a press is not available Use a leather plastic or rubber mallet to drive the pinion through the bearing cage CAUTION Be careful when rem...

Page 183: ...UST fit under the inner race of the cone to remove the cone cor rectly without damage 7 If the spigot bearing needs to be replaced place the drive pinion in a vise Install a soft metal cover over each vise jaw to protect the drive pinion 8 Remove the snap ring if equipped from the end of drive pinion with snap ring pliers that expand 9 Remove the spigot bearing from the drive pinion with a bearing...

Page 184: ...SHTS05Z050200044 ALTERNATE LOCATIONS 1 PART NUMBER TOOTH COMBINATION NUMBER GEAR SET MATCH NUMBER PINION CONE VARIATION NUMBER 2 PART NUMBER TOOTH COMBINATION NUMBER 3 GEAR SET MATCH NUMBER PINION CONE VARIATION NUMBER 4 PART NUMBER TOOTH COMBINATION NUMBER GEAR SET MATCH NUMBER 5 PART NUMBER TOOTH COMBINATION NUMBER GEAR SET MATCH NUMBER 4 5 1 2 3 SHTS05Z050200045 Parts Number Location Convention...

Page 185: ... can break off and cause serious personal injury Observe all warnings and cautions provided by the press manufac turer to avoid damage to components and serious personal injury 1 ASSEMBLY OF DRIVE PINION BEARINGS AND BEARING CAGE 1 Place the bearing cage in a press 2 Support the bearing cage with metal or wood blocks 3 Press the bearing cup into the bore of bearing cage until cup is flat against b...

Page 186: ...RIVE PINION WITH SNAP RING NOTICE The following procedure applies to all axles except Some 160 Series single axles may use snap rings 1 Place the drive pinion in a press with the gear head or the teeth toward the top 2 Press the spigot bearing on the end of drive pinion The bearing must be flat against the gear head Use a sleeve of the correct size against the bearing inner race 3 Use snap ring pl...

Page 187: ...ft NOTICE If a three ball stake tool is used rotate the tool 180 degrees 4 Stake the end of the drive pinion at a minimum of five points Rotate the punch as many times as required for a minimum of five points Repeat Step 3 for each point 4 INSTALLATION OF TWO PIECE SPIGOT BEARING ON THE DRIVE PINION NOTICE This procedure applies to some 160 Series single rear axles These axles may also use a one p...

Page 188: ... part of the flame is approxi mately 0 25 inch 6 mm long Keep the white part of the flame approximately 0 125 inch 3 mm from the top of the stem Move the flame around the outer diameter of the top of the pinion stem The green temperature indicating liquid will turn black before the blue liq uid does Heat the stem until the blue liquid turns black at a point in the middle of the window 5 Remove the...

Page 189: ...eat this procedure until there are six evenly spaced stake marks around the stem 9 With a press or a soft mallet and sleeve install the outer race and roller assembly into its bore in the carrier Use a sleeve that is the same size as the outer race Press the bearing until it is squarely against the shoulder in the bottom of its bore 5 INSTALLATION OF DRIVE PINION 1 Apply axle lubricant to the bear...

Page 190: ... around the bearing cage several times 5 Attach a spring scale to the end of the cord 6 Pull the cord on a horizontal line As the bearing cage rotates read the value indicated on the scale Record the reading 7 Measure the diameter of the bearing cage where the cord was wound Measure in inches or centimeters 8 Divide the dimension in half to get the radius Record the radius dimension 1 PRESS 2 SLEE...

Page 191: ...08 N m for new pinion bearings or 10 30 lb in 1 13 3 39 N m for used pinion bearings in good condition adjust the spacer and repeat Steps 1 to 9 To increase preload Install a thinner bearing spacer To decrease preload Install a thicker bearing spacer 11 Check the bearing preload with the drive pinion and cage assembly installed in the carrier Follow the procedures to adjust pinion bearing preload ...

Page 192: ...b in 1 13 3 39 N m for used pinion bearings in good condition remove the pinion and cage assembly from the carrier Adjust the spacer and repeat Steps 1 to 7 To increase preload Install a thinner bearing spacer To decrease preload Install a thicker bearing spacer 9 After adjusting pinion bearing preload remove the drive pinion and bearing cage from the carrier Refer to page DF02 21 10 Install a new...

Page 193: ...all the seal d After the triple lip seal is installed a gap of approximately 0 015 0 030 inch 0 38 0 76 mm between the flange and bearing cage is normal e Check the gap with a feeler gauge at several points around the seal The gap must be within 0 015 0 030 inch 0 38 0 76 mm The difference between the largest and smallest gap measure ment must not exceed 0 010 inch 0 0254 mm 1 PRESS 2 SLEEVE 3 SUP...

Page 194: ... pinion cone number is a plus number subtract the num ber from the old shim pack thickness that was measured in 8 2 5 If the old pinion cone number is a minus number add the number to the old shim pack thickness that was measured in 8 2 6 Find the pinion cone PC variation number on the new drive pinion that will be installed Record the number 7 If the new pinion cone number is a plus number add th...

Page 195: ...k Example Inches mm 1 Old Shim Pack Thickness Old PC Number PC 2 inches 0 05 mm Standard Shim Pack Thickness New PC Number PC 5 inches 0 13 mm New Shim Pack Thickness 0 030 0 002 0 028 0 005 0 033 0 760 0 050 0 710 0 130 0 840 2 Old Shim Pack Thickness Old PC Number PC 2 inches 0 05 mm Standard Shim Pack Thickness New PC Number PC 5 inches 0 13 mm New Shim Pack Thickness 0 030 0 002 0 032 0 005 0 ...

Page 196: ...e hub for damage 3 If the carrier uses a POSETM seal element install a new POSETM seal a Lightly lubricate the yoke journal with the same lubricant used in the axle housing b Partially install the POSETM seal onto the yoke 0 25 0 5 inch 6 13 mm c Before installing the yoke onto the drive pinion lubricate the yoke with the same lubricant used in the axle housing 4 Slide the yoke over the input shaf...

Page 197: ...t usable A new seal is required This will occur if a yoke is installed into the seal and then removed 1 Remove the replacement unitized seal from the package 2 Select the correct seal driver from page DF02 38 Each seal driver is designed to correctly install a specific diameter seal To determine the yoke seal diameter measure the yoke journal Refer to page DF02 38 3 Position the seal on the driver...

Page 198: ...ects your skin Work in a well ventilated area Do not use gasoline or solvents that contain gasoline Gasoline can explode You must use hot solution tanks or alkaline solutions correctly Read the manufacturer s instructions before using hot solution tanks and alkaline solutions Then carefully follow the instruc tions safe eye protection 1 Use a clean shop towel and a safe cleaning solvent to clean t...

Page 199: ...er or mallet can damage the yoke or flange 5 Install the input yoke flange onto the drive pinion shaft The yoke or flange must be fully seated against the outer differential bearing before the nut is torqued to specifications 6 Install the drive pinion nut and washer if required on the input pinion shaft and against the yoke collar Tighten the nut against yoke collar to torque specifications Refer...

Page 200: ...r replace parts Assemble the ring gear on the flange case half Repeat the procedure in Tight Fit Yokes and POSETM Seal Refer to page DF02 36 8 Use a press and the correct size sleeve to install the bearing cones on both of the case halves 9 Apply axle lubricant on the inside surfaces of both case halves spider or cross thrust washers side gears and differential pinions 10 Place the flange case hal...

Page 201: ...ews and washers or bolts nuts and washers if equipped into the case halves The distance between the fasten ers must be equal Tighten the fasteners to the correct torque value in a progressive criss cross pattern opposite each other Refer to page DF02 12 b Install the other fasteners into the case halves Tighten the fasten ers to the correct torque value Refer to page DF02 12 16 Check the different...

Page 202: ...lue exceeds 50 lb ft 67 8 N m Disassemble the dif ferential gears from the case halves Inspect the case halves spider gears and thrust washers Repair or replace parts Assemble the parts and repeat 14 2 to 4 15 INSTALLATION OF DIFFERENTIAL AND RING GEAR ASSEMBLY 1 Clean and dry the bearing cups and bores of the carrier legs and bearing caps 2 Apply axle lubricant on the inner diameter of the bearin...

Page 203: ...rts can occur Do not force the bearing caps into position 8 Seat each bearing cap with a light leather plastic or rubber mallet The caps must fit easily against the bearings adjusting rings and car rier Do not force the bearing caps into position If bearing caps do not correctly fit into position Check the align ment of match marks between caps and carrier Remove the caps and repeat 15 6 to 8 9 In...

Page 204: ...two pry bars between the bearing adjusting rings and ends of the differential case The pry bars must not touch the differen tial bearings b Insert two pry bars between the differential case or ring gear and the carrier at locations other than described in 3 a The pry bars must not touch the differential bearings 4 Tighten the bearing adjusting ring until the dial indicator reads ZERO end play Move...

Page 205: ... the dimension is less than specifications Repeat 18 3 and 18 4 as needed 19 CHECK RING GEAR RUNOUT 1 Attach a dial indicator onto the carrier mounting flange 2 Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear Set the dial indicator to ZERO 3 Rotate the differential and ring gear Read the dial indicator Runout must not exceed 0 008 inch 0 20 mm ...

Page 206: ...ion teeth If the backlash reading is within specifications Check the tooth contact patterns If the backlash reading is not within specifications Adjust back lash as needed 5 Loosen one bearing adjusting ring one notch then tighten the opposite ring the same amount To increase backlash Move the ring gear away from the drive pin ion To decrease backlash Move the ring gear toward the drive pinion NOT...

Page 207: ...s check tooth contact patterns on the drive side of the gear teeth 1 Adjust the backlash of a new gear set to either 0 012 inch 0 305 mm or 0 015 inch 0 380 mm depending on the size of the ring gear Adjust the backlash of an old gear set to the setting that you mea sured before the carrier was disassembled Refer to page DF02 46 2 Apply a marking compound onto approximately 12 gear teeth of the rin...

Page 208: ...ch the wear pattern in the ring gear The new contact pattern will be smaller in area than the old wear pattern A high contact pattern indicates that the drive pinion was not installed deep enough into the carrier A low contact pattern indicates that the drive pinion was installed too deep in the carrier If the contact patterns require adjustment Continue by following 21 5 to move the contact patte...

Page 209: ... to move the contact patterns toward the heel of the ring gear teeth c Repeat 21 2 to 4 and 21 6 until the contact patterns are at the correct location in the length of the gear teeth CAUTION If the carrier has cotter keys lock the adjusting rings only with cotter keys If the carrier has roll pins reuse the roll pins or lock the adjust ing rings with cotter keys Do not force a roll pin into a cott...

Page 210: ... ends 3 Install the thrust screw Clearance between the thrust screw and the ring gear must be 0 025 0 045 inch 0 65 1 14 mm 4 Loosen the thrust screw 1 2 turn 180 degrees 5 Tighten the jam nut if equipped to the correct torque value against the carrier Refer to page DF02 12 1 THRUST SCREW AND JAM NUT 1 SHTS05Z050200119 1 Loosen thrust screw 1 2 turn SHTS05Z050200120 1 Hold thrust screw in position...

Page 211: ...in a well ventilated area Do not use gasoline or solvents that contain gasoline Gasoline can explode You must use hot solution tanks or alkaline solutions correctly Read the manufacturer s instructions before using hot solution tanks and alkaline solutions Then carefully follow the instruc tions 1 Use a cleaning solvent and rags to clean the inside of the axle hous ing and the carrier mounting sur...

Page 212: ...he mating surface of the hub and around the edge of each fastener hole 3 Install the gasket and the axle shaft into the housing The gasket and the flange of the axle shaft must fit flat against the wheel hub 4 Install the Grade 8 nuts and hardened washers on the stud Lock washers are an acceptable alternative Tighten the stud nuts to the torque specified Shaft to Hub Torque Fastener Chart Non Tape...

Page 213: ... acceptable alternative Tighten the stud nuts to the torque specified Shaft to Hub Torque Fastener Chart Tapered Dowel Applications Fastener Thread Size Torque Value Grade 8 Nuts lb ft N m Plain Nut Lock Nut Stud Nut Axle Shaft 0 44 20 50 70 81 102 40 65 67 88 0 50 20 75 115 115 156 65 100 102 136 0 56 18 110 165 176 224 100 145 149 197 0 62 18 150 230 244 312 130 190 203 258 Studs All Install the...

Page 214: ... Use a cleaning solvent to clean ground or polished parts or surfaces Kerosene or diesel fuel oil can be used for this purpose Do not use gasoline 2 Use a tool with a flat blade if required to remove sealant material from parts Be careful not to damage the polished or smooth surfaces CAUTION Do not use hot solution tanks or water and alkaline solutions to clean ground or polished parts Damage to p...

Page 215: ...re and prevent corrosion 7 INSPECT PARTS It is very important to inspect all parts carefully and completely before the axle or carrier is assembled Check all parts for wear and replace damaged parts 1 Inspect the cup cone rollers and cage of all tapered roller bearings in the assembly If any of the following conditions exist replace the bear ing The center of the large diameter end of the rollers ...

Page 216: ...ollers There is damage on the cup and cone inner race surfaces that touch the rollers CAUTION A drive pinion and ring gear are machined as a matched set When you replace either a drive pinion or a ring gear you must replace both parts as a matched set Do not mix old and new parts Damage to components can result WEAR MARKS SHTS05Z050200128 ETCHING AND PITTING SHTS05Z050200129 1 SPALLING AND FLAKING...

Page 217: ...ther remains dirty after cleaning replace the breather c Apply compressed air to the breather If compressed air does not pass through the breather replace the breather d Install the breather in the axle housing 8 REPAIR OR REPLACE PARTS NOTICE Threads must be without damage and clean so that accurate adjust ments and correct torque values can be applied to fasteners and parts 1 Replace any fastene...

Page 218: ...teners with pre applied adhesive 1 Use a wire brush to clean the oil and dirt from threaded holes 2 Install new fasteners with pre applied adhesive to assemble parts Do not apply adhesives or sealants to fasteners with pre applied adhe sive or to fastener holes 3 Tighten the fasteners to the required torque value for that size fas tener 3 ORIGINAL OR USED FASTENERS 1 Use a wire brush to clean the ...

Page 219: ...and bearing caps Apply the adhesive around the cir cumference of the smooth ground surfaces only Do not place adhe sive on threaded areas 4 Install the main differential assembly bearing cups and bearing caps into the carrier Refer to page DF02 42 5 Adjust preload of the differential bearings backlash and tooth contact patterns of the gear set as required Refer to page DF02 44 46 2 THREE BOND 1216...

Page 220: ...break off and plug lubrication passages Damage to components can result 4 Apply 0 125 inch 3 mm diameter continuous bead of the silicone gasket material around one surface Also apply the gasket material around the edge of all fastener holes on that surface 5 Assemble the components immediately to permit the silicone gasket material to compress evenly between the parts Tighten fasteners to the requ...

Page 221: ...e manufacturer s emergency procedures Have your eyes checked by a physician as soon as possible 10 Apply a 0 25 inch 6 mm bead of Loctite 5699 silicone gasket mate rial to the housing face Do not use Three Bond 1216E silicone prod ucts 11 Install two long studs in the carrier to guide the carrier into the hous ing 12 Immediately install the carrier into the housing to permit the silicone gasket ma...

Page 222: ...he POSETM seal on the hub until the lips are from 0 25 0 50 inch 6 4 12 7 mm from the end of the hub Do not install the POSETM seal against the shoulder NOTICE The POSETM seal will position itself correctly as the yoke or flange is pressed on the shaft 4 Before you install the yoke or flange on the shaft apply the same lubricant used in the axle housing to the hub 5 Install the yoke or flange usin...

Page 223: ...t the vehicle from moving 2 Use a jack or other lifting tool to raise the vehicle so that the wheels to be serviced are off the ground Support the vehicle with safety stands 3 Place a drain pan under the rear axle 4 Remove the plug from bottom of axle housing Drain lubricant from the assembly 5 Disconnect the driveline universal joint from the pinion input yoke or flange on the carrier 6 Remove th...

Page 224: ...K ASSEMBLY 1 Removal of the lock cylinder a Remove the sensor switch b Remove the cylinder by turning hex nut at the top of the cylinder with a wrench The cylinder may be secured to the carrier casting with Loctite adhesive or equivalent pre applied liquid adhesive To brake down these secured fasteners follow the heating proce dure Refer to page DF02 58 c Remove the shift shaft spring and shift fo...

Page 225: ...r Slide the piston to the port end of the cylinder 6 Coat the DCDL cylinder threads with Loctite 518 Gasket Eliminator 7 Screw the DCDL cylinder in place Tighten the cylinder to 80 100 lb ft 109 136 N m torque 8 Snap the shift collar into the fork Engage the shift collar splines with the splines of the differential case Use the manual actuation cap screw to move the shift collar splines into the d...

Page 226: ... the engine to get the system air pressure to the normal level WARNING During DCDL disassembly when the DCDL is in the locked or engaged position and one of the vehicle s wheels is raised from the floor do not start the engine and engage the transmission The vehi cle can move and cause serious personal injury 2 Place the differential lock switch in the cab of the vehicle in the unlocked or disenga...

Page 227: ...BR01 1 BR01BRAKE EQUIPMENT MODELS WITH HYDRAULIC BRAKE BR01 001 SERVICE BRAKE ASSEMBLY BR01 2 DESCRIPTION BR01 2 DIAGRAM BR01 3 TROUBLESHOOTING BR01 5 BRAKE SYSTEM AIR BLEEDING BR01 9 POWER STEERING SYSTEM AIR BLEEDING BR01 11 BRAKE TEST BR01 12 ...

Page 228: ... pump and an integral flow switch It is powered by either the power steering pump or other hydraulic source The backup pump provides a secondary power source for the hydraulic booster and is controlled by the integral flow switch The master cylinder is a split system type with separate fluid chambers pistons and outlet ports for the front and rear brake circuits A differential pressure switch is e...

Page 229: ... 8 POWER STEERING FLUID LINE ELECTRICAL CIRCUIT OIL PIPE OIL HOSE AIR PIPE NYLON TUBE 3 1 4 7 6 10 9 2 5 12 12 13 13 11 20 19 16 CIRCUIT OF AIR HORN CIRCUIT OF CAB AIR SUSPENSION SEAT 16 25 21 23 23 22 CIRCUIT OF AIR SUSPENSION 16 21 23 23 24 22 CIRCUIT OF AIR SUSPENSION HEIGHT CONTROL CIRCUIT OF EXHAUST BRAKE UNLOADER 16 16 18 17 14 15 4 SHTS068010100002C ...

Page 230: ...brake 5 Power steering oil reservoir 19 Magnetic valve 6 Power steering pump 20 Air horn if so equipped 7 Power steering gear 21 Air suspension protection valve 8 Backup pump motor 22 Leveling valve 9 Relay 23 Air suspension bellows 10 Hydro max controller 24 Magnetic valve if so equipped 11 ABS modulator and ECU 25 Air suspension seat 12 Speed sensor front 13 Speed sensor rear 14 Air compressor ...

Page 231: ...ill brake fluid Excessive pedal travel though there is response upon working the pedal Insufficient brake fluid in the master cylinder Search the cause of insufficient fluid repair or replace it Then refill fluid and bleed air Air trapped in the brake lines Bleed air from brake lines Leakage of fluid from brake system Check the leak point repair or replace Poor quality brake fluid or improper flui...

Page 232: ...ntrol system pipings Leakage of brake fluid from brake sys tem Tighten further or replace gasket Not enough braking or too much pedal resistance Lack of power steering pump pressure Improper operation of power steering pump Repair or replace Clogging of brake system Replace pipe hose etc Not enough braking or too much pedal resistance Not enough power steering pump pressure or rise of power steeri...

Page 233: ... cylinder Replace master cylinder assembly Swollen pressure seals of master cylin der Replace master cylinder assembly Improper return of the master cylinder piston Replace master cylinder assembly Delay pedal return Broken return spring Replace master cylinder assembly Restricted fluid return line of the power steering or hydraulic pump Remove the obstruction and replace the line Swollen power pi...

Page 234: ...l or caliper as required Replace pads in axle sets Loose caliper on caliper mounting bracket Retighten Leakage between booster and mas ter cylinder Primary pressure seal or backup ring of the master cylinder is worn or dam aged Replace master cylinder assembly Seal or O ring of the booster end cap assembly is worn or damaged Replace booster assembly Leakage from booster or power steering pump Seal...

Page 235: ...voir level above minimum could result in more air entering system mak ing it impossible to effectively bleed the system 4 Bleed the brake system Put a wrench on the brake actuator bleeder fitting Start with the farthest from the modulator typically the right rear then attach a length of clear plastic tubing to the bleeder fitting Make sure the tube fits snugly 5 Submerge the tubing in a container ...

Page 236: ... cap and dispose of used brake fluid NOTICE The brake fluid level shall be within the range of 1 in 25 4mm below bottom of ring Fill to bottom of ring if brake fluid is more than 1 in 25 4mm below bottom of ring Remove the excess brake fluid from the reservoir when the worn brake pads are replaced otherwise there is a possibility the brake fluid will overflow from the master cylinder reservoir Bot...

Page 237: ... NOTICE Block the rear wheels 3 TURN THE STEERING WHEEL FULLY IN BOTH DIRECTIONS SEVERAL TIMES 4 CHECK THE FLUID LEVEL IN THE OIL RESERVOIR 1 Add fluid if necessary WARNING When checking the fluid level of the power steering reservoir or add ing fluid to the reservoir be careful not to contaminate fluid with dirt in the reservoir Fluid contaminated with dirt can result in a shorter life of the pum...

Page 238: ...y come on there is a malfunction See trouble shooting to find the problem 8 RECHECK THE FLUID LEVEL WHEN THE ENGINE IS STOPPED 1 If necessary add or decrease the power steering fluid to match between MAX and MIN CAUTION If air bleeding is not done properly and the engine is stopped power steering fluid could overflow from the reservoir BRAKE TEST EN0680101F300003 Measure the braking effect of each...

Page 239: ...MENT MODELS WITH FULL AIR BRAKE BR01 1 BR01BRAKE EQUIPMENT MODELS WITH FULL AIR BRAKE BR01 002 SERVICE BRAKE ASSEMBLY BR01 2 DESCRIPTION BR01 2 DATA AND SPECIFICATIONS BR01 3 DIAGRAM BR01 4 TROUBLESHOOTING BR01 5 ...

Page 240: ...ach line comprises of a group of valves and brake chambers one wheel Two stop light switches one line are used to operate the stop lights Spring brake control system Single line for rear spring brake chambers The line comprises a control valve which controls air flow the other neces sary valve and spring brake chambers A parking brake switch is used to turn OFF the warning buzzer and to turn ON th...

Page 241: ... wheel brake MERITOR 16 5 x 7 or 15 x 8 625 Q Plus Cam Brake with Cast Spider automatic slack adjuster Slack length 5 5 or 6 0 type handed Drum 16 5 in Outboard mounted Rear Spring brake chamber MGM TR3030 3030 x 2 50 in standard Brake valve Bendix E 8P Check valve Bendix SC 3 Spring brake control valve Bendix PP DC Spring brake modulating valve Bendix SR 7 Rear relay valve Bendix R 14 No 102860 A...

Page 242: ...ol valve 17 Air horn if so equipped 7 Air compressor 18 Air suspension seat 8 Air tank Front 19 Differential lock 9 Air tank Rear 20 Leveling valve 10 Relay valve for service brake 21 Air suspension bellows 11 Spring brake modulating valve 7 4 2 6 13 13 16 15 5 12 2 11 10 14 14 18 5 5 15 19 17 15 15 5 5 21 21 20 8 9 5 21 21 20 CIRCUIT OF CAB AIR SUSPENSION CIRCUIT OF AIR SUSPENSION CIRCUIT OF AIR ...

Page 243: ...wet with grease or oil Replace lining Defective lining material Improper combination Replace lining Non uniform lining contact Correct Non uniform brake chamber rod stroke Check automatic slack adjuster Distorted drums Correct or replace Excessive abrasion of drums Correct or replace Unequal or unstable braking Con trol system Clogging of brake system Replace pipe hose etc Unequal or unstable brak...

Page 244: ...lining rivet Replace or tighten the rivet further Lining rivet in contact with drum Replace lining and rivet Deformation or wear of drum Repair or replace Intrusion of foreign matter between drum and lining Clean the surface of lining or replace Brake squeal Others Loose hub bearing Adjust or replace bearing Symptom Possible cause Remedy Prevention ...

Page 245: ...5 DATA AND SPECIFICATIONS BR02 5 DESCRIPTION BR02 5 PRINCIPLE OF OPERATION BR02 7 COMPONENT LOCATOR BR02 9 HYDRO MAX BOOSTER BR02 10 OVERHAUL BR02 10 MASTER CYLINDER BR02 16 OVERHAUL BR02 16 PRESSURE TESTS BR02 18 ABS MODULATOR BR02 19 DATA AND SPECIFICATIONS BR02 19 DESCRIPTION BR02 19 WHEEL BRAKE TYPE 4 PISTON BR02 20 DATA AND SPECIFICATIONS BR02 20 DESCRIPTION BR02 21 TROUBLESHOOTING BR02 22 ...

Page 246: ...ake hydraulic line including the pipes connection hoses etc If any leak is found repair or replace with the corre sponding parts b When checking for leaks check also the following items and repair or replace with the corresponding parts as required a Check that the pipes and hoses are not hitting or rubbing other parts Check that the pipe clips are not loose b Check that the pipes have no cracks a...

Page 247: ...pads are replaced otherwise there is a possibility the brake fluid will overflow from the master cylinder reservoir NOTICE Be sure to use clean brake fluid Note that if a foreign substance is mixed with the brake fluid components of the brake line may be dam aged and their functions may be degraded thereby causing insuffi cient braking force Before removing the brake fluid reservoir cap clean the ...

Page 248: ...ed out light with a new one 2 Check the differential pressure switch Purposely loosen either the front or rear brake line Start the engine depress the brake pedal and confirm that the warn ing lights up Confirm warning light condition with other brake line front and rear If in both conditions the warning light comes on the differential pressure switch is normal USA CANADA Brake pressure warning li...

Page 249: ...HYDRO MAX HYDRAULIC BRAKE BOOSTER AND MASTER CYLINDER DATA AND SPECIFICATIONS EN1680102I200001 DESCRIPTION EN1680102D100001 Manufacturer BOSCH Type HYDRO MAX II and master cylinder Master cylinder diameter 50 80 mm 2 00 in SAPH168010200004 ...

Page 250: ...quires complete assembly replacement 1 Reservoir cap with diaphragm 9 Check valve seat 2 Differential pressure switch 10 Check ball 3 Tube seat 11 Hydro Max booster assembly 4 Master cylinder assembly 12 Check ball retainer 5 Flow switch 13 Adapter 6 O ring 14 Face seal 7 Flow piston 15 Backup pump 8 Flow piston spring 16 Backup pump relay SAPH168010200005 ...

Page 251: ...w switch opens the backup pump elec trical circuit during normal operation A separate check valve in the backup pump prevents back flow through the pump during normal power applications In the event normal flow from the power source is interrupted the backup pump provides the power at a reduced rate for stopping Upon flow interruption the Integral flow switch closes energizing a relay providing el...

Page 252: ...SERVICE BRAKE HYDRAULIC BRAKE BR02 8 NOTICE This illustration is a representative model for operation reference SAPH168010200006 ...

Page 253: ... 17 Bushing 5 Sub harness 18 Brake pedal 6 Harness clamp 19 Collar 7 Hydro Max booster and master cylinder 20 Pedal pad 8 Retainer 21 Power steering fluid reservoir 9 Plane washer 22 Hose clamp 10 Clevis pin 23 Power steering fluid hose 11 Pedal bracket 24 Power steering fluid pipe 12 Seal 25 Pipe clamp 13 Shaft A 20 30 204 305 15 22 D 33 9 40 7 346 415 25 30 B 18 26 184 265 14 19 E 22 34 224 346 ...

Page 254: ... pressure switch flow switch backup pump sub harness and relay 2 Remove the sub harness from the backup pump terminal 3 DISCONNECT THE HYRDAULIC HOSE AND PIPE FROM THE HYDRO MAX BOOSTER Drain the power steering fluid 4 DISCONNECT THE MASTER CYLINDER HINT By removing the brake pipe bracket or brake hose clips it is pos sible to remove the Hydro Max booster without removing the master cylinder from ...

Page 255: ... will drain out from Hydro Max booster 3 Remove and discard the four face seals 4 Remove the check ball If necessary 2 REMOVE THE FLOW SWITCH ASSEMBLY 1 Remove the flow switch 2 Remove and discard the O ring from the flow switch 3 Using a small magnet remove the flow piston and spring 3 REMOVE THE INLET CHECK VALVE 1 Using a hook wire remove and discard the inlet check valve seat with O ring from ...

Page 256: ... the check ball in the delivery port If removed If not replaced make sure the check ball is in the delivery port 2 Lubricate and install the four face seals in the adapter and backup pump 3 Install the adapter and backup pump NOTICE Ensure that the delivery ports for hydraulic pump adaptor and Hydro Max booster correspond during installation Do not confuse mating surfaces Install the backup pump i...

Page 257: ...to Hydro Max booster and tighten the nuts Tightening Torque 33 9 40 7 N m 346 415 kgf cm 25 30 lbf ft 2 Install the brake pipe bracket or brake hose clips 3 CONNECT THE HYRDAULIC HOSE AND PIPE FROM THE HYDRO MAX BOOSTER 1 Connect hydraulic pipe and tighten the flare nut Tightening Torque 22 34 N m 224 346 kgf cm 16 25 lbf ft Stop light switch cover Brake pedal Srop light switch Pin SAPH16801020001...

Page 258: ...D TERMINAL 6 BLEEDING OF HYDRO MAX SYSTEM Refer to POWER STEERING SYSTEM AIR BLEEDING of chapter BRAKE EQUIPMENT MODELS WITH HYDRAULIC BRAKE BR01 11 WARNING Any Hydro Max booster or brake hydraulic line removed or discon nected should be properly bled before attempting to move the vehicle as the braking force will not be sufficient 7 BLEEDING OF BRAKE HYDRAULIC SYSTEM If the master cylinder was re...

Page 259: ...SERVICE BRAKE HYDRAULIC BRAKE BR02 15 8 BRAKE PEDAL HEIGHT Check that the pedal height H from the floor is within the stan dard dimension Standard 162 5 172 5 mm 6 4 6 7 in Flooe panel SAPH168010200024 ...

Page 260: ... personal injury or property damage 1 BLOCK THE WHEELS 2 DISCONNECT THE BRAKE PIPES 1 Drain the fluid from the master cylinder into a container 2 Disconnect the brake pipe from the master cylinder NOTICE Observe the position of the brake pipe to master cylinder before removal to prevent mix up during assembly 3 Cover the pipe end to prevent entry of foreign matter 3 DISCONNECT THE MASTER CYLINDER ...

Page 261: ... to remove any metal fragments IMPORTANT POINTS MOUNTING 1 CONNECT THE MASTER CYLINDER 1 Connect the master cylinder to Hydro Max booster 2 Tighten the nut Tightening Torque 33 9 40 7 N m 346 415 kgf cm 25 30 lbf ft 2 CONNECT THE BRAKE PIPES 1 Remove cover from the pipe end 2 Connect the brake pipe to the master cylinder Tightening Torque 20 30 N m 204 305 kgf cm 15 22 lbf ft 3 BRAKE SYSTEM AIR BL...

Page 262: ...hile the engine is not running The backup pump should start and produce pressure approximately 5 515 kPa 56 kgf cm2 800 lbf in2 3 Warm up the engine until the power steering fluid reaches normal operating temperature 4 Depress the brake pedal while the engine is at idling speed The pressure should be approximately 12 400 kPa 126 kgf cm2 1 800 lbf in2 2 AIR BLEEDING 1 Remove the pressure gauge 2 Bl...

Page 263: ...CATIONS EN1680102I200002 DESCRIPTION EN1680102D100003 NOTICE For removal and installation of ABS MODULATOR refer to chapter BRAKE CONTROL ABS HYDRAULIC E ver sion DN03 20 Manufacturer MERITOR WABCO Type Hydraulic ABS modulator E version Modulator valve SAPH168010200031 ...

Page 264: ... PISTON FIXED MOUNT CALIPER Brake pad Thickness Above Metal New 0 73 18 5 mm Minimum Thickness Above Metal Discard 0 125 3 2 mm Brake Fluid High Performance Brake Fluid DOT 3 or DOT 4 Rotor Rotor Diameter 15 38 390 7 mm Thickness New 1 54 39 1 mm Thickness Discard 1 42 36 1 mm Vehicle Model HINO 238 258 268 338 NE8J NF8J Front Rear ...

Page 265: ... Tube Nuts 7 16 24 9 12 lb ft 12 2 16 3 N m Bleed Screw 7 16 24 9 12 lb ft 12 2 16 3 N m Lining Rail Covers M8x1 25x14 12 18 lb ft 16 3 24 5 N m Rotor to Hub Bolt 9 16 12 bolt 100 125 lb ft 136 0 170 0 N m Rotor to Hub Bolt 9 16 18 with Lock Nuts 70 95 lb ft 95 2 129 2 N m Rotor to Hub Bolt 9 16 18 with Plain Nuts 130 165 lb ft 176 8 224 4 N m Support to Axle 5 8 18 bolt 9 16 18 bolt 190 250 lb ft...

Page 266: ...n parts Replace the parts and realign Excessive front bearing clearance Readjust the bearing to specifications Vehicle Pulls to One Side Brake fluid oil and or grease on linings Install new pads in the axle sets Unmatched linings uneven lining wear distorted pads Install new pads in the axle sets Rough rotor surfaces on one rotor Resurface or replace the rotor in the axle sets Seized or frozen pis...

Page 267: ...aximum specified Lack of rotor parallelism Check the parallelism with a microme ter Resurface or install a new rotor as required Loose wheel bearing Readjust the bearing to the specified torque Brake Noise Scraping Rust or mud build up on edges of rotor and on caliper housing Clean or replace as necessary Worn pad or pad installed backward Replace the pads in the axle sets only with the friction s...

Page 268: ...d replacement is not necessary or desir able Replace the pads on both wheel ends on the same axle 2 REPLACE BRAKE PADS 1 Raise and support the vehicle 2 Remove the wheel and tire assembly according to manufacturer s rec ommendation 3 Remove the master cylinder reservoir filler cap Check the brake fluid level in the reservoir If necessary remove fluid to keep the reservoir from overflowing when com...

Page 269: ... personal injury can result 1 Raise and support the vehicle 2 Remove the tire and wheel assembly according to manufacturer s instructions 3 Remove the brake hose hold down clamp bolt if equipped 4 Remove the brake hose tube from the caliper 5 Remove four caliper to support assembly bolts Do not disassemble the four bolts joining the two halves of the caliper Brake hose hold down clamp bolt SAPH168...

Page 270: ... the lateral runout and or the thickness variation exceed the above values Resurface or replace the rotor 2 Remove the caliper Refer to Brake Caliper in this section 3 Remove the hub spoke wheel and rotor assembly from the axle according to vehicle manufacturer s recommendation 4 Remove the hub to rotor attachment fasteners hat shaped rotor For the U shaped rotor remove the studs holding the hub a...

Page 271: ...be a small amount of seal engagement remaining Remove the C clamp and the wood block The pistons may now be removed by hand 8 To remove the pistons from the other side of the caliper place the block of wood now over the empty bores from where the pistons have been removed with a thick sheet of rubber 3 8 inch between the wood and the caliper bores NOTICE Use the C clamp to hold the block of wood i...

Page 272: ...ARTS 1 CLEAN PARTS FOR GROUND OR POLISHED METAL PARTS CAUTION Do not use hot solution tanks or water and alkaline solutions to clean ground or polished parts Damage to parts will result Use a cleaning solvent or kerosene or diesel fuel to clean ground or polished metal parts or surfaces 2 FOR ROUGH METAL PARTS Use a cleaning solvent or a weak alkaline solution in a hot solution tank to clean rough...

Page 273: ...ean out and dry grooves and passages 2 Dip new piston seals in new clean DOT 3 hydraulic brake fluid and install in piston seal groove in caliper piston bores Make sure that they are properly seated Apply a thin film of silicon grease or brake fluid to the caliper bore seal land between the piston boot and seal groove Apply the grease or brake fluid around the entire circumfer ence of the caliper ...

Page 274: ...e pis ton boot bead is seated back against the shoulder of the projecting end of the piston Boots for the 64 mm and 70 mm pistons are color coded 6 If required replace the two stainless steel wear rails by removing the button head bolts NOTICE Inspect the caliper prior to reinstalling it onto the support Pistons must be fully retracted into the caliper Piston boots must be fully seated in the cali...

Page 275: ...e lateral runout exceeds 0 015 inches 0 381 mm the rotor may be rotated to a different mounting hole position on the hub or spoke wheel to reduce the value 2 CALIPER 1 Inspect the caliper for leakage damage or defects to piston seals or pistons If leakage damage or defect is found caliper disassembly may be required 2 To install reverse the removal process 3 Bleed the brake system and road test th...

Page 276: ...atic 5 Fill the master cylinder reservoir with new clean high performance DOT 3 brake fluid or equivalent Make several brake applications to move the brake pistons and linings out into contact with the brake rotors 6 Recheck master cylinder reservoir and top off as necessary to manu facturer s recommended level 7 Bleed the brake system 8 Install the tire and wheel assembly according to the manufac...

Page 277: ...aliper CAUTION Use a crocus cloth to remove minor stains and corrosion from the cal iper bore Do not use abrasives including an emery cloth If you can not remove minor stains and corrosion replace the caliper bore to avoid damage to components 7 Inspect the caliper bore for minor stains and corrosion If these conditions are evident Use a crocus cloth to remove stains or corrosion Clean the caliper...

Page 278: ...2 lb ft 12 2 16 3 N m 5 Now again open the inner bleeder screw and purge the air and tighten the bleeder screw to 9 12 lb ft 12 2 16 3 N m 6 Repeat this procedure for all other brakes in the sequence specified in step 2 7 Test brakes prior to returning vehicle to service A firm pedal should be felt during brake application ...

Page 279: ...4 INSPECTION AND REPAIR BR02 35 SPRING BRAKE CONTROL VALVE BR02 37 DESCRIPTION BR02 37 COMPONENT LOCATOR BR02 38 INSPECTION AND REPAIR BR02 39 BRAKE CHAMBER FRONT BR02 42 DATA AND SPECIFICATIONS BR02 42 DESCRIPTION BR02 42 COMPONENT LOCATOR BR02 43 OVERHAUL BR02 44 INSPECTION AND REPAIR BR02 45 BRAKE CHAMBER REAR BR02 46 DATA AND SPECIFICATIONS BR02 46 DESCRIPTION BR02 47 COMPONENT LOCATOR BR02 48...

Page 280: ...oves air system contaminants in solid liquid and vapor form before they enter the brake system It provides clean dry air to the components of the brake system which increases the life of the system and reduces maintenance costs The necessity for daily manual draining of the reservoirs is eliminated Air Connection Port ID Function Connection QTY 1 IN Inlet Port air in 1 21 PRI Delivery Port out to ...

Page 281: ... connections and the purge valve assembly The removable purge valve assembly incorporates the purge valve mechanism and a turbocharger cut off feature that is designed to prevent loss of engine turbo boost pressure during the purge cycle of the AD IS air dryer and reservoir system For ease of maintenance all replaceable assemblies can be serviced without removal of the air dryer and reservoir syst...

Page 282: ...and dry the air deliver air to the vehicle s primary reservoir secondary reservoir and accessories and control the compressor dryer charge cycle AIR DRYER AND RESERVOIR SYSTEM OPERATION GENERAL The AD IS air dryer and reservoir system alternates between two operational modes or cycles during operation the Charge Cycle and the Purge Cycle The following descriptions are separated into these cycles o...

Page 283: ...rly the governor also supplies air pressure to the AD IS air dryer and reservoir system purge control channel The AD IS air dryer and reservoir system purge piston moves down in response to this air pressure causing the purge valve to open to the atmosphere and the turbo cut off valve to close off the supply of air from the compressor this will be further discussed in the Turbo Cut off Feature sec...

Page 284: ...anged it may be necessary to upgrade the compressor size Refer to Bendix Specification BW 100 A Appendix D to determine if any changes are necessary c Location of the air dryer and reservoir system is too close to the air compressor Refer to Bendix Specification BW 100 A Appendix B for discharge line lengths d In areas where more than a 30 degree range of temperature occurs in one day small amount...

Page 285: ...he vehicle power lead If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check to see if a good ground path exists b Thermostat and Heater Operation NOTICE These tests are not possible except in cold weather operation Turn off the ignition switch and cool the thermostat and heater assembly to below 40 degrees Fahrenheit Using an ohm meter check the...

Page 286: ...top the engine and remove ignition key when working under or around the vehicle When working in the engine com partment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with mov ing rotating leaking heated or electrically charged component...

Page 287: ... connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and syst...

Page 288: ...assembly and related com ponents to change the purge valve subassembly Pressure Protection Valve Boot Replacement Part Number 5005163 AD IS Air Dryer Replacement Replaces the complete air dryer assembly Includes air dryer assembly and governor AD IS Air Dryer Splash Shield Replacement Kit Part Number 5006698 Purge Reservoir Drain Valve Replaces the drain valve on the purge reservoir SEE THE AD IS ...

Page 289: ...e valve is being removed Install a T fitting into the port Using any adapters necessary reinstall the safety valve in one of the branches of the T fitting Using any adapters necessary install the air supply line into the remaining T fitting port After testing the T fitting for any air leakage by using a soap solution after charging to system cut out pressure a 1 bubble in 10 seconds is acceptable ...

Page 290: ... use solvents 3 Inspect for physical damage to the bore and the check valve seat If the bore is damaged by scratches etc that would prevent delivery check valve from seating replace the AD IS air dryer 4 Inspect the delivery check valve o rings etc for wear or damage Replace if necessary using the check valve replace ment kit available at authorized Bendix parts outlets 5 Inspect all air line fitt...

Page 291: ... and fan the brakes so that the system pressure reaches governor cut in The purge valve will return to its closed position The purge reservoir has a drain valve which is opened by moving the center lever away from its closed position Open the drain valve and wait 10 seconds to allow any residual purge pressure to be released Release the lever closing the drain valve Carefully remove the air dryer ...

Page 292: ...d with high air usage accessories such as trailer pump off systems or central tire inflation the air for these accessories must by pass the dryer reservoir system D Desiccant requires replacement D Replace desiccant cartridge assembly E Air by passes desiccant cartridge assembly E If vehicle uses Holset compressor inspect feed back check valve for proper installation and opera tion F Air dryer not...

Page 293: ... should be constantly sloping from compressor to air dryer with as few bends as pos sible C Pressure protection valve s in air dryer will not open C Replace air dryer pressure protection valves are not serviceable D Refer to Symptom 4 D Refer to Symptom 4 Remedy A E Refer to Symptom 7 E Refer to Symptom 7 Remedies A and B 6 Air dryer does not purge or exhaust air A Faulty air dryer purge valve A A...

Page 294: ...e reduced substantially by increasing the dis charge line volume This can be accomplished by adding a 90 cubic inch or larger reservoir between the compressor and the AD IS air dryer and reservoir system 10 The air dryer purge piston cycles rapidly in the com pressor unloaded noncom pressing mode A Compressor fails to unload A Check air hose from governor to compressor for a missing kinked or rest...

Page 295: ...E FULL AIR BRAKE BR02 17 CHECK VALVE DATA AND SPECIFICATIONS EN0680202I200001 DESCRIPTION EN0680202C100002 Type Spring type wafer type valve INLET INLET OUTLET OUTLET SPRING WAFER TYPE CHECK VALVE SHTS068020200008 ...

Page 296: ...eable items If a valve does not meet the Opera tional and Leakage tests it should be replaced at any authorized Ben dix parts outlet 5 TESTING AND TROUBLESHOOTING Perform 2 OPERATION LEAKAGE CHECK 6 IMPORTANT PLEASE READ When working on or around a vehicle the following general pre cautions should be observed 1 Park the vehicle on a level surface apply the parking brakes and always block the wheel...

Page 297: ...ment hardware tubing hose fittings etc should be of equiv alent size type and strength as original equipment and be designed specifically for such applications and systems 10 Components with stripped threads or damaged parts should be replaced rather than repaired Repairs requiring machining or welding should not be attempted unless specifically approved and stated by the vehicle or component manu...

Page 298: ...FT 3 REMOVE THE PEDAL BRACKET ASSEMBLY 1 Loosen the bolts and remove the pedal bracket assembly 4 REMOVE THE BRAKE PEDAL 1 Tap the shaft lightly using a brass rod and a hammer remove the brake pedal from the pedal bracket assembly NOTICE Do not pull out the shaft because the brake pedal and the clutch pedal are installed by one shaft 5 DISCONNECT THE PUSH ROD JOINT FROM THE BRAKE PEDAL LEVER 6 REM...

Page 299: ...nsert 2 snap rings to the pedal shaft 4 INSTALL THE PEDAL BRACKET ASSEMBLY Install the pedal bracket assembly with bolts Tightening Torque 18 26 N m 184 265 kgf cm 13 19 lbf ft 5 INSTALL THE CLUTCH MASTER CYLINDER AND THE STEERING SHAFT 6 CONNECT THE NYLON TUBE TO THE BRAKE VALVE CONNEC TOR Tightening Torque 3 8 35 45 N m 375 459 kgf cm 26 33 lbf ft 1 2 50 60 N m 510 612 kgf cm 37 44 lbf ft NOTICE...

Page 300: ... ft 8 ADJUST AND INSPECT THE STOP LIGHT SWITCH 1 After installing bushing to the switch bracket insert the stop light switch then twist it clockwise while making contact with the tip of the switch and the buffer and fix it 2 After installing the switch when releasing the brake pedal make sure there is no contact between the switch and buffer Confirm the operation of the switch surely 3 Check the c...

Page 301: ...EWS DEL 2 BODY ATTACHING SCREWS LOWER BODY 14 DEL 1 UPPER BODY 15 SHTS068020200017 9 Screw 21 Relay piston spring 10 Exhaust diaphragm 22 Primary piston 11 Washer 23 Graduating spring 12 Exhaust cover 24 Washer 13 Inlet valve 25 Primary piston spring seat nut 14 Seal ring 26 Spring seat 15 Primary piston retainer 27 Rubber spring 16 Lock nut 28 Piston O ring 17 Stem 30 O ring 18 Spring seat 31 O r...

Page 302: ... piston spring seat nut 14 Seal ring 26 Spring seat 15 Primary piston retainer 27 Rubber spring 16 Lock nut 28 Piston O ring 17 Stem 30 O ring 18 Spring seat 31 O ring 19 Stem spring 32 Retaining ring 20 Relay piston 33 Primary inlet and exhaust valve 17 20 24 30 32 11 10 13 21 31 33 LOWER BODY EXHAUST COVER ATTACHING SCREWS QTY 4 BODY ATTACHING SCREWS QTY 4 12 14 23 27 15 19 18 22 25 26 UPPER BOD...

Page 303: ...ing accurate test gauges 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 primary cir...

Page 304: ...o contain the primary piston return spring for E 8P 23 stem spring 19 and the relay piston spring 21 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 rec ommended that the primary piston and relay piston be manually or mechanically contained while the nut and stem are being removed 8 Using a...

Page 305: ...the stem 8 Place the washer 24 over the stem 17 and on top of the relay pis ton 20 9 Install primary return spring E 8P 23 in upper body piston bore 10 For E 8P Install the primary piston rubber spring sub assembly 1 4 and 5 over the stem into the up per body piston bore 11 Compress piston s For E 8P the relay piston 20 and retaining ring into the upper body from either side and hold compressed ei...

Page 306: ...ect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove disassemble or assemble a compo nent until you have read and thoroughly understand the recom mended procedures Use only the proper tools and observe all...

Page 307: ...ntical conditions mainte nance and maintenance intervals will vary Experience is a valuable guide in determining the best maintenance interval for any one partic ular operation 1 Every 3 months or 25 000 miles or 900 operating hours check for proper operation Type Diaphragm type with double check valve combined Pressure difference between signal and outlet pressure 29 4 kPa 0 3 kgf cm2 4 26 lbf in...

Page 308: ...age is permitted 5 If the R 14 is used to control the spring brakes place the park control in the released position and coat the balance port with a soap solution to check the diaphragm and its seat Leakage equivalent to a 1 inch bubble in 3 seconds is permitted NOTICE If the anti compound feature is in use the line attached to the balance port must be disconnected to perform this test If the valv...

Page 309: ...authorized Bendix parts outlet 6 ASSEMBLY NOTICE All torque specified in this manual are assembly torque and can be expected to fall off slightly after assembly Do not re torque after ini tial assembly torque fall For assembly hand wrenches are recom mended Prior to assembly lubricate all o rings o ring bores and any sliding surface with a silicone lubricant equivalent to Dow Corning 10 1 Install ...

Page 310: ... that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or elec trically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and al...

Page 311: ...SERVICE BRAKE FULL AIR BRAKE BR02 33 SPRING BRAKE MODULATING VALVE DESCRIPTION EN0680202C100005 PARK CONTROL FROM DASH VALVE BALANCE PORT EXHAUST DELIVERY SUPPLY PORT SHTS068020200020 ...

Page 312: ...G STATIC PISTON SPRING O RING O RING O RING LOWER BODY VALVE RETAINER SPRING 1 4 20 MACHINE SCREWS INLET EXHAUST VALVE LOWER VALVE GUIDE RETAINING RING EXHAUST PORT 10 TORX HEAD SCREW DIAPHRAGM WASHER DIAPHRAGM RETAINING RING VALVE SEAT O RING O RING SPRING BALL CHECK VALVE O RING CHECK VALVE GUIDE SUPPLY PORT O RING SPRING IN LINE SINGLE CHECK VALVE PARK CONTROL PORT CHECK VALVE COVER CONTROL POR...

Page 313: ...should drop to zero promptly A lag more than 3 seconds in drop of pressure would indicate faulty operation d With the parking control valve in the park position gradually apply foot brake valve and note a pressure reading increase on the gauge installed in the SR 7TM valve delivery port e Place parking control valve in release position f Drain the reservoir which supplies the rear service brake ci...

Page 314: ...ded procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix replacement parts components and ...

Page 315: ...ING BRAKE CONTROL VALVE DESCRIPTION EN0680202C100006 EXHAUST SUPPLY BUTTON COVER DELIVERY Ports Port Embossed I D Primary Reservoir Supply Supply 11 Secondary Reservoir Supply Supply 12 Delivery Delivery 21 Exhaust Exhaust 3 SHTS068020200022 ...

Page 316: ...SERVICE BRAKE FULL AIR BRAKE BR02 38 COMPONENT LOCATOR EN0680202D100003 BODY INDEX TABS GUIDE SPOOL PLUNGER STEM COVER CHECKVALVESEAT BUTTON SCREW 1 4 2 7 8 3 9 5 6 PLUNGER SHTS068020200023 ...

Page 317: ...e plunger stem with a soap solution Leakage should not exceed a 1 bubble in 5 seconds There should be no leakage from the secondary reservoir supply port b With the button out supply the valve with 120 psi from the sec ondary reservoir supply port There should be no leakage from the primary reservoir supply port c With the button in coat the exhaust port and the plunger stem with a soap solution L...

Page 318: ...roughly dry 2 Inspect all re usable parts for excessive wear or damage Inspect the body for gouges or deep scuffing Replace key numbers 1 9 and any parts not determined usable with genuine Bendix replacements 8 ASSEMBLY Before assembly lubricate all o rings o ring grooves rubbing sur faces and bores with Bendix silicone lubricant Pc No 291126 or equivalent 1 Place check valve 9 into its seat in th...

Page 319: ... from contact with moving rotating leaking heated or elec trically charged components 5 Never connect or disconnect a hose or line containing pressure it may whip 6 Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove disassemble or assemble a compo nent u...

Page 320: ...PECIFICATIONS EN0680202I200004 DESCRIPTION EN0680202C100007 P N Series 1420 Model C20 Size 20 Stroke 2 25 Part Number 1420001 Wt Lbs 7 55 A 4 16 B 3 41 C 6 92 D 4 75 E 5 8 11UNC F 5 8 18UNF Inlets 3 8 NPTF X Min in the caged position 8 00 E F D C A B X SHTS068020200024 ...

Page 321: ...004 1 Kit NP Chamber b 7 Kit Center Hole Shield 2 Kit Nuts Bolts 8 NP Chamber Assembly 3 Clamp Band Assembly 9 Kit Nuts Washers 4 Diaphragm 10 Hex Nut Yoke 5 Kit Push Rod Assembly b 11 Pressure Cap 2 inlets steel a 6 Return Spring 5 6 8 9 10 2 3 4 1 11 SHTS068020200025 ...

Page 322: ...e 2 Align the aligning mark A of the chamber clamp and chamber cover 3 Insert the bolt from opposite side of drain hole and tighten the bolts evenly with nut within the specified torque 2 CHECKING FOR AIR LEAKAGE 1 Apply soapy water to the chamber as shown and charge with com pressed air of 830 kPa 8 5 kgf cm2 121 lbf in2 from the inlet port B then check for leakage 3 INSTALLING CLEVIS 1 Install t...

Page 323: ...k R or L which was applied when dis mounting When connecting the clevis with the slack adjuster lubricate the clevis pin hole and clevis pin with sufficient chassis grease INSPECTION AND REPAIR EN0680202H300002 Inspection Item Standard Limit Remedy Inspection Procedure Cover clamp push rod return spring retainer dust seal holder and chamber Wear and damage Replace If neces sary Visual check ...

Page 324: ... Diaphragm type P N Series 3430 Model TR3030 Size 3030 Stroke 2 50 P N Combination 3430051 P N Single Piggyback 3430001 P N Piggyback Plus Kit 3430008 Wt Combination Lbs 20 0 Wt Single Lbs 11 6 A 9 04 B 6 66 C 8 31 D 8 21 E 4 75 F 5 8 11UNC G 5 8 18UNF Inlets 3 8 NPTF X Min in the caged position 8 00 b ...

Page 325: ...SERVICE BRAKE FULL AIR BRAKE BR02 47 DESCRIPTION EN0680202C100008 F G A B E C D X SHTS068020200031 ...

Page 326: ...ers 3 Clamp Band Assembly 10 Hex Nut Yoke 4 Diaphragm 11 Kit WeathersealTM Plug 5 Kit Push Rod Assembly b 12 Kit Release Bolt 6 Return Spring 13 Piggyback 7 Kit Center Hole Shield 14 Kit Piggyback Plus 3 4 5 6 8 9 10 11 12 13 2 1 14 Center Hole Shield Permits visual inspection of stroke alert but prevents entry of contaminants 7 SHTS068020200032 ...

Page 327: ...nspect the exterior surfaces of the unit for signs of damage from outside sources corrosion and or rust If any of these are seen or suspected cautiously remove the complete combination chamber by following the directions in Section 3 on page BR02 51 of this man ual Per CVSA out of service criteria any non manufactured hole or crack will place the vehicle out of service Not Shown 3 Inspect SERVICE ...

Page 328: ... END CAP with O ring being present and in good condition will void the MGM Brakes Warranty without remedy 2 MANUAL RELEASE PARKING BRAKES 1 Before releasing the parking brakes chock wheels of the vehicle to prevent a vehicle movement 2 Remove the plastic end cap from the spring brake chamber 3 Using a 3 4 inch wrench unscrew the release nut and remove the nut flat washer and release bolt from thei...

Page 329: ...rse the order of 1 1 7 above When re installing the release bolt flat washer and release nut into the storage pocket MGM Brakes recommends 10 Lbs Ft torque on nut against the flat washer 3 REMOVAL AND INSTALLATION INSTRUCTIONS FOR COMBINA TION CHAMBERS NOTICE Before removing air brake chamber to be replaced to ensure that the brake chamber being replaced was properly installed with the correct rod...

Page 330: ... rod is not square make corrections by repositioning the chamber on the mounting bracket and or by shimming the slack adjuster to the right or left on the camshaft as required 8 Apply a non hardening sealing compound to the hose fittings and re install both of the air lines to the chamber being sure each is mated to the correct air inlet port according to the markings made earlier MGM Brakes recom...

Page 331: ...ery important to recog nize that no foundation adjustments can be made at either the spring brake chamber or at the service brake chamber and that all stroke adjustments must be made at the slack adjuster according to the specific recommendations of the foundation brake manufacturer or the vehicle manufacturer 4 PROCEDURE TO CUT THE SERVICE PUSH ROD TO PROPER LENGTH WARNING Do not attempt to servi...

Page 332: ... to allow assembly of the yoke 10 Thread yoke onto the push rod Yoke from removed unit may be reused provided yoke pin hole is not worn Adjust yoke to the same Y dimension as measured from the removed unit 11 Hold yoke to prevent it from turning and tighten locknut against yoke 25 35 Lbs Ft torque TO INSTALL NEW UNIT ON VEHICLE Refer to MGM Brakes Service Manual for the model that is being install...

Page 333: ...ingle spring brake securely in place remove the clamp ring to allow removal of the single brake from the service chamber IMPORTANT At this time take the opportunity to inspect all parts in the ser vice chamber especially the diaphragm and replace the return spring and any other parts which may be damaged or worn Use only genuine MGM Brakes Engineered replacement parts 1 2 inch Minimum Engagement A...

Page 334: ... for air leaks around the circumference of the service clamp ring by spraying with soapy water or leak detec tion solution If bubbles appear firmly tap the circumference of the clamp ring with a hammer and retighten the clamp nuts until leaks cease MGM Brakes recommends 30 35 Lbs Ft torque on the clamp hex nuts 10 On all MGM Brakes models fitted with an EXTERNAL BREATHER TUBE wipe the open end of ...

Page 335: ...gm in Step 5 5 Use only genuine MGM Brakes Engi neered replacement diaphragms WARNING When servicing a 3 inch long stroke model brake be sure to replace with the correct diaphragm Installation of a standard 2 50 inch stroke diaphragm in a 3 inch long stroke chamber could result in catastrophic failure of the unit IMPORTANT It may not be necessary to disconnect the air lines from the spring brake d...

Page 336: ... manual slacks various slack lengths and different slack adjuster manufacturers IMPROPERLY ADJUSTED BRAKES ON APPLIED Maximum recommended readjustment stroke has been exceeded See chart on right for recommended readjustment stroke MGM Brakes Stroke Alert Excessive Stroke Warning Type 9 12 16 16L 20 20L 24 24L 24LP3 30 30LP3 36 Effective Area SQ IN 9 12 16 16 20 20 24 24 24 30 30 36 Approx Diaphrag...

Page 337: ...move it from the vehicle following the instructions in Section 3 on page BR02 51 for combination chambers or Section 5 on page BR02 54 for single piggyback chambers Be sure to release the brake per Section 2 on page BR02 50 of this manual Never attempt to remove the head which contains the power spring Observe all safety precautions Place the unit in a steel con tainer and use an acetylene torch t...

Page 338: ...R BRAKE BR02 60 PROTECTION VALVE DATA AND SPECIFICATIONS EN0680202I200006 DESCRIPTION EN0680202C100009 Type Spring type Operating pressure Close 70 PSI DELIVERY PORT INLET PORT PISTON SPRING VALVE CAP PR 4 SHTS068020200051 ...

Page 339: ...v ery side of the valve should remain at the highest pressure previously attained 3 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 permissible at bottom of valve 3 Drain the air pressure from the delivery side of the p...

Page 340: ...or elec trically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove disassemble or assemble a compo nent until you have read and thoroughly understand the rec...

Page 341: ...ling shoes operated by camshaft and automatic slack adjuster in all wheels Brake drum inside diameter x lining width Front 15 x 4 in 381 x 102 mm 16 5 x 5 in 419 x 127 mm Rear 16 5 x 7 in 419 x 178 mm Brake drum inside diameter x lining width Low floor type vehicle with full air brake Front 15 x 4 in 381 x 102 mm Rear 15 x 8 625 in 381 x 219 mm ...

Page 342: ...each bolt 7 16 20 60 75 lb ft 81 102 N m 1 2 20 85 115 lb ft 115 156 N m 9 16 18 130 165 lb ft 176 224 N m 5 8 18 180 230 lb ft 244 312 N m HOLD DOWN CLIP 2 some models 0 250 28 thread 105 135 lb in 12 15 N m DUST SHIELD MOUNTING 4 or 6 some models 0 312 18 thread 12 20 lb ft 16 27 N m 0 375 16 thread Grade 8 30 50 lb ft 41 68 N m Grade 5 25 35 lb ft 34 47 N m ANCHOR PIN SET SCREW 2 some models 0 ...

Page 343: ...hoe 16 Capscrew chamber bracket 5 Camshaft S head 17 Fitting grease 6 Washer camhead 18 Washer camshaft thick 7 Seal camshaft grease 19 Slack Adjuster automatic 8 Bushing camshaft 20 Washer spacing 9 Pin return spring 21 Snap Ring camshaft 10 Roller brake shoe 22 Dust Shield 11 Retainer shoe roller 23 Capscrew dust shield 12 Spring brake shoe return 24 Plug 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1...

Page 344: ...SERVICE BRAKE FULL AIR BRAKE BR02 66 SHTS068020200054 ...

Page 345: ...rocedures before you begin to service components 2 Read and observe all Caution and Warning safety alerts that precede instructions or procedures you will perform These alerts help to avoid damage to components serious personal injury or both 3 Follow your company s maintenance and service installation and diagnostics guidelines 4 Use special tools when required to help avoid serious personal inju...

Page 346: ...ound Support the vehicle with safety stands WARNING Before you service a spring chamber carefully follow the manufac turer s instructions to compress and lock the spring to completely release the brake Verify that no air pressure remains in the service chamber before you proceed Sudden release of compressed air can cause serious personal injury and damage to components d If the brake has spring ch...

Page 347: ...is d Follow the manufacturer s instructions to remove the wheel and drum from the axle 3 Brake Shoes All Q Plus and Q Series 15 Inch and 16 5 Inch Brakes 1 Push down on the bottom brake shoe Pull on the cam roller retainer clip to remove the bottom cam roller 2 Lift the top brake shoe and pull on the cam roller retainer clip to remove the top cam roller 3 Lift the bottom shoe to release the tensio...

Page 348: ...ings from the spider and spider bracket WARNING Solvent cleaners can be flammable poisonous and cause burns Examples of solvent cleaners are carbon tetrachloride and emulsion type and petroleum base cleaners Read the manufacturer s instruc tions before using a solvent cleaner then carefully follow the instruc tions Also follow the procedures below Wear safe eye protection Wear clothing that protec...

Page 349: ...ster If you turn the adjusting nut incorrectly you will damage the pawl teeth A damaged pawl will pre vent the slack adjuster from automatically adjusting clearance between the linings and drum Damage to components can result d Use a lb in torque wrench and turn the adjusting nut COUNTER CLOCKWISE to rotate the gear 360 degrees 22 turns of the wrench as you read the torque scale on the wrench The ...

Page 350: ...Install both bushings into the bracket Install the seals with the seal lips toward the slack adjuster Components Meritor Specification NLGI Grade Grease Type Outside Temperature Automatic Slack Adjuster O 616 A 1 Clay Base Down to 40 F 40 C O 692 1 and 2 Lithium Base Down to 40 F 40 C O 645 2 Synthetic Oil Clay Base Down to 65 F 54 C Clevis Pins Any of Above See Above See Above See Above O 637 1 1...

Page 351: ...an result To install a new brake drum so that it fits correctly over a Q Plus brake shoe you must install a Q Plus camshaft to prevent damage to com ponents 5 INSTALLATION 1 Camshaft a Install the cam head thrust washer onto the camshaft Apply Mer itor specification O 617 A or O 617 B grease to the camshaft bushings and journals b Install the camshaft through the spider and bracket so that the cam...

Page 352: ...ritor automatic slack adjusters manufactured after January 1990 have lubrication holes in the gear splines Do not operate the actuator rod before you install the slack adjuster Lubricant can pump through the holes and onto the splines Damage to components can result e If the automatic slack adjuster gear has a 10 tooth spline apply Meritor specification O 637 part number 2297 U 4571 anti seize com...

Page 353: ...ou service an automatic slack adjuster or chamber Do not reuse retainer clips Discard used clips When you remove a retainer clip it can bend or gap apart and lose retention Damage to components can result NOTICE Meritor recommends that you replace cotter pins with clevis retainer clips at assembly b Install new clevis pin retainer clips or cotter pins to secure the cle vis pins Retainer clips must...

Page 354: ...le in the correct slack adjuster template for the drum brake you re servic ing b Select the hole at the small end of the template that matches the slack adjuster arm length Position and hold the hole on the cen ter of the camshaft c Look through the small clevis pin slot on the template to see if the small clevis hole completely aligns within the slot If the small clevis hole doesn t align within ...

Page 355: ...rings rollers anchor pins and cam bushings at each reline Q Plus and Q Series 16 5 Inch Brakes a Place the upper brake shoe into position on the top anchor pin Hold the lower brake shoe on the bottom anchor pin Install two new brake shoe retaining springs MINIMUM 1 2 MAXIMUM 1 8 THREADED CLEVIS SHTS068020200072 Threads Torque 1 2 20 20 30 lb ft 27 41 N m 5 8 18 35 50 lb ft 48 68 N m 3 750 AND 3 81...

Page 356: ...s the retainer ears to fit into the retainer between the brake shoe webs d Push the camshaft roller retainer into the brake shoe until the ears lock into the shoe web holes e Use Meritor specification grease O 617 A or O 617 B to lubricate the camshaft roller pin and anchor pin SHTS068020200075 WEBS SQUEEZE EARS SHTS068020200076 WEB HOLE PUSH SHTS068020200077 CAM ROLLER PIN Lubricate here only CAM...

Page 357: ...ournals Only Camshaft Bushings O 616 A 1 Clay Base Down to 40 F 40 C O 617 A or O 617 B 1 2 Lithium 12 Hydroxy Stearate or Lithium Com plex Refer to the grease manufac turer s specifications for the tem perature service limits O 645 2 Synthetic Oil Clay Base Down to 65 F 54 C O 692 1 and 2 Lithium Base Down to 40 F 40 C Camshaft Splines Any of Above See Above See Above See Above O 637 1 1 2 Calciu...

Page 358: ...se a wrench to turn the manual adjusting nut COUNTER CLOCKWISE until the brake shoes are fully retracted and the lin ing clears the drum Then back off the adjusting nut one half turn in the opposite direction c Measure the distance from the center of the large clevis pin to the bottom of the air chamber while the brake is released The mea surement you obtain is X in figure d Use a pry bar to move ...

Page 359: ...Verify that no air pressure remains in the service section of the cham ber b Verify that pressure is 100 psi 689 kPa in the air tanks Deter mine the size and type of brake chambers on the vehicle c With the brakes released mark the push rod where it exits the chamber Measure and record the distance Have another person apply and hold the brakes on full application d Measure push rod travel adjusted...

Page 360: ...ecified by the vehicle manufacturer This will help to ensure that the brakes perform correctly and meet Department of Transportation DOT performance regulations Also note that the drums and linings on a front axle can be different than drums and linings on a rear axle 2 Single Axles Always reline both wheels of a single axle at the same time Always install the same linings and drums on both wheels...

Page 361: ...ottom position depending on the location of the camshaft If the camshaft is behind the axle the top shoe is the primary shoe If the cam is in front of the axle the top shoe is the primary shoe 9 BEFORE YOU RETURN THE VEHICLE TO SERVICE 1 Check the complete air system for worn hoses and connectors With air pressure at 100 psi 689 kPa brakes released and engine off loss of tractor air pressure must ...

Page 362: ...e camshaft bracket for broken welds cracks and correct alignment Replace damaged brackets 3 Check anchor pins for corrosion and wear Replace worn or damaged anchor pins 4 Check brake shoes for rust expanded rivet holes broken welds and correct alignment Replace a shoe with any of the above conditions 2 16 5 INCH BRAKE SHOES ONLY Anchor pin holes must not exceed 1 009 inches 25 63 mm in diame ter T...

Page 363: ...heat checking heat spotting scoring pitting and distortion Replace drums as required Do not turn or rebore brake drums which decreases the strength and heat capacity of the drum b Measure the inside diameter of the drum in several locations with a drum caliper or internal micrometer Replace the drum if the diameter exceeds the specifications supplied by the drum manu facturer 5 Check dust shields ...

Page 364: ...R CLIP SMALL CLEVIS PIN ACTUATOR ROD BOOT PISTON RETAINING RING BOOT RETAINING CLAMP ACTUATOR PISTON PULL PAWL ASSEMBLY Correct position for unhanded design Shown 90º out of position for handed design GASKET WORM WORM RETAINING RING WORM GREASE SEAL MANUAL ADJUSTING NUT END OF WORM JAM NUT COLLAR HOUSING ROLLER PIN ACTUATOR ADJUSTING SLEEVE GEAR GREASE FITTING GEAR RETAINER SEAL SHTS068020200088 ...

Page 365: ...ue is required to rotate worm when slack is removed from vehicle In service slack maximum worm torque 45 lb in 5 09 N m New or rebuilt slack maximum worm torque 25 lb in 2 83 N m Rebuild or replace slack adjuster Excessive looseness exists between the splines of the camshaft and the slack adjuster gear Replace powershaft gear or auto matic slack adjuster as needed A cam brake has worn components c...

Page 366: ...RETAINER CLIP ACTUATOR ASSEMBLY RETAINER SEAL GEAR FACE SEAL GREASE FITTING WORM RETAINING RING WORM GREASE SEAL HOUSING WORM GEAR MANUAL ADJUSTING NUT END OF WORM BUSHING GASKET PULL PAWL ASSEMBLY Replaces all previous pawl assemblies NOTE Parts shown in this box are not serviceable or interchangeable with parts from earlier models SHTS068020200089 LARGE CLEVIS PIN SPRING OFFSET CLEVIS COTTER PIN...

Page 367: ...ained in this publication was current at the time of printing and is subject to revision without notice or liability 1 You must understand all procedures and instructions before you begin maintenance and service procedures 2 You must follow your company s maintenance and service guidelines 3 You must use special tools when required to avoid serious personal injury and damage to components Meritor ...

Page 368: ...s of the chamber manufacturer Sudden release of a compressed spring can cause serious personal injury Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle sup ported only by jacks Jacks can slip and fall over Serious per sonal injury can result 1 If the brake has a spring brake compress and lock the spring so that the brake is relea...

Page 369: ...uster 2 Remove the boot from the housing Pull the actuator assembly from the housing 3 Use a small screwdriver to push down on one side of the piston retain ing ring to force the ring out of the groove 4 Extend the coils of the ring 5 Use pliers to unwind the ring and pull it out of the groove 6 Use a new ring when you assemble the slack adjuster 7 Pull the actuator rod piston and pin from the act...

Page 370: ...djusting nut and wind the worm out of the bore 14 Remove the retaining rings and thrust washers from both sides of the gear 15 Fit a small screwdriver into the notch at the end of the retaining ring 16 Remove the end of the retaining ring from the groove 17 Unwind the ring by hand and pull it out of the groove 18 Remove the thrust washer CAUTION Push one seal out of one side of the slack adjuster ...

Page 371: ...age to parts will result Only use solvent cleaners on metal parts Damage to parts will result 2 CLEAN PARTS 1 Use solvent cleaners to clean all automatic slack adjuster parts that have ground or polished surfaces for example the gear the worm and the inner bores of the housing 2 Use soap and water to clean non metal parts 3 Use soft paper or cloth that is free from dirt oil or abrasives to dry the...

Page 372: ... set and seals are not service able on automatic slack adjusters manufactured AFTER January 1993 If you are working on a current model skip to Step 10 1 ASSEMBLY 1 Remove any corrosion preventive material that may have been applied to the parts you will assemble 2 Use grease to lubricate the gear bore in the housing CAUTION Follow Steps 3 4 and 5 exactly when you install the seals so that the shar...

Page 373: ...ng pliers to install the retaining ring into the worm bore CAUTION Install the seal with the lips OUTSIDE of the bore and the metal retainer INSIDE of the bore to prevent contamination from enter ing the slack adjuster housing Damage to components can result Do not hit the seal after it reaches the bottom of the bore Dam age to seal will result 12 Place the seal directly over the worm bore Use a h...

Page 374: ...sealant to seal the top of the boot to the round part of the rod 22 Fasten the bottom of the boot to the housing with a retaining clamp 23 Conventional Pawl Install the pawl assembly into the housing Tighten the capscrew to a torque of 15 20 lb ft 20 27 N m 24 Pull Pawl Remove the screwdriver or equivalent tool The pull pawl will re engage automatically 25 Use a grease gun to lubricate the slack a...

Page 375: ...5 lb in 2 83 N m during the complete 360 degree rotation of the gear 30 If the torque value remains less than 25 lb in 2 8 N m The slack adjuster is working correctly 31 If the torque value exceeds 25 lb in 2 8 N m The slack adjuster is not working correctly Disassemble the slack adjuster Check that the slack adjuster is assembled correctly Check that parts are aligned correctly 22 TURNS ROTATE GE...

Page 376: ...lack adjuster that is used with each brake chamber size Chamber and Automatic Slack Adjuster Sizes 6 Place blocks in front of and behind the vehicle s wheels to prevent it from moving WARNING When you work on a spring chamber carefully follow the service instructions of the chamber manufacturer Sudden release of a com pressed spring can cause serious personal injury 7 If the brake has a spring bra...

Page 377: ...ehicle in service 12 Disengage the pawl Turn the manual adjusting nut to align the holes in the slack adjuster arm and the clevis 13 If the slack adjuster has a welded clevis Apply anti seize com pound to the two clevis pins Install the clevis pins through the clevis and the slack adjuster 14 If the slack adjuster has a threaded clevis Refer to page BR02 100 CAUTION Always replace used clevis pin ...

Page 378: ... the table in figure 2 AUTOMATIC SLACK ADJUSTER TEMPLATES Order the correct automatic slack adjuster template from Meritor s Customer Service Center at 800 535 5560 CAUTION There are five different installation templates for Meritor automatic slack adjusters The templates are NOT interchangeable You MUST use the correct template and you MUST adjust the clevis position as described below If you use...

Page 379: ... 2 Select the hole in the template that matches the length of the slack adjuster Hold that hole on the center of the camshaft 3 Look through the slot in the template If necessary adjust the position of the clevis until the small hole in the clevis is completely visible through the template slot Color of Template Part Number Use to Install Slack Adjusters On Dark brown TP 4786 Truck or tractor drum...

Page 380: ...in service NOTICE During preventive maintenance on an in service brake check both the free stroke as described below and the adjusted chamber stroke as described on page BR02 104 On some applications you may find the in service free stroke to be slightly longer than specified in Step 5 However this is not neces sarily a concern as long as the adjusted chamber stroke is within the limits shown in t...

Page 381: ... Brakes 3 4 inch 7 8 inch 19 1 22 2 mm 6 If it is necessary to adjust the stroke turn the adjusting nut 1 8 turn in the direction shown in figure and check the stroke again Continue to measure and adjust the stroke until it is adjusted correctly 7 Release a pull pawl or install a conventional pawl WARNING When you work on a spring chamber carefully follow the service instructions of the chamber ma...

Page 382: ... the gauges in the cab to ensure that air pressure in the tanks is 100 psi 689 kPa 3 Determine the size and type of brake chamber you are inspecting 4 With the brakes released mark the push rod where it exits the cham ber Measure and record the distance 5 Have another person apply and hold the brakes one full application 6 Measure push rod travel distance adjusted chamber stroke from where the pus...

Page 383: ...Harrison Olathe KS 66061 as Corrosion Control part number SA 8249496 Use anti seize compound on the clevis pins of all slack adjusters Also use anti seize compound on the automatic slack adjuster and cam splines if the slack adjuster gear has no grease groove and holes around its inner diameter Type Outside Diameter inches Brake Adjustment Limit inches 6 4 1 2 1 1 4 Should be as short as possible ...

Page 384: ...he grease fitting If necessary install a camshaft into the slack adjuster gear to minimize grease flow through the gear holes 6 Lubricate until new grease purges from around the inboard camshaft splines and from the pawl assembly 7 Measure the gap between the clevis and the collar on a Quick Con nect clevis Replace the clevis if the gap exceeds 0 060 inch 1 52 mm Components Meritor Specification N...

Page 385: ... VERSION BR03 1 BR03ABS ABS HYDRAULIC E VERSION BR03 001 ABS BR03 2 OVERVIEW BR03 2 COMPOSITION AND OPERATION BR03 3 FUNCTION BR03 6 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS BR03 7 OVERVIEW AND FUNCTION BR03 8 ...

Page 386: ...eels are locked it becomes impossible to steer the vehicle and if the rear wheels are locked the rear of the vehicle may fishtail from side to side Also when wheel locking occurs it is not possible to make effective use of friction between the tires and the road surface This may cause the braking distance to be increased ABS uses wheel sensors mounted on the axles to constantly monitor the rotatio...

Page 387: ...s mounted near sen sor ring on the axles are sent to the ABS ECU The ABS ECU then calcu lates the wheels rotational speed acceleration deceleration and amount of slippage based on these signals If the limit values for the wheel s deceleration or slippage ratio are exceeded the ABS ECU immediately transmits signals to the ABS modula tor to adjust any excess braking force ABS system operates as foll...

Page 388: ...es sure reduction Front left pres sure maintenance Front left pres sure reduction Rear right pres sure maintenance Rear right pres sure reduction Rear left pressure maintenance sole Rear left pressure reduction sole Exhaust brake cut relay Malfunction code diagnostic code Output signals solenoid valve solenoid valve solenoid valve solenoid valve solenoid valve solenoid valve noid valve noid valve ...

Page 389: ...orce is controlled to ensure that it is within the range where the friction coefficient is high shaded portion of the graph without locking the wheels This ensures efficient braking perfor mance OPERATION The ABS ECU calculates the wheel speed and wheel acceleration speed for each of the 4 wheels from 4 wheel sensor signals and determines the wheel slip conditions And depending on these conditions...

Page 390: ...ed off and the normal brake system is restored while ABS control continued for the other system This configuration is designed to minimize the effects of any malfunction on ABS function EXHAUST BRAKE CONTROL FUNCTION The ABS of this vehicle is equipped with a function that controls the exhaust brake while ABS is operating If the exhaust brake is applied inde pendently or in conjunction with the se...

Page 391: ... any vehicle being driven in front of you ABS does not operate when the vehicle is starting ac celerating or turning and will not assist in maintaining directional stability or steerability or in shortening the brak ing distance Even if the ABS is operational where the coefficient of friction is very low such as on an icy roadway skidding inability to steer and instability may occur because of ins...

Page 392: ...e optimal range Regardless of whether the vehicle is stopped or being driven and whether or not the brakes are being applied the circuit consisting of the wheel sen sors modulator assembly ABS ECU and wire harnesses are constantly being checked by the ABS ECU s fail safe circuit If some sort of malfunc tion occurs the fail safe circuit warns the driver by lighting the ABS warning light At the same...

Page 393: ...ABS ABS HYDRAULIC E VERSION BR03 9 SAPH068010300009 ...

Page 394: ...om the master cylinder produced when the brake pedal is depressed brake fluid is fed through port A to the wheel cylinder Brake fluid is not sent to the pump side at this time because of the check valve 1 installed on that side Then when the brake pedal is released the wheel cylinder brake fluid is returned to the master cylin der through the pressure maintenance solenoid valve port A to the Hydro...

Page 395: ... cylinder brake fluid is fed through the pressure reduc tion solenoid valve port B to the reservoir reducing the wheel cylinder fluid pressure While the ABS is in operation the ABS ECU outputs a normal operating signal to the pump which pumps out the brake fluid that accumulates in the reservoir and returns it to the Hydro booster Each Port Status ABS ECU signal Port status Pressure mainte nance s...

Page 396: ...rt A and the pressure reduction solenoid valve port B simultaneously close according to control signals from the ABS ECU This closes both the Hydro booster side and reservoir side oil routes maintaining the wheel cylinder fluid pressure Each Port Status ABS ECU signal Port status Pressure mainte nance solenoid valve ON Port A Closed Pressure reduction solenoid valve OFF Port B Closed SAPH068010300...

Page 397: ...di tion and Hydro booster brake fluid is fed to the wheel cylinder caus ing the wheel cylinder fluid pressure to rise If there is any brake fluid remaining in the reservoir at this time it is pumped out by the pump and sent to the wheel cylinder The speed of the pressure increase is controlled by combination of the pressure increase and the pressure maintenance Each Port Status ABS ECU signal Port...

Page 398: ...heels rotational status SENSOR RING The sensor rings are press fitted into the insides of the wheel hubs of each wheel or integrated in the brake rotor on the front and rear axles and they face the wheel sensors described in the preceding section The sensor rings are made of a magnetic material and teeth are cut into the surface which faces the wheel sensor at regular intervals Also when the senso...

Page 399: ...el sensors and sensor rings WARNING LIGHT The ABS is equipped with the following warning light 1 ABS WARNING LIGHT This light indicates the status of the ABS It lights once when the starter switch is turned on and automatically goes off if the ABS is functioning normally If a malfunction occurs in the ABS while the vehi cle is being driven the light comes on to alert the driver Also used as the di...

Page 400: ...ized Hino dealer ABS WIRE HARNESSES 1 Front axle ABS wire harness The wire harness that runs from the side frame to the front axle wheel sensor must absorb the steering angle of the front wheel and the movement of the chassis springs It is therefore necessary to always maintain an optimal spacing between the clips The optimal spacing between the clips is achieved when the wheel sensor connectors a...

Page 401: ... functioning of the ABS For this reason caution plates indicating LEFT and RIGHT are affixed to the wire harnesses Be sure to check when connecting the har nesses The wheel sensor wire harnesses just like the front axle har nesses must absorb the movement of the chassis springs It is therefore necessary to always maintain an optimal spacing between the clips When disassembling and re assembling co...

Page 402: ...ull with excessive force Doing so can cause the pins of the harness connectors to be deformed 4 Remove unnecessary connectors and do not plug them 5 When inspecting using a circuit tester insert the test probe from the wire harness side Never insert the test probe from the pins of harness connectors as this can cause bad contacts 6 When unplugging the harness connectors do not allow water oil dust...

Page 403: ... 5 Installation of a radio or other electronic equipment All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS ECU and wire harness as possi ble Installation of certain electronic and radio equipment can also cause the ABS ECU to malfunction All such equipment must also conform to all applicable laws If you wish to install a radio or other electronic ...

Page 404: ... BR03 002 ABS BR03 2 OVERVIEW BR03 2 COMPOSITION AND OPERATION BR03 3 FUNCTION BR03 6 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS BR03 7 OVERVIEW AND FUNCTION BR03 8 INSPECTION FRONT WHEEL BRAKE BR03 13 INSPECTION REAR WHEEL BRAKE BR03 15 ...

Page 405: ...the vehicle and if the rear wheels are locked the rear of the vehicle may fishtail from side to side Also when wheel locking occurs it is not possible to make effective use of friction between the tires and the road surface This may cause the braking distance to be increased ABS uses wheel sensors mounted on the axles to constantly monitor the rotation of the wheels If any of the wheels is startin...

Page 406: ...em Pulse signals transmitted by the sensor rings mounted on the wheel hubs rotated together with the wheels and the wheel sensors mounted near sen sor ring on the axles are sent to the ABS ECU The ABS ECU then calcu lates the wheels rotational speed acceleration deceleration and amount of slippage based on these signals If the limit values for the wheel s deceleration or slippage ratio are exceede...

Page 407: ...ght wheel sensor Rear left wheel sensor Rear right wheel sensor Exhaust brake cut relay ABS warning light Malfunction code diagnostic code ABS ECU ABS control valve for front left wheel ABS control valve for rear left wheel ABS control valve for rear right wheel ABS control valve for front right wheel SHTS068020300003 ...

Page 408: ...the wheels rotational speed the wheel acceleration decelera tion and the air pressure at the ABS control valve outlet change over time after the brakes are applied When the brakes are applied the vehicle s speed and the wheels rotational speed drop and at the same time the wheel acceleration deceleration speed also drops At point T1 a gap begins to open between the wheels rotational speed and the ...

Page 409: ... and the normal brake system is restored while ABS control continued for the other system This configuration is designed to minimize the effects of any malfunction on ABS function EXHAUST BRAKE CONTROL FUNCTION The ABS of this vehicle is equipped with a function that controls the exhaust brake while ABS is operating If the exhaust brake is applied inde pendently or in conjunction with the service ...

Page 410: ...n maintaining directional stability or steerability or in shortening the brak ing distance Even if the ABS is operational where the coefficient of friction is very low such as on an icy roadway skidding inability to steer and instability may occur because of insufficient traction by the tires Where engine braking as a result of downshifting oc curs on a surface with a low coefficient of friction s...

Page 411: ...stopped or being driven and whether or not the brakes are being applied the circuit consisting of the wheel sen sors control valves ABS ECU and wire harnesses are constantly being checked by the ABS ECU s fail safe circuit If some sort of malfunction occurs the fail safe circuit warns the driver by lighting the ABS warning light At the same time the ABS system that is experiencing the malfunc tion...

Page 412: ... 3 is closed and pilot chamber 14 is open to the atmosphere Also solenoid coil 2 is also not energized so solenoid valve 4 is closed As a result air passes through pilot hole 10 and enters pilot chamber 12 It then pushes up diaphragm 11 and closes exhaust valve 13 SHTS068020300010 Pressure increase Solenoid valve for driving inlet valve 3 Solenoid valve for driving exhaust valve 4 Time 0 Valve ope...

Page 413: ...amber 7 and acts on pilot chamber 14 On the other hand since solenoid coil 2 is not energized solenoid valve 4 is closed and air flows through pilot hole 10 and acts on pilot cham ber 12 This causes diaphragms 5 and 11 to shut off their air pas sages and the chamber 8 pressure that is to say the air acting on the brake chamber is maintained at the pressure that was current when the switch from the...

Page 414: ...tted into the insides of the wheel hubs of each wheel on the front and rear axles and they face the wheel sensors described in the preceding section The sensor rings are made of a mag netic material and teeth are cut into the surface which faces the wheel sen sor at regular intervals Also when the sensor ring performs one complete rotation the sensor generates pulse signals corresponding to the nu...

Page 415: ...ed reaches about 6 km h 4 mile h Then note that even when the warning light is lit the ABS system unaf fected by the malfunction continues to operate Also the brake whose ABS system experiences the malfunction is reverted to normal braking operation without ABS When a Diagnosis switch is turned ON this light will goes on and off which indicates defect code 8 EXHAUST BRAKE CUT RELAY When this relay...

Page 416: ...g loose from the wheel hub use a dolly block and press it in with a press again 3 INSPECTION OF THE CLAMPING BUSHING 1 Make sure that wheel sensor is securely fixed 2 Change the clamping bushing when it can be pulled off or pushed in with a weak force 4 MOUNTING THE SENSOR RING 1 Place the sensor ring on the wheel hub and use the dolly block and a press to evenly pressure mount it NOTICE Warming u...

Page 417: ...hassis grease to the hub of the wheel sensor Then push it forcefully into the clamping bushing until you feel that the wheel sensor has made contact with the sensor ring NOTICE When inserting the wheel sensor do not tap on it with a hammer or attempt to pry it into place with a screwdriver or the like Doing so could damage the wheel sensor 3 Slowly turn the wheel hub and brake drum and confirm tha...

Page 418: ...mes loose from the wheel hub use a dolly block and a press to pressure mount it again 3 INSPECTION OF THE CLAMPING BUSHING 1 Make sure that the wheel sensor is securely fixed 2 Change the clamping bushing when it can be pulled off or pushed in with a weak force 4 MOUNTING THE WHEEL SENSOR 1 Push in the clamping bushing until the stopper makes contact with the wheel sensor holder 2 Push the wheel s...

Page 419: ...or by using a round end bar until the sensor contacts with the sensor ring NOTICE Do not tap with a hammer or turn when pushing the wheel sensor This may damage the wheel sensor 4 Mount the axle shaft to the wheel hub and tighten the bolt on the axle shaft Refer to CHAPTER REAR AXLE 8 ABS WIRE HARNESSES 1 Front axle ABS wire harnesses The front axle chassis harnesses particularly the ones that pas...

Page 420: ...ABS ABS FULL AIR BR03 17 SHTS068020300032 ...

Page 421: ...f the ABS system For this reason caution plates indicating LEFT and RIGHT are affixed to the harnesses Be sure to check when connecting the harnesses The left harness is on the left side of the vehicle when viewed from the behind and facing toward the front and the right harness is on the right side of the vehicle The wheel sensor harnesses are arranged along the top of the rear axle housing There...

Page 422: ...ith excessive force Doing so can cause the pins of the harness connectors to be deformed 4 Remove unnecessary connectors and do not plug them 5 When inspecting using a circuit tester insert the test probe from the wire harness side Never insert the test probe from the pins of harness connectors as this can cause bad contacts 6 When unplugging the harness connectors do not allow water oil dust or a...

Page 423: ...tallation of a radio or other electronic equipment All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS ECU and wire harness as possi ble Installation of certain electronic and radio equipment can also cause the ABS ECU to malfunction All such equipment must also conform to all applicable laws If you wish to install a radio or other electronic equipm...

Page 424: ...UST BRAKE BR05 1 BR05EXHAUST BRAKE BR05 001 EXHAUST BRAKE SYSTEM BR05 2 SYSTEM DIAGRAM BR05 2 TROUBLESHOOTING BR05 3 ADJUSTMENT BR05 3 BRAKE CYLINDER BR05 5 DATA AND SPECIFICATIONS BR05 5 DESCRIPTION BR05 5 ...

Page 425: ...ht 11 Signal of neutral 5 Engine U2 ECU 12 Wiper and retarder switch Manual T M 6 U2 exhaust relay A From power source 7 Signal of engine stop B From air tank 8 6 10 12 5 11 7 4 A B 9 1 2 3 Manual transmission Automatic transmission and ultrashift transmission No 2 10 and 12 circuit are less Three is No 3 instead of this with automatic transmission and UltraShift transmission One point chain line ...

Page 426: ...does not conform to the standard shift the mounting position of the sensor in the direction of rotation at the long hole of the sensor for adjustment or replace the sensor with new one Specific value Units V Symptom Possible cause Remedy Prevention Switch does not work Defective contacts Check and correct Open circuit in harness Check and correct Valve does not close Valve clogged with carbon Remo...

Page 427: ...TRANSMIS SION The clutch switch should not be knocked against With the clutch pedal release the clearance between the plastic bush and the clutch switch s tip should be 0 5 1 5 mm 0 020 0 059 in Assembly standard 0 5 1 5 mm 0 020 0 059 in SHTS06Z080500004 ...

Page 428: ...A AND SPECIFICATIONS EN06Z0805I200001 DESCRIPTION EN06Z0805C100001 Type Butterfly valve 6 8 4 7 9 10 1 2 3 5 11 12 SHTS06Z080500005 1 Control cylinder 7 Body 2 Plate 8 Seal ring 3 Plate 9 Lever 4 Valve 10 Pin 5 Shaft 11 Clevis 6 Bush 12 Pin ...

Page 429: ...1 BR07PARKING BRAKE BOSCH 12 BR07 001 PARKING BRAKE ASSEMBLY BR07 2 DATA AND SPECIFICATIONS BR07 2 DESCRIPTION BR07 2 TROUBLESHOOTING BR07 3 COMPONENT LOCATOR BR07 4 OVERHAUL BR07 6 INSPECTION AND REPAIR BR07 20 ADJUSTMENT BR07 21 ...

Page 430: ...uplex Cam mechanical brake internal expanding acting type Parking brake control type Lever type control with control cable Drum inside diameter 304 8 mm 12 0 in Brake lining Width 76 2 mm 3 0 in SHTS06Z080700001 1 Parking brake lever 5 Parking brake cable 2 Knob 6 Parking brake switch 3 Brake lever bracket 7 Parking brake assembly 4 Knob cover ...

Page 431: ...er Apply system over adjusted Adjust or repair per manufacture s rec ommended procedures Brake does not release Internal damage to brake Inspect and replace damaged compo nents Apply cable bound up Check cable for corrosion binding kinks or damage The parking brake lever in the cab is binding Check the parking brake lever assem bly for damage or corrosion Repair or replace as needed Brake does not...

Page 432: ...EN06Z0807D100001 PARKING BRAKE LEVER Tightening torque Unit N m kgf cm lbf ft 1 Parking brake lever 5 Parking brake switch 2 Knob 6 Bolt 3 Brake lever bracket 7 Knob cover 4 Clevis 8 Bolt A 42 62 430 630 31 46 B 1 1 1 9 12 19 0 9 1 4 SHTS06Z080700002 ...

Page 433: ...PARKING BRAKE BOSCH 12 BR07 5 PARKING BRAKE SHTS06Z080700003 ...

Page 434: ...river through the adjusting hole to engage the adjusting nut teeth Move the teeth upward enough times to retract the brake shoes to clear the drum If the drum is rusted to the axle input flange yoke pilot tap the center of the brake drum with a nonmetallic mallet to loosen 5 Inspect the brake per the INSPECTION PROCEDURE in this service manual 6 Detach adjuster cable from adjuster lever slide cabl...

Page 435: ...r to allow easier access to the spring on the lever side NOTICE If the brake is a Release 2 level design with a lever guide present it will need to be removed to provide access to the spring underneath with the tool shown in Figure 9 Upon removal of the hold down springs the shoes and the adjuster nut screw assembly will fall if not secured by hand 10 Remove brake shoes from backing plate 11 Disas...

Page 436: ...juster nut and the socket ends of the adjuster nut and install the screw fully into the adjuster nut Insure the screw moves in and out freely If any damage to the threads prohibits free movement or if the starwheel is damaged replace adjuster assembly See Figure 4 NOTICE Only use the approved lubricants as specified Do not substitute When installing new shoes make sure the shoe with the adjuster c...

Page 437: ...Figure 6 11 The shoe cage should be adjusted now per the SHOE CAGE ADJUSTMENT PRIMARY procedure or after the drum has been rein stalled per the SHOE CAGE ADJUSTMENT ALTERNATE procedure in this service manual 12 Make a final inspection of the shoe linings and the inside of the drum to ensure that no grease or other contamination was accidentally applied WARNING Keep grease and other foreign materia...

Page 438: ...BOSCH 12 BR07 10 14 Lower the vehicle and test the brake for proper function before return ing the vehicle for service use If necessary make adjustments per the vehicle manufacturer s service manual SHTS06Z080700009 ...

Page 439: ...tate the axle input flange yoke as necessary to provide clearance for the measurement caliper 3 Place the pre adjusted caliper over the shoes at the center of the shoes 4 To adjust brake rotate the starwheel until the shoes touch the mea surement caliper jaws It is necessary to disengage the adjuster lever away from the starwheel See Figure 7 NOTICE During adjustment the calipers should be moved u...

Page 440: ...rect access through the access slot to the adjuster lever In these cases an adjuster lever tool can be made from 3 32 diameter welding filler rod See Figure 10 2 Insert the adjuster lever tool or a thin flat bladed screw driver through the adjusting slot in the backplate and push on the adjuster lever to disengage it from the adjuster starwheel Insert a brake adjusting tool or flathead screwdriver...

Page 441: ...CTING THE BRAKE SHOES LOOSEN BRAKE NOTICE Some vehicles may not have enough clearance behind the park brake to have direct access through the access slot to the adjuster lever In these cases an adjuster lever tool can be made from 3 32 inch diame ter welding filler rod See Figure 10 SHTS06Z080700012 ...

Page 442: ...he adjuster lever from the adjuster nut starwheel teeth With adjuster lever disengaged as shown in Figures 8 and 9 insert a brake adjust ing tool or screw driver through the adjusting hole to engage the adjusting nut teeth Move the teeth upward enough times to retract the brake shoes to clear the drum If the drum is rusted to the axle input flange yoke pilot tap the center of the brake drum with a...

Page 443: ...ebris from anchor post hole NOTICE For brakes with a hex socket head anchor screw use an M10 x 1 5 tap brakes manufactured prior to April 2002 For brakes with an external hex head anchor screw use and M12 x 1 75 tap brakes manufactured after April 2002 2 Apply Chevron heavy duty lithium complex extreme pressure grease or equivalent to the cam plate lugs where they contact the shoes and the apply l...

Page 444: ...ent proper functioning of the brake selfadjust feature 4 Tighten the anchor screw per the appropriate specification For the internal hex socket anchor screw tighten to 50 3 Nm 37 2 ft lbs For the external hex head anchor screw tighten to 100 10 Nm 74 7 ft lbs CAUTION To tighten the anchor screw only use a recently calibrated known good clicker type torque wrench set to the correct torque specifica...

Page 445: ...grease and other foreign materials away from the shoe lining and drum surfaces Contamination of shoe linings or drum surface may result in degradation of brake holding capability possibly result ing in personal injury or property damage 9 Inspect service then reinstall drum per the vehicle manufacturer s service manual 10 Lower vehicle and remove the blocks or wheel chocks from the front wheels 11...

Page 446: ... and anchor screw See section on ANCHOR SCREW LEVER AND CAM REPLACEMENT for service details 6 Inspect various springs and hold down pins Figure 13 for excessive wear heat discoloration heavy corrosion or other damage and replace as necessary See section on SHOE REPLACEMENT for ser vice WARNING Whenever possible work on brakes in a separate area away from other operations Always wear a respirator a...

Page 447: ...unevenly has deep grooves heavy corrosion or excessive runout 10 Inspect the parking brake lever apply cable for excessive wear or damage and replace as necessary 11 Inspect the axle pinion oil seal for leakage that can contaminate the park brake system parts and repair as necessary See the section REAR AXLE for details 12 After a thorough inspection if the brake and its components are found to be...

Page 448: ...ECTION AND REPAIR EN06Z0807H300001 Unit mm in Inspection item Standard Limit Remedy Inspection procedure Brake lining Lining thickness 7 00 0 277 0 76 0 03 Replace Measure Brake drum Inside diameter 304 8 12 305 7 12 035 Replace Measure ...

Page 449: ...on on the cable 3 Confirm that the male thread end of a turnbuckle is fitted into the female thread more than 12 7 mm 0 5 in 4 Check that there is no drag feeling of the brake with parking lever released 5 Check proper working holding and cancellation of parking brake by actually operating the parking brake lever 3 BRAKE BURNISHING 1 Burnishing of lining When replacing lining or drum of parking br...

Page 450: ...KE BOSCH 12 BR07 22 2 Confirmation of parking brake application After completing all brake adjustment stop the vehicle on a safe slope or using a brake tester confirm whether the parking brake is securely applied ...

Page 451: ...Pub No S1 UNAE11A 1 2 13 11 Hino Motors Sales U S A Inc PRINTED IN JAPAN 41180 Bridge Street Novi MI 48375 Telephone 248 699 9300 ...

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