PREVOST LE MIRAGE XLII BUS SHELLS Maintenance Manual Download

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COACH MANUFACTURER

MAINTENANCE MANUAL

LE MIRAGE XLII

BUS SHELLS

PA1564

EDITION)

Summary of Contents for LE MIRAGE XLII BUS SHELLS

Page 1: ...COACH MANUFACTURER MAINTENANCE MANUAL LE MIRAGE XLII BUS SHELLS PA1564 1ST EDITION...

Page 2: ...PA1564 1st edition Date July 2007 Starting from vehicle 8 9277 Featuring DDC S60 2007 engine with Aftertreatment System...

Page 3: ...Number VIN 6 5 FASTENER STRENGTH IDENTIFICATION 8 5 1 SELF LOCKING FASTENERS 9 5 2 RECOMMENDATIONS FOR REUSE 9 5 3 SIX LOBED SOCKET HEAD 9 ILLUSTRATIONS FIGURE 1 DETROIT DIESEL SERIES 60 5 FIGURE 2 A...

Page 4: ...ges at any time without notice NOTE Typical illustrations may be used therefore minor illustration difference may exist when compared to actual parts or other publications Pr vost Car occasionally sen...

Page 5: ...ss o Welding rod conforms to A5 1 of AWS American Welding Society specifications E 7018 type welding rod with 1 8 diameter 3 2 mm o Current 100 amperes to 150 amperes optimum at 120 amps It is importa...

Page 6: ...utlined by the wording and symbols DANGER Directs the operator s attention to unsafe practices which could result in serious personal injury or death WARNING Directs the operator s attention to unsafe...

Page 7: ...cated on a tag on the pump Fig 5 The pump is mounted on the engine beside the crankshaft pulley FIGURE 5 POWER STEERING PUMP NAMEPLATE 00035 4 1 6 Coach Final Record The Coach Final Record is a record...

Page 8: ...ations Fig 7 It gives the operating conditions under which certification was made FIGURE 7 ENGINE COMPARTMENT 00173 4 1 10 Fuel Tank Label The fuel tank label is molded on the side of the fuel tank To...

Page 9: ...Section 00 GENERAL INFORMATION PA1564 7 FIGURE 9 VEHICLE IDENTIFICATION NUMBER 00050 YEAR CODE YEAR CODE 2000 Y 2006 6 2001 1 2007 7 2002 2 2008 8 2003 3 2009 9 2004 4 2010 A 2005 5 2011 B...

Page 10: ...he same or greater strength than the original fasteners the same number marking or higher It is also important to select replacement fasteners of the correct size Correct replacement fasteners are ava...

Page 11: ...lops torque per the chart in table two If there is any doubt replace with a new self locking fastener of equal or greater strength e Tighten the fastener to the torque specified in the applicable sect...

Page 12: ...Section 00 GENERAL INFORMATION 10 PA1564 FIGURE 13 METRIC US STANDARD CONVERSION TABLE 00005...

Page 13: ...Section 00 GENERAL INFORMATION PA1564 11 FIGURE 14 CONVERSION CHART 00006...

Page 14: ......

Page 15: ...ules Wear safety goggles Set the battery master switch to the OFF position first Recommendations This procedure should be performed by qualified personnel only Effective Revision 0 Issued with multipl...

Page 16: ...es VIP 1 00 Location Main power compartment and dashboard Set the battery master switch to the OFF position Place the ignition switch to the OFF position 1 05 Location Main power compartment Trip circ...

Page 17: ...he electronic ground terminals from the stud Using electric tape insulate the 2 largest gage wires Make sure the ring terminals do not touch each others and the vehicle body NOTE With disconnection of...

Page 18: ...or C717 Unplug 3 connectors per I O B modules Unplug 3 connectors on the I O A module 1 15 1 20 Location Front electrical compartment VIP COACH Disconnect the I O A I O B ABS master ID CECM and CPC mo...

Page 19: ...PROCEDURE NO PR060034 REVISION 3 Page 5 of 15 Unplug 1 connector from the master ID Disconnect CPC connectors Unplug 3 connectors from the CECM Unplug connector C92...

Page 20: ...Location pneumatic accessory panel inside right console Remove the access panel on the right console R H side of dashboard Disconnect both I O B modules 1 30 Location Evaporator compartment Remove th...

Page 21: ...ou can do welding on the vehicle ENSURE THAT THE WELDING GROUND RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE CHASSIS LOCATED NEAR THE WELDING POIN...

Page 22: ...r electrical compartment and dashboard Set the battery master switch to the OFF position Place the ignition switch to the OFF position 2 05 Location Rear electrical compartment Trip circuit breakers C...

Page 23: ...s and the vehicle body NOTE With disconnection of the electronic ground terminals disconnecting the engine ECM transmission TCM and the dashboard electronic components telltale module HVAC module radi...

Page 24: ...partment Disconnect I O A I O B ABS master ID CECM and CPC modules and also disconnect connector C92 Disconnect the 3 connectors from the I O B and I O A modules Disconnect the 2 connectors from the A...

Page 25: ...evious steps are done you can do welding on the vehicle ENSURE THAT THE WELDING GROUND RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE CHASSIS LOCATE...

Page 26: ...on in to open the circuit 2 10 Location Rear Junction Box Disconnect the electronic ground terminals from this stud Warning The remaining terminals may still be energized Use electric tape make sure t...

Page 27: ...ransmission module A1 Disconnect 3 connectors from each I O B Disconnect 3 connectors from each I O A Location Front Electrical Compartment Disconnect I O A I O B ABS master ID CECM CPC keyless module...

Page 28: ...PROCEDURE NO PR060034 REVISION 3 Page 14 of 15 Disconnect connectors from CPC Disconnect connector from master ID Disconnect 3 connectors from CECM Disconnect connector C92...

Page 29: ...the vehicle ENSURE THAT THE WELDING GROUND RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE CHASSIS LOCATED NEAR THE WELDING POINT AS MUCH AS POSSIBL...

Page 30: ......

Page 31: ...Check Engine Telltale Light Awl 7 4 1 2 Stop Engine Warning Light Rsl 8 4 1 3 Stop Engine Override Switch Seo 8 4 1 4 Diagnostic Data Link Ddl Connectors 8 4 2 READING DIAGNOSTIC CODES FLASHING LIGHT...

Page 32: ...PC 6 FIGURE 5 THE CPC COMMUNICATES OVER THE J1587 AND J1939 DATA LINKS TO THE VEHICLE 6 FIGURE 6 ELECTRONIC FOOT PEDAL ASSEMBLY 7 FIGURE 7 FLASHING FAULTS CODES 8 FIGURE 8 ENGINE OIL LEVEL DIPSTICK 27...

Page 33: ...Diesel Electronic Control is a system that monitors and determines all values required for the operation of the engine A diagnostic interface is provided to connect to an external diagnosis tester Bes...

Page 34: ...fuel filter 7 Fuel pump 8 Air compressor 9 Engine oil filling tube 10 Bosch alternators 2 11 Engine oil dipstick 12 EGR delta pressure sensor 13 EGR valve 14 Intake throttle 15 EGR mixer 16 Intake man...

Page 35: ...GR pressure for EGR control EGR Temperature Sensor Senses EGR exhaust temperature after EGR cooler Used for EGR system diagnosis Engine Coolant Temperature Sensor ECT Sensor Senses coolant temperature...

Page 36: ...roit Diesel Reprogramming must be done at a Detroit Diesel authorized service center However some changes may be performed to the cruise control and road speed limiter using a diagnostic data reader s...

Page 37: ...1 DIAGNOSTIC SYSTEM Diagnostics is a standard feature of DDEC VI The purpose of this feature is to provide information for problem identification and problem solving in the form of a code The MCM and...

Page 38: ...e DDEC system operation For more information see Detroit Diesel Troubleshooting Guide 6SE492 4 2 READING DIAGNOSTIC CODES FLASHING LIGHT METHOD DDEC VI makes use of two types of codes Active and inact...

Page 39: ...234 2112 J1939 Park Brake Switch Signal from Source 2 is missing 70 19 SID 234 2112 J1939 Park Brake Switch Signal from Source 3 is erratic 70 13 SID 234 2112 J1939 Park Brake Switch Signal from Sourc...

Page 40: ...Oil Level Very Low 100 18 PID 100 2121 Oil Pressure Low 100 1 PID 100 2121 Oil Pressure Very Low 107 0 PID 107 2122 Air Filter Restriction High 107 4 PID 107 2122 Air Filter Signal Circuit Failed Low...

Page 41: ...5 J1939 CCVS Message from Source 3 is missing 558 2 SID 230 2134 Idle Validation Switch Inputs Reversed 558 5 SID 230 2134 Idle Validation Switch 2 Circuit Failed Low 558 6 SID 230 2134 Idle Validatio...

Page 42: ...600 13 SID 243 2143 J1939 Cruise Control Coast Switch Signal from Source 3 is missing 602 19 SID 242 2144 J1939 Cruise Control Accelerate Switch Signal from Source 1 is erratic 602 13 SID 242 2144 J1...

Page 43: ...30 13 SID 253 2152 SCR Number Out of Range 630 14 SID 155 2615 MCM Fault Codes Unavailable via J1939 and J1587 630 14 SID 155 2615 MCM Fault Code Table Inconsistant Upgrade MCM Software 630 14 SID 155...

Page 44: ...ircuit Failed High 714 4 SID 262 2235 Digital Output 3 08 Circuit Failed Low 714 5 SID 262 2235 Digital Output 3 08 Open Circuit 715 3 SID 263 2241 Digital Output 4 10 Circuit Failed High 904 9 SID 23...

Page 45: ...211 2333 Accelerator Pedal Supply Voltage Circuit Failed Low 3510 4 SID 211 2333 Pwm Accelerator Pedal Supply Voltage Missing 3510 3 SID 211 2333 Accelerator Pedal Supply Voltage Circuit Failed High 3...

Page 46: ...essure Circuit Failed Low 100 3 PID 100 1114 Engine Oil Pressure Circuit Failed High 100 1 PID 100 1114 Engine Oil Pressure Low 100 2 PID 100 1114 Oil Pressure Plausibility Engine Running 100 2 PID 10...

Page 47: ...mperature Sensor Circuit Failed High 412 4 PID 412 1233 EGR Temperature Sensor Circuit Failed Low 412 20 PID 412 1233 EGR Temperature Drift High Box 412 21 PID 412 1233 EGR Temperature Drift Low Box 4...

Page 48: ...ng and Safety Unit Valve Seals Check 615 14 SID 155 1615 High Pressure Pump Leakage or TDC Position Wrong 615 4 SID 155 1615 Flap In Front of EGR Cooler Circuit Failed Low 615 3 SID 155 1615 Flap In F...

Page 49: ...rankshaft Position Sensor Open Circuit 636 4 SID 21 1235 Crankshaft Position Sensor Short to Ground 636 8 SID 21 1235 Crankshaft Position Sensor Time Out 636 14 SID 21 1235 Crankshaft Position Sensor...

Page 50: ...4 Value Out of Range 655 14 SID 5 1251 Injector Cylinder 5 Needle Control Valve Abnormal Operation 655 10 SID 5 1251 Injector Cylinder 5 Needle Control Valve Abnormal Rate of Change 655 5 SID 5 1251...

Page 51: ...Failed Open 1072 4 SID 79 1422 Jake Brake Stage 1 Circuit Failed Low 1072 3 SID 79 1422 Jake Brake Stage 1 Circuit Failed High 1072 5 SID 79 1422 Jake Brake Stage 1 Circuit Failed Open 1073 4 SID 80 1...

Page 52: ...d 1351 4 SID 155 1615 Switchable Air Compressor Circuit Failed Low 1351 3 SID 155 1615 Switchable Air Compressor Circuit Failed High 1351 5 SID 155 1615 Switchable Air Compressor Circuit Failed Open 1...

Page 53: ...Position Error 2797 4 SID 317 1523 Injector Needle Control Valve Cylinder 1 2 3 Shorted to Ground 2797 4 SID 317 1524 Injector Needle Control Valve Cylinder 4 5 6 Shorted to Ground 2797 4 SID 317 161...

Page 54: ...ID 51 1541 Intake Throttle Valve Spring Response Time Not Plausible 3464 7 PID 51 1541 Intake Throttle Valve Stuck 3464 14 PID 51 1541 Intake Throttle Valve Integrated Absolute Error Plausibility 3464...

Page 55: ...ure Sensor Drifted Low In Range Fault Low Box 3609 21 SID 370 1554 DPF Inlet Pressure Sensor Drifted Low In Range Fault High Box 3610 3 SID 371 1555 DPF Outlet Pressure Circuit Failed High 3610 4 SID...

Page 56: ...1625 DPF Ash Clean Request 3720 16 SID 155 1625 DPF Ash Clean Request Derate 4076 4 PID 110 1212 Engine Coolant Inlet Temperature Circuit Failed Low 4076 3 PID 110 1212 Engine Coolant Inlet Temperatu...

Page 57: ...n authorized Detroit Diesel service outlet for the cause Fuel or coolant dilution of lube oil can result in serious engine damage The vehicle may be provided with an oil reserve tank in the engine com...

Page 58: ...filter adapter with a clean rag 6 Lightly coat the filter gasket seal with clean engine oil 7 Install the new filter on the adapter and tighten manually until the gasket touches the mounting adapter...

Page 59: ...t assembly includes the engine transmission including retarder if so equipped air compressor alternator and transmission oil cooler Remove the power plant assembly as follows CAUTION Tag hoses and cab...

Page 60: ...nect the steel braided airline from the A C compressor air bellows 19 Remove the power steering pump leaving the supply and discharge hoses connected to it Fig 12 20 Disconnect the oil delivery hose f...

Page 61: ...Shaft Removal 34 Inspect the power plant assembly to ensure that nothing will interfere when sliding out the cradle Check for connections or hoses not mentioned in this list as some vehicles are equip...

Page 62: ...M 5 Start engine for a visual check Check fuel oil cooling pneumatic and hydraulic system connections for leakage Test operation of engine controls and accessories 10 VALVE COVER REMOVAL Refer to the...

Page 63: ...SECTION 01 ENGINE PA1564 33 FIGURE 13 POWER PLANT CRADLE INSTALLATION 01140...

Page 64: ...causes battery cables improperly connected fuse blown faulty battery equalizer activate the DDEC self diagnostic system and contact your Detroit Diesel service center engine does not rotate what is th...

Page 65: ...ng system Contact Detroit Diesel or Pr vost Action Service step 3 see note 2 note 2 see the analog voltage indicator on the dashboard or consult the MCD Message Center Display on the telltale panel Se...

Page 66: ...ter elements Make AC Rochester Div GMC 25014505 Make A C Filter PF 2100 Type Full Flow Pr vost number 510458 Torque specification Engine oil filter Tighten 2 3 of a turn after gasket contact Filters E...

Page 67: ...ary Fuel Tank if so equipped 8 5 1 3 Transverse Fuel Tank 9 5 2 TANK INSTALLATION 9 5 3 FUEL TANK VERIFICATION 10 5 4 POLYETHYLENE FUEL TANK REPAIR 10 6 PRIMING FUEL SYSTEM 11 7 FUEL PUMP INSTALLATION...

Page 68: ...GURE 6 DAVCO FUEL PRO 382 FUEL FILTER 7 FIGURE 7 DAVCO FUEL PRO 382 EXPLODED VIEW 7 FIGURE 8 208 US GAL MAIN FUEL TANK 90 US GAL AUXILIARY FUEL TANK OPTIONAL W5 9 FIGURE 9 250 US GALLONS FUEL TANKS MA...

Page 69: ...one replaces the primary fuel filter Leaving the pump under pressure the fuel flows through a secondary fuel filter and a shut off valve then to the cylinder head The fuel reaches the injectors in the...

Page 70: ...extent clamps and ties can fatigue with age To ensure continued proper support inspect fasteners frequently and tighten or replace them as necessary Refer to the schematic diagram of the fuel system F...

Page 71: ...diesel fuel or motor oil and place it in bowl groove 5 Screw new filter element onto bowl snugly by hand CAUTION Do not use tool to tighten Tighten by hand only 6 Lubricate filter seal with clean dies...

Page 72: ...an fuel oil about two thirds 2 3 Apply a thin coat of clean fuel oil on gasket 5 Install new filters Tighten until filter is snug against the gasket with no side movement Rotate an additional 1 2 turn...

Page 73: ...clean After ensuring the seal is properly positioned at the base of the cover install the cover and collar onto the fuel processor Tighten the collar by hand until secure 10 Fill the cover full of cl...

Page 74: ...hicles equipped with a transverse tank or an auxiliary tank drain it as well since it is directly connected to the main tank It is possible to drain both tanks through only one plug but the other tank...

Page 75: ...eath the vehicle unscrew the bolt on left and right hand side securing the tank foot Unscrew the two screws at the center of the tank then disconnect the two hoses previously joining the tanks 3 Unscr...

Page 76: ...body at the recommended jacking points 5 4 POLYETHYLENE FUEL TANK REPAIR NOTE Fuel level must be lower than perforation to carry out this procedure DANGER Park vehicle safely apply parking brake stop...

Page 77: ...the elements onto the adaptor inserts until the gaskets make full contact with the adaptor head and no side movement is evident Tighten filters an additional one half turn by hand or as indicated on...

Page 78: ...ry to avoid fouling the engine s Aftertreatment Device ATD Improper fuel use will reduce the efficiency of the engine s Aftertreatment System and may permanently damage the system CAUTION Owners of 20...

Page 79: ...care should be taken when installing air cleaner assembly The pre filter should be installed snugly in the air duct and clamped tightly to the air cleaner inlet to prevent any dust infiltration into t...

Page 80: ...n regarding the DDR see 01 ENGINE in this manual check the throttle counts at idle and full throttle positions Proper pedal output should be 20 30 counts at idle and 200 235 at full throttle If adjust...

Page 81: ...ilter Water Separator Element Prevost number 510795 Racor Primary Fuel Filter Water Separator optional May be used instead of regular primary filter never use with a primary filter Make Racor Type Rep...

Page 82: ...1 2 turn after gasket contact Fuel tank Capacity Standard W5 208 US gallons 787 liters Standard WE 250 US gallons 945 liters Optional W5 90 US gallons 341 liters Air Cleaner Make Nelson Prevost Numbe...

Page 83: ...ASSEMBLY 5 3 1 DIFFUSER ADJUSTMENT 5 3 2 MAINTENANCE 6 3 3 DIFFUSER ADAPTER 6 ILLUSTRATIONS FIGURE 1 EXHAUST SYSTEM 2 FIGURE 2 FLEXIBLE COUPLING 3 FIGURE 3 AFTERTREATMENT DEVICE ATD 3 FIGURE 4 OPENING...

Page 84: ...leaking exhaust system could allow toxic gases to enter the vehicle Damage to surrounding components from hot gases could result as well Replace damaged or corroded exhaust components immediately Ins...

Page 85: ...until DPF ash cleaning is required This information is stored in DDEC VI and will be accessible by using the Detroit Diesel Diagnostic Link This allows you the opportunity to plan for the DPF ash cle...

Page 86: ...DPF compartment access door and lift the door open 3 Hold the door open by inserting the support rod s free end into the receptacle located on the left side of the DPF CAUTION After inserting the supp...

Page 87: ...up to 1200 F 650 C at the DPF outlet The diffuser decreases the exhaust gasses temperature to 475 F 246 C approximately at 6 inches above the diffuser The diffuser is an important component of the exh...

Page 88: ...ntervals inspect diffuser grille for stress cracking Check for proper functioning of the rain cap inside the diffuser housing make sure that it moves freely Make sure that the water drain tube is not...

Page 89: ...Inhibitor Test Procedures 8 5 7 COOLANT RECOMMENDATIONS 8 5 7 1 Coolant Not Recommended 9 5 7 2 Additives Not Recommended 9 5 7 3 Vehicles Without Coolant Filters 9 5 7 4 Vehicles With Coolant Filter...

Page 90: ...5 FIGURE 7 CHARGE AIR COOLER HOSE CLAMPS 6 FIGURE 8 THERMOSTAT HOUSING IMAGE DDC 6 FIGURE 9 SURGE TANK SIGHT GLASS 7 FIGURE 10 HEATER LINE SHUTOFF VALVES W5 9 FIGURE 11 HEATER LINE SHUTOFF VALVES WE...

Page 91: ...s below normal operating temperature the closed thermostats direct coolant flow from the thermostat housing through the by pass tube to the water pump Coolant is recirculated through the engine to aid...

Page 92: ...a coolant filter Coolant must be discarded in an environmentally safe manner 2 1 VEHICLES WITHOUT COOLANT FILTERS Refer to Nalcool 3000 with Stabil Aid bulletin annexed to the end of this section for...

Page 93: ...lean pipe connections and apply a thin layer of a non hardening sealing compound Replace worn out clamps or clamps that pinch hoses 3 1 CONSTANT TORQUE HOSE CLAMPS ON COOLANT LINES All hose clamps of...

Page 94: ...gular basis During vehicle operation and shutdown the screw tip will adjust according to the temperature and pressure changes Checking for proper torque should be done at room temperature 4 THERMOSTAT...

Page 95: ...dly rises Coolant must therefore be carefully selected and properly maintained Select and maintain coolant in order to meet the following basic requirements Provide for adequate heat transfer Provide...

Page 96: ...to check engine coolant for nitrite concentration Nitrite concentration is an indication of Supplemental Coolant Additive SCA level Nitrite must be maintained within recommended levels Coolant must b...

Page 97: ...ed cooling system can result in severe burns from the expulsion of hot coolant fluid 5 7 3 Vehicles Without Coolant Filters Refer to Nalcool 3000 with Stabil Aid bulletin annexed to the end of this se...

Page 98: ...MP DRAIN PLUG 05093 6 Open engine drain cock 7 Remove the transmission oil cooler Drain flush and inspect Refer to Section 7 TRANSMISSION for oil cooler maintenance or preventive replacement CAUTION D...

Page 99: ...ollows 1 Drain the coolant from the engine 2 Refill with clean water CAUTION If the engine is hot fill slowly to prevent rapid cooling and distortion of the engine castings 3 To thoroughly circulate t...

Page 100: ...flushing gun in the hose 4 Turn on the water until the jackets are filled and then turn on the air in short blasts Allow jackets to fill with water between air blasts 5 Continue flushing until the wa...

Page 101: ...ntial that the radiator core be kept clean and free from corrosion and scale at all times 10 1 MAINTENANCE MAINTENANCE Inspect the exterior of the radiator core every 25 000 miles 40 000 km or once a...

Page 102: ...t shaft is the same as removal but in reverse order FIGURE 18 TIGHTENING SPECIFICATION 05123A 12 2 IDLER REPLACEMENT If an idler is defective replace as follow WARNING Set the ignition to the OFF posi...

Page 103: ...al control system malfunction and the engine is overheating execute the following procedure 1 Set the ignition key to the ON position 2 Activate the dashboard Telltale Light Test switch 3 times within...

Page 104: ...cooling system performance 7 When questions arise obtain answers before proceeding Assistance is available through the authorized Field Sales distributor serving your area 13 3 INSPECTION DANGER Set t...

Page 105: ...o drain into a suitable container 4 Replace the seal and screw the drain plug back in torque 26 lbf ft 5 Unscrew and remove the side filler plug 6 Unscrew and remove the top filler plug 7 Add gear lub...

Page 106: ...Accident Risk Always use extreme caution when working in the vicinity of hot rotating or moving parts FIGURE 25 DRIVE BELT ROUTING 05137 1 Wrap the new drive belt around the fan drive mechanism pulley...

Page 107: ...evost Number 685125 DDC Power Cool 23512138 Prestone Heavy Duty AF977 bulk 72702 3 78 L 70119 205L 70102 4L Corrosion Inhibitor and Coolant Stabilizer Supplier number Detroit Diesel 23507857 Supplier...

Page 108: ......

Page 109: ...innig com Mail webinfo linnig com Reparaturanleitung LINNIG Drehschwingungsd mpfer LDD au er LDD12 Austausch Gummid mpfer 127 032 mit EB0112 Repair instructions LINNIG Torsional vibration damper LDD e...

Page 110: ...27 032 Gummid mpfer Rubber damper Amortiguadores de goma 3 65 003 IN STAR LIKO Schraube IN STAR LIKO screw Tornillo IN STAR LIKO Attention Beause of differnt versions of the torsional vibration damper...

Page 111: ...4 tornillos M5 o 3 tornillos M6 IN STAR LIKO de la tapa de la polea 1 Remove 4 socket head cap screws M5 resp 3 IN STAR LIKO screws M6 on the cover 1 4 Zyl Schrauben M5 bzw 3 IN STAR LIKO Schrauben M6...

Page 112: ...ew IN STAR LIKO screws 65 003 M6 on the pulley Tighening torque Ma 10 Nm 7 5 lbs ft 7 Deckelmontage Bei LK 4 90 4 neue Zyl Schrauben 50 002 M5 mit Loctite 270 versehen und Deckel an Riemenscheibe ansc...

Page 113: ...16 3 5 3 Load Test 16 3 5 4 Testing Battery Cables 17 3 6 BATTERY CHARGING 18 3 6 1 Battery Charging Guide 19 3 6 2 Emergency Jump Starting With Auxiliary Booster Battery 19 3 7 CLEANING AND INSPECTI...

Page 114: ...9 1 5 Front Turn Signal 40 9 1 6 Optional Xenon Headlamp 40 9 2 STOP TAIL DIRECTIONAL BACK UP AND HAZARD WARNING LIGHTS 41 9 2 1 Lamp Removal and Replacement 41 9 2 2 Center Stoplights and Cyclops Li...

Page 115: ...H ALTERNATORS INSTALLATION 34 FIGURE 20 ALTERNATORS AND ACCESSORIES MOUNTING TORQUES 34 FIGURE 21 BOSCH 24V 140A WITH SMALL HVAC SYSTEM 35 FIGURE 22 BOSCH 24V 140A WITH CENTRAL HVAC SYSTEM 35 FIGURE 2...

Page 116: ...Circuit breaker code o Connector code o Diode number code o Resistor number code o Fuse code 1 1 1 Using Wiring Diagram Three methods are used to work with electric wiring diagrams Situation You have...

Page 117: ...specific size as designated on the wiring diagram When replacing a wire the correct size must be used Never replace a wire with one of a smaller size The vehicle electrical system is provided with dif...

Page 118: ...cuit manually to do so simply press down the blue tab on breaker to trip the circuit breaker repair defective circuit and afterwards toggle yellow lever upwards to reset the circuit breaker and close...

Page 119: ...to the OFF position If the vehicle will not be operated for a long period more than 2 weeks it is recommended in order to prevent the batteries from discharging to trip main circuit breakers 1 and 2 l...

Page 120: ...TOR TOOL Prevost 683766 Using a small flat blade screwdriver open both hinged secondary locks Insert the extractor on the front of the connector over the terminal cavity Remove the terminal by disenga...

Page 121: ...ion 06 ELECTRICAL PA1564 9 2 XLII MOTORHOMES ELECTRICAL COMPARTMENTS AND JUNCTION BOXES FIGURE 3 ELECTRICAL COMPARTMENTS XLII 45E BUS SHELLS 06648 FIGURE 4 ELECTRICAL COMPARTMENTS XLII 45 BUS SHELLS 0...

Page 122: ...Unlock 24V Door lock Unlock R11 R17 Not Used 12V wake up mode R32 24V Door lock Unlock R21 R25 Emergency Engine ECM R33 24V Door lock Unlock Fuses F50 Delco Regulator F71 Spare F51 24VD Customer F72 1...

Page 123: ...nt R H side area Fig 6 They are accessible through engine R H side door and can be identified as follows 1 Distribution CB1 150 A 12 volts 2 Distribution CB2 50 A 24 volts 3 Front Distribution CB3 70...

Page 124: ...aster ID ZF Steering Ctrl A44 A45 I O B I O B A31 A36 Keyless CECM A46 A72 I O B CPC Relays R18 24V Wake up mode R22 Engine ECU Power R19 12V Wake up mode Fuses F1 CECM Power F24 Mirror F2 Front start...

Page 125: ...llow small amounts of gases produced in the battery to escape The special chemical composition inside the battery reduces gassing to a very small amount at normal charging voltages Besides reducing ga...

Page 126: ...battery relays are turned to the OFF position all electrical supply from the batteries is cut off with the exception of the following items o Battery equalizer check module o ECM o Transmission Contr...

Page 127: ...TTERY RATING Each of the 12 volt batteries used on the vehicle has the following rating o Reserve capacity 195 minutes o Cold cranking amps 950 0o F 18o C o Weight filled 59 lb 26 7 kg The reserve cap...

Page 128: ...ttery should be tested as described in this section On rare occasions the test indicator may turn light yellow In this case the integral charging system should be checked Normally the battery is capab...

Page 129: ...rgized during these tests afterward toggle yellow lever upwards to reset the circuit breakers 1 Check voltage drop between grounded negative battery terminal and vehicle frame by placing one prod of t...

Page 130: ...battery cables NOTE If this connection cannot be made because of the alligator clamp design the load value for testing must be reduced from 290 to 260 amperes On rare occasions such as those that occu...

Page 131: ...s will require a much longer period of charging than a charger that can supply 30 amperes or more 3 6 2 Emergency Jump Starting With Auxiliary Booster Battery DANGER Do not jump start vehicles equippe...

Page 132: ...of the boosted vehicle NOTE Jumper cables must withstand 500 cranking amperes If cable length is 20 feet 6m or less use 2 0 AWG gauge wires If cable length is between 20 30 feet 6 9m use 3 0 AWG wire...

Page 133: ...roper charging of a run down battery or loose hold down clamp bolts 7 High resistance connections or defects in the cranking system 3 10 BAT BATTERY VOLTAGE INCORRECT TELLTALE LIGHT If the BAT battery...

Page 134: ...s symbol in the wiring diagram Before taking voltage readings to track the source of a problem first verify if the module is supplied by 12V or 24V if not residual voltage on the module inputs outputs...

Page 135: ...s verification of the sensors at the rear of the vehicle Certain inputs are doubled ex turn signal switch on multi function lever and also other inputs activate at the same time For these inputs 2 bee...

Page 136: ...n 4 seconds o Push the ON OFF button on the driver s side HVAC control module 5 times that makes 3 transitions from OFF to ON o A beep can be heard indicating the motor test mode has started Using the...

Page 137: ...sor clutch activated 3 times 5 seconds delay o Radiator fan clutch is disengaged fan can be turned freely by hand 3 seconds delay o Fan clutch engages in speed 1 fan can be turned by hand but with a c...

Page 138: ...m Front electrical compartment Evaporator compartment Rear Junction Box Plug Connector 563589 Socket Connector 563590 Plug with integrated Termination Resistor 563593 C5S C13S C5 C1 C1S C3 C3S C100 C1...

Page 139: ...the engine MCM is powered and get the ignition signal Check replace fuse F78 and F79 None of the Multiplexed functions are operating including the basic limp home functions door opening flashers wipe...

Page 140: ...anually control the temperature by playing with the cabin passenger set point Set above 22 C 72 F to heat and below 22 C 72 F to cool Defroster fan not functioning Windshield wipers not functioning in...

Page 141: ...these symptoms 2 Check reset circuit breaker CB1 3 Check replace fuse F33 and F34 4 Probe gray connector on module to see if it is powered Low beam headlights and flasher on right side not functionin...

Page 142: ...ker CB4 tripped Module A54 is not powered or is faulty 1 Check reset circuit breaker CB4 2 Check the SYSTEM DIAGNOSTIC menu of the message center display MCD Select FAULT DIAGNOSTIC and ELECTRICAL SYS...

Page 143: ...ns OFF and stays OFF until the soft fuse is reset Turn the ignition key to the OFF position and turn to the ON position again This resets all soft fuses No backlighting in the instrument cluster Circu...

Page 144: ...ORITY MODULES FOR BREAKDOWN SERVICE Modules A43 IO A and A44 IO B affect lower priority functions These modules can therefore be used as spare parts for breakdown service while on the road Functions l...

Page 145: ...ars and is displayed alternately with CAN during that sequence will be displayed up to 6 times and the audible alarm will ring Wait until CAN is replaced by that remains for more than 10 seconds At th...

Page 146: ...Section 06 ELECTRICAL PA1564 34 FIGURE 19 TWIN BOSCH ALTERNATORS INSTALLATION FIGURE 20 ALTERNATORS AND ACCESSORIES MOUNTING TORQUES...

Page 147: ...tightening of the pulleys can be performed once the belt is installed This will help keep the pulley from turning when tightening 4 Install the snubber bracket 5 fig 19 using three flanged bolts Do n...

Page 148: ...comes first FIGURE 25 ALTERNATOR DRIVE BELT 01180 6 BATTERY EQUALIZER VoltMaster Battery Equalizer Owner s Manual 100 amps is annexed at the end of this section Refer to Electrical Compartments and J...

Page 149: ...ight assembly consists of two headlamp module 90 mm 3 inch equipped with a 12 volt halogen bulb and one 100 mm 4 inch 12 volt LED turn signal lamp Outer lamps have a double function both low and high...

Page 150: ...four movable vertical tapes should be located on the screen at the left and right limits called for in the specification with reference to centerlines ahead of each headlight assembly 3 The headlight...

Page 151: ...vertical direction for low beam headlights or the low beam of a dual beam headlight shall be as described in Table 1 In the horizontal direction the left edge of the high intensity zone shall be loca...

Page 152: ...unit LED located on each front corner and should be replaced as an assembly Turn signal is visible from both front and side Removal and Replacement 1 Pull the release handle located inside the front...

Page 153: ...ff This prevents flutter and flashing This counter is put out of action when the lamp cutoff time repetition interval is longer than 1 3 s so that temporary non defect disturbances that result in imme...

Page 154: ...RANCE IDENTIFICATION AND MARKER LIGHTS The vehicle is equipped with marker identification and clearance lights LED The clearance lights are mounted at each corner of the coach near the top and the ide...

Page 155: ...LIGHTS Optional halogen fog lights can be mounted on this vehicle to give the driver better visibility in foggy weather or to improve the range of vision just ahead of the coach 9 6 1 Bulb Removal an...

Page 156: ...back in place CAUTION Do not touch halogen bulbs with bare hands as natural oils on skin will shorten bulb life span 10 2 2 Removal and Replacement of In Station Fluorescent Tubes 1 Start by pulling o...

Page 157: ...HTING Hi Lo beam 930291 9004 65 45 W 12 2 Lo Beam Xenon optional 930388 D2S 35 W 12 2 Docking cornering 930319 9415 37 5W 12 4 Fog 930361 H3 55 W 12 2 License plate sealed 930266 TL 15206 12 2 Marker...

Page 158: ...31 Pr vost Number 563030 Type Maintenance free Terminal type Top Stud Group size 31 Volts 12 Load test amperage 290 Reserve capacity minutes 195 Cold cranking in amps At 0o F 18o C 950 each battery Ma...

Page 159: ...Vanner Model 60 100D Amperes 100 amps Pr vost Number 563334 Starter Make Mitsubishi Electric Corporation MELCO Model Number M009T82479 Type 105P70 Voltage 24 Pr vost Number 510752 No load test Volts...

Page 160: ......

Page 161: ...diagram for the 105P70 Ground float type sometimes referred to as Insulated or Isolated Ground The circuit diagram contains a start switch a magnetic switch and a starter solenoid When the start switc...

Page 162: ...measuring the voltage between the S terminal in the starter solenoid and the ground The switch should not be closed for more than 3 seconds If this time is exceeded the starter solenoid may be damaged...

Page 163: ...starter The H coil is assumed to be layer shorted M terminal nut tightening torque 20 to 30 N m Figure 6 TESTING HOLD IN WINDINGS GROUND FLOAT TYPE Below are the resistance values for the P and H coi...

Page 164: ...zen bearings 4 No current draw indicates a Open field coils b Open armature coils c Broken brush springs worn brushes or high insulation resistance between brushes and commutator 5 Extremely low revol...

Page 165: ...or 0120 689 552 Edition 001 All rights rest with Robert Bosch Corp including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC Repair an...

Page 166: ...All rights rest with Robert Bosch Corp including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC Modifications Edition Date Name Modif...

Page 167: ...3 7 3 1 Lubricant Quantities 13 8 EXPLODED VIEW 14 9 ALTERNATOR DISASSEMBLY AND TESTING 15 9 1 REAR COVER REMOVAL 15 9 2 VOLTAGE REGULATOR REMOVAL 15 9 2 1 Brush Replacement 16 9 3 NOISE SUPPRESSION C...

Page 168: ...REGULATOR AND CAPACITOR INSTALLATION 33 11 FUNCTIONAL TESTING 35 11 1 GENERAL INFORMATION 35 11 1 1 Power Output Tests 35 11 1 2 Voltage Trace Evaluation 35 11 2 POWER OUTPUT TESTING 35 11 2 1 Test B...

Page 169: ...ights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 1 General This manual contains repair and testing instructions with corresponding test specifi...

Page 170: ...ession the alternator is equipped with capacitors with a long storage time Cleaning of alternator components may cause and electrical discharge when they are immersed in cleaning fluid This discharge...

Page 171: ...stance 7 5 W 0 10 T1 RL 28V70 140A Power Output Test Alternator Speed RPM Load Current Inductive A Test Duration Min 1500 76 30 T1 RL 28V70 140 A 6000 136 10 Following completion of the output test al...

Page 172: ...in Collector ring diameter Used 31 5 mm 1 240 in minimum New 16 0 mm 0 630 in minimum Carbon Brush Projection Used 7 0 mm 0 275 in minimum 3 3 Tightening Torques Item Number Description Metric Nm SAE...

Page 173: ...All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 4 Alternator Schematic Figure 3 Alternator Voltage Regulator Schematic 1 Alternator B Battery Posit...

Page 174: ...2 98 T1ALTFinal DOC 5 Alternator Coding T 1 R 28V 70 140A Rated current in amps measured at 6000 rpm Rated current in amps measured at 1500 rpm Alternator Voltage Direction of Rotation Or R Clockwise...

Page 175: ...nator components may cause and electrical discharge when they are immersed in cleaning fluid This discharge may cause combustible liquids to ignite Alternator components with capacitors should only be...

Page 176: ...0 986 619 362 Die Spigot for Arbor Press Used with KDLJ 6011 KDLJ 6012 KDLJ 6015 KDLJ 6010 0 986 618 124 Bearing Remover KDLJ 6009 0 986 618 121 Press Tool for Roller Bearing KDLJ 6021 0 986 618 139...

Page 177: ...inal DOC 7 3 Lubricants and Adhesives Description Manufacturer Number Bosch Number UNIREX N3 5 975 560 125 Ft1 v 34 5 700 009 000 Roller Bearing Grease VS 15164 Ft 5 975 560 000 Molycote Paste Ft 70 v...

Page 178: ...all Bearing 3 Cover Plate 6 Rotor 6 9 Collector Ring 10 Roller Bearing 11 Collector Ring End Shield 12 Rectifier 12 13 Seal 15 Washer Screw Assembly 17 Transistor Regulator 17 3 8 Compression Spring 1...

Page 179: ...air intake cover Figure 5 Figure 5 Air Intake Cover Removal 1 Note The voltage regulator must be removed before any further disassembly of the alternator takes place The brushes of the regulator can b...

Page 180: ...7 mm 0 276 the brush must be replaced Figure 7 2 To replace the brushes the brush lead must be unsoldered and the brush removed from the regulator 3 Insert the new brush into the regulator and solder...

Page 181: ...r the capacitor lead should be shorted to the capacitor mounting strip to discharge the capacitor Failure to do so may cause the capacitor to discharge while being cleaned 9 4 Pulley and Fan Removal 1...

Page 182: ...to be performed a Using tester WPG 012 00 Bosch Number 0 684 201 200 Figure 11 i Connect the negative black lead of the tester to the collector end shield and the positive red lead to each of the sta...

Page 183: ...e stator connection solder joints No current should pass through the rectifier assembly vi Connect the negative black lead of the tester to the D Terminal and the positive red lead to each of the stat...

Page 184: ...terior of the stator indicates a breakdown of the stator insulation and a short to ground If continuity is present the stator must be replaced 9 8 Rectifier Assembly Removal 1 Loosen and remove the th...

Page 185: ...d read between 3 1 and 3 5 k kilohm If the resistance is above or below this range the W terminal is to be replaced as an assembly Figure 15 2 Loosen the nut retaining terminal W to the collector end...

Page 186: ...ded rod KDAW 9995 14 into extractor KDAW 9995 6 f Slide the receiver cup KDAW 9995 0 5 onto threaded rod g Screw on handle and rotate until the bearing race comes out of the collector end shield 9 11...

Page 187: ...DOC 3 Press out rotor 4 Remove spacer ring from rotor shaft Notes Protect the threads of the rotor from damage prior to pressing Always replace the drive end bearing if the rotor has been pressed out...

Page 188: ...ring from the drive end shield 9 14 Removal of Collector Ring End Inner Bearing Race from Rotor 1 With a universal bearing puller remove the inner race of the endshield bearing Figure 20 Notes Place j...

Page 189: ...21 2 Using insulation tester KDAW 9983 or equivalent apply 80 VAC to the rotor claw poles and each of the collector rings If the insulation tester lights there is a short to ground within the rotor Fi...

Page 190: ...t be replaced b Each collector ring maximum run out 0 03 mm 0 0012 in If the run out exceeds the maximum the collector rings can be machined down to a minimum of 31 5 mm 1 240 in diameter If the requi...

Page 191: ...lead for the rotor windings does not become damaged while sliding the collector rings over the lead 4 Lining up the slot in tool KDLJ 6012 Bosch Number 0 986 618 126 with the rotor lead press the coll...

Page 192: ...bly 1 Insert sealed ball bearing into the drive end shield 2 Align the holes of the bearing cover plate with the holes in the drive end shield 3 Start the four screws which hold the bearing cover plat...

Page 193: ...the bottom of the collector end housing bearing bore with an additional 2 g 0 07 oz of UNIREX N3 grease 5 Coat the sealing lip of the radial lip seal and pack the seal with 2 g 0 07 oz of UNIREX N3 g...

Page 194: ...30 11 Insert terminal W into collector end shield in location marked W Make sure the locating lug of the terminal assembly indexes the end shield correctly 12 Place insulator and flat washer onto ter...

Page 195: ...ating washer flat washer and nut to terminal studs B and D Figure 33 6 Install flat washer and nut onto terminal stud B Figure 33 7 Check that the soldering lug of terminal W is still in the proper lo...

Page 196: ...tor leads to the rectifier assembly with rosin core solder 10 6 Rotor and Drive End Shield Installation 1 Place collector end shield and stator assembly on a suitable surface so the rotor and drive en...

Page 197: ...heard the rotor and drive end shield assembly must be removed the cause determined and repaired before continuing Once the problem has been corrected start at step 1 of this section 11 Remove the ali...

Page 198: ...n aligning the mounting holes pay attention to the force used as damage can occur to the brushes 5 Install the three 3 regulator mounting screws and torque to 1 3 to 1 7 Nm 11 5 to 15 in lbs Figure 38...

Page 199: ...minimum criteria Characteristic Minimum Specification Variable Speed Control 0 12 000 RPM Drive Motor 4 kW 5 4 hp Load Bank Capability 170 A 28 V for 10 minutes 80 A 28 V for 30 minutes Output Voltag...

Page 200: ...o test bench manufacturers operating instructions for correct terminology of test leads Refer to figure 39 for a schematic outline of alternator to test bench connections Compare this schematic to the...

Page 201: ...ernator output and speed during the test period 9 Remove load and operate the alternator at 7000 rpm for one minute to allow the alternator to cool 10 Refer to the test bench operating instructions an...

Page 202: ...2 Normal Pattern This image represents a properly functioning alternator The D C voltage produced has a small harmonic wave Small spikes may be superimposed on the oscilloscope screen if the voltage...

Page 203: ...hts of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 3 Open Exciter Diode This pattern displays a characteristic dip in the normally smooth wave characteri...

Page 204: ...ALTFinal DOC 11 3 4 Open Positive Rectifier Diode This pattern identifies an open positive rectifier diode In the case of multiple diodes in parallel all of the diodes on the circuit must be open An e...

Page 205: ...ALTFinal DOC 11 3 5 Open Negative Rectifier Diode This pattern identifies an open negative rectifier diode In the case of multiple diodes in parallel all of the diodes on the circuit must be open An e...

Page 206: ...ncluding patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 6 Shorted Exciter Diode This pattern identifies a shorted exciter diode...

Page 207: ...ding patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 7 Shorted Positive Rectifier Diode This pattern identifies a positive rectif...

Page 208: ...ding patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 8 Shorted Negative Rectifier Diode This pattern identifies a negative rectif...

Page 209: ...Bosch Corp including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 9 Open Phase of Stator This pattern illustrates a stator wit...

Page 210: ......

Page 211: ...ly 4 Family 5 60 10B 60 100C 60 60 65 60 66 60 60 20A 60 100D 60 60M 65 60M 66 80 60 50A 60 100E 60 80 65 80 66 100 60 50E 60 100 65 100 60 50M Table of Contents Introduction 2 Specifications 3 Theory...

Page 212: ...tery Equalizer connects to the 24 volt 12 volt and ground terminals of the battery system When the 12 volt loads require power the Battery Equalizer ensures that the current is taken equally from both...

Page 213: ...unting Location Mount on a flat surface close to the batteries to allow short cable runs Vertical mounting with terminals down is recommended Location should be protected from battery acid and gases 2...

Page 214: ...the voltage balance and therefore the charge acceptance rate of each battery Family 3 and Family 4 Equalizers hold Battery A and B voltages to within 0 05 volts under light loads and to within 0 1 vo...

Page 215: ...ng small adjustments to keep the batteries in balance Scenario 2 Both 24 volt and 12 volt loads present alternator is OFF The Battery Equalizer will insure that both batteries will discharge at the sa...

Page 216: ...CH 24V ALT _ 24V VANNER Battery Equalizer 12V GND 12V Battery B 12V Battery A 12V 12 Volt Loads VANNER DC to AC Inverter 120VAC To AC Loads 24 Volt Loads 24V F2 F1 MARINE ENGINE BATTERY SYSTEM HOUSE B...

Page 217: ...aining batteries or flammable materials Safety goggles should always be worn when working near batteries Mounting Location The Equalizer may be mounted in any orientation however the recommended orien...

Page 218: ...ttery Disconnect Switch 24V VANNER Battery Equalizer 12V GND 12V Battery B 12V Battery A 12V 12 Volt Loads Radio 24 Volt Loads 24V 24V ALT _ HIGH CURRENT DIODE BATTERY DISCONNECT SWITCH F2 F1 The syst...

Page 219: ...309 51 9 26 0 10 4 8 7 6 5 5 2 2 6 1 191930333 65 4 32 7 13 1 10 9 8 2 6 5 3 3 1 0 191930333 82 9 41 4 16 6 13 8 10 4 8 3 4 1 2 0 191930346 105 5 52 7 21 1 17 6 13 2 10 5 5 3 Fuse F1 20 amp 30 amp 80...

Page 220: ...onnect that same 12 volt lamp between the 12 and GND terminals of the Equalizer The lamp should light and stay lit If the lamp does not light the light then goes out or the light dims the Equalizer re...

Page 221: ...itions may occur during bus maintenance it is recommended that the service personnel verify the circuit breaker is IN before releasing the bus for service and the tour bus operator do the same in his...

Page 222: ...ts 3 Measure the input voltage between the 24 and GND posts of the equalizer This voltage should be between 25 5 volts and 29 0 volts If it isn t then check the alternator and 24 volt voltage regulato...

Page 223: ...e therefore the DC connection sequence is not an issue Family 3 4 and 5 Equalizers will not function properly unless all three battery connections are made Battery A and Battery B voltages both must b...

Page 224: ...r out of balance If Battery A voltage falls below approximately 8 volts the equalizer will shut itself OFF To correct the overload condition the 12 volt load must be reduced or the equalizer capacity...

Page 225: ...There are no other warranties that extend beyond those described on the face of this warranty Some states do not allow limitation on how long an implied warranty lasts so the above limitations may not...

Page 226: ...S MANUAL BATTERY EQUALIZER OWNER S MANUAL 16 Vanner Incorporated 4282 Reynolds Drive Hilliard Ohio 43026 1 800 AC POWER 1 800 227 6937 Tel 614 771 2718 Fax 614 771 4904 www vanner com e mail pwrsales...

Page 227: ...o install momentary light test switches or just one 1 light test switch provided three 3 isolating diodes are installed so as to enable the operator to check the lamps to determine if they are functio...

Page 228: ...onnections 2 Demand for 12 volt power exceeding rated amperage output of Battery Equalizer causing batteries to go out of balance Reduce 12 volt loads Install larger or additional Battery Equalizer 3...

Page 229: ...FAULT CODE MANUAL Created on 00 04 25 15 30 1 FAULT CODE MANUAL B7L B7TL B12...

Page 230: ...l suppliers Due to problems with retrieving updated documents new signal specifications etc we cannot guarantee that the information is 100 correct Therefore we are very grateful to retrieve any notif...

Page 231: ...number with the VIC 8 8 Comparing HW SW id with the VIC 8 9 Fault codes ABS MID 136 10 10 Fault codes BIC MID 140 234 13 11 Fault codes CECM MID 164 14 12 Fault codes CIM MID 164 15 13 Fault codes EE...

Page 232: ...f the instrument cluster there is a small display that can show various information about the bus From this display it is possible to read the fault codes that may have been set in one or more of the...

Page 233: ...ner of the instrument can display an icon of some sort depending on the bus status If this is the case then press Esc on the windscreen wiper handle to go to the main menu If the language of the displ...

Page 234: ...n wiper handle to move to that line Press the Return button again and the fault code set in the transmission ECU will now be displayed on the screen The fault codes can be displayed in both numeric an...

Page 235: ...ext mode The information about the PID number or SID PPID or PSID together with the explanation of the FMI number associated with the fault might help you to draw a conclusion of what may have caused...

Page 236: ...rn buton on the windscreen wiper handle The fleet id and the chassis number should occur on the display 8 Comparing HW SW id with the VIC Just as with the chassis number the VIC can be used to verify...

Page 237: ...4 25 15 30 9 The image below shows the HW SW id for the CECM the display cannot display both SW id and HW id at the same time therefore you have to use the up down buttons on the windscreen wiper hand...

Page 238: ...or wheel sp RF 136 SID 2 10 Speed drop out Sensor wheel sp RF 136 SID 2 11 Abnormal speed Sensor wheel sp RF 136 SID 2 12 Frequency too high Sensor wheel sp RF 136 SID 3 1 Air gap Sensor wheel sp L1R...

Page 239: ...SID 7 6 Shorted to ground Modulator valve LF 136 SID 8 1 Open circuit in and outlet Modulator valve RF 136 SID 8 3 Shorted to UBATT Modulator valve RF 136 SID 8 5 Open circuit Modulator valve RF 136...

Page 240: ...alve R 136 SID 19 6 Diff lock shorted to ground ATC valve R 136 SID 23 5 Warning lamp ABS Warning light bulb 136 SID 231 5 SAE J1939 Control link SAE J1939 data link 136 SID 231 6 SAE J1939 Control li...

Page 241: ...ake pressure 1 234 PID 118 9 Brake pressure 2 Brake pressure 2 234 PID 120 9 ZF Allison oiltemp Hyd retard oil temp 234 PID 158 0 Yellow lamp Control unit battery potential Battery potential 234 PID 1...

Page 242: ...4 Chassis data link 164 PSID 23 3 D data link 164 PSID 23 4 D data link 164 PSID 31 3 Output CECM 164 PSID 31 4 Output CECM 164 PSID 31 5 Output CECM 164 PSID 32 5 Panel switch 164 PSID 33 3 Warning...

Page 243: ...ID SID FMI Seriousness Component function Display text 164 PSID 31 3 Short circuit to battery 164 PSID 31 4 Short circuit to ground 164 PSID 3 4 Alternator not charging 164 PSID 4 4 Alternator not cha...

Page 244: ...re sensor Boost pressure 128 PID 102 4 Yellow lamp Boost pressure sensor Boost pressure 128 PID 105 3 Yellow lamp Boost air temperature sensor Intake manif temp 128 PID 105 4 Yellow lamp Boost air tem...

Page 245: ...Injector Cylinder SID 128 SID 1 6 11 Yellow lamp Injector Injector Cylinder SID 128 SID 17 3 Fuel shut off valve Fuel Valve 128 SID 17 4 Fuel shut off valve Fuel Valve 128 SID 17 5 Fuel shut off valv...

Page 246: ...rol link SAE J1939 data link 128 SID 231 11 Yellow lamp SAE J1939 Control link SAE J1939 data link 128 SID 231 12 Yellow lamp SAE J1939 Control link SAE J1939 data link 128 SID 232 3 Yellow lamp 5 V s...

Page 247: ...rature sensor Transm oil temp 130 PID 190 11 Engine speed Engine speed 130 PID 191 11 Output speed Output shaft speed 130 PID 234 14 Frequency output Software no 130 SID 1 12 Control solenoid valve tu...

Page 248: ...SID 3 3 Solenoid valve D shorted high Solenoid valve 3 130 SID 3 4 Solenoid valve D shorted ground Solenoid valve 3 130 SID 3 5 Solenoid valve D circuit break Solenoid valve 3 130 SID 4 3 Solenoid va...

Page 249: ...shorted high 222 SID 11 4 Retarder current shorted ground 222 SID 11 5 Retarder current circuit break 222 SID 12 3 Retarder accumulator shorted high 222 SID 12 4 Retarder accumulator shorted ground 2...

Page 250: ...air press 222 PPID 31 3 Retarder air press Retarder air press 222 PPID 31 5 Retarder air press Retarder air press 222 PPID 34 0 ECU 12V Output ECU 12V Output 222 PPID 34 1 ECU 12V Output ECU 12V Outp...

Page 251: ...amp Repeated movement of the lever between position 1 and position 0 will display the next fault code in line if the same fault code is shown two times in a row there are no more fault codes set in th...

Page 252: ...ription 35 Internal fault concerning ROM CRC check EEPROM data record 36 2 2 way valve fault 37 Non plausibility of brake pedal operation 38 Pressure sensor fault 41 Time out 500ms press signal VECU 4...

Page 253: ...nd retarder feeding sensor Output supply 1 144 PPID 73 3 Yellow lamp Extra throttle and wet tank feeding sensor Output supply 2 144 PPID 73 4 Yellow lamp Extra throttle and wet tank feeding sensor Out...

Page 254: ......

Page 255: ...ing gear which has similar level of damage as these See the next page for the method to measure the depth of the damage Depth of wear damage on ring gear Service Bulletin A1 M1N 1729EN Flywheel Ring G...

Page 256: ...Measurement method Dimension between the mounting surface and the end surface of ring gear Dimension between the mounting surface and the damage depth portion of ring gear Less than 0 5mm...

Page 257: ...H RETARDER 12 7 CLEANING AND INSPECTION OF THE ALLISON AUTOMATIC TRANSMISSION 12 7 1 BREATHER 13 8 ALLISON TRANSMISSION INSTALLATION 13 9 TROUBLESHOOTING 14 9 1 ALLISON AUTOMATIC TRANSMISSION 14 9 1 1...

Page 258: ...TRANSMISSION PA1564 2 FIGURE 9 ENGINE CRANKING POSITION 11 FIGURE 10 MODINE OIL COOLER 12 FIGURE 11 COOLER WITH RETARDER 12 FIGURE 12 AIR PRESSURE REGULATOR TYPICAL 14 FIGURE 13 TRANSMISSION CONTROL...

Page 259: ...it computes shift points and clutch pressures to meet immediate needs Using closed loop adaptive logic the electronic control looks at a number of parameters during the shift and makes minute adjustme...

Page 260: ...nd clogged passages Check the oil level using the procedures in Cold Check and Hot Check Record any abnormal level on your Maintenance Records Always check the oil level reading at least twice when th...

Page 261: ...hen selecting the Gauge Mode refer to the Operator s Manual for added information 2 Park the vehicle on a level surface and shift to Neutral N Apply the parking brake and allow the engine to idle 500...

Page 262: ...fluid level be maintained at all times because the transmission fluid cools lubricates and transmits hydraulic power If the fluid level is too low the converter and clutches do not receive an adequate...

Page 263: ...ow 25 F 32 C If a preheat kit is not available the TCM will restrict full operation until the sump temperature is increased 3 8 OIL CONTAMINATION At each oil change examine the drained oil for evidenc...

Page 264: ...Synd TM TES 295 Approved Fluid And Gold Series Filters MTH equipped with retarder MTH without retarder Filters Filters Main Main Fluid Initial Break in 5 000 miles 8 000 km Internal Lube Auxiliary Flu...

Page 265: ...e Former Gold Series filter kits are completely cancelled and serviced with current High Capacity filter kits However if you are using stocked Gold Series filter kits with TES 295 approved fluid TranS...

Page 266: ...US qts 23 liters 28 US qts 26 5 liters if equipped with retarder and check the oil level using the Fluid Level Check Using Pushbutton Shift Selector procedure in this section 4 INSTALLATION OF ALLISON...

Page 267: ...may drain from oil lines when they are disconnected 9 Disconnect all sensors on L H side of the transmission 10 Disconnect main wiring harness 11 Disconnect the air supply line steel braided hose fro...

Page 268: ...and allow engine to cool Close both heater line shutoff valves refer to Section 05 Cooling 1 To drain the cooling system proceed as per Section 05 Cooling paragraph 5 Draining If the cooling system is...

Page 269: ...olycote G or equivalent 5 Raise transmission and position the flywheel pilot boss into the flexible plate adapter Align the guide bolt previously installed in the flywheel with the flexible plate hole...

Page 270: ...sion Control Module The Allison automatic transmission has a new Transmission Control Module TCM which involves specific diagnostic incident codes The TCM is located in the coach rear junction box FIG...

Page 271: ...shbutton shift selector d 1 P 0 7 SELECT 2 2 MONITOR d1 code list position The position which a code occupies in the list Positions are displayed as d1 through d5 code list position 1 through code lis...

Page 272: ...approximately 10 minutes has passed The system will automatically return to the normal operating mode o Turn off power to the TCM shut off the engine using the ignition key NOTE If clearing a code whi...

Page 273: ...1 High Yes DNS SOL OFF hydraulic default P0702 Transmission Control System Electrical TransID Yes Use TID A calibration P0703 Brake Switch Circuit Malfunction No No Neutral to Drive shifts for refuse...

Page 274: ...ault P0966 Pressure Control Solenoid 2 PCS2 Control Circuit Low Yes DNS SOL OFF hydraulic default P0967 Pressure Control Solenoid 2 PCS2 Control Circuit High Yes DNS SOL OFF hydraulic default P0968 Pr...

Page 275: ...mperature Sensor Circuit High Input No Use default retarder temp values P2761 TCC PCS Control Circuit Open Yes Inhibit TCC operation P2763 TCC PCS Control Circuit High Yes Inhibit TCC operation P2764...

Page 276: ...kup clutch with torsional damper Integral standard Gearing Type Patented constant mesh helical planetary Ratio First 3 51 1 Second 1 91 1 Third 1 43 1 Fourth 1 00 1 Fifth 0 74 1 Sixth 0 64 1 Reverse 4...

Page 277: ...RIPTION 2 2 REMOVAL DISASSEMBLY REASSEMBLY AND INSTALLATION 2 3 CLEANING INSPECTION AND LUBRICATION 3 3 1 CLEANING AND INSPECTION 3 3 2 LUBRICATION 3 4 EXPLANATION OF COMMON DAMAGES 3 5 TROUBLESHOOTIN...

Page 278: ...dle bearings Furthermore a slip joint on the propeller shaft compensates for variations in distance between the transmission and the differential or between the output retarder optional on the automat...

Page 279: ...temperatures or NLGI No 1 suitable for extremely low temperatures Refer to Spicer Universal Joints and Driveshafts Service Manual under heading Inspection and Lubrication See lubrication procedures f...

Page 280: ...e yoke Prevost number 580043 U joint kit slip yoke Supplier number 5 510X U joint kit slip yoke Prevost number 580062 Cap and bolt kit bolt torque 115 135 lbf ft 156 183 N m Supplier number 6 5 70 18X...

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Page 293: ...12 AXLE SHAFT SEALING METHOD 7 2 TAG AXLE 7 2 1 RETRACTING TAG AXLE 7 2 2 RETRACTING TAG AXLE FOR REPAIR PURPOSES 8 2 3 GREASE LUBRICATED WHEEL BEARINGS 8 2 4 REMOVAL AND INSTALLATION 8 2 4 1 Removing...

Page 294: ...r FIGURE 3 DRIVER CONTROLLED DIFFERENTIAL LOCK 11028 1 3 DRIVE AXLE LUBRICATION Additional lubrication information is covered in the Meritor Technical Bulletin TP 9539 Approved Rear Drive Axle Lubrica...

Page 295: ...e sure the axle is cold or at room temperature 3 Clean the area around the fill plug Remove the fill plug from the differential axle housing bowl Fig 4 4 The oil level must be even with the bottom of...

Page 296: ...nsion 6 Remove cable ties securing the ABS cables if vehicle is so equipped to service brake chamber hoses Disconnect the ABS cable plugs from the drive axle wheel hubs NOTE When removing drive axle i...

Page 297: ...ements for replacement If the axle has been removed for repairs or servicing and if all the parts are reinstalled exactly in the same place the axle alignment is not necessary However if the suspensio...

Page 298: ...e the sensor from the right side of the front wheel is mounted on the right side of the tag axle For corresponding wheel mount sensor reference numbers refer to figure 7 o Adjust tag axle according to...

Page 299: ...e sealant and its packing 3 Assemble components immediately to permit the silicone sealant to compress evenly between parts a Place a new gasket then install the axle shaft into the wheel hub and diff...

Page 300: ...lubricated and have seals fitted as part of the manufacturing process The bearings are greased for life and there is no need or facility for re lubrication Front and tag axle wheel hub bearings need t...

Page 301: ...CAUTION On vehicles equipped with an automatic transmission with or without the output retarder move tag assembly very carefully Pay special attention to the U shaped section as the transmission end c...

Page 302: ...ive axle ratio World Transmission 4 88 1 Standard 4 56 1 Optional NOTE The drive axle alignment consists in aligning the axle with reference to the frame The axle must be perpendicular to the frame Ta...

Page 303: ...SPICER SPECIALITY AXLE DIVISION place product photo here SERVICE MANUAL GENERAL INFORMATION NDS Axle range BACK RETOUR...

Page 304: ...xle Division products are subject to continual development and we reserve the right to modify procedures and to make changes in specifications at any time without prior notice and without incurring ob...

Page 305: ...INTENANCE PROCEDURE WARNING FAILURE TO FOLLOW INDICATED PROCEDURES CREATES A HIGH RISK OF PERSONAL INJURY TO THE SERVICE TECHNICIAN NOTE FAILURE TO FOLLOW INDICATED PROCEDURES MAY CAUSE COMPONENT DAMA...

Page 306: ...SONAL INJURY ALWAYS WEAR APPROPRIATE PERSONAL PROTECTION EQUIPMENT P P E WHEN PERFORMING ANY MAINTENANCE WORK SOLVENT CLEANERS IF SOLVENT BASED CLEANERS ARE TO BE USED THE MANUFACTURERS INSTRUCTIONS S...

Page 307: ...ature of Spicer Speciality Axle Division products certain terms and wordsrequire clarification hence the following list ENGLISH U S A SWIVEL KNUCKLE COTTER PIN DRAW KEY AXLE BED I BEAM STEERING LEVER...

Page 308: ...through either your vehicle manufacturer or through Spicer Speciality Axle Division spares department The use of non Spicer service parts may cause premature component failure and void the warranty Th...

Page 309: ......

Page 310: ...POLICY Capability ratings features and specifications vary depending upon the model type of service Applications approvals must be obtained from Spicer Speciality axle division We reserve the right t...

Page 311: ...SPICER SPECIALITY AXLE DIVISION place product photo here Maintenance Manual NDS axles Lubrication and Maintenance NDS Axle range Issue D BACK RETOUR...

Page 312: ...interval altered Updated spec Mar 2000 13 B Tie rod torques added New tie rod Mar 2000 14 B Tie rod torques added New tie rod Mar 2000 15 B Air cylinder torques added New spec Mar 2000 18 B Air cylind...

Page 313: ...n on off highway refuse or other severe service applications 1 1 2 Grease points as shown in fig no 1 Greasing points Fig No 1 Recommended lubrication LITHIUM BASE ROLLER BEARING GREASE NLGI NUMBER 2...

Page 314: ...E UNIT IS DAMAGED DISPLACED AND A NEW UNIT MUST BE FITTED 2 2 To check front wheel Toe In a To preserve correct steering and avoid excessive tyre wear tracking or alignment of front wheels should be c...

Page 315: ...n need for bush bearing attention and possible renewal is in evidence b Checking vertical slackness This is measured by a dial indicator anchored to axle beam and having its pointer placed vertical ag...

Page 316: ...et metal tool eg spatula with cut out fig no 5 to push up the sealing boot without damaging it until ball pin surface is visible Degrease the ball pin surface If there is corrosion of the ball pin or...

Page 317: ...bly is stable and that no further relaxation is occuring see graphic on following page for correct tightening sequence of wheel nuts 3 1 Care of wheels Check for CRACKS in wheels especially around the...

Page 318: ...cal Publications Spicer Speciality Axle Division WHEELNUT TIGHTENING TORQUE SEQUENCE 6 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 8 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 10 STUD FIXING...

Page 319: ...tted Every 30000 miles 48000 km or whenever brake drums are removed for axle maintenance purposes they should be checked for crazing Brake drums with crazing in excess of that shown in fig 6 below and...

Page 320: ...for the following Heat checking Cracks Grooves scoring Blue marks Banding Polished discs Heat checking can be light or heavy If light heat checking type cracks fine and light are found as shown in Fig...

Page 321: ...s been exposed to very high temperatures If Blue marks banding are found the reason for the high temperatures must be investigated and corrected Refer to the Brake manufacturer for details if left unc...

Page 322: ...Page No 12 NDS2 issue A Spicer SpecialityAxle Division Technical Publications Spicer Speciality Axle Division BACK RETOUR...

Page 323: ...Bottom lever bolts M20 x 2 5 grade 12 9 520 575 lbs ft 705 780NM NDS 80 Bottom lever bolts M24 x 3 grade 10 9 751 830 lbs ft 1018 1125 NM NDS 80 27 Ball pin nut F4845T assembly 155 170 lbs ft 210 230...

Page 324: ...24 x 3 grade 10 9 751 830 lbs ft 1018 1125 NM NDS 80 25 Ball pin nut F4845T assembly 155 170 lbs ft 210 230 NM All axles Ball pin nut F4109T assembly 184 206 lbs ft 249 279 NM All axles Ball pin nut F...

Page 325: ...44 712NM 6 Brake Caliper Mounting Bolt M14 x 1 5 174 192 lbs ft 236 260NM Brake Caliper Mounting Bolt M16 x 1 5 266 294 lbs ft 360 399NM Brake Caliper Mounting Bolt M18 x 1 5 372 412 lbs ft 504 559NM...

Page 326: ...l nut M18 x 1 5 235 260 lbs ft 318 352NM Wheel nut M20 x 1 5 285 315 lbs ft 386 427NM Wheel nut M22 x 1 5 475 525 lbs ft 644 712NM 8 Hub flange retaining bolt M14 x 1 5 174 192 lbs ft 236 260NM 9 Brak...

Page 327: ...SCRIPTION TIGHTENING TORQUE 1 Wheel nut M18 x 1 5 235 260 lbs ft 318 352NM Wheel nut M20 x 1 5 285 315 lbs ft 386 427NM Wheel nut M22 x 1 5 475 525 lbs ft 644 712NM 20 Hub flange retaining bolt M14 x...

Page 328: ...475 525 lbs ft 644 712NM 5 Brake air cylinder retaining nuts M16 X 1 5 133 155 lbs ft 180 210NM 6 Brake Caliper Mounting Bolt M14 x 1 5 174 192 lbs ft 236 260NM Brake Caliper Mounting Bolt M16 x 1 5...

Page 329: ...DESCRIPTION TIGHTENING TORQUE 1 Wheel nut M18 x 1 5 235 260 lbs ft 318 352NM Wheel nut M20 x 1 5 285 315 lbs ft 386 427NM Wheel nut M22 x 1 5 475 525 lbs ft 644 712NM 7 Hub flange retaining bolt M14 x...

Page 330: ...ications approvals must be obtained from Spicer Speciality Axle Division We reserve the right to change or modify our product specifications configurations or dimensions at any time without notice SPI...

Page 331: ...SPICER SPECIALITY AXLE DIVISION Maintenance manual Model NDS Hub and brake assembly With Knorr Bremse Disc brake Fitted to offset barrel swivel...

Page 332: ...ons Spicer Speciality Axle Division Page No Issue Description Alteration Reason Date All A New Manual Mar 2000 11 B Page added all subsequent pages re numbered Brake disc checking added Oct 2000 7 C O...

Page 333: ...t plugs to connections to prevent dirt ingress 2 Loosen but do not remove brake caliper retaining bolts 3 Using suitable lifting equipment support the brake caliper 4 Remove brake caliper retaining bo...

Page 334: ...lange bolts with 2 studs loosely fitted NOTE REPLACEMENT STUDS SHOULD PROTRUDE BEYOND FRONT FACE OF HUB FLANGE TO AID REMOVAL 8 Gently tap hub flange outwards using a hide faced hammer 9 Support weigh...

Page 335: ...o remove WARNING COMPONENT IS HEAVY ENSURE WEIGHT IS FULLY SUPPORTED BEFORE REMOVING 15 Place brake disc on a suitable work bench and inspect for cracks and defects Replace if necessary See Lubricatio...

Page 336: ...d remove 21 Place on a suitable workbench and inspect for wear damage taking care not to damage the ABS exciter ring in the process NOTE THE UNITISED BEARINGS USED ON THE NDS RANGE OF AXLES ARE NON SE...

Page 337: ...ntained in swivel axle bed reassembly section before attempting to reassemble hub end 2 Fit Unitised hub bearing guide sleeve onto swivel stub see chart at front of swivel section 3 Lightly smear the...

Page 338: ...Technical Publications Spicer Speciality Axle Division OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED 5 Place unitised hub bearing thrust washer onto axle stub 6 Fit hub nut 7 Tighten to specified t...

Page 339: ...ully position brake disc onto unitised hub bearing 10 Tap securely home using a hide faced hammer to avoid damaging the brake disc itself 11 Remove the modified hub flange bolt at this point 12 Carefu...

Page 340: ...cer Speciality Axle Division 1 2 5 8 4 6 7 3 1 2 5 10 4 8 6 9 3 7 1 7 13 3 9 11 6 2 8 14 4 10 12 5 HUB FLANGE BOLT TIGHTENING TORQUE SEQUENCE FOR 8 BOLT FIXING HUB FLANGE BOLT TIGHTENING TORQUE SEQUEN...

Page 341: ...ition stylus of dial test indicator onto brake disc as shown 18 Rotate the hub through 360 and note any movement of the dial test indicator NOTE MAXIMUM AXIAL RUNOUT IS 0 1mm 19 Should axial runout ex...

Page 342: ...USH SHOULD BE FITTED WHENEVER A NEW SENSOR IS FITTED IF FITTING A NEW SENSOR AND BUSH INTO AN ABS READY AXLE SENSOR AND BUSH SHOULD BE SUPPLIED FROM THE SAME MANUFACTURER 24 Push sensor through bush u...

Page 343: ...may not be steady due to the possibility of pole wheel run out and the inconsistent speed of the wheel d The maximum reading Vmax must not be more than 80 greater than the minimum reading Vmin ie If...

Page 344: ...liper is selected 29 Insert brake caliper retaining bolts and tighten hand tight 30 Tighten brake caliper bolts to secure assembly 31 Remove caliper lifting equipment WARNING BRAKE CALIPER IS HEAVY EN...

Page 345: ...ure distance over hubs wheel rims both in front and behind axle centre c Front measurement B should be 0 0 to 0 04 0 0 to 1mm LESS than rear measurement A d Any adjustment on type A socket and tie rod...

Page 346: ...nterfaces of wheelnuts wheel rim hub then re fit road wheels securing with wheel nuts and tighten in correct sequence as shown on following page to specified torque NOTE INTERFACES MUST BE FREE FROM D...

Page 347: ...nical Publications Spicer Speciality Axle Division WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 6 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 8 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 1...

Page 348: ...Page No 18 Manual No NDS8 Spicer Speciality Axle Division Technical Publications Spicer Speciality Axle Division TP1193...

Page 349: ...N OF NDS HUB END WITH SEPARATE BRAKE BRACKET PART NUMBER DESCRIPTION 1 Wheel nut Not Supplied By Spicer Speciality Axles 2 Hub flange 3 Wheel stud 4 Brake Caliper 5 Air chamber 6 Brake Caliper Mountin...

Page 350: ...CATION POLICY Capability ratings features and specifications vary depending upon the model type of service Applications approvals must be obtained from Spicer Speciality axle division We reserve the r...

Page 351: ...s in housing 61163 71163 drive axles come standard with six magnets in housing and 3 use of approved extended drain interval lubricants per Table B Drive axles excluded are RC 26 633 634 and RC 26 27...

Page 352: ...ed Mag Synthetic EP 75W 90 80W 140 Allied Oil and Supply Incorporated Altra Syntec GT 7 75W 90 80W 140 Allegheny Petroleum Products Amalie Synthetic Gear Lubricant 75W 90 80W 140 Amalie Refining Compa...

Page 353: ...ompany SHP Gear Lube 75W 90 80W 140 Kendall Lubricants Spirax S 75W 90 80W 140 Shell Lubricants SYN HD Gear Oil 75W 90 80W 140 Lyondell Lubricants Syn Axle Lubricant 12345841 75W 90 80W 140 General Mo...

Page 354: ...140 Aceites Y Parafinas Industriales Syn Star GL 75W 90 80W 140 Productos Texaco S A de C V Transintex Plus EP 75W 90 80W 140 Raloy Lubricantes S A de C V Name of Lubricant Viscosity Manufacturer Syn...

Page 355: ...uipped with Traction Equalizer Replace the factory installed lubricant with an approved lubricant and one of the additives specified in the following table After the initial change interval Change the...

Page 356: ...the time the publication was approved for printing and is subject to change without notice or liability Meritor Heavy Vehicle Systems LLC reserves the right to revise the information presented or to...

Page 357: ...checked by a physician as soon as possible Procedures 1 Remove all old gasket material from both the axle and the carrier surfaces Figure 1 Figure 1 2 Clean the surfaces where you will apply the silic...

Page 358: ...All Rights Reserved Printed in the USA Maintenance Manuals The information in this Technical Bulletin updates the following Maintenance Manuals MM Title Date 5B Tandem Axle Forward Rear Drive Units 09...

Page 359: ...DRYER PURGE TANK 8 8 AIR LINES 8 8 1 COPPER PIPING 8 8 2 FLEXIBLE HOSES 8 8 3 NYLON TUBING 8 8 4 AIR LINE OPERATING TEST 8 8 5 AIR LINE LEAKAGE TEST 8 8 6 MAINTENANCE 9 9 PRESSURE REGULATING VALVES 9...

Page 360: ...Checking Brake Pads 19 25 1 13 Torque specifications 19 26 SAFE SERVICE PROCEDURES 19 27 AIR BRAKE TROUBLESHOOTING 20 28 BRAKE AIR CHAMBER 24 28 1 MAINTENANCE 24 28 2 EMERGENCY PARKING BRAKE MANUAL R...

Page 361: ...DELCO SWITCH 11 FIGURE 13 BENDIX SWITCH 11 FIGURE 14 R 12 12 FIGURE 15 R 14 12 FIGURE 16 QR 1 12 FIGURE 17 SR 7 12 FIGURE 18 PR 4 13 FIGURE 19 LP 3 13 FIGURE 20 DC 4 13 FIGURE 21 BRAKE PAD CHECK 15 FI...

Page 362: ...4 4 FIGURE 43 ABS MODULATOR VALVE 27 FIGURE 44 ABS SENSOR LOCATION 28 FIGURE 45 SPRING CLIP 28 FIGURE 46 ABS 6S 5M CONFIGURATION 29 FIGURE 47 HOSE FITTINGS 32 FIGURE 48 HOSE FITTING 33 FIGURE 49 HOSE...

Page 363: ...a pneumatic relay valve R 12 will start with the rear axles and will be followed by the front axle thus providing uniform braking on a slippery road The vehicle is also equipped with an Anti Lock Bra...

Page 364: ...artment R H side door It is used to dissipate heat and to reduce noise produced by the air compressor cycling on and off FIGURE 3 FRONT SERVICE COMPARTMENT 12218 4 AIR SYSTEM EMERGENCY FILL VALVES All...

Page 365: ...The air pressure gauges located on the dashboard see Owner s Manual are connected to the DC 4 double check valve located on the pneumatic accessory panel in the front service compartment The latter is...

Page 366: ...tings and dirt Blow out piping with compressed air Any such particles will destroy sealing seats in air control units Also new piping must be the same size as the old one 8 2 FLEXIBLE HOSES A flexible...

Page 367: ...ove the doors and is used to limit the air pressure in belt tensioners to 50 2 psi 345 15 kPa for WE and to 45 2 psi 310 15 kPa for W5 MTH Fig 7 The optional regulator is located above the rear juncti...

Page 368: ...onnected to the air compressor Lubricating oil returns to the engine crankcase through the air compressor drive assembly Maintenance and repair information on the Bendix BA 921 air compressor is suppl...

Page 369: ...he following procedure 1 Replace the linkage loosen threaded rod lock nuts and screw or unscrew the threaded adjustment rod in order to obtain a 45 o brake pedal inclination Fig 11 2 Tighten threaded...

Page 370: ...ion on these valves is supplied in the applicable booklet annexed to this section under reference number SD 03 1064 FIGURE 14 R 12 12074 FIGURE 15 R 14 12207 17 QUICK RELEASE VALVES QR 1 The quick rel...

Page 371: ...re indicators is supplied in the applicable booklet annexed to this section under reference number SD 06 1600 The air system includes two low pressure switches Fig 19 both located on the pneumatic acc...

Page 372: ...axle is in the normal driving loaded position The spring type emergency brakes are mounted on the drive and tag axles and will apply automatically if primary system pressure falls below 40 psi 276 kP...

Page 373: ...all pneumatic components in the braking system are functioning properly NOTE A residual pressure of 2 3 PSI in the system is sufficient to prevent the brakes from releasing Also the stop light switch...

Page 374: ...e lining clearance or lining thickness as specified for drum brakes The roadside inspector should use the following instructions to determine that the air disc brakes are within proper adjustment and...

Page 375: ...ee months or more often depending on the type of operation Sliding Test Refer to Fig 31 a Using hand pressure only the caliper 1 must slide freely with its guide pin arrange ments 4 7 across a distanc...

Page 376: ...ppets are fully retracted and clean pad seat area Slide caliper to full outboard position and install outside pad Slide caliper to full inboard position and install inside pad WARNING It is recommende...

Page 377: ...ake pads all four pads on an axle have to be changed at the same time There is no inner or outer pad since all pads are the same Worn pads should be replaced in the same position FIGURE 35 BRAKE PAD C...

Page 378: ...sh your hands before eating drinking or smoking Do not wear your work clothes home Vacuum your work clothes after use and then launder them separately without shaking to prevent fiber dust from gettin...

Page 379: ...Section 12 BRAKE AND AIR SYSTEM PA1564 21 FIGURE 38 AIR OPERATED BRAKING SYSTEM WE...

Page 380: ...Section 12 BRAKE AND AIR SYSTEM PA1564 22 FIGURE 39 AIR OPERATED BRAKING SYSTEM W5...

Page 381: ...restricted clean or replace element or faulty line o Check compressor head or discharge line for carbonization or restriction Clean or replace as necessary o If discharge valves leak pull head and cor...

Page 382: ...For more information on this policy refer to Bendix Pr vost product notification annexed at the end of Section 12 of Maintenance Manual 28 BRAKE AIR CHAMBER Since this vehicle is equipped with Knorr B...

Page 383: ...brake turn the nut counterclockwise Rein stall access plugs on the spring chambers and release stud tools in their storage places Tag Axle 1 Block the wheels to prevent the vehicle from moving 2 Turn...

Page 384: ...edure for assembly Tap clamp ring to ensure proper seating Check for proper operation before placing vehicle in service 29 ANTI LOCK BRAKING SYSTEM ABS This device has been designed to ensure stabilit...

Page 385: ...speed average speed from each wheel data and compares the speed of each wheel with this reference speed to determine which wheel is accelerating or decelerating As soon as wheel deceleration or wheel...

Page 386: ...he axle connect a suitable AC voltmeter across the output terminals With the hubs rotating at 30 rpm the output voltages should read from 50 to 1999 mV to be acceptable 29 2 4 Sensor Installation The...

Page 387: ...Section 12 BRAKE AND AIR SYSTEM PA1564 29 FIGURE 46 ABS 6S 5M CONFIGURATION...

Page 388: ...ABS Indicator Lamp Service brake relay valve Dash mounted trailer ABS Indicator Lamp 30 1 2 The EC 60TM controller s ATC function utilizes the following components Drive axle traction control valve Da...

Page 389: ...steer where the vehicle s rear end slides out due to tire slide on the rear axle situation Factors that influence yaw stability are wheelbase suspension steering geometry weight distribution front to...

Page 390: ...full motion of the steering column can be achieved without pulling apart the connectors 8 Reinstall the steering column covers The sensor is not protected against dirt or water intrusion so care must...

Page 391: ...eter inches Number of additional turns required following hand tightening 1 4 3 3 8 to 1 2 4 5 8 to 3 4 3 FIGURE 49 HOSE FITTING 12055 AB Type Copper Piping Hand tighten nut Fig 50 From that point tig...

Page 392: ...iccant cartridge Pr vost number 3097369 Flip Flop Control Valve Make Bendix Westinghouse Model TW 1 Type On Off Pr vost number 640136 Emergency Parking Brake Control Valve Make Bendix Westinghouse Mod...

Page 393: ...e Indicators Make Bendix Westinghouse Model LP 3 Contact close 66 psi 455 kPa Pr vost number 640975 Air Pressure Regulator Make Norgren Adjustable output range 0 80 85 psi 0 552 586 kPa Recommended pr...

Page 394: ...Tag Brakes Make Knorr Bremse Type 16 as emergency Pr vost number 641431 Brake Lining All Axles Make Knorr Bremse Pr vost number 611049 Pr vost number 641226 ABS ANTILOCK BRAKING SYSTEM ABS MODULATOR...

Page 395: ...ervice conditions showed signi cant performance reductions Insufficient pad strength caused cracking across the friction material Shear testing of the friction material adhesion resulted in the fricti...

Page 396: ...h NIOSH should be worn at all times during brake servicing Workers must wash before eating or drinking should not use tobacco products in any form shower after working and not wear work clothes home W...

Page 397: ...air system When compressor cut out is reached dry air is allowed to flow back to regenerate the desiccant bed The SIX 6 different applications available for the DRYest are illustrated on the next page...

Page 398: ...egeneration Valve Port 22 plugged Dryer Inlet Port 1 Turbo Protection Valve Compressor Reservoir Port Unloader Port Governor Supply Tank Primary Secondary Dryer Output Port 21 Port 22 Dryer Inlet Port...

Page 399: ...ed by the vehicle or component manufacturer 11 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition General The vehicle in...

Page 400: ...ir dryer purges with an audible exhaust of air If system 2 E or 2 F is used the purge will be followed by a steady pulsating flow of air indicating that the system is unloaded and is venting to atmosp...

Page 401: ...d 25 output compressor Safety valve 1 Desiccant cartridge is plugged 1 Excessive oil passage from compressor is open Check for worn compressor Replace desiccant cartridge 2 Ice block in dryer 2 Check...

Page 402: ...12 V Heater 47110020 9 24 V Heater 47110021 10 Integrated Turbo Protection Valve 47189189 Not Shown Service Parts Brake Systems Division North American Sales Service Organization 10707 N W Airworld D...

Page 403: ...E PORT 2 CRANKCASE WATER PORT CRANKCASE COVER CYLINDER HEAD VALVE PLATE ASSEMBLY OILPORT APPLICATION SPECIFIC AIR INLET PORT WATER PORT GOVERNOR CONNECTION conducting air and engine coolant into and o...

Page 404: ...ills the cylinder bore above the piston See figures 4 7 AIR COMPRESSION LOADED When the piston reaches approximately bottom dead cen ter BDC the inlet reed valve closes Air above the piston is trapped...

Page 405: ...enters the head and passes through inter nal passages in the cylinder head and valve plate assembly and is returned to the engine Proper cooling is important in maintaining discharge air temperatures...

Page 406: ...efer to the tabulated technical data in the back of this manual for oil pressure minimum values COMPRESSOR DRIVE Check for noisy compressor operation which could indi cate excessive drive component we...

Page 407: ...available from an authorized Bendix parts outlets Unloader In order to test the inlet and discharge valves and the un loader piston it is necessary to have shop air pressure and an assortment of fitti...

Page 408: ...ented in this manual 1 Block the wheels of the vehicle and drain the air pres sure from all the reservoirs in the system 2 Drain the engine cooling system and the cylinder head of the compressor Ident...

Page 409: ...1 Head Gasket 2 1 Unloader Cover 7 1 O Ring 12 Intentionally Left Blank 3 1 Unloader Cap Gasket 8 1 Unloader Piston 13 1 Inlet Reed Valve Gasket 4 1 Unloader Balance Piston 9 1 O Ring 14 1 O Ring 5 1...

Page 410: ...e certain the unloader vent passage under the un loader cover 2 in the head is open and free of debris INSPECTION OF PARTS CYLINDER HEAD VALVE PLATE 1 Carefully inspect the cylinder head gasket surfac...

Page 411: ...f the balance piston 4 making certain the stamped logo is visible 10 Press and hold the unloader cover 2 in place on the cylinder head and install both unloader cover cap screws 1 Torque the cover cap...

Page 412: ...loaded 1800 RPM 1 3 HP Maximum inlet air temperature 250 F Maximum discharge air temperature 400 F Minimum oil pressure required at engine idling speed 15 PSI Minimum oil pressure required at maximum...

Page 413: ...intake should not be connected to any part of the exhaust gas recirculation E G R system on the engine D Insufficient compressor D For water cooled portions of the compressor cooling compressor runs 1...

Page 414: ...efects exist 2 Noisy compressor A Loose drive gear or A Inspect the fit of the drive gear on the compres operation components sor crankshaft The gear or coupling must be completely seated and the cran...

Page 415: ...ulty sections of the discharge vehicle manufacturer Do line not downsize the original equipment compressor D Slipping drive components D Check for faulty drive gears and couplings and replace as neces...

Page 416: ...Replace or repair the compressor as necessary C Loose crankcase end C Check the cap screw torques and tighten as cover or bottom cover necessary Replace gaskets or o ring D Loose oil supply or return...

Page 417: ...n as necessary improper antifreeze Check coolant flow through compressor to as strength sure the proper antifreeze mixture reaches the compressor C Faulty compressor C If casting porosity is detected...

Page 418: ...16 BW2158 Honeywell Commercial Vehicle Systems Company 4 2001 Printed in USA...

Page 419: ...gm and piston The LP 3 is available with either one terminal or two The single terminal unit utilizes a metallic gasket between body and case to ground the lower contract strip The two terminal unit u...

Page 420: ...ions at the Low Pressure Indicator 5 Disconnect the air line and mounting bolts or unscrew the Indicator from the fitting and remove INSTALLING 1 Install in a convenient location for servicing 2 Conne...

Page 421: ...the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 6 Never connect or d...

Page 422: ......

Page 423: ...ndently from the trailer The PP 5 is unique in having an auxiliary piston in the lower cover which upon receiving a pneumatic signal of 18 psi or more will cause the valve to move from the applied to...

Page 424: ...resent in the delivery volume and leakage at the exhaust port should not exceed a 1 bubble in five seconds Note If any of the above push pull valves do not function as described or if leakage is exces...

Page 425: ...ain the air pressure from all reservoirs before beginning any work on the vehicle 4 Following the vehicle manufacturer s recom mended procedures deactivate the electrical system in a manner that remov...

Page 426: ...recautions pertaining to use of those tools 9 Use only genuine Bendix replacement parts com ponents and kits Replacement hardware tubing hose fittings etc should be of equivalent size type and strengt...

Page 427: ...r controlled devices They may be lever or button operated direct or remote control The TW 1 Figure 1 is normally panel mounted with a steel zinc or nylon manually operated lever Some are equipped with...

Page 428: ...s No leakage permitted If the TW valve does not function as described or if leakage occurs it is recommended that it be replaced with a new unit or repaired with genuine Bendix parts REMOVING Secure t...

Page 429: ...sed to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 6 Never connect or disconnect a hose or line containing pressure it may whi...

Page 430: ......

Page 431: ...DESCRIPTION Double Check Valves are used in an air brake system to direct a flow of air into a common line from either of two sources whichever is at the higher pressure They may be used for directing...

Page 432: ...aced with genuine Bendix parts The follow ing instructions should prove helpful DISASSEMBLY 1 Remove end cap s from valve 2 Remove grommets if applicable 3 Remove shuttle and or shuttle guide disc and...

Page 433: ...leaking heated or electrically 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 pressu...

Page 434: ...4 main local global operation trouble m e n u search search shooting BW1846 AlliedSignal Truck Brake Systems Co 1 1999 Printed in U S A...

Page 435: ...alves can also be used to delay filling of auxiliary reservoirs to insure a quick build up of brake system pressure The PR 2 and PR 4 pressure protection valves have one 1 4 N P T F supply port and on...

Page 436: ...the pressure indicated on the valve s label or in the vehicle handbook The gauge on the delivery side of the valve should continue to show loss of pressure while the gauge on the supply side should st...

Page 437: ...ing heated or electrically 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 h...

Page 438: ......

Page 439: ...to it from the foot brake valve or other source The R 12 and R 14 Relay Valves are designed for either reservoir or frame mounting A universal mounting bracket is furnished that permits easy intercha...

Page 440: ...change holding the brake application at that level EXHAUST OR RELEASE When air pressure is released from the service port and air pressure in the cavity above the relay piston is ex hausted air press...

Page 441: ...ins the body to check for seal ring leakage no leakage 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...

Page 442: ...R1 BOBTAIL PROPORTIONING VALVE FRONT AXLE SERVICE RESERVOIR REAR AXLE SERVICE RESERVOIR SPRING BRAKES GAUGE SR 5 TRAILER SPRING BRAKE VALVE SUPPLY LINE SERVICE LINE E 7 E 12 OR E 15 R 14 RELAY VALVE R...

Page 443: ...e body 9 Install the exhaust cover assembly in the body taking care not to damage the o ring 10 While depressing the exhaust cover install the retain ing ring Make certain the retainer is completely s...

Page 444: ...d kits Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 10 Components w...

Page 445: ......

Page 446: ...8 main local global operation trouble m e n u search search shooting BW1431 AlliedSignalTruckBrakeSystemsCo 1 1999 PrintedinU S A...

Page 447: ...pressure forces the edges of the diaphragm down and air flows out the delivery port When air pressure being delivered beneath the diaphragm equalsthepressurebeingdeliveredbythebrakevalve above the dia...

Page 448: ...ly and securely Torque to 30 60 inch pounds 3 Perform tests as outlined in Operating and Leakage Tests section IMPORTANT PLEASE READ When working on or around a vehicle the following general precautio...

Page 449: ...herefore provides the driver with a less sensitive feel when making a brake application The E 10P Dual Brake Valve is generally used on busses where smooth brake applications contribute to passenger c...

Page 450: ...TCOVER ATTACHINGSCREWS BODY ATTACHING SCREWS 13 12 FIGURE 3 TYPICAL PIPING SCHEMATIC TP 5TRACTOR MV 3 BRAKE SLACK COMPRESSOR SUPPLY RESERVOIR 1 SERVICE 2 SERVICE DOUBLE CHECK SPRING SLACK TRAILER CONT...

Page 451: ...e such as broken air lines and broken or missing parts Every 3 months or 25 000 miles or 900 operating hours Clean any accumulated dirt gravel or foreign material away from the heel of the treadle plu...

Page 452: ...with genuine Bendix parts available at authorized Ben dix parts outlets Refer to figures 4 5 and 6 for item numbers referenced in parenthesis REMOVAL 1 Chock the vehicle wheels or park the vehicle by...

Page 453: ...BODY EXHAUST COVER ATTACHING SCREWS QTY 4 BODY ATTACHING SCREWS QTY 4 12 UPPER BODY 14 16 28 9 17 24 32 11 10 13 14 9 30 LOWER BODY BODY ATTACHING SCREWS QTY 4 12 EXHAUST COVER ATTACHING SCREWS QTY 4...

Page 454: ...obal operation trouble m e n u search search shooting FIGURE 5 E 8P BRAKE VALVE EXPLODED VIEW FIGURE 6 E 10P BRAKE VALVE EXPLODED VIEW FIGURE 5 E 8P BRAKE VALVE EXPLODED VIEW FIGURE 6 E 10P BRAKE VALV...

Page 455: ...otate clockwise until the top surface of the spring seat is even with the top surface of the piston Set aside 6 Place relay piston spring 21 in concave portion of relay piston 20 and install relay pis...

Page 456: ...ury resulting from contact with moving rotating leaking heated or electrically charged com ponents 6 Never connect or disconnect a hose or line con taining pressure it may whip Never remove a componen...

Page 457: ...9 main local global operation trouble m e n u search search shooting BW2066 AlliedSignal Truck Brake Systems Co 7 1999 Printed in USA...

Page 458: ......

Page 459: ...y failure occur in the service brake system 3 Prevents compounding of service and spring forces The valve has one park control one service control one supply one balance four delivery NPTF ports and a...

Page 460: ...UPPER BODY VALVE RETAINER SPRING LOWER BODY SPRING CHECK VALVE GUIDE O RING O RING DOUBLE CHECK VALVE O RING CHECK VALVE COVER DIAPHRAGM WASHER RETAINING RING VALVE SEAT DIAPHRAGM 10 TORX HEAD SCREW R...

Page 461: ...3 FIGURE 3 SYSTEM SCHEMATIC WITH PP DC PARK CONTROL FIGURE 4 SYSTEM SCHEMATIC WITH PP 1 PARK CONTROLAND DC 4 DOUBLE CHECK VALVE DC 4...

Page 462: ...TORSABOVE 107 PSI FIGURE 6 Once the SR 7 valve delivery pressure reaches 107 psi nominal the inlet and exhaust are closed valve lap position This maintains the spring brake hold off pressure at 107 ps...

Page 463: ...akes by pulling the dash valve button out exhausts spring brake air pressure through the SR 7 exhaust port FIGURE 8 PARKING INLET VALVE SEATED SECONDARY RESERVOIR CONSTANT PRESSURE CONTROL LINE PRESSU...

Page 464: ...E PORT LOSS OF PRIMARY CIRCUIT PRESSURE CONTROL PORT SECONDARY CIRCUIT PRESSURE SECONDARY RESERVOIR NO PRESSURE CONTROL LINE PRESSURE DELIVERY TO SPRING BRAKES CONTROL PORT LOSS OF SECONDARY CIRCUIT P...

Page 465: ...ressure reading Correct spring brake actuator hold off pressure is 107 psi nominally 3 Place parking control valve in park position gauge reading should drop to zero promptly A lag more than 3 seconds...

Page 466: ...d and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 9 Use only genuine Bendix replacement parts components and...

Page 467: ...el slip due to driveline inertia by communicating with the engine s controller and increasing the engine torque The EC 60 advanced model providesABS based stability features referred to as ESP Electro...

Page 468: ...Bendix Roll Stability Program RSP is an all axle ABS solution that helps reduce vehicle speed by reducing the engine s throttle and applying all vehicle brakes as needed reducing the vehicle s tenden...

Page 469: ...d in an environmentally protected area All wire harness connectors must be properly seated The use of secondary locks is strongly recommended Cab ECUs utilize connectors from the AMP MCP 2 8 product f...

Page 470: ...nk code mode and is typically located on the vehicle s dash panel Optional ABS Off Road Switch and Indicator Lamp Operation Advanced EC 60 controllers use an optional dash mounted switch for the opera...

Page 471: ...Diagnostic Trouble Codes DTCs are present on the ECU 2 When full ABS operation is not available due to presence of a DTC on the ECU 3 If the ECU is unplugged or has no power 4 When the ECU is placed...

Page 472: ...or ATC intervention the lamp will ash rapidly 2 5 times per second When the ECU is placed in the ATC Mud Snow off road mode the lamp will ash slowly at a rate of once every 2 5 seconds Trailer ABS Ind...

Page 473: ...ng normal braking brake pressure is delivered through theABS PMV and into the brake chamber If the ECU does not detect excessive wheel slip it will not activate ABS control and normal vehicle service...

Page 474: ...ance both methods are recommended ATC ESP Lamp Output ATC Mud Snow Switch Input Advanced ECUs control the ATC ESP dash lamp as follows The ATC ESP dash lamp illuminates 1 During power up e g when the...

Page 475: ...The vehicle operator can activate the Mud Snow function with a switch on the dash panel Alternately a J1939 message may be used to place the vehicle in this mode The ATC ESP Indicator Lamp will ash s...

Page 476: ...em Always operate the vehicle safely drive defensively anticipate obstacles and pay attention to road weather and traf c conditions ABS ATC and ESP stability systems are no substitute for prudent care...

Page 477: ...trol and ESP are turned off This test mode is used to avoid torque reduction or torque increase and brake control activation when the vehicle is operated on a dynamometer for testing purpose The Dynam...

Page 478: ...and Pressure Sensor Diagnostic Trouble Code ESP is disabled ABS and ATC remain active Load Sensor Diagnostic Trouble Code ESP is disabled ABS and ATC remain active Steer Axle TCV Diagnostic Trouble Co...

Page 479: ...tions and systems 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless speci cally stated and approv...

Page 480: ...he steering column body 5 Slide the sensor over the column to remove Take note if the sensor label is facing upward or downward Installation 1 Obtain a new sensor The sensor is not repairable in the e...

Page 481: ...cs V4 0 or higher See Troubleshooting Diagnostic Trouble Codes Yaw Rate Sensor for the calibration procedure BRAKE DEMAND SENSOR CALIBRATION Calibration must be performed under the following condition...

Page 482: ...5 seconds If the switch is held for more than 5 seconds the ECU will register a malfunctioning switch 3 Pauses between pressing the switch when a sequence is required e g when changing mode must not...

Page 483: ...enter the various diagnostic modes Blink Code Timing The ECU responds with a sequence of blink codes The overall blink code response from the ECU is called a message Each message includes depending on...

Page 484: ...meter Test Mode The Dynamometer Test Mode is used to disable ESP ATC when needed e g when performing any vehicle maintenance where the wheels are lifted off the ground and moving including dyno testin...

Page 485: ...oblems using Diagnostic Trouble Code reporting via LEDs Reset Diagnostic Trouble Codes on Bendix ABS ECUs by holding a magnet over the reset in center of RDU tool for less than 6 seconds Enter the Sel...

Page 486: ...tics V4 0 Software Bendix ACom Diagnostics V4 0 is a PC based software program and is designed to meet RP 1210 industry standards developed by the Truck Maintenance Council TMC This software provides...

Page 487: ...page 28 12 Miscellaneous pages 30 31 13 ECU page 29 14 Wheel Speed Sensors page 22 15 Wheel Speed Sensors page 22 16 Pressure Modulator Valves page 24 17 Pressure Modulator Valves page 24 18 Drive Axl...

Page 488: ...etween sensor leads and other sensors Check for corroded damaged wiring or connectors between the ECU and the wheel speed sensor Adjust sensor to contact exciter ring Rotate wheel and verify a minimum...

Page 489: ...Axle Speed Sensor Repair Tests 1 Take all measurements at ECU harness connector pins in order to check wire harness and sensor Probe the connector carefully so that the terminals are not damaged 2 Whe...

Page 490: ...orroded damaged wiring or connectors between ECU and PMV Verify 4 9 to 5 5 ohms from REL to CMN HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between EC...

Page 491: ...ouble codes If one of these is found troubleshoot these trouble codes rst before the PMV Cab mount ECU Looking into wire harness connector 4 Connector Pin PMV Location 1 Left Steer Axle Hold 2 Left St...

Page 492: ...tween TCV and TCV common Check for corroded damaged wiring or connectors between ECU and TCV The ECU is not con gured for ESP orATC but has detected the presence of a TCV Verify TCV wiring Inspect for...

Page 493: ...voltage under load Check vehicle battery and associated components Check for damaged wiring Check for damaged or corroded connectors and connections Check condition of fuse Measure ignition voltage E...

Page 494: ...mmunications Invalid data received from the engine or retarder Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify presence of engine and or retarder on J1939 Ve...

Page 495: ...ECU 04 15 ECU 06 16 ECU 0E 17 ECU 0D 18 ECU 19 19 ECU 1C 20 ECU 27 21 ECU 1D 22 ECU 1E 23 ECU 28 24 ECU 37 25 ECU Internal VIN Mismatch The ECU internally stored VIN does not match the VIN of the vehi...

Page 496: ...controller and voltage Verify condition and wiring of the retarder relay Check operation of diagnostic blink code switch Check wiring of diagnostic blink code switch and ABS WL Verify ABS WL ground i...

Page 497: ...rement Retarder disable to Voltage Open Circuit no continuity or Ground 2 Verify vehicle has retarder relay 3 Verify proper wiring from ECU to retarder relay Differential Lock Solenoid 1 Measure resis...

Page 498: ...being used SAS signal is invalid Verify proper installation of the SAS Verify proper wiring between the ECU and the SAS Check SAS output Verify that correct SAS is being used Loss of CAN communicatio...

Page 499: ...ering Angle Sensor and power ground SAS Wire Harness Terminal Measurement 4 to Voltage Ground Verify open circuit no continuity 3 to Voltage Ground Verify open circuit no continuity 4 To perform a cal...

Page 500: ...programming Perform YRS calibration procedure YRS calibration error Verify proper installation of the YRS Verify proper wiring between the ECU and the YRS Check YRS output Verify that correct YRS is...

Page 501: ...the Yaw Rate Sensor and power ground SAS Wire Harness Terminal Measurement 4 to Voltage Ground Verify open circuit no continuity 3 to Voltage Ground Verify open circuit no continuity 4 To perform a c...

Page 502: ...per installation of the YRS LAS Verify proper wiring between the ECU and the YRS LAS Check YRS LAS output Verify that correct YRS LAS is being used Verify proper ECU programming Perform LAS calibratio...

Page 503: ...resistance between input voltage and ground at the sensor wiring harness connector Test Measurement Power and Ground Input 4 75 to 5 25 volts B Power Input A Ground Input 2 Verify wiring between the...

Page 504: ...d ATC ORS X3 Connector Pin Assignments Pin Designation Pin Designation Pin Designation 1 ABS ORS 6 PMV AA Left CMN 11 WSS AA Left 2 Diff Lock SOL1 7 PMV AA Left REL 12 WSS AA Right 3 TCV CMN SA 8 Stop...

Page 505: ...lly routed to avoid contact with rotating elements Wiring must be properly secured approximately every 6 to 12 inches using UV stabilized non metallic hose clamps or bow tie cable ties to prevent pinc...

Page 506: ...AMP Twist Lock Bayonet 1 967325 2 1 967325 3 929975 1 12077411 929975 1 12155975 WS 24 Wheel Speed Sensor Connectors Packard GT 150 series Packard Metripack 150 2 series Deutsch DTM06 series Packard M...

Page 507: ...BRAKE Speed Sensor Mounting Block 100 Tooth typical Speed Sensor Exciter Ring WS 24 Speed Sensor Hub Assembly WS 24 speed sensor 100 Tooth Exciter Ring Mounting Block Max Gap Sensor to Exciter 015 In...

Page 508: ...IR REQUIRED 5A 18 20 20 MOMENTARY SWITCH 18 STOP LAMP SWITCH INPUT REQUIRED FOR ATC AND ALL WHEEL DRIVE VEHICLES MAY BE PROVIDED VIA HARDWARE INPUT OR J1939 COMMUNICATION 20 21 ADDITIONAL AXLE WSS AND...

Page 509: ...oint where retardation and stability are maximized The brake pressure that is best for the wheel in question is directed individually into each brake chamber J1587 The SAE heavy duty standard diagnost...

Page 510: ...l Speed Sensor DTCs 4 6 DA Left WSS Erratic Sensor Signal 4 8 Wheel Speed Sensor DTCs 5 6 DA Right WSS Erratic Sensor Signal 5 8 Wheel Speed Sensor DTCs 14 6 AA Left WSS Erratic Sensor Signal 6 8 Whee...

Page 511: ...ressure Modulator Valve DTCs 20 5 Trailer PMV HLD Solenoid Shorted to Voltage 42 5 Pressure Modulator Valve DTCs 7 6 SA Left PMV HLD Solenoid Open Circuit 43 5 Pressure Modulator Valve DTCs 8 6 SA Rig...

Page 512: ...olenoid Open Circuit 18 13 TCV DTCs 18 4 TCV DA Con guration Error 19 4 TCV DTCs 19 1 TCV SA Solenoid Shorted to Ground 19 3 TCV DTCs 19 2 TCV SA Solenoid Shorted to Voltage 19 5 TCV DTCs 19 3 TCV SA...

Page 513: ...Error Inside Model Based Limits 99 12 Lateral Acceleration Sensor DTCs 23 6 LAS Plausibility Error Outside Model Based Limits 99 14 Lateral Acceleration Sensor DTCs 23 7 Erratic ESP Sensor Signal 77...

Page 515: ...bers on the same side of a tandem axle the modulator is sometimes mounted ahead of a quick release valve which provides quick exhaust of service applications during normal braking In the case of indiv...

Page 516: ...K A wiring harness connects the vehicle modulators to the controller TheABS controller is able to simultaneously and independentlycontroltheindividualmodulators Whenvehicle power is supplied to theABS...

Page 517: ...Hold Diaphragm Spring Brake Chamber Brake Valve Exhaust Diaphragm Exhaust Valve Exhaust Port M 32 Modulator M 32QR Modulator Bias Valve Delivery Port Supply Port Supply or Hold Diaphragm Spring Brake...

Page 518: ...reapplication of air pressure to the brake actuator The solenoids in the modulator are controlled independently by the antilock controller ECU An experienced driver of a vehicle without ABS who encoun...

Page 519: ...solenoid allows application air to flow to the control side of the exhaust diaphragm which then seals the exhaust passage With the exhaust diaphragm seated further exhaust of brake chamber air pressur...

Page 520: ...ice technicians 1 Park the vehicle on a level surface and block or chock the wheels Release the parking brakes and build the air system to governor cut out 2 Turn the engine ignition key to the OFF po...

Page 521: ...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 h...

Page 522: ...cation made during VALVE REMOVAL step 5 4 Reconnect the electrical connector to the modulator 5 After installing the valve test all air fittings for excessive leakage and tighten as needed TECHNICAL...

Page 523: ...RONT AND TAG AXLE STUDS 5 7 HUB MOUNTED WHEELS 6 7 1 CARE OF WHEELS 6 8 FRONT AND TAG AXLE WHEEL HUBS 6 8 1 HUB BEARING INSPECTION 6 9 DRIVE AXLE WHEEL HUBS 7 9 1 BEARING ADJUSTMENT 7 9 2 DISASSEMBLY...

Page 524: ...s Check all parts for damage and make sure that wheel nuts are tightened to the proper torque In the case of a new vehicle or after a wheel installation stud nuts should be tightened every 100 miles 1...

Page 525: ...500 lbf ft 610 680 Nm for aluminum wheel CAUTION Insufficient mounting torque can result in damage to parts Excessive mounting torque can cause studs to break and the wheel to crack in stud hole area...

Page 526: ...The following measures should be taken to maintain original appearance of the aluminum wheels 1 Remove any tar from wheel surface with a good quality tar remover 2 Spray Alcoa Cleaner Pr vost 683529...

Page 527: ...side of the broken one must also be replaced since they could have been subjected to excessive strain and may be fatigued When installing wheel studs to hubs check nuts retaining the wheel stud to wh...

Page 528: ...ply retighten very loose wheel fixings or wheels that are continually becoming loose Find out why they are loose and whether any damage has been caused Use trained personnel and keep records of all at...

Page 529: ...Replace the lock ring and adjust nut dowel pin in one of the holes The ring may be turned over if necessary to allow more accurate bearing adjustment 4 Tighten lock nut and check bearing adjustment R...

Page 530: ...of air pressure To avoid the hazards of under inflation always maintain tires at their recommended inflation pressure Improper inflation decreases tire life NOTE Bus Shells vehicles before being conv...

Page 531: ...ease Check inflation pressure on all tires including the spare tire using an accurate tire gauge NOTE The recommended tire inflation pressures are given in the applicable documents supplied with the v...

Page 532: ...within 1 8 3 mm of the same rolling radius NOTE It is recommended that all tires on coach be of the same type 11 3 WHEEL BALANCING Before balancing wheels must be clean and free from all foreign matt...

Page 533: ...rtification plate according to the tire selection WARNING Special tire selection may lower maximum allowable speed limit even below posted speed limit For maximum safety check with tire manufacturer C...

Page 534: ......

Page 535: ...te 207 Mississauga Ontario Canada L5R 3L1 800 668 1150 Alcoa Inc Wheel Products International 1600 Harvard Ave Cleveland Ohio 44105 800 242 9898 www alcoawheels com 08 02 New Dura Bright wheels shed d...

Page 536: ...Wheel Service Center at 800 242 9898 option 2 or 888 279 3055 Limited Warranty FOR HEAVY DUTY TRUCKS TRUCK TRAILERS AND BUSES Dura Bright wheels denoted by Alcoa part numbers ending with a 4 and 7 wi...

Page 537: ...um of one inch from the periphery of any hand hole 3 Location of stamped identification on inside of wheel should be as close to the factory identification stamping as possible Note Use of an impressi...

Page 538: ...um of one inch from the periphery of any hand hole 3 Location of stamped identification on inside of wheel should be as close to the factory identification stamping as possible Note Use of an impressi...

Page 539: ...Wheel Service Center at 800 242 9898 option 2 or 888 279 3055 Limited Warranty FOR HEAVY DUTY TRUCKS TRUCK TRAILERS AND BUSES Dura Bright wheels denoted by Alcoa part numbers ending with a 4 and 7 wi...

Page 540: ......

Page 541: ...y wash away brightens the wheel Now your wheels can look their best with less effort than with any previous steel or aluminum wheel That lets you save money and time and still hit the road with clean...

Page 542: ...ilable are listed below Other wheel part numbers may be available upon request Contact your Alcoa sales representative for availability Do not exceed maximum wheel load Customer must compare OEM vehic...

Page 543: ......

Page 544: ...alkaline Dura Bright Surface Treated Wheels are warranted against a Filiform corrosion worm or hair like lines generally milky in appearance underneath surface protective treatment and emanating from...

Page 545: ...thread engagement stud located wheels ball seat mounting 29 4 9 Tightening stud located ball seat cap nuts 29 4 10 Single dualed and wide base wheels hub piloted mounting two piece flange nuts 31 4 1...

Page 546: ...t hole diameter 3 22 5x7 50 15 DC 7200 53 6 28 5 32 120 TR545D 873100 3 4 016000 1 1 8 017000 2225 3 4 Stud 5995 L R 1 1 8 Stud 5996 L R 5988 L R 7896 L R 5996 L R 150 Front 076015 Rear 077015 DB 4 22...

Page 547: ...011000 39874 39874 181 Front 076018 or 076085 Rear 077018 or 077085 DB DF 27 22 5x12 25 15 DC 11 000 71 5 8 4 68 120 TR545E 823660A 011000 39874 39874 181 Front 076018 or 076085 Rear 077018 or 077085...

Page 548: ...e 1 Capacity ratings as dual or single in highway service bias ply or radial Load ratings in lbs for items 39 through 50 rounded to nearest multiple of 5 2 Some wheels may bear part numbers not shown...

Page 549: ...eel when the outer wheel is removed During tire changes thoroughly examine the entire wheel Pay particular attention to the rim contour and the surfaces of the rim On tube type wheels carefully inspec...

Page 550: ...d A wheel that has been exposed to excessive heat may appear to be in good condition if it has been cleaned Even if a wheel does not appear to be obviously burned check the valve hole and labels for e...

Page 551: ...e the circumference of the bead seat on the open side see illustration below with a ball tape Ball tapes used for measuring wheel circumference can be purchased from the Tire and Rim Association Inc 1...

Page 552: ...ar can also be caused by improperly seated tires Inspect the tire for proper seating on the wheel The tire beads may not be seated properly If so remove the wheel from the vehicle deflate and break th...

Page 553: ...acks emanating from stud hole to stud hole Causes are undersized diameter of wheel support surface see specifications below support surface not flat incorrect attachment parts see 4 12 page 34 and ins...

Page 554: ...ome of these are salt chloride compounds used for snow removal and highly alkaline materials If the air used to fill tubeless tires or the tire itself is not dry the areas of the wheel under the tire...

Page 555: ...an lead to damaged ball seats on stud located wheels and can damage the disc surface of hub piloted wheels Remove damaged wheels from service Damaged hub piloted bolt hole Elongation from true round d...

Page 556: ...he gutter Such projections must be removed Remove the wheel from service if damaged Cracking in bottom of gutter flange Occasionally circumferential cracks may appear in the bottom of the gutter area...

Page 557: ...ble Rim Gauge Alcoa P N 000700 Daylight in this area indicates acceptable rim No daylight in this area indicates excessive wear Remove from service immediately Irregular wear on the surface of the rim...

Page 558: ...sharp enough to cut the rubber on the sharpness indicator gauge the edge can be removed per the edge removal procedures below If the rubber is not cut then the wheel can be returned to service withou...

Page 559: ...thod of removing the edge Operators should use all care to keep a uniform edge when using these tools photo 5 Air or Electric Grinder Another quick and effective method of removing the sharp edge caus...

Page 560: ...h metal to smooth the edge Take care to make sure the edge removal is as uniform as possible Avoid gouging the wheel 16 2 Rim flange wear continued CAUTION Removing sharp edges with hand or power tool...

Page 561: ...ce Manual or OSHA safety wall charts and procedures 17 2 Rim flange wear continued WARNING Welding or brazing the rim flange or any area of an Alcoa aluminum wheel will weaken the wheel Weakened or da...

Page 562: ...for damage Do not use a damaged or severely corroded wheel See Section 2 page 5 4 Clean the wheel face with mild detergent and the tire bead seat areas with a wire brush Be sure the wheel is dry befo...

Page 563: ...arate violently This violent separation can cause serious injury or death Always contain the tire wheel assembly in an inflation cage during inflation WARNING WARNING Recommendations for mounting tube...

Page 564: ...Fulfillment Markinetics Inc P O Box 809 Marietta OH 45750 WARNING Use of a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel can lead to an unco...

Page 565: ...0 Tire Size Tire Size for both radial Approved for both radial Approved and bias tires Rim Widths and bias tires Rim Widths Recommendations for demounting tubeless tires 3 4 WARNING An aluminum wheel...

Page 566: ...ween bead and flange a short distance from the spanned area Pry bead free of rim repeating process until entire bead is free from wheel Insert straight end of tire tool between beads and both rim flan...

Page 567: ...ace the studs on each side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with the stud manufacturer for regular maintenance and stud replacemen...

Page 568: ...ad flange nut Mounts dualed wheels with 32mm bolt holes to wheel centering hubs Right hand threads used on both sides of vehicle P N 4307 32 M22x1 5 RH threads 2 piece 33mm hex head flange nut Mounts...

Page 569: ...unting surface Mounting surface End of stud End of stud 4 Stud located ball seats are spherical 4 4 The nut seat for the stud located ball seat mounting system is a precision machined spherical surfac...

Page 570: ...e treated wheels to protect the wheel contact surfaces from marring DiscMate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum as shown below Correct si...

Page 571: ...laced between the contact surfaces of the Dura Bright wheel and the brake drum and between the dual aluminum wheels as shown below On occasion Alcoa aluminum truck wheels are operated dualed with a st...

Page 572: ...can run loose cause stud breakage and disengage from the vehicle which can cause serious injury or death Loose running wheels can lead to stud breakage Use only cap nut 7896R or L or its equivalent wh...

Page 573: ...seat cap nuts 4 9 The number of turns to disengage a 1 1 8 inch nut should be at least five full turns At least seven full turns should be required to disengage a 3 4 inch nut WARNING Lubricants shoul...

Page 574: ...heel hub or drum Do not use aerosol cans for lubrication of stud threads On vehicles equipped to accept wheels manufactured for use with the stud located ball seat mounting system wheel studs on the r...

Page 575: ...o either the right or left side of the vehicle The same flange nut is used to mount dualed or single wheels Proper stud standout for single wheels is 2 inch 50 8mm minimum dualed wheels require 2 81 i...

Page 576: ...orquing of flange nuts should be done in recommended sequences WARNING Undertorqued flange nuts allow wheels to run loose and fatigue studs or lose nuts Overtorquing can stretch studs causing them to...

Page 577: ...ighten all two piece flange nuts then tighten to the recommended torque following the proper sequence shown below for your type wheel After 50 100 miles of operation torque should be rechecked Check t...

Page 578: ...proper hardware assemblies The following are examples of incorrect wheel assemblies Incorrect use of ball seat cap nut Do not use ball seat cap nuts with hub piloted wheels Incorrect use of two piece...

Page 579: ...re they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting practices should be reviewed For proper nut torque refer to the chart below Mount Nut...

Page 580: ...or straightening to repair damage from striking curbs or other causes The special alloy used in these wheels is heat treated and uncontrolled heating will weaken the wheel Do not rework weld heat or b...

Page 581: ...s abrasive brushes steel wool scouring pads or strong chemicals such as acids or lye based products Never spray cold water on extremely hot wheels Always allow time to cool before cleaning 2 When tire...

Page 582: ...such as Alcoa DiscMates is highly recommended The use of the Alcoa Hub Cover System on Alcoa Dura Bright wheels will also assist in limiting such damage and help maintain the appearance of your Alcoa...

Page 583: ...hart The following is the Alcoa Aluminum Wheel inter changeability information from the OSHA Multipiece Rim Matching Chart For a complete matching chart write to U S Department of Labor Occupational H...

Page 584: ...k ring which is not clearly identifiable WARNING Use of a Firestone 5 side and lock ring assembly with a wheel machined for Firestone DT or Goodyear LW split side ring and vice versa can lead to explo...

Page 585: ...ng groove If a split side ring is required start the leading edge and walk the side ring onto the wheel Seat the second end of the split side ring or lock ring with a rubber plastic or leather facet m...

Page 586: ...n subjected to uncontrolled excessive heat such as a tire fire wheel bearing failure or braking system drag seize or a high pressure tire wheel separation 1 Before removing wheel from vehicle remove t...

Page 587: ...re if gouging the rim is to be avoided A stop welded to the tool is recommended Insert the tapered end of the tire tool into the notch on the locking ring Pry up carefully to avoid bending the ring an...

Page 588: ...ter which contains at least the same instructions safety precautions and other information contained in the charts that is applicable to the types of wheels being serviced Installing a rim wheel means...

Page 589: ...uals and the contents of this standard iii Where an employer knows or has reason to believe that any of his employees is unable to read and understand the charts or rim manual the employer shall assur...

Page 590: ...n line valve with a pressure gauge or a presettable regulator and iii A sufficient length of hose between the clip on chuck and the in line valve if one is used to allow the employee to stand outside...

Page 591: ...ss the employer can demonstrate that performance of the servicing makes the employee s presence in the trajectory necessary 11 No heat shall be applied to a multi piece wheel or wheel component f Safe...

Page 592: ...ce accidents among employees who service large vehicle rim wheels Reprints of the charts are available through the Occupational Safety and Health Administration OSHA Area and Regional Offices The addr...

Page 593: ...which supports the rim DISC WHEEL A one piece forged or two piece welded assembly of a disc and a rim DROP CENTER The well or center portion of the wheel rim FLAT BASE WHEEL A multi piece wheel with a...

Page 594: ...ation for pounds per square inch REVERSIBLE Term applied to a disc wheel which can be reversed on the hub without changing the position of the tire centerline RIM CENTERLINE A line to the radial axis...

Page 595: ...is equal to or greater than the tire manufacturer s recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel on pages 2 and 3 Both inset and ou...

Page 596: ...52 9 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 inch 9 1 9 Conversion Tables...

Page 597: ...imeters to Inches Millimeters x 0 03937 Inches PSI to kPa PSI x 6 8948 kPa kPa to PSI kPa x 0 145 PSI Pounds to Kilograms Pounds x 0 4536 kg Kilograms to Pounds kg x 2 2050 Pounds Foot pounds to Kilog...

Page 598: ...Wheel and Forged Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright 2004 Alcoa Wheel and Forged Products All Rights Reserved Form E37 13584 Printed in USA 03...

Page 599: ...SCRIPTION 5 6 2 REMOVAL AND INSTALLATION 5 6 3 MAINTENANCE 6 7 STEERING WHEEL 6 7 1 REMOVAL 6 7 2 INSTALLATION 6 8 STEERING COLUMN 6 8 1 REMOVAL 6 9 TURNING ANGLE ADJUSTMENT 6 10 STEERING LINKAGE ADJU...

Page 600: ...ARTMENT 4 FIGURE 4 STEERING COLUMN 6 FIGURE 5 STEERING STOP SCREW 6 FIGURE 6 DRAG LINK TO BELL CRANK CONNECTION 7 FIGURE 7 PITMAN ARM ADJUSTMENT 7 FIGURE 8 FIXING NUT PUNCH MARK 8 FIGURE 9 DRAG LINK I...

Page 601: ...ransfers the turning motion of the steering wheel to the steering arms Hydraulic components are added to transmit increase and regulate steering control forces These elements are 1 A hydraulic power c...

Page 602: ...orsion bar which is pinned with the valve slide and the worm keeps the control valve in the neutral position as long as no opposing force is applied to the steering wheel The steering housing contains...

Page 603: ...Perform troubleshooting of the steering gear as outlined in the ZF SERVOCOM Repair Manual the ZF SERVOCOM Operating Servicing Maintenance and Inspection Instructions and the TRW Power Steering Pump S...

Page 604: ...accessible from the front driver s area To access these joints proceed as follows 1 From the front driver s compartment area remove the three plastic fasteners on steering column lower cover Remove t...

Page 605: ...y detected while rotating the steering wheel in both directions Replace defective parts CAUTION Front wheel alignment should be checked and adjusted if necessary any time a component of the steering s...

Page 606: ...g a protractor check the angle of the pitman arm refer to Fig 7 for details 3 The pitman arm should be adjusted with reference marks aligned or to an angle of 90 in relation with the vertical axis tow...

Page 607: ...Every precaution should be taken to prevent entry of dirt grit lint or other foreign matter into lubricant containers Replace fittings that have become broken or damaged Lubrication intervals as well...

Page 608: ...urn the steering wheel when the vehicle is stationary and especially when service brakes are applied wheel locking will oppose the effect of steering geometry which tends to make the front wheels rota...

Page 609: ...5 psi 150 Bar Gear ratio center 22 2 1 Gear ratio extremities 26 2 1 Minimum pump flow for 1 5 hwt sec 4 22 gpm 16 lpm Power Steering Gear Make ZF SERVOCOM Model 8098 Supplier number 8098 988 570 Prev...

Page 610: ...ler Oil capacity 4 US qts 3 7 liters Supplier number 91410A Prevost number 660982 Make Nelson Muffler Element filter Supplier number 83804 E Element filter Prevost number 660987 Power Steering Hydraul...

Page 611: ...r v i c e S e r v i c e 8090 I 04 06 e Design Operation Maintenance Inspection ZF Servocom Types 8090 8095 8097 and 8098 ZF Lenksysteme GmbH D 73522 Schw bisch Gm nd Telephone 07171 31 0 Fax 07171 31...

Page 612: ...teering efforts the driver has to exert on the steering wheel are low e g 30 N corresponding to approx 3 kg In the event of a failure of the hydraulic assistance for example owing to lack of oil the e...

Page 613: ...der The piston transforms the rotation of the steering input shaft C and of the worm D into an axial motion which it transmits to the sector shaft F The piston B and the worm C are positively connecte...

Page 614: ...steering gear The 3 functional drawings to Figs 1 to 3 give a simplified representation of the steering valve and the oil flow In addition these figures give a cross sectional view of the steering va...

Page 615: ...grooves of the valve rotor are displaced clockwise and the inlet slots K are opened wider to admit the oil while the inlet slots J are closed to the same extent and thus obstruct the feeding of oil t...

Page 616: ...ed to the left the piston will shift to the left Fig 3 Therefore pressure build up now takes place in the right hand cylinder chamber The control grooves of the valve rotor are displaced counter clock...

Page 617: ...hand adjusting screw If the piston is shifted to the right or to the left towards the lock stop the valve pins T and U are actuated by the adjusting screws X and Y fastened in the housing and the cyl...

Page 618: ...the safety inspection SP the work detailed in Chapter III Servicing work para s 3 5 3 10 has to be carried out in addition Following a test drive and a subsequent visual inspection of the complete ste...

Page 619: ...nnections for leakproof ness and damages The piston rod of the steering cylinder may be covered by a thin oil film but there must not be any oil drops Note When cleaning with a high pressure cleaning...

Page 620: ...AS steering gears Oil level check with the engine stopped The oil must be topped up to the upper mark of the oil dipstick Oil level check with the engine running When the engine is running the oil lev...

Page 621: ...e checked within the scope of the normal inspec tion In addition the safety inspection SP rules applying in the country of registration of the vehicle being inspected have to be complied with 3 1 Insp...

Page 622: ...em steering column bevel box steering gear drag links and steering cylinder for correct fastening Check whether the locking plate and the split pin are still perfectly secured By turning the steering...

Page 623: ...please refer to Chapter III para 5 3 7 Light operation of the steering gear part of SP If the steering system has a hydraulic defect this is indicated by increased steering efforts Start the engine At...

Page 624: ...k the steered axle up Unscrew the pressure and return lines from the steering gear Then have the engine run for a short time maximum 10 seconds to allow the oil to be sucked from the pump and the oil...

Page 625: ...o be removed from the vehicle and opened at a ZF Service Centre 4 2 Oil filling Attention When the steering system is filled with oil there is a risk of impurities getting into the steering oil circui...

Page 626: ...g wheel several times from lock to lock and while doing so watch the oil level Top up with oil if required In addition for vehicles equipped with a ground driven emergency steering pump Jack up the dr...

Page 627: ...nothing but oil is coming out Re tighten the screw 20 or 128 using a torque of 12 3 Nm Versions with set screw 20 and 128 Slacken the collar nut 21 or 129 of the topmost set screw 20 or 128 until not...

Page 628: ...r adjustments of the front axle were carried out 5 1 Hydraulic steering limitation with manual setting Fig 9 Fit a pressure gauge pressure range up to 250 bar or tool 1 ZF Servotest power steering tes...

Page 629: ...in 40 50 bar up to 20 dm3 min 50 60 bar above 20 dm3 min 70 80 bar To correct slacken the corresponding collar nut 21 or 129 and screw the set screw 20 or 128 Fig 14 in or out If a higher pressure is...

Page 630: ...ept Fig 11 5 2 Automatically adjusting hydraulic steering limitation Fig 12 Attention Steering gears with automatically adjusting steering limitations must not be rotated manually to the end positions...

Page 631: ...ively The opening of the steering limiter valve is determined by the position of the sliding bushes on the screws 20 and 128 5 2 2 Setting Note This setting Fig 14 can only be carried out after the st...

Page 632: ...the steering limiter valve is constantly open which means that with as well as without hydraulic assistance the steering wheel can only be rotated further at an in creased effort Repeat the setting o...

Page 633: ...valve insert 32 into the housing bore Remove o ring rests Fit a new greased O ring 31 to the screw 30 and screw it in again Tightening torque 30 10 Nm 3 Screws 20 and 128 Screw in new screws 20 and 1...

Page 634: ...he switching range by rotating the cover 221 Tightening torque Cap screws 223 5 5 Nm Testing tool Multimeter Note The switching range is set by varying the screw in depth of the switch 222 Washers 222...

Page 635: ...the spacing sleeves 233 the screening plate 234 and the cap screws 235 Tightening torque 2 8 Nm Check The installed position of the potentiometer 232 must be identical with the position as marked dur...

Page 636: ...n measurements paths 1 and 2 Measurement path 2 See Fig 20 Measurement path 1 See Fig 20 Additionally Plug in a jumper from blue to blue Plug in a jumper from red to red Unplug the green cable of path...

Page 637: ...drop arm or removing the drop arm by means of hammer blows is not permitted as such action may cause changes to the material and or inner damages to the steering gear 1 3 Additionally for vehicles wi...

Page 638: ...sleeves in the installed position only if this is possible Connecting lines and screwed connections must be thoroughly cleaned and deburred 2 1 Rotate the steering wheel to the straight ahead driving...

Page 639: ...e please refer to the technical cover sheet of the spare parts list If no data is given in the list the values below shall apply Depending on the vehicle type space restrictions may require a previous...

Page 640: ...and rear wheels 2 8 Put the drop arm on the serration making sure that the marks on the drop arm and on the sector shaft coincide see Fig 23 Screw the locking nut 50 on and tighten it applying the tor...

Page 641: ...further movement to the left is possible If the steering gear cannot be rotated any further to the left the lock stop and the axle stop respectively must be re set Attention It must be guaranteed tha...

Page 642: ...hapter III 2 16 Check the oil level Before pulling out the oil dipstick thoroughly clean the oil tank and its immediate vicinity to prevent dirt from getting into the hydraulic fluid Attention If the...

Page 643: ...universal tools For special applications special tools recom mended by the vehicle manufacturer may therefore be necessary Ordering ref No Tool 1 ZF Servotest 600 tester 7418 798 600 Tool 2 Dial with...

Page 644: ...Special Tools Instructions on Design Operation Maintenance and Inspection 33 Ordering ref No Tool 6 Adapter cable 7418 798 567 Tool 7 Servotronictest tester 7418 798 545...

Page 645: ...lay can be identified by the noticeable rattling noise occurring when the steering wheel is turned to and fro or stiff operation are ascertained replace the defective components 1 3 Checking for leaka...

Page 646: ...urn the steered wheels to the straight ahead driving position Corrections can be made by screwing the ball joint on the drag link further in or out Attention If the steering wheel position is not corr...

Page 647: ...ump and tool 1 ZF Servotest power steering tester Fig 26 This means that pressure relief takes place ahead of built in tool 1 On steering systems of this type the nameplate of the pump or of the press...

Page 648: ...excessive heating up of the inner parts of the pump and in consequence a premature wear of these parts Specified value maximum pressure see nameplate 10 Open the shut off valve again Wird der Sollwert...

Page 649: ...ox 1300 r p m The pump is now in the flow setting range Specified value see spare parts list Checking the minimum flow rate With the engine running at idling speed progressively close the shut off val...

Page 650: ...Troubleshooting Flow rate dm 3 min Pump speed r p m Minimum values Pump speed r p m Flow rate dm 3 min Minimum values Instructions on Design Operation Maintenance and Inspection 39...

Page 651: ...min 70 80 bar Repeat this test for the other direction of rotation Setting the steering limitation see Chapter III para 5 1 6 4 2 Automatically adjusting hydraulic steering limitation Carry out the te...

Page 652: ...e Set tool 1 ZF Servotest 6 to a flow rate which is 0 5 dm3 min higher than the maximum permis sible leakage oil value Repeat the leakage oil test as described above The leakage oil value measured in...

Page 653: ...vehicle is RH steered as per vehicle manufac turer s instructions Put tool 2 on the steering wheel and attach the pointer to the dashboard or to the wind screen Fig 30 Raise the engine speed to appro...

Page 654: ...ring system Universal joints steering column Stiff operation Check Replace Oil filter soiled Replace Steering gear defective Repair Replace Replace Pump defective Repair Replace Replace Stiff operatio...

Page 655: ...lumn Eliminate stiff operation Steering gear defective Repair Replace Replace Exact straight ahead driving impossible Oil level too low Repair leakage Top up with oil Top up with oil Bleed steering sy...

Page 656: ...e be low No tripping of potentiometer 232 Replace steering gear Wrong operation of poten tiometer 232 Wrong setting Set potentiometer Wrong cabling Check cabling Cap screws 223 and 235 loose Check and...

Page 657: ...nance and Inspection IX Key to numbers in figures and exploded drawing 20 Set screw screw 20 1 O ring 20 9 Screw 21 Collar nut 22 Valve insert 23 O ring 30 Screw 31 O ring 32 Valve insert 54 Sealing r...

Page 658: ...Inspection 47 Customer Steering gear version Vehicle manufacturer Pump manufacturer Vehicle type or model Pump version Mileage Emergency steering pump 1 Test drive carried out yes no Complaints 2 Tes...

Page 659: ...type or model Pump version Mileage Emergency steering pump 1 Inspection intervals see Chapter III 2 Test drive carried out yes no Complaints 3 Visual inspection carried out yes no Complaints 4 Oil fil...

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Page 761: ...EERING ARMS 11 2 9 1 Removal 11 2 9 2 Installation 11 2 10 LUBRICATION FITTINGS 11 3 BALL JOINTS 13 3 1 LOWER AND UPPER A ARM BALL JOINT 13 3 1 1 Inspection 13 3 1 2 Stripping Down 13 3 1 3 Assembly 1...

Page 762: ...ADJUSTMENT 28 10 HEIGHT CONTROL VALVE 29 10 1 LOADING POSITION 30 10 2 NEUTRAL POSITION 30 10 3 UNLOADING POSITION 30 10 4 MAINTENANCE 30 10 5 REMOVAL AND INSTALLATION 30 11 LEVEL LOW LEVELING SYSTEM...

Page 763: ...AL BALL JOINT 15 FIGURE 21 STEERING LINKAGE MEASURE 16 FIGURE 22 FRONT END ALIGNMENT DIAGRAM 18 FIGURE 23 AIR SPRINGS 19 FIGURE 24 AIR SPRING AND SHOCK ABSORBER 20 FIGURE 25 SHOCK ABSORBER 21 FIGURE 2...

Page 764: ...The bell crank and idler arm are connected by a relay rod A drag link connected to the bell crank and the pitman arm which is mounted to the steering gear transfers the turning motion of the steering...

Page 765: ...in this section To check steering maximum turning angle proceed with the following method 1 Check if front tires rub against the frame or if the steering gear has been serviced CAUTION If clamps are...

Page 766: ...PENSION PA1564 6 FIGURE 3 CLAMP POSITIONING 16169 FIGURE 4 CLAMP POSITIONING 16178 FIGURE 5 CLAMP POSITIONING 16172 FIGURE 6 CLAMP POSITIONING 16179 FIGURE 7 CLAMP POSITIONING 16170 FIGURE 8 CLAMP POS...

Page 767: ...14057 2 3 PITMAN ARM REMOVAL 1 Remove cotter pin nut and washer from drag link ball stud at pitman arm 2 Disconnect drag link from pitman arm using jaw style pullers pressure screw type WARNING Alway...

Page 768: ...change position of pitman arm 4 Install stud with nut and torque to 150 200 lbf ft 203 271 Nm Align nut with cotter pin slot tighten and install a new cotter pin 5 Torque mounting clamp bolt nut to 40...

Page 769: ...ording to figure 11 Grease must be able to exit the bell crank or idler arm mechanism For grease retainer installation use tool Pr vost 110683 3 Install bell crank or idler arm onto its mounting spind...

Page 770: ...bsorb shocks Strike the studs with a brass hammer to loosen end assemblies 3 Remove stud nuts then remove studs 4 Position new relay rod studs into bell crank and idler arm then tap stud ends with a b...

Page 771: ...n 1 Install steering arm onto steering knuckle 2 Torque steering arm to steering knuckle fixing bolts Torque short bolt M20 X 65 to 520 575 lbf ft 705 780 Nm Torque long bolt M24 X 100 to 751 830 lbf...

Page 772: ...and the other on the crank bell every 6 250 miles 10 000 km with good quality lithium base grease NLGI No 2 Shell Retinax LX or equivalent Apply grease gun pressure to the fitting until lubricant appe...

Page 773: ...load on the joint in all of the degrees of freedom in an axial radial etc sense with a suitable lever tool After the load is taken off the joint has to spring back into its starting position Free play...

Page 774: ...ll joint by lifting the front of the vehicle Apply a load on the joint in all of the degrees of freedom in an axial radial etc sense with a suitable lever tool After the load is taken off the joint ha...

Page 775: ...difference between the two dimensions is greater than 0 060 1 5mm then the ball joint should be replaced FIGURE 20 UPPER A ARM CENTRAL BALL JOINT 16116 4 FRONT END ALIGNMENT Proper front end alignmen...

Page 776: ...at the bottom B Fig 22 Front Axle Caster The inclination of the king pin from vertical in the fore and aft direction C Fig 22 4 2 FRONT END INSPECTION Before checking front end alignment make the foll...

Page 777: ...height from the floor Incorrect toe in results in excessive tire wear and steering instability with a tendency to wander 4 4 1 Toe In Check 1 Check the camber adjustment and adjust if necessary 2 Hois...

Page 778: ...16133 ALIGNMENT SPECS See Figure 22 Minimal Nominal Maximal Load Non converted Converted Non converted Converted Non converted Converted A WHEEL CAMBER 0 2 0 150 0 35 0 0 0 55 0 200 B KING PIN INCLINA...

Page 779: ...kage is detected replace bellows WARNING To prevent personal injury do not apply more than 10 psi 69 kPa air pressure to the unmounted air spring 5 2 REMOVAL NOTE Front air springs can be removed with...

Page 780: ...ry air system at normal operating pressure 95 125 psi 655 860 kPa coat the air line connections and air spring mounting areas with a water and soap solution Bubbles will indicate an air leak and none...

Page 781: ...in figure 24 with the mounting stud protruding through the hole in the mounting bracket and the shock absorber eyes over the mounting pins Install the outer washer 6 Place a rubber joint and washer o...

Page 782: ...Section 16 SUSPENSION PA1564 22 FIGURE 26 SWAY BAR FRONT SUSPENSION 16138D FIGURE 27 SWAY BAR REAR SUSPENSION 16014...

Page 783: ...3 8 REAR SUSPENSION For a description of all these systems refer to the appropriate heading in this section FIGURE 28 REAR SUSPENSION COMPONENTS 16140 FIGURE 29 DETAILS OF REAR SUSPENSION 16106 FIGURE...

Page 784: ...Removal NOTE Suspension air springs drive and tag axles can be removed without removing the entire axle assembly 1 Safely support vehicle at the recommended body jacking points To gain access to a giv...

Page 785: ...ins at the proper torque of 500 550 lbf ft 680 750 Nm when shock absorber replacement occurs If a shock absorber becomes inoperative complete unit must be replaced CAUTION When a shock absorber is fou...

Page 786: ...nd lower 3 Place the inner washers with washer convex side facing the shock absorber rubber bushing on each shock absorber pin Fig 33 4 Install the shock absorber eyes over the mounting pins then the...

Page 787: ...REMOVAL 16011 2 Place a flat steel disc slightly smaller than the outside diameter of the bushing Fig 35 3 Using an arbor press or a suitable driving tool press or drive the old bushing out of the rod...

Page 788: ...rom the accessory air tank to the air springs is controlled by three height control valves The two rear valves are mounted to the subframe one on each inner side of rear wheelhousing and connected to...

Page 789: ...rt on subframe to top of the lower air spring support on axle refer to figure 39 for more details If adjustment is required begin with the drive axle 2 Loosen the clamp on the height control valve rub...

Page 790: ...ve After installation check for leakage using a soap and water solution 11 LEVEL LOW LEVELING SYSTEM Bus shells are equipped with LEVEL LOW leveling system The purpose of the LEVEL LOW is to adjust su...

Page 791: ...E posi tion the air is entrapped between air springs and five way three position air control valves to ensure the adjusted level will be kept WARNING Never move vehicle with selector knob in any other...

Page 792: ...bottom drain valve Fig 42 It is recommended to purge the primary air tank by its bottom drain valve every 12 500 miles 20 000 km or once a year whichever comes first FIGURE 43 REAR VALVE LOCATION 122...

Page 793: ...SWIVEL ASSEMBLY 13 1 HUB BEARING INSPECTION An inspection should be made at intervals of 30 000 miles 48 000 km Apply parking brake raise wheels off the ground and support axle on stands When the whe...

Page 794: ...or bush bearing attention and possible renewal is in evidence 13 2 2 Checking Vertical Slackness This is measured by a dial indicator an chored to axle beam and having its pointer placed vertical agai...

Page 795: ...Torque Rod Mounting Bracket Stud 4 90 110 122 150 Torque Rod Mounting Bracket Nut 4 140 155 190 210 Idler Arm and Bell Crank Mounting Spindle Nut 8 90 105 122 142 Jacking Point Bracket Nut 8 70 80 95...

Page 796: ...ae West Nominal diameter 11 5 304 mm Pr vost number 630259 Drive axle air springs Make Goodyear Tire and Rubber Model 1100 Type Double Flare Nominal diameter 11 5 292 mm Pr vost number 630105 Front ax...

Page 797: ...nt Suspension Make Pr vost Pr vost number 630020 Sway bar bushing Drive Axle Make Pr vost Pr vost number 130953 Sway bar link Make Tennaco Automotive Pr vost number 630230 Shock absorber bushings Make...

Page 798: ......

Page 799: ...ring regular maintenance schedules however at least linehaul applications every 100 000 miles vocational applications every 50 000 miles The visual inspection should include the shock itself leakage a...

Page 800: ...ays of operation CAUSE Oil vapor is necessary to lubricate the rod seal At high operating temperatures this results in oil mist and precipitation EFFECT none ACTION none 2 Misting Appearance might be...

Page 801: ...ly visible around the bottom it likely stems from an outside source CAUSE worn damaged or overheated seal EFFECT loss of oil loss of damping function loss of ride control and safety ACTION replace lea...

Page 802: ...ubber bushing is visibly deformed or damaged eye or loop is eccentrically deformed sleeve is not centered within bushing CAUSE extensive use of rebound stop incorrect ride height shock may be too shor...

Page 803: ...r scratches reservoir tube OBSERVATION Paint scratched off reservoir tube CAUSE suspension is misaligned shock is under unintended lateral or longitudinal preload EFFECT noise corrosion of reservoir t...

Page 804: ...measure temperature of shock absorbers 4 Both shocks should be warmer than the original reference point similar in temperature 5 A cool or significantly colder shock absorber likely is a failure and n...

Page 805: ...1 1 Front Bumper 18 6 1 2 Front Crest 18 6 1 3 Headlights 19 6 1 4 Rear View Mirrors 19 6 1 5 Windshield Wipers 20 6 1 6 Windshield 20 6 1 7 Front face Body Panel 22 6 1 8 Entrance Door 22 6 1 9 Front...

Page 806: ...7 1 7 Front face Body Panel 48 7 1 8 Entrance Door 49 7 1 9 Front Electrical Service Compartment Door 49 7 1 10 Upper Lateral Window 50 7 1 11 Front Cap 50 7 2 ZONE 2 51 7 2 1 Upper Side Panel 51 7 2...

Page 807: ...WINDOW EXPLODED VIEW SASH 26 FIGURE 20 ELECTRIC SLIDING WINDOW EXPLODED VIEW 28 FIGURE 21 REMOVING THE SASH 29 FIGURE 22 DISENGAGING THE BOTTOM OF THE SASH 29 FIGURE 23 PROPER ALIGNMENT 30 FIGURE 24 P...

Page 808: ...R H SIDE DOOR 54 FIGURE 60 RADIATOR DOOR 55 FIGURE 61 ZONE 5 55 FIGURE 62 BAGGAGE COMPARTMENT DOOR 56 FIGURE 63 BAGGAGE DOOR CATCH STRIKER 57 FIGURE 64 CONDENSER DOOR 57 FIGURE 65 EVAPORATOR DOOR 57 F...

Page 809: ...r compartment or Baggage compartment 7 Entrance door 8 Entrance door power window 9 Engine compartment rear doors 10 Rear view mirror 11 Reclining bumper 12 Front electrical service compartment 13 Dri...

Page 810: ...filler door 6 Condenser compartment or Baggage compartment 7 Entrance door 8 Entrance door power window 9 Engine compartment rear doors 10 Rear view mirror 11 Reclining bumper 12 Front electrical ser...

Page 811: ...g corrosion and must be considered as part of the regular service intervals The entire underside of the vehicle is sprayed with a heavy application of asphalt base undercoating The operating environme...

Page 812: ...LLY INSPECT WHEELHOUSING COATING MAKE SURE DISCHARGE TUBES ARE FREE FROM OBSTRUCTIONS APPLY UNDERCOATING LOCALLY AS NECESSARY APPLY UNDERCOATING LOCALLY AS NECESSARY REMOVE ANY OBSTRUCTION OR REPLACE...

Page 813: ...1 Avoid rubber parts 2 0 Dry all water sprayed parts Surface temperature and dew point must be respected before applying rust inhibitor Air pressure system may be used refer to annex 1 for surface tem...

Page 814: ...using Entire braking system 4 0 Rear wheelhousing a Mask all rubber joints Braking system must also be protected refer to arrows Commercial aluminum foil may be used for masking Entire braking system...

Page 815: ...mping system are required to apply the rust inhibitor If the application is done inside a paint room select high speed ventilation Minimum required thickness is 10 mils wet or 5 mils dry 7 0 Remove al...

Page 816: ...7 10 11 13 15 7 3 1 4 6 9 10 12 14 14 6 1 2 5 7 10 11 13 15 14 6 1 2 6 8 10 12 14 16 13 5 0 4 6 9 11 14 15 17 12 4 1 4 7 10 12 14 16 18 11 4 1 5 9 11 13 15 17 19 10 3 2 6 9 12 14 16 18 20 10 2 3 7 10...

Page 817: ...V at the broken or cracked portion Sides of V should have a shallow pitch for maximum bonding area NOTE Roughening the surface improves adhesion of resin If part is warped from original shape use clam...

Page 818: ...ll dirt grease and paint from area to ensure good bonding surface Feather the cleaned area all around Fig 3 FIGURE 3 FIBERGLASS REPAIR 18089 Cut a piece of fiberglass mat slightly larger than area bei...

Page 819: ...old Park vehicle in the shade whenever possible o Do not park under trees which drop sap or near factories with heavy smoke fallout Tree sap and industrial fallout may mar or spot a freshly painted su...

Page 820: ...ations 3 Maintain adequate ventilation at all times 4 Dispose of any leftover paint mix properly 5 Wear rubber gloves rubber apron and face shield during all phases of paint and chemical handling 5 3...

Page 821: ...repair installation and replacement for various doors panels and windows pertaining to W5 MTH The paragraph divides the vehicle into zones to facilitate the search each zone is then sub divided into c...

Page 822: ...install bumper reverse the removal procedure WARNING Front bumper is heavy Use proper lifting equipment to support the bumper during the removal and installation operations to avoid personal injury F...

Page 823: ...oid continuous heating Use the appropriate switch on the dashboard to activate the defroster system on both mirrors simultaneously The mirrors can easily be adjusted by using the remote controls locat...

Page 824: ...ror head behind the mirror glass Turn pointer knob to the left for mirror head adjustments and to the right for convex mirror adjustment then push down on either of the button s 4 sides to adjust the...

Page 825: ...a loop Spray soapy water onto rope and rubber extrusion Fig 14 o Slide windshield into rubber seal groove starting with the bottom curved side edge Using a plastic spatula move the rubber seal lip as...

Page 826: ...self adhesive tape Remove the Sika bead and self adhesive tape residue with the scraper o Pry loose the front face body panel using the lever o While somebody cuts the Sika bead and double face self a...

Page 827: ...or finishing joints of front electrical service compartment door refer to procedure SAV280021 included at the end of this section For gluing of driver s window refer to procedure SAV290013 included at...

Page 828: ...ield wire and a pair of handles Gloves goggles or face shield Fixed Window Removal 1st Method NOTE This method is used only in the case of a regular fixed side window For the fixed upper portion of aw...

Page 829: ...f this section For the installation of awning or sliding window refer to procedure SAV00038 included at the end of this section For gluing of lateral fixed window refer to various procedures SAV00037...

Page 830: ...Proximity sensor magnet Fixing frame FIGURE 18 ELECTRIC AWNING WINDOW EXPLODED VIEW FRAME 18586 Roller Swivelling arm Releasing bar Guide Guide Motor support Horizontal latch handle Window pane Relay...

Page 831: ...ONVERTER CHECKLIST Check the electrical circuit proximity sensor A The latching system will not operate without power Is there electrical power to the latching circuit The horizontal latch handle on t...

Page 832: ...belt line trim seal Check for missing parts or misaligned parts A The frame and sash are misaligned Is there any interference between the sash and frame Is there clearance between the sash and the roc...

Page 833: ...o disengage the bottom of the sash from the window frame Figure 22 FIGURE 22 DISENGAGING THE BOTTOM OF THE SASH Installation 1 Align the leading edge of the slot on the lower cam follower block with t...

Page 834: ...the slot of the cam follower block Do the same at the rear of the sash 4 Pull down on the release latches and rotate the sash inwards until it is parallel with the window frame 5 Release the latches...

Page 835: ...assembly 6 3 ZONE 3 FIGURE 26 ZONE 3 6 3 1 Rear Cap The fiberglass rear cap does not need any maintenance except painting as needed It is held in place with adhesive If ever it has to be replaced mak...

Page 836: ...tool Razor sharp window scraper A pair of locking pliers Isopropyl alcohol o Remove damaged engine compartment door from vehicle o Install the damaged door onto an appropriate support o Wearing glove...

Page 837: ...is section 6 4 2 Engine Compartment R H Side Door Engine compartment R H side door may be adjusted for proper fit by untightening hinge bolts 1 Loosen the bolts 1 Fig 30 holding the hinge to the vehic...

Page 838: ...gap needed between exterior finishing panels 4 Tighten the bolts 5 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation T...

Page 839: ...oosen the screws fixing the hinge to hinge attachment or hinge to door assembly Loosening the screws allows the compartment door assembly to be shifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adj...

Page 840: ...wooden block between one of the panto graph arms and the upper frame 2 Remove cap screw lock washer and flat washer retaining lower arm to door 3 Remove spring pins and lock washers fastening the pan...

Page 841: ...hifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjust condenser door assembly position at the hinge 4 Tighten the screws 5 Respect the required gap between exterior finishing panels 6 Check that...

Page 842: ...ording to distance required between exterior finish ing panels o Tighten the nuts o Check that the door swings freely and closes properly FIGURE 39 FUEL FILLER DOOR 03046 6 6 ZONE 6 FIGURE 40 ZONE 6 6...

Page 843: ...anel Insert a flat screwdriver between the side panel and the vehicle chassis in the top left and right corners Use the c clamp to peel the side panel from the back structural panel as far as the midd...

Page 844: ...Fitted With Slide Out Removal Refer to paragraph 6 7 1 for procedure CAUTION Because most junction panels are only riveted and not spot welded be careful when removing a side panel not to damage adjac...

Page 845: ...ce Manual Section 26 Paragraph 16 for the procedure on slide out exterior finishing panels windows 6 9 ZONE 9 FIGURE 43 ZONE 9 6 9 1 Slide Out Exterior Finishing Panels Windows Refer to Maintenance Ma...

Page 846: ...Section 18 BODY PA1564 42 6 10 BODY PANEL AND WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE OUT FIGURE 44 BODY PANEL WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE OUT...

Page 847: ...Section 18 BODY PA1564 43 6 11 BODY PANEL AND WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE OUT FIGURE 45 BODY PANEL WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE OUT...

Page 848: ...WE MTH ZONING 7 1 ZONE 1 FIGURE 47 ZONE 1 7 1 1 Front Bumper The front bumper can be tilted downward to give access to the bumper compartment Pull the release handle located inside front service compa...

Page 849: ...FRONT BUMPER REMOVAL WARNING The compartment behind the bumper is not designed for storage Never store loose objects in this compartment since they can interfere with the steering linkage mechanism U...

Page 850: ...mbly Mount the mirror arm base to the coach Insert the ball stem into the mirror arm and tighten the socket setscrews NOTE Position the ball cup halves so the joint between them lies on the centerline...

Page 851: ...to release the Velcro Disconnect the heater grid at the two connectors Connect the connectors of the new mirror s grid to the harness Install the lens by positioning the lens in the mirror frame and...

Page 852: ...inside of vehicle to insert the windshield into the rubber seal groove o Insert the top curved corner then finish with the top of windshield o At the top of windshield clean surface between fiberglass...

Page 853: ...the removal of entrance door body panel you will need Pneumatic Zip gun type tool Razor sharp window scraper o Before removing body panel you can to ease repair uninstall entrance door from vehicle If...

Page 854: ...a knife Face shield o In the case of driver s window only open front service compartment door o Mark the position of the driver s window for future reference o From inside of vehicle cut Sika bead aro...

Page 855: ...ference to the vehicle o This procedure requires accuracy and it is possible not to succeed on the first at tempt From the inside of vehicle a sec ond person ensures the rod passes through o Remove th...

Page 856: ...ral fixed window and SAV00044 for making the Simson joint around fixed windows All these procedures are included at the end of this section 7 2 3 Electric Awning Windows For window or components repla...

Page 857: ...ng gloves goggles and ear plugs pry loose body panel using a Zip gun or lever starting from the edge opposite the curved side o Use the Zip gun to detach completely the stainless steel body panel from...

Page 858: ...R H side door may be adjusted for proper fit by untightening hinge bolts 1 Loosen the bolts 1 Fig 59 holding the hinge to the vehicle structure to shift the door IN or OUT and UP or DOWN 2 Loosening...

Page 859: ...s the door to be shifted LEFT or RIGHT and UP or DOWN 3 Adjust the door position depending on the gap needed between exterior finishing panels 4 Tighten the bolts 5 Check that the door swings freely a...

Page 860: ...wooden block between one of the panto graph arms and the upper frame 2 Remove cap screw lock washer and flat washer retaining lower arm to door 3 Remove spring pins and lock washers fastening the pan...

Page 861: ...hifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjust condenser door assembly position at the hinge 4 Tighten the screws 5 Respect the required gap between exterior finishing panels 6 Check that...

Page 862: ...ording to distance required between exterior finish ing panels o Tighten the nuts o Check that the door swings freely and closes properly FIGURE 66 FUEL FILLER DOOR 03046 7 6 ZONE 6 FIGURE 67 ZONE 6 7...

Page 863: ...ry fix side panel Warning Panel weights over 200 pounds E Insert a flat screwdriver between the side panel and the vehicle chassis in the top left and right corners Make sure to separate side panel fr...

Page 864: ...ED TIG WELDING SPOTS SAV00216 SMOOTH SIDE PANEL GLUING SLIDE OUT VERTICAL MOLDING SAV00217 SMOOTH SIDE PANEL CUTTING HORIZONTAL FINISHING MOLDING AT SLIDE OUT LEVEL SAV00220 7 7 2 Side Crest o Clean v...

Page 865: ...Section 18 BODY PA1564 61 7 9 BODY PANEL AND WINDOW SPACING FOR WE MTH FITTED WITH SLIDE OUT FIGURE 70 BODY PANEL WINDOW SPACING FOR WE MTH FITTED WITH SLIDE OUT...

Page 866: ...figures 71 to 76 WARNING Extra lift capacity may be required if luggage or any other type of load e g conversion equipment are onboard the vehicle CAUTION The suspension of the vehicle must be in the...

Page 867: ...secure vehicle with tie downs Check that overall height will clear obstacles on the route to follow and obtain required permits The vehicle can also be towed by lifting the front axle or by towing fro...

Page 868: ...ft the vehicle from under the front axle and adequately secure the underside to the tow vehicle lifting attachment with chains 5 Observe safety precautions when towing 9 2 TOWING WITHOUT LIFTING WARNI...

Page 869: ...MEMORANDUM SEALANT GLUING PRODUCT PROCEDURE NO SAV000001 REVISION 14 2006 06 09 GLUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 10 DISCARD AS PER P908 WEAR GLOVES WEAR SAFETY GLASSES...

Page 870: ...r 50 drying time and job time are increased Keep in mind that it is forbidden to use products parts to prepare and or glue surfaces if temperature is below 15 C Using Sika Products and Solvent in Nalg...

Page 871: ...g operation again Before applying any other product If surface seems dusty greasy or with finger marks start cleaning operation again Section B Sika 205 1 Apply For a smooth surface aluminum stainless...

Page 872: ...ow to evaporate Do not use pads supplied in the box Minimum time 5 minutes Mandatory After 2 hours Remove dust using Chix cloth repeat application If surface seems dusty dust using dry Chix cloth repe...

Page 873: ...inutes After 2 hours Remove dust using damp CHIX cloth pure water Mandatory 206 G P After 8 days Reactivate with Aktivator as per section C Minimum time 10 minutes After 2 hours Remove dust using damp...

Page 874: ...oduct Mandatory After 2 hours Start cleaning operation again Before applying any other product If surface seems dusty greasy or with finger marks start cleaning operation again Section F Sika Remover...

Page 875: ...se belt sander Ridged surface Sand bottom of creases by hand Change paper or belt on a regular basis as per procedure In the case of Stainless steel eliminate reflection mirror image Important aspects...

Page 876: ...se a knife Zip Gun or braided windshield wire Cleaning If required remove dirt dust sand calcium grease using Anti silicone Good adherence of glue to surface If glue or primer become unstuck Remove fo...

Page 877: ...minutes max 90 min 4 hrs minimum Sika 254 booster pump 25 minutes max See specific PR 2 5 hrs minimum Sika Ultrafast II 10 minutes max See specific PR 6 hrs minimum Sika 255 15 minutes max See specif...

Page 878: ...be This product is good for 9 months Coding example 601251 First number indicates year 6 2006 Next 2 numbers indicate month 01 January Next 2 numbers indicate day 25 25th Add 9 months to the manufactu...

Page 879: ...ICATION PROCEDURE NO SAV000001A REVISION 00 2006 06 09 GLUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 4 Section 1 Triangular Beads Application Section 2 Irrelevant Section 3 Finishing Joint aroun...

Page 880: ...SION 00 Page 2 of 4 Section 1 Triangular Beads Application Rules Nozzle must be as perpendicular to the surface as possible Nozzle must be positioned to follow the direction of movement towards the re...

Page 881: ...h down the joint using a plastic spatula D As needed remove the small lines left by the plastic spatula by smoothing down the joint with a finger and water or soapy water E Carefully remove masking ta...

Page 882: ...01A REVISION 00 Page 4 of 4 Joint must be parallel visually straight and without notch C D Cavity in the sealant joint due to the plastic spatula and or sealant shrinking Accepted Notch Repeating notc...

Page 883: ...t Before cleaning make sure there is no paint gravel guard or urethane residue If necessary remove using sander Structure Sanding A Clean using anti silicone in the direction of the arrows See SAV0000...

Page 884: ...Use white clothes 684009 for vertical backers B Apply 3 4 wide masking tape in the center of vertical backers Make sure that grit blasting is uniform on the whole surface 1 05 C Apply Sika 206 G P Use...

Page 885: ...PROCEDURE NO SAV00027 REVISION 01 Page 3 of 3 1 10 Apply foam tape 1 8 x 1 4 in the center of side panel horizontal supports and at each end if needed...

Page 886: ......

Page 887: ...tubing underneath C Install engine air intake panel in position 2 Vertically Adjust side panel with reference to 1 side panel ridges max 1mm Make sure to meet standard 3mm 1 with reference to structu...

Page 888: ...g a scraper or damp cloth 2 00 Make sure that structure is sealed at the back of engine air intake panel location Add some Sikaflex 221 if required 2 05 Check side panel for defects S S Side panel Pre...

Page 889: ...If accessible seal the back of vertical backers as indicated in picture Use Sika 221 grey Awnings Reinforcement Plates 3 05 Apply Sika 252 or 255 onto the awnings reinforcement plates A B C D Height o...

Page 890: ...and rivet install engine air intake panel in position 2 and rivet Check gap between 2 panels Install side panels 3 4 5 6 and rivet making sure to check the gap 3 4 5mm between side panels Check adjust...

Page 891: ...some kind of supports for temporary side panel holding Measure height of 4th ridge from top of structural tubing on backer located between side panels 4 and 5 should be 320 5 mm Take the measurement f...

Page 892: ...structure Note Make sure that junction panel does not overrun the bottom of Slide out by more than 3mm A Measure distance between rear tubing and slide out 5439 mm This measurement should be 3 mm lon...

Page 893: ...h reference to side panel 5 horizontal alignment of 1 mm max Vertically Rear line up with side panel 5 ridges 1mm Check that 4th ridge is lined up with dash 3 If difference is too big readjust side pa...

Page 894: ...el located between side panels 2 and 3 Rear line up with side panel 4 ridges 1mm H Side Panel 2 Horizontally Lined up with reference to slide out window pane 1 mm gap of 3 mm 1 5 0 with reference to s...

Page 895: ...junction panel between side panels 2 and 3 K Metal Strip 10 Vertically Gap of 8mm with reference to side panel 3 Horizontally Gap of 3 5 5 mm with reference to side panel 4 L Metal Strip 9 Vertically...

Page 896: ...ction panels C Install junction panel between side panels 5 and 7 3 00 D Remove side panel 7and metal strips 9 and 10 and junction panels A Reactivate side panels junction panels and structure See SAV...

Page 897: ...be located D Apply Sika 221 onto all junction panels perimeter Make sure to fill creases Rivet junction panels onto structure Hand press junction panels to flatten Sika bead E Apply Sika 221 black to...

Page 898: ...PROCEDURE NO SAV00029 REVISION 00 Page 8 of 9 Junction Panel 4 5 Junction Panel 5 7 Junction Panel 7 8 Junction Panel 2 3...

Page 899: ...y Sika 221 Booster onto side panels B Curing time 4 hours C Seal corners between metal strips and structure using Sika 221 black 4 00 D Seal side panel ridges using Sika 221 vehicle not slide out If s...

Page 900: ......

Page 901: ...ide panels will stain the S S Sealing joint height onto vertical tubing 6mm maximum C Clean using anti silicone See SAV000001 Section A D Apply Sika 205 Use a plastic spatula and a Chix cloth to get t...

Page 902: ......

Page 903: ...age 1 of 1 Junction Panel Preparation A Clean using anti silicone both junction panel sides See SAV000001 Section A B Normally in the center of the junction panel there is a masking tape Apply one if...

Page 904: ......

Page 905: ...CTURE PREPARATION Effective 9082 REVISION 01 DATE 06 10 11 Spec 15 0 LVA077 Page 1 of 2 A Clean structure using anti silicone See SAV000001 Section A B Sand structure using Scotchbrite See SAV000001 S...

Page 906: ...1 Page 2 of 2 C Clean structure and window frames using anti silicone See SAV000001 Section A D Apply Sika 206G P onto structure and window frames See SAV000001 Section D EDGES EDGE EDGE EDGE EDGE EDG...

Page 907: ...e panel will be glued Affix foam tape in the center of vertical and horizontal members 1 05 Not fitted with slide out Affix a double face self adhesive tape 3 16 x1 4 at the bottom of the structure wh...

Page 908: ...PROCEDURE NO SAV00036 REVISION 01 Page 2 of 2 WE OR W5 Fitted with front slide out Glue a neoprene foam tape 3 16x1 2 1 15 Glue a piece of window rubber seal at the top in the curvature...

Page 909: ...of each rubber seal Draw a 13mm about long line in the center of the post B Glue the vertical rubber seals in the center of the post where fixed windows will be installed MTH Remove strips from rubber...

Page 910: ......

Page 911: ...VA081 Spec 15 0 Page 1 of 5 Section 1 Awning Window Installation 1 00 Glue 2 stops onto the horizontal structure tubing or underneath the window A Check that D O T AS 3 is present and readable Glue 4...

Page 912: ...e SAV000001 Section A 1 05 B Apply Sika Aktivator See SAV000001 Section C 1 07 Add a bead of Sika 252 on each side 1 10 Apply Sika 252 onto structure and onto 2 welding joints in the lower bottom corn...

Page 913: ...smooth down the excess of Sika Important Do not remove the white blocks They will be removed when the batteries will be connected B If required clean up surfaces using Sika 208 1 25 C Manually close...

Page 914: ...ply Sika 252 onto structure and onto 2 welding joints in the lower bottom corners Triangular bead 12mm X 10mm A Check that D O T AS 3 is present and readable 2 10 B Install and center window into the...

Page 915: ...son should push the window from outside the vehicle while another one tightens the frame from inside A From inside the vehicle add a bead of Sika 252 or 255 in the window upper corners as required 2 2...

Page 916: ......

Page 917: ...B Apply 206 G P primer See SAV000001 Section D 1 05 Apply Sika 221 black Booster onto structure Triangular bead at the top Use the applicator 25mm x 15mm Triangular bead in the radius 20mm x 10mm Tria...

Page 918: ...the glue is cured verify with a finger that it is Tack Free Distance between panel and windows 8 2mm WE only Adjust gaps between slide out box frame windows and fiberglass panel as per the following s...

Page 919: ...heck panel alignment flatness with adjacent panel or windows 2mm max at the front and 3mm max at the rear Use go nogo 31133 Do not use a metal ruler onto glass to prevent scratching Important Vehicle...

Page 920: ......

Page 921: ...1 Section E 1 00 C Apply Sika Aktivator See SAV000001 Section C Windows Installation A Apply Sika 255 or Ultrafast onto fixed window perimeter Triangular bead 20mm X 10mm B Install fixed window into t...

Page 922: ...pression time 8 hours minimum 30 minutes with Ultrafast F Install suction cup puller onto fixed window in order to compress the bead Compression time 8 hours minimum 30 minutes with Ultrafast Importan...

Page 923: ...between the 2 Awning windows is 2mm Note These dimensions are references given by engineering If the assembly is out of tolerance the aesthetic aspect will have to be evaluated Interior Tolerance The...

Page 924: ......

Page 925: ...lue inside the vehicle all around the window B Single Glass Add a bead of Sika 252 or 255 if necessary to get a joint of 10 12 mm Note Do not use Simson glue C Thermos Glass Add Simson glue black 70 0...

Page 926: ...PROCEDURE NO SAV00044 REVISION 00 Page 2 of 2 Slide out...

Page 927: ...on A 1 00 B Apply Sika Aktivator See SAV000001 Section C Half Window Preparation Bonding surface must be clean If it is greasy clean using anti silicone as per SAV000001 Section A and or use a scraper...

Page 928: ...the structure because the joint would be too damaged D Check window alignment flatness with adjacent panel or windows 2mm max at the front and 3mm max at the rear Use go nogo 31133 Do not use a metal...

Page 929: ...trafast Important Make sure that half window flatness with reference to the adjacent windows remains acceptable I Smooth down using a brush excess of glue inside the vehicle all around the window Remo...

Page 930: ......

Page 931: ...tivator See SAV000001 Section C edge Structure Preparation A Affix neoprene foam tape 3 16x1 2 1 05 B Affix another piece in the corner onto the rubber seal Window Gluing A Apply Sika 255 or Ultrafast...

Page 932: ......

Page 933: ...ture Preparation S S A Clean using anti silicone See SAV000001 Section A B Sand using belt sander See SAV000001 Section G Sand using grit coarse belt Change paper on a regular basis C Clean using anti...

Page 934: ......

Page 935: ...Panel Preparation S S A Clean using anti silicone See SAV000001 Section A B Sand using belt sander See SAV000001 Section G Sand using grit coarse belt Change paper on a regular basis C Clean using an...

Page 936: ...indications SECTION A A A Clean using anti silicone See SAV000001 section A 2 05 B Apply and compress foam tape 1 8 x1 2 onto mid reinforcement A Use supports to hold up side panel weight Adjust heig...

Page 937: ...ction B B Section C C A Apply Sika 252 onto structure Watertight Joint 2 25 B WE Slide Out L H side only Apply a bead near the rectangular section Bead height in the area of the rectangular section 6...

Page 938: ...TIG spots WE A Install pulling equipment at the other end of side panel B Make a final adjustment in height C WE Slide out Adjust pressure in the box frame cylinder to 6600 PSI 100 0 D Pull side panel...

Page 939: ...from WE slide out reinforcement bar E Remove protective film from double face self adhesive tape F Compress top and bottom section of side panel A Cut excess of side panel Make sure that cut is paral...

Page 940: ......

Page 941: ...174 Page 1 of 2 Engine Air Intake Panel Gluing 1 00 Make sure that sealing of structure has been performed properly Engine Air Intake Panel Preparation S S 1 05 Entertainer 1 10 Install foam tape 1 8...

Page 942: ...nuous Triangular bead 10mm x 8mm Panel Installation A Install 2 supports onto structure and lay down panel SECTION A A View B B Adjust supports so that panel is 2 1mm lower than tubing C Position pane...

Page 943: ...ches as far as the corner See SAV000001 section B 1 00 B Apply Sika 252 black at the junction of both tubing leave 43 mm minimum without Sika to ensure gluing of window rubber On top of smooth side pa...

Page 944: ......

Page 945: ...cone See SAV000001 Section A 1 05 D Apply Sika 206 G P See SAV000001 Section D S S Body Panel Preparation E Coat Body Panel Preparation black A Clean using anti silicone See SAV000001 Section A B Sand...

Page 946: ......

Page 947: ...Drilling Back Panel 1 00 Install back panel onto frame and drill Back Panel A Clean frame using anti silicone See SAV000001 Section A B Apply Sika 205 onto body panel and frame perimeter See SAV000001...

Page 948: ...E Apply Sika 205 aound the opening in the frame See SAV000001 Section B F Apply Sika 221 gey onto the perimeter Bead diameter about 4mm G Lay down back panel and rivet 1 10 Install latch Caution Inst...

Page 949: ...0 Page 3 of 7 Damper A Apply foam tape 1 16x1 2 underneath damper box B Install and rivet 1 15 C Install filter A C Junction Box 1 20 Install A C junction box Install 3 tie mount and rivet Marker Ligh...

Page 950: ...yer in the frame C Remove body panels 1 40 D Remove metal burrs using a disc sander Lower Body Panel Preparation A Remove blue plastic film and inspect body panel Reinstall transparent plastic film 1...

Page 951: ...1 Section A S S Frame Preparation A Apply masking tape onto hinge B Clean using anti silicone See SAV000001 Section A C Sand using Scotchbrite See SAV000001 Section G D Clean using anti silicone See S...

Page 952: ...d the opening B Install grid 1 65 C Apply Sika 221 grey again aroud the grid Body Panel Installation A Apply some butyl tape onto the frame and remove protective tape liner B Apply Sika 221 grey onto...

Page 953: ...ests perfectly against the frame Remove protective tape from hinge Hold down body panel using masking tape Curing time 4 hours minimum F If upper body panel is ridged Seal lower body panel rivets usin...

Page 954: ......

Page 955: ...ng 1 00 Position back panel Apply masking tape to hold it in place 1 05 Drill using a 11 drill bit 1 10 Remove masking tape and back panel Section 2 Frame Squareness and Flatness Verification Verify t...

Page 956: ...a 205 at the top of the handle handle exterior side B Apply Sika 221 Bead diameter 3 16 3 05 C Smooth down the joint with your finger A Apply Sika 205 at the bottom of the handle handle exterior side...

Page 957: ...205 from the interior of the frame hinge side See SAV000001 Section B B Apply Sika 221 Bead diameter 3 16 3 25 C Smooth down the joint with your finger Section 4 Locking System Installation If require...

Page 958: ...motor cable into the insulation cavity 5 10 Reinstall back panel and rivet Section 6 Upper Panel Installation Important Make sure that all bonding surfaces are clean and free of dust residue or dry gl...

Page 959: ...using anti silicone See SAV000001 Section A 6 05 D Apply Sika 206 G P See SAV000001 Section D E Coat Body Panel Preparation 6 10 Clean using anti silicone Repeat this step if panel seems greasy See S...

Page 960: ...d 8mm wide X 9mm high Important There should be no more than 18 minutes between the beginning of the glue application and the panel installation onto the frame 6 20 B Apply Sika 221 around the handle...

Page 961: ...y Sika 221 onto the rivet heads 6 35 D Clean the excess of sealant and rivet heads using Sika 208 6 40 Install and adjust handle 6 45 Install the lock Important Make sure that the lock gasket rests pe...

Page 962: ...ee and also at the top so that the portion inserted underneath the upper panel is free 7 05 D Inspect the body panel to make sure that it is free of bumps or defects Frame A Apply Sika 205 onto frame...

Page 963: ...o help removal using a blowtorch 8 10 Lift body panel edge using a pair of pliers Pull the panel while cutting the Sika bead Important Remove rivet shanks fell inside the door 8 15 Prepare surface See...

Page 964: ...PROCEDURE NO SAV00177 REVISION 00 Page 10 of 10 Appendix 1 Replacement Repair Remove part See SAV000001 Section 2 A1 00 Preparation and gluing See SAV000001 Section 2 and or do procedure again...

Page 965: ...Section G C Clean using anti silicone See SAV000001 Section A 1 00 D Apply Sika 205 See SAV000001 Section B S S Panel Preparation A Clean using anti silicone See SAV000001 Section A B Use Scotchbrite...

Page 966: ...face self adhesive tape 1 16 x 1 4 onto perimeter of frame 1 15 B Apply Sika 252 A Remove protective film from double face self adhesive tape and lay down panel onto frame 1 20 B Press panel against f...

Page 967: ...Rear Cap and Engine Air Intake Snap on Finishing Molding Installation Snap On Finishing Molding Pre positioning A Position snap on finishing molding and put a pencil mark underneath the snap on finish...

Page 968: ...52 Apply Sika 320 mm long from the edge of engine air intake panel 1 05 E Smooth down the joint using a plastic spatula If necessary remove masking tape Section View 1 10 Clean using anti silicone the...

Page 969: ...rner molding onto snap on finishing molding Level corner molding and draw a line above it to establish the rear snap on finishing molding proper positioning Important Make sure corner molding follows...

Page 970: ...a 252 A Glue corner molding onto snap on finishing molding 2 10 B Compress molding with a nylon block Section 3 Rear Finishing Molding Gluing 3 00 Measure distance between 2 corner moldings and cut th...

Page 971: ...ing tape See SAV000001 Section A B Sand using orbital sander See SAV000001 section G Be careful not to scratch side panels apparent area not hidden by finishing molding C Clean using anti silicone sid...

Page 972: ...221 or 252 B Smooth down the joint with a plastic spatula Important There must be no more than 15 minutes between the start of cavity filling and the installation of molding 5 15 C W5 Fitted With Slid...

Page 973: ...ition front upper and lower finishing moldings onto vehicle B Draw a line onto moldings in line with the end of the last side panel Cut the excess of molding and file down the end 6 05 C 1 Remove blue...

Page 974: ...ut Upper Finishing Molding in front of slide out Apply foam tape 1 4 x1 4 at the bottom There must be 3 100mm 25 long clearings 7 05 Apply Sika 252 Do not apply Sika in front of the previous clearings...

Page 975: ...on A Apply foam tape 1 4 x1 4 8 00 B Make 3 100mm 25 long clearings in the bottom foam tape 8 05 Apply Sika 252 Do not apply Sika in front of the previous clearings Lower Finishing Molding Installatio...

Page 976: ......

Page 977: ...0001 Section G C Clean using anti silicone See SAV000001 section A 1 00 D Apply Sika 205 See SAV000001 Section B W5 W0 Molding Preparation SS A Clean using anti silicone See SAV000001 section A B Sand...

Page 978: ...ue the molding underneath the chalk line making sure it is lined up with the horizontal side molding maximum 1mm B WE Position and glue the molding making sure it is lined up with the horizontal side...

Page 979: ...tion Primer E Sand using Scotchbrite SAV000001 Section G 1 00 F Clean using anti silicone SAV000001 Section A W5 W0 Corner Molding Preparation SS A Clean using anti silicone SAV000001 Section A B Sand...

Page 980: ...WE X3 Apply Sika 252 A Apply corner molding so that it is level and lined up maximum 1mm with engine compartment R H side door molding or radiator door molding 1 15 B Apply some masking tape onto the...

Page 981: ...01 Section A B Use Scotchbrite to sand frame See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A 1 05 D Apply Sika 205 See SAV000001 Section B Front Face Preparation beige prim...

Page 982: ...MTH Onto front face Triangular bead 8mm MTH A Affix moldings Note Affix moldings so that the joint falls on the center of the vertical molding B Compress moldings using hands 1 25 C Use masking tape...

Page 983: ...SAV000001 Section A B Use Scotchbrite to sand molding See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A 1 00 D Apply Sika 205 See SAV000001 Section B Entrance Door or Front E...

Page 984: ...1 2 onto the door 1 20 Apply Sika 252 onto the door Triangular bead 8mm MTH Molding Installation 1 25 Line up with front and side moldings Even within 1mm 1 35 MTH If necessary adjust entrance door ha...

Page 985: ...uired straighten horizontal moldings using a grinder Molding Preparation SS A Clean using anti silicone See SAV000001 Section A B Sand using a Scotchbrite See SAV000001 Section G C Clean using anti si...

Page 986: ...Sand using a Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A D Apply Sika 205 See SAV000001 Section B Front Fender Preparation E coat 1 15 E Clean using anti si...

Page 987: ...ng Installation A Position top of the molding even with 1mm maximum top of horizontal finishing molding B Drill molding using a 30 drill bit and rivet 1 30 C Seal rivet heads using Sika 221 1 35 Seal...

Page 988: ......

Page 989: ...ed cut the excess Molding Preparation aluminum A Sand using a Scotchbrite See SAV000001 Section G B Clean using anti silicone See SAV000001 Section A 1 05 C Apply Sika 205 See SAV000001 Section B 1 10...

Page 990: ...SION 00 Page 2 of 2 1 20 Apply Sika 252 onto molding A Glue molding 6mm from side panel Important Make sure that molding hides Sika 221 bead 1 25 B Compress molding with hands MOLDING EDGE OF SIDE PAN...

Page 991: ...ing vertical moldings A Apply masking tape on each side of the welding spots B Clean using anti silicone See SAV000001 Section A C Sand side panel using a Scotchbrite See SAV000001 Section G D Clean u...

Page 992: ......

Page 993: ...i silicone See SAV000001 Section A B Sand using a Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A Molding Preparation stainless D Clean using anti silicone See...

Page 994: ...y Sika 252 black J Apply moldings Distance of 9mm 2 with reference to slide out panel and line up at the top with fiberglass or lateral fixed window behind driver K If applicable clean up the excess w...

Page 995: ...OUT LEVEL MTH 9090 Effective REVISION 00 DATE 06 10 20 L00015 Page 1 of 1 Cutting Upper Horizontal Finishing Molding A Wait 24 hours before cutting horizontal molding at Slide Out level 1 00 B Using a...

Page 996: ......

Page 997: ...iter 683446 Anti silicone 682989 Silver sealant 680462 Tack cloth Blue Loctite Sika 221 grey CHIX cloth 682384 Glass cleaner 683926 Blue cloth 682383 Sika 205 1 liter 683097 Sika 252 black Sika Remove...

Page 998: ...window motor 1 05 Install electric motor onto door frame Section 2 Door Assembly Power Window Frame Preparation E Coat 2 00 Clean bonding area using anti silicone See SAV000001 Section A Window Prepar...

Page 999: ...s in contact with window pane A Apply Sika 255 onto frame B Affix the frame onto window pane 2 15 C Secure assembly using clamps Door Frame Preparation SS A Clean using anti silicone See SAV000001 Sec...

Page 1000: ...anti silicone See SAV000001 Section A 2 25 D Apply Sika 206 G P See SAV000001 Section D Fiberglass Preparation beige primer A Sand using Scotchbrite See SAV000001 Section G 2 30 B Clean using anti si...

Page 1001: ...255 onto door frame Note Leave a gap at the bottom about 50mm for water dripping 2 45 Apply Sika 255 onto window pane 2 50 Lay down and center window pane onto door frame Window pane must extend 1mm a...

Page 1002: ...so that it is even with panel Tolerance is 4 2mm between window pane and fiberglass panel 2 60 B Compress window pane using hands Compress window pane upper corners using clamps Section 3 Gluing of SS...

Page 1003: ...ti silicone See SAV000001 Section A B Sand using Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A 3 05 D Apply Sika 205 See SAV000001 Section B 3 10 Affix double...

Page 1004: ...Compress panels using evenly distributed clamps Curing time 8 hours minimum Section 4 Installation of mechanisms Power Window Installation A Insert two seals in the power window frame B Apply some loc...

Page 1005: ...iper Installation 1 Position window wiper Note If rubber is too long cut the excess F 2 Drill three 5 32 holes into the molding and secure using screws 4 05 Fix cable harness A Adjust power window tra...

Page 1006: ...Do the finishing joints See Section 5 steps 5 15 5 20 4 20 Install Keyless pad 4 25 Install locking plates Lock Installation A If necessary put together the lock 4 30 B Install lock Note Make sure tha...

Page 1007: ...rommet into the frame A Cut pneumatic tubing Note The green tubing is shorter than the red one 4 40 B Identify both tubing at each end A green one and a red one Upper Lock Installation A Feed both pne...

Page 1008: ...sure that door handle is parallel with fiberglass panel Door Handle Mechanism Installation adjustment A Install door handle mechanism B Adjust mechanical parts and micro switches Finish installing rod...

Page 1009: ...1 Section A C Apply double face self adhesive tape 1 8 x 1 4 onto deflector D Apply some grey Simson glue onto deflector E Position glue deflector 4 70 F Using soapy water smooth down the joint with y...

Page 1010: ...0001 Section A B Peel back from the membrane with the exception of the area where the mechanism is located prevent mechanism from bonding to the membrane C Glue the membrane so that it bonds 100 with...

Page 1011: ...r Drill 9 7 64 dia holes and fasten plate using screws Installation of Window Interior Finishing Molding A Position plastic molding onto the door frame to check for proper fit Note If it does not fit...

Page 1012: ...r Section 5 Finishing Joints A Apply Sika 221 to fill in the pleats and light perimeter B Using soapy water smooth down the joints with your finger 5 00 C If necessary clean up the excess using Sika 2...

Page 1013: ...indow wiper end S S portion 5 07 D Smooth down the joint with your finger then remove masking tape A Apply Sika 221 at the top of the door and on the window pane sides B Using soapy water smooth down...

Page 1014: ...PROCEDURE NO SAV280020 REVISION 14 Page 18 of 18 Section 6 Replacement Repair Remove part See SAV000001 Section 2 6 00 Preparation and gluing See SAV000001 Section 2 and or do procedure again...

Page 1015: ...LY Page 1 of 12 Material Scotchbrite grey 680226 Sika 206 G P 1 liter 683446 Anti silicone 682989 Silver sealant 680462 CHIX cloth 682384 Simson 70 03 grey Blue cloth 682383 Glass cleaner Sika Remover...

Page 1016: ...lean using anti silicone See SAV000001 Section A B Sand using Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A 1 10 D Apply Sika 206 G P See SAV000001 Section D...

Page 1017: ...self adhesive tape 1 32 x 1 4 onto the whole window frame perimeter Section View 1 25 Fix window frame onto door frame Important Make sure that top of window frame is lined up with top of door frame...

Page 1018: ...sing hands Use a ruler 1 40 Perform steps in section 3 A Door Exterior Install appropriate number of c clamps and wooden blocks all around B Door Interior Install appropriate number of c clamps and wo...

Page 1019: ...0 Important Make sure window pane slides perfectly within its frame 1 55 If necessary clean up the excess all around door frame using Sika 208 Clean using anti silicone see SAV000001 section A and app...

Page 1020: ...corners from the inside 1 65 C Apply glue 680066 into Norryl molding and affix window wiper Important Anti friction side must be on window pane side 1 70 Install door locking mechanism components Not...

Page 1021: ...ntersection of the 2 seals and also sparingly in order to fix the seals to the window frame C Clean window using glass cleaner D Insert pane into window frame E Fix electric motor and all components c...

Page 1022: ...ed using anti silicone See SAV000001 Section A B Peel back from the membrane with the exception of the area where the mechanism is located prevent mechanism from bonding to the membrane C Glue the mem...

Page 1023: ...B Affix double face self adhesive tape 1 16 x 1 2 inside Norryl C Position Norryl onto door and temporary fix using Quick grip 2 20 D Drill 5 30 holes and screw in molding Latch Cover Installation A...

Page 1024: ...e SAV000001 Section A 3 00 C Apply Sika 206 G P See SAV000001 Section D MTH Body Panels Preparation S S A Cut and remove from the appropriate areas on the 2 panels the blue protective film B Clean usi...

Page 1025: ...PROCEDURE NO SAV280021 REVISION 18 Page 11 of 12 Affix double face self adhesive tape 1 16 x 1 2 3 10 MTH Apply Sika 252 onto panels 3 15 A MTH AFFIX NEAR THE EDGE...

Page 1026: ...rivet F Seal rivets using silver sealant MTH Finishing Joint A Apply Simson 70 03 Fill in the space between body panels and fiberglass panel at the indicated location 3 20 B Using soapy water smooth...

Page 1027: ...AV280022 REVISION 10 2006 06 04 GLUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 5 Material Anti silicone 682989 Chiffon CHIX 682384 Sika 215 1 liter 683916 Chiffon Bleu 682383 Sika 205 1liter 6830...

Page 1028: ...ce Door or Front Service Door Final Adjustment Door Adjustment with reference to front face Line up each door groove with front face groove within 3mm max Aligning door pleats with front fender pleats...

Page 1029: ...l A Apply Simson 70 03 black at the seal 4 corners each side of the tape B Glue seal 4 corners Upper corners Press corners against door frame Lower corners Glue onto bottom of door frame may vary depe...

Page 1030: ...ers Press corners against door frame Lower corners Glue 10mm lower than bottom of door frame may vary depending on seal length C Glue the rest of the seal Important Seal must be positioned correctly t...

Page 1031: ...eur Interior Hinge Cover Preparation ABS A Clean using anti silicone See SAV000001 Section A 6 00 B Apply Sika 215 See SAV000001 Section D Hinge Preparation E Coat 6 05 Clean using anti silicone See S...

Page 1032: ......

Page 1033: ...URE QUALIFIED PERSONNEL ONLY Page 1 of 5 Material Anti silicone 682989 Scotchbrite grey 680226 CHIX cloth 682384 Blue cloth 682383 Sika 205 1liter 683097 Sika 252 black Simson 70 03 grey Equipments Gl...

Page 1034: ...before gluing Verify especially the corners by lifting the blue paper Remove blue paper from the adhesion side Stainless Steel Panel A Clean using anti silicone See SAV000001 section A B Sand using s...

Page 1035: ...e SAV000001 section A OR Primed door beige primer A Sand using Scotchbrite See SAV000001 section G 1 10 B Clean using anti silicone See SAV000001 section A Install double face self adhesive tape onto...

Page 1036: ...dy panel 1 25 Lay down stainless steel body panel onto fiberglass door Note Be careful upon installing the upper or lower small body panel Make sure that drip hole is in the bottom 1 30 Check body pan...

Page 1037: ...PROCEDURE NO SAV280032 REVISION 4 Page 5 of 5 Appendix 1 Replacement A1 00 Remove body panel A1 05 See SAV000001 section 2 A1 10 For gluing procedure refer to section 1...

Page 1038: ......

Page 1039: ...grey 680226 Sika 206 G P 1 liter 683446 Anti silicone 682989 CHIX cloth 682384 Blue cloth 682383 Glass cleaner 683926 Sika 221 black booster Sika Remover 208 685101 Sika 205 1liter 683097 Sika Aktivat...

Page 1040: ...ly some masking tape Structure Preparation A Clean using anti silicone See SAV000001 Section A B Sand using Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A 1 05...

Page 1041: ...Window Pane Preparation A Clean using glass cleaner interior surface and edges See SAV000001 Section E 1 DOT AS2 inscription must be present at the bottom left corner of the window B Apply Sika Aktiva...

Page 1042: ...puller Line up window exterior flatness with adjacent surfaces If necessary use quick grip at bottom of window Conforming time 90 minutes minimum A Remove excess of glue on the window exterior B Remo...

Page 1043: ...e SAV000001A section 3 for details of finishing joint A Apply Sika 205 into cavity See SAV000001 Section B 3 00 B Fill cavity with Sika 255 Appendix 1 Replacement Repair Remove part See SAV000001 Sect...

Page 1044: ......

Page 1045: ...L ONLY Page 1 of 6 Material Sika 206 G P 1 liter 683446 Anti silicone 682989 CHIX cloth 682384 Blue cloth 682383 Glass cleaner 683926 Sika Remover 208 685101 Sika 205 1liter 683097 Sika 252 black Soap...

Page 1046: ...P primer as per SAV000001 section D Fiberglass Preparation Gel Coat side Faire le c t int rieur ext rieur de la lunette A Clean using anti silicone See SAV000001 Section A B Apply masling tape onto fr...

Page 1047: ...3 of 6 Apply masking tape onto window pane Interior Exterior 1 15 A Glue 4 stops 790392 onto fiberglass 1 20 B Affix a double face self adhesive tape 1 8 x 1 8 onto fiberglass structure perimeter STO...

Page 1048: ...th front of driver s window If necessary adjust window height by adding shims R H side Once centered apply some masking tape at the bottom of the window and mark for future reference will help for cen...

Page 1049: ...ted area must be flush within 2mm A Install suction cup puller in the window center from inside of vehicle Note Make sure window rests against structure frame without deforming window pane 1 45 B Conf...

Page 1050: ...ide of vehicle make two joints 1 60 B Smooth down the joints and remove masking tape 1 65 Reinstall markers light Appendix 1 Replacement Repair Remove part See SAV000001 Section 2 A1 00 Preparation an...

Page 1051: ...f 8 Material Alcohol 680536 Scotchbrite grey 680226 Anti silicone 682989 CHIX cloth 682384 Sika 221 grey Blue cloth 682383 Sika 221 black booster Sika Remover 208 685101 Sika 205 1 liter 683097 Sika 2...

Page 1052: ...surface A Clean using anti silicone See SAV000001 Section A B Sand using Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A 1 05 D Apply Sika 205 See SAV000001 Sec...

Page 1053: ...black onto structure 1 20 B Smooth down the joint with a finger or spatula to prevent bumps Section 2 Smooth Body Panel Gluing 2 00 Apply a foam tape onto body panel and peel back A Apply Sika 221 bo...

Page 1054: ...ure curvature B Front Body Panel Install body panel in the best possible position Allow the panel to float on the glue Make the final adjustment and then press body panel using hands 1 Lean the body p...

Page 1055: ...ace between body panel and structure C Smooth down the joints with a finger and soapy water 2 35 D Remove masking tape If required clean up surfaces with Sika 208 Section 3 Gluing of Ridged Body Panel...

Page 1056: ...1mm B Front Body Panel Install body panel in the best possible position Allow the panel to float on the glue Make the final adjustment and then press body panel using hands 1 Lean the body panel again...

Page 1057: ...oint A Apply masking tape onto body panel edge and structure B Apply Sika 221 grey in order to fill the space between body panel and structure C Smooth down the joints with a finger and soapy water 3...

Page 1058: ...4 Front Fender With Reference To Body Panel 4 00 Front fender with reference to body panel Appendix 1 Repair A1 00 See SAV000001 Section 2 Out of alignment between body panel ridge and front fender ri...

Page 1059: ...PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 5 Material Anti silicone 682989 Scotchbrite grey 680226 Sika 206 G P 1 liter 683446 CHIX cloth 682384 Sika 221 booster Blue cloth 682383 Sika Remover 208 6...

Page 1060: ...nd using Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A D Apply Sika 206 G P See SAV000001 Section D 1 00 Section 2 E Coat black Body Panel Preparation Clean u...

Page 1061: ...ne See SAV000001 Section A B Sand using Scotchbrite See SAV000001 Section G C Clean using anti silicone See SAV000001 Section A D Apply Sika 206 G P See SAV000001 Section D 3 00 Apply double face self...

Page 1062: ...SAV000001 Section A 4 00 C Apply Sika 206 G P See SAV000001 Section D 4 10 Apply double face self adhesive tape 1 16 x 1 2 SECTION 5 GLUING Important Make sure that all bonding surfaces are clean and...

Page 1063: ...BODY PANEL GLUING 5 15 Apply Sika 221 booster 5 20 Install body panels Compress for 4 hours minimum RIDGED BODY PANELS 5 25 Apply Sika 252 to fill the ridges Appendix 1 Repair A1 00 See SAV000001 Sec...

Page 1064: ......

Page 1065: ...LUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 4 Material Scotchbrite grey 680226 Anti silicone 682989 CHIX Cloth 682384 Blue Cloth 682383 Sika 205 1litre 683097 Sika Remover 208 685101 Sika 252 b...

Page 1066: ...ee SAV000001 Section G C Clean using anti silicone See SAV000001 Section A 1 05 D Apply Sika 205 See SAV000001 Section B Fiberglass Preparation A Sand using Scotchbrite See SAV000001 Section G B Clean...

Page 1067: ...Installation A B C A Apply double face tape 1 32 x on top of center piece B Apply double face tape 1 8 x underneath center piece C Apply Sika 252 1 20 D Center and position center piece with referenc...

Page 1068: ...rd eraser Note Position side panel before compressing double face tape D If applicable remove excess of Sika and clean surfaces using Sika 208 Section view A Position entrance door and service door fr...

Page 1069: ...LE 12 8 2 REFRIGERANT 13 8 2 1 Procurement 13 8 2 2 Precautions in Handling Refrigerant 13 8 2 3 Treatment in Case of Injury 13 8 2 4 Precautions in Handling Refrigerant Lines 14 8 3 PUMPING DOWN 16 8...

Page 1070: ...ansion Valve 32 9 9 2 A C 33 9 10 TEMPERATURES PRESSURES 35 9 11 TORCH BRAZING 36 9 12 LEAK TESTING 36 10 SMALL HVAC SYSTEM AIR CONDITIONING COMPONENTS 36 10 1 COMPRESSOR 36 10 2 COMPRESSOR REMOVAL 36...

Page 1071: ...GRINDING TECHNIQUE 24 FIGURE 27 IMPROPER GRINDING TECHNIQUE 24 FIGURE 28 GRINDING WITH THE BRUSH SEATER STONE 25 FIGURE 29 SEATING SURFACE OF THE BRUSH 25 FIGURE 30 EVAPORATOR MOTOR 26 FIGURE 31 CONDE...

Page 1072: ...r enters the vehicle on the L H side through the recirculation damper located inside the evaporator compartment door Fig 2 The damper can be fully opened for normal operation or closed for extreme wea...

Page 1073: ...o prevent battery discharge HVAC system will not operate if vehicle charging system is not working properly 5 1 DRIVER S UNIT OPERATION The temperature control in the driver s area is provided directl...

Page 1074: ...95 1806 40 104 1465 45 113 1195 50 122 980 55 131 808 60 140 670 65 149 559 70 158 468 75 167 394 80 176 333 85 185 283 90 194 241 95 203 207 100 212 178 105 221 153 110 230 133 115 239 115 120 248 1...

Page 1075: ...ompartment R9 24V Condenser fan R H R10 24V Condenser fan L H R12 24V Evaporator fan R20 Water pump R26 Pre heating Diodes evaporator compartment D9 Pre heating D10 Pre heating D16 Baggage compartment...

Page 1076: ...NSER COIL CLEANING 22243A CAUTION Direct the pressure straight through the coil to prevent bending of fins and do not use extremely high pressure Do not use hot water steam or caustic soap 6 2 DRIVER...

Page 1077: ...ssure water jet to avoid damaging filter CAUTION Be sure not to reverse filter upon installation 7 HVAC SYSTEM PARTICULARITIES TESTING AND TROUBLESHOOTING Before undertaking any troubleshooting on the...

Page 1078: ...r motor cooling demand The 2nd speed engages if the cabin area air temperature is 1 degree above the set point and it revert to speed 1 if the temperature gets equal or below the set point Conditions...

Page 1079: ...s Bad wiring Check reset circuit breaker CB9 HVAC condenser fans not functioning in speed 1 Module A54 is not powered or is faulty 1 Check the SYSTEM DIAGNOSTIC menu of the message center display MCD...

Page 1080: ...ts required for a closed circuit refrigeration system are shown in Figures 16 and 41 The air conditioning system used on XLII series vehicle is of the Closed type using R 134a 1 The refrigerant flowin...

Page 1081: ...with the eyes serious injury could result Always wear goggles to protect the eyes when opening refrigerant connections All refrigerant cylinders are shipped with a heavy metal screw cap The purpose o...

Page 1082: ...ed lines from parts stock 4 When disconnecting any fitting in the refrigeration system the system must first be discharged of all refrigerant However proceed very cautiously regardless of gauge readin...

Page 1083: ...Section 22 HEATING AND AIR CONDITIONING PA1564 15 FIGURE 16 REFRIGERANT CIRCUIT CENTRAL SYSTEM 22247...

Page 1084: ...nts NOTE Before attempting any repair between compressor and receiver tank use a recovery unit to remove refrigerant from the system NOTE On vehicles equipped with a small A C system only refer to Sma...

Page 1085: ...seat the compressor valves by turning out all the way 8 Shut down the vacuum pump 9 Remove the hoses 10 Reinstall the caps at the suction valve take off points 8 5 1 Double Sweep Evacuation Procedure...

Page 1086: ...Section 22 HEATING AND AIR CONDITIONING PA1564 18 FIGURE 17 DOUBLE SWEEP EVACUATION SET UP...

Page 1087: ...he system is now ready for operation CAUTION The evacuation of the system must be made by authorized and qualified personnel only Refer to local laws for R 134a recuperation 8 7 REFRIGERANT SYSTEM CLE...

Page 1088: ...filter dryer Also check the liquid line dryer for signs of restriction If the pressure drop across the filter dryer exceeds 12 to 14 psig 82 75 to 96 5 kPa with a 40 F 5 C evaporator coil temperature...

Page 1089: ...ley positioning the other end close to the compressor clutch pulley Figs 21 22 2 Check the distance between each extremity of straight edge 1 Fig 22 and the first drive belt If they are different loos...

Page 1090: ...ace and be neither as hot as the normal discharge temperature nor as cool as the normal suction temperature Blown Head Gaskets Symptom Loss of unit capacity at low temperature Even cylinder head tempe...

Page 1091: ...e the evaporator motor and coil access panel 4 Identify the L H side discharge duct inside compartment and remove the Phillips head screws retaining the flexible member to duct FIGURE 24 EVAPORATOR MO...

Page 1092: ...e new motor brushes are provided with a preformed seating face which is approximately the same curvature as the commutator Grinding honing will give an exact match in curvature The advantage of prefor...

Page 1093: ...m brushes DANGER Use a dust mask to prevent inhalation of dust particles Protect against electrical shock when working on energized equipment Protect against falling or slipping when working on rotati...

Page 1094: ...rs Fig 31 28 5 V 0 6 HP 0 42 kW and cages are installed in the condenser compartment on R H side of vehicle in order to ventilate the condenser coil They are mounted on a support fastened to the floor...

Page 1095: ...TER DRYER A filter dryer also located in the condenser compartment is installed on the liquid refrigerant line after the receiver tank It is used to absorb moisture and foreign matter from refrigerant...

Page 1096: ...not corrected at an early stage The moisture indicator permits an early detection of moisture in the system and when corrected by a desiccant charge system contamination is greatly minimized 9 7 LIQU...

Page 1097: ...mbly valve to open allowing a flow of refrigerant liquid into the evaporator The remote bulb and power assembly is a closed system The pressure within the remote bulb and power assembly corresponds to...

Page 1098: ...ntinued absorption of heat from the surrounding atmosphere The degree to which the gas refrigerant is superheated is related to the amount of refrigerant being fed to the evaporator and the load to wh...

Page 1099: ...ture reading is 40o F 4 4o C subtract 32o F 0o C and the result will be 8o F 4 4o C of superheat CAUTION Before proceeding to the expansion valve adjustment check for restriction on suction side for c...

Page 1100: ...ce valve Air filter screens clogged Clean or replace air filter screens Clogged lines Clean repair or replace lines LOW SUCTION PRESSURE LOW SUPERHEAT Uneven or inadequate evaporator loading due to po...

Page 1101: ...condition of air filter and motors Insufficient air flow Dirty or iced evaporator Dirty air filter Blowers inactive Clogged ducts No flow of refrigerant through expansion valve Filter dryer is clogge...

Page 1102: ...psi 171 9 psi 199 8 psi the pressure in the condenser is inferior to the pressure corresponding to the exterior temperature in this case the condenser pressure may be too low Check for refrigerant le...

Page 1103: ...8 5 127 6 40 40 0 14 7 101 4 30 34 4 9 8 67 6 20 29 3 8 26 2 10 23 1 8 12 4 0 18 6 3 43 4 10 12 11 6 80 20 7 18 0 124 1 30 1 25 6 176 5 40 4 34 5 237 9 50 10 44 9 309 6 60 16 56 9 392 3 70 21 1 70 7 4...

Page 1104: ...tration by an intense blue Do not confuse this change in color with the change caused by shutting off the air supply through the hose by holding the end too close to an object The procedure for testin...

Page 1105: ...ows the approximate amount of oil to be added to the system when replacing a component Component replaced Typical amount of oil Evaporator Condenser Filter Dryer 50 cm 1 7 ozs 30 cm 1 0 ozs 10 cm 0 3...

Page 1106: ...Section 22 HEATING AND AIR CONDITIONING PA1564 38 FIGURE 39 REFRIGERANT CIRCUIT SMALL SYSTEM 22350...

Page 1107: ...top engine and allow engine coolant to cool b Locate the normally open hot water pneumatic valve on the ceiling of the spare wheel compartment Fig 40 move the pilot solenoid valve red tab to close the...

Page 1108: ...Section 22 HEATING AND AIR CONDITIONING PA1564 40 FIGURE 42 CENTRAL HEATING SYSTEM COMPONENTS 22338...

Page 1109: ...HVAC UNIT DRAIN COCK 22128 11 1 2 Filling Heating System 1 Ensure that the drain hose is reconnected and the manual vent and drain cock are closed 2 Open the surge tank filler cap and slowly fill the...

Page 1110: ...gainst the cylinder thereby keeping the water valve open The driver s heater water valve requires a minimum amount of maintenance The valve should be free of dirt sediment that might interfere with it...

Page 1111: ...mbly o Description The flow of hot water to the vehicle s central heater core is controlled by a 3 way pneumatic water valve assembly The valve located in the evaporator compartment is designed so tha...

Page 1112: ...igure 49 Fasten pilot solenoid vale to the pneumatic water valve Reconnect air supply pressure and electrical current to the pilot solenoid valve c Check for proper operation o Pilot Solenoid Valve a...

Page 1113: ...trical wiring from the motor WARNING Before proceeding with the following steps check that coolant has cooled down d Disconnect water lines from pump at flange connections Place a container to recover...

Page 1114: ...placing brushes a The face of a new brush is carefully cut to cause proper seating during the wear in period b Improper installation can harm both the brush and the commutator c Replacement brushes sh...

Page 1115: ...IGURE 51 WATER RECIRCULATING PUMP CENTRAL HVAC SYSTEM 22091 ITEM DESCRIPTION QTY 1 Housing 1 2 O Ring 1 3 Washer SS 2 4 Rotor Assembly 1 5 Shaft SS 1 6 Screw Cap Hex Soc Head 8 32 X 3 8 8 7 Adaptor 1...

Page 1116: ...ner to recover coolant and disconnect silicone hose from hot water pneumatic valve d From inside of vehicle remove the two finishing panels in front of unit Remove the three screws fixing the unit fro...

Page 1117: ...Section 22 HEATING AND AIR CONDITIONING PA1564 49 FIGURE 52 CEILING OF THE SPARE WHEEL COMPARTMENT FIGURE 53 HEATER LINE SHUTOFF VALVES W5...

Page 1118: ...Section 22 HEATING AND AIR CONDITIONING PA1564 50 FIGURE 54 HEATER LINE SHUTOFF VALVES WE...

Page 1119: ...Section 22 HEATING AND AIR CONDITIONING PA1564 51 FIGURE 55 SMALL HEATING SYSTEM COMPONENTS 22337...

Page 1120: ...Prevost number 563008 Brush Prevost number 562951 Condenser fan motors Make US MOTOR Type TF 12 Voltage 28 5 V DC Current draw 20 amps Horsepower 0 57 Revolution 1950 rpm Insulation Class F Motor 20...

Page 1121: ...ake Carrier Transicold Capacity 41 CFM Model 05G 134A No of cylinders 6 Bore 2 50 8 mm Operating speed 400 to 2200 rpm 1750 rpm Nominal Minimum speed for lubrification 400 rpm Nominal horsepower 15 Oi...

Page 1122: ...97 Prevost number with Delco 270 300 Amp Alternator 506664 Compressor V belt Make Dayco Model BX100 Prevost number with two BOSH Alternators 506681 Condenser coil Central system Make Carrier Transicol...

Page 1123: ...rmally open Voltage 24 V DC Prevost number 871252 Seal kit Water Side 871311 Seal kit Actuator Side 871312 Seal kit Pilot Solenoid Valve 871313 Hot water pneumatic valve Central system Make Burkert Ty...

Page 1124: ......

Page 1125: ...Compressor 62 11052 Rev A WORKSHOP MANUAL for MODEL 05G TWIN PORT COMPRESSOR R...

Page 1126: ...WORKSHOP MANUAL COMPRESSOR MODEL 05G TWIN PORT...

Page 1127: ...ork on the equipment alone MAINTENANCE PRECAUTIONS Be sure power is turned off before working on motors controllers solenoid valves and electrical control switches Tag circuit breaker and power supply...

Page 1128: ...other means relieve pressure in replacement compressor before removing plugs WARNING Do not unscrew capscrews all the way before breaking seal Entrapped pressure could result in injury CAUTION The hi...

Page 1129: ...1 5 2 Pressure Operated Unloaders 1 5 COMPRESSOR REPLACEMENT 2 1 2 1 COMPRESSOR REMOVAL 2 1 2 2 COMPRESSOR REPLACEMENT 2 1 2 2 1 Installing Compressor Unloaders 2 1 2 2 2 INSTALLING COMPRESSOR 2 2 COM...

Page 1130: ...2 2 Oil Level in Sight Glass 2 2 Figure 3 1 Shaft Seal Reservoir 3 1 Figure 3 2 Cylinder Head Valve Plate 3 2 Figure 3 3 Installing Suction Valves 3 2 Figure 3 4 Checking Suction Valve 3 2 Figure 3 5...

Page 1131: ...m of the crankcase for maintenance WARNING Do not operate compressor unless suction and discharge service valves are open Capacity of the Model 05G Twin Port compressor is determined by piston displac...

Page 1132: ...ice Valve 2 High Pressure Connection 3 Low Pressure Connection 4 Suction Service Valve 5 Guage Connection 6 Oil Fill Plug 7 Oil Level Sight Glass 8 Bottom Plate 9 Oil Drain Plug 10 Oil Pump See Figure...

Page 1133: ...ilter screen and pick up tube to the oil pump located in the bearing head assembly The crankshaft is drilled to enable the pump to supply oil to the main bearings connecting rod bearings and the shaft...

Page 1134: ...on in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind t...

Page 1135: ...e Discharge gas bleeds into the valve chamber the pressure closes the piston bypass valve 5 and the cylinder bank loads up Discharge gas pressure forces the discharge piston check valve 6 open permitt...

Page 1136: ...pressor is to be returned for overhaul or repair install the pads on the compressor for sealing purposes during shipment Service replacement compressors are furnished with cylinder head bypass piston...

Page 1137: ...l new locknuts on compressor mounting bolts and new gaskets on suction and discharge service valves b Check oil level in sight glass See Figure 2 2 If necessary add or remove oil c Leak test evacuate...

Page 1138: ...ndition Replace any defective or excessively worn parts c Inspect suction and discharge valve seats on valve plate d If unloaders are installed inspect operation of unloader e After cleaning ensure al...

Page 1139: ...es e Place the valve plate and new valve plate gasket on cylinder deck ensuring that the valve plate is properly positioned on the four dowel pins f Using a small screwdriver operate the suction valve...

Page 1140: ...end thrust washer on the two dowel pins located on the bearing head See Figure 3 5 CAUTION Ensure that thrust washer does not fall off dowel pins while installing oil pump b Install the bearing head...

Page 1141: ...Insure that the back side of the lipseal seats on the shoulder machined in the cover clutch mounting hub g Using clean refrigerant oil lubricate the new O ring and install it into the outside groove o...

Page 1142: ...ush piston rod assemblies out of the way and remove crankshaft and seal end thrust washer b Remove and check operation of oil return check valves See Figure 3 11 The check valves are free floating dev...

Page 1143: ...installing new piston rings it is necessary to break the hard glazed surface of the cylinder in order to reduce the wearing in period of the new rings Break the glaze by honing lightly in an up and d...

Page 1144: ...et metal b Install connecting rod caps on connecting rods using new capscrews special and flat washers Reuse of the old capscrews is not recommended Ensure that the caps are installed on the locating...

Page 1145: ...20 10 to 13 1 4 to 1 8 Connecting Rod Counter Weight 5 5 to 7 0 8 to 1 0 Crankshaft Setscrew 1 4 28 8 to 18 1 1 to 2 5 Unloader Valve 1 4 28 12 to 16 1 7 to 2 2 Discharge Valve Backer 5 16 18 16 to 20...

Page 1146: ...Rod Diameter 1 3768 34 9707 1 3760 34 9504 0020 0 051 Piston Pin Bearing 0 6883 17 4752 0 6878 17 4701 001 0 0254 CRANKSHAFT Crankpin Diameter 1 3740 34 8996 1 3735 34 8869 0025 0 0635 Throw Height 37...

Page 1147: ...em 1 3 O Oil 1 1 Oil Level 2 2 Oil Adding 3 7 Oli Pump Maintenance 3 2 P Pistons Rods and Rings 3 5 R Reference Data 1 1 Running Gear Removal 3 4 S Service Valves 1 3 Shaft Seal Maintenance 3 3 Shaft...

Page 1148: ...ansicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 357 7223 Fax 1 706 355 5435 Central America and Mexico Ejercito Nacional No 418 Piso 9 Torre Yumal Col Chapultepec Morales 11570 Mexico D F Tel...

Page 1149: ...Compressor 62 11053 Rev B SERVICE PARTS LIST for MODEL 05G TWIN PORT COMPRESSOR 1 2 3 4 5 6 R...

Page 1150: ...T ROD AND PISTON GROUP 5 6 SHAFT END GROUP 6 7 SHAFT SEAL RESERVOIR AND SHAFT END FLANGES 7 8 UNLOADERS 8 9 VALVE PLATE ASSEMBLY 10 10 UNLOADER VALVE PLATE ASSEMBLY 11 11 CYLINDER HEAD SIDE 12 12 CYLI...

Page 1151: ...No Oil Trailer 18 00091 106 6GCG008WB03131 18 00059 130RM Standard Bottom Cover 37 CFM Contoured Pistons Star Flange 1 Electric Unloader No Oil Truck Supra 9XX 18 00091 108 6GDG00DUA0313A 18 00059 12...

Page 1152: ...embly or kit COMPRESSOR OIL CHART Part Number Oil Type Viscosity Refrigerants Application Packaging 07 00275 00 Mineral 150 R 12 R 22 R 500 R 502 Large Bus 1 Gallon x 6 07 00377 00 Mineral 300 R 12 R...

Page 1153: ...1 10 17 13020 00 Capscrew 1 2 13 x 2 1 2 Inches Long SAE Grade 8 4 11 17 40007 00 Gasket Capscrew 1 2 Inch 4 12 17 10812 00 Cap Service Valve Plastic 1 12 17 10806 10 Cap Service Valve Brass 1 9 17 4...

Page 1154: ...ressors 1 2 17 44117 00 Capscrew Hex Head 3 8 16 x 2 1 4 Inches Long SAE Grade 8 22 3 17 44037 00 Plug O Ring 7 16 20 Includes 1 4 42 00243 07 O Ring 1 5 17 40020 00 Oil Filter Screen Assembly 1 6 17...

Page 1155: ...yle Compressors 1 2 17 44117 00 Capscrew Hex Head 3 8 16 x 2 1 4 Inches Long SAE Grade 8 22 3 17 44037 00 Plug O Ring 7 16 20 Includes 1 4 42 00243 07 O Ring 1 5 17 40020 00 Oil Filter Screen Assembly...

Page 1156: ...es Long SAE Grade 5 8 2 17 44137 00 Oil Pump and Bearing Head Includes 1 3 17 44037 00 Plug O Ring 7 16 20 Includes 2 4 42 00243 07 O Ring 2 5 17 44139 00 O Ring Pump Cover Plate 1 6 17 40204 00 Pin R...

Page 1157: ...ndard 12 5 17 55025 00 Ring Compression 020 Inch Oversize 12 6 17 40324 00 Key Crankshaft 1 4 x 1 4 x 1 1 2 Inches Long For Shaft Mounted or No Clutch 1 6 68G2 9072 Key Crankshaft For Housing Mounted...

Page 1158: ...4773 00 O Ring Stator 1 7 17 44766 00 Hub Assembly Housing Mounted Clutch Threaded No Groove Trailer Includes 1 7 17 44767 00 Hub Assembly Housing Mounted Clutch Threaded W Grease Groove Bus Includes...

Page 1159: ...d 3 8 16 X 0 75 Inch Long Grade 8 1 5 17 44119 00 Gasket End Flange Ultra Style or Full Ring Flange Used With Items 6 and 7 1 6 17 44025 00 End Flange Ultra Style Trailer 1 7 17 44002 00 End Flange Fu...

Page 1160: ...8 62 11053 8 UNLOADERS 11 9 10 8 7 6 4 5 3 2 1 COILS 29 12 12 13 14 6 6 7 8 8 15 16 17 18 19 20 21 22 4 5 3 23 24 25 26 27 28 OR Pressure Valve Electric Valve Valve Plug...

Page 1161: ...e 115 VAC With 42 inch Wire Leads Includes 17 10829 00 Coil Valve 230 VAC With 42 inch Wire Leads Includes 13 17 40408 02 Cap Snap 1 14 22 50078 02SV Connector 2 Wire 22 02804 00 Coil Only Mates W 22...

Page 1162: ...Assembly Center or Side Bank With No Unloader Includes 1 2 17 44113 00 Capscrew HexHead 1 4 28 x 3 8 Inch Long 4 3 17 10715 00 Lockwasher 1 4 Inch 4 4 17 44750 00 Backer Discharge Valve 2 5 17 44749 0...

Page 1163: ...x 3 8 Inch Long 4 3 17 10715 00 Lockwasher 1 4 Inch 4 4 17 44750 00 Backer Discharge Valve 2 5 17 44749 00 Valve Discharge 2 6 NSS Valve Plate 1 7 17 44748 00 Valve Suction 2 8 17 40057 00 Dowel Pin...

Page 1164: ...0013 00 Gasket Capscrew 5 16 Inch 2 3 17 01042 04 Valve Service 7 8 Inch ODF 1 8 Inch FPT Gauge Port Includes 1 3 14 00206 01 Valve Service 7 8 Inch ODF M15 Gauge Port For R 134a Includes 1 4 17 10812...

Page 1165: ...4 06 Gasket Shaft Seal 1 3 17 44746 00 Gasket Valve Plate 3 4 17 44118 00 Gasket End Flange 1 5 17 44119 00 Gasket End Flange 1 6 17 44129 00 Gasket Bottom Plate 1 7 17 44747 00 Gasket Cylinder Head C...

Page 1166: ...iner 1 8 68 G 2 9072 Key Crankshaft Special 1 9 17 10308 00 Capscrew Hex Head 3 8 16 x 1 1 4 Inches Long SAE Grade 8 1 10 50 01122 01 Clutch Assembly 24 VDC 2 C Grooves 9 Inch Diameter Includes 1 11 5...

Page 1167: ...Rotor Armature 4 Grooves 2 A 2 B 10 35 Inch Diameter Includes 1 13 34 01186 00 Ring Snap 1 14 04 00130 00 Bearing Rotor 1 10 50 01122 12 Clutch Assembly 24 VDC 2 5V Grooves 8 7 Inch Diameter Includes...

Page 1168: ...Ring Felt and Retainer 1 7 68 G 2 9072 Key Crankshaft Special 1 8 17 10308 00 Capscrew Hex Head 3 8 16 x 1 1 4 Inches Long SAE Grade 8 1 9 50 00226 09 Clutch Assembly 24 VDC 4 Grooves 2A 2B 10 35 Inch...

Page 1169: ...ing 1 9 50 01130 20 Clutch Assembly 12 VDC 2 B Grooves 10 35 Inch Diameter Includes 1 10 50 00226 41 Coil 12 VDC 1 11 50 50040 03 Rotor Armature 2 B Grooves 10 35 Inch Diameter Includes 1 12 50 50040...

Page 1170: ...8 4 3 2 1 14 Item Part Number Description Qty 1 34 00613 07 Capscrew Hex Head 3 8 UNF x 7 8 Inch Long SAE Grade 8 1 2 AU 11AR 241 Washer Lock Spring 3 8 Inch 1 3 34 00616 00 Washer 13 32 ID x 1 1 2 OD...

Page 1171: ...meter 6 50 50011 00 Coil 24 VDC 1 6 50 50014 00 Coil 12 VDC 1 7 50 50015 00 Ring Retaining External 1 8 50 50016 00 Ring Retaining Internal 1 9 50 50017 00 Bearing 1 10 17 10308 00 Capscrew Hex Head 3...

Page 1172: ...Valve 2 2 68PD 2 102 3 Solenoid Coil 24 VDC 2 3 12 00334 02 Switch Pressure UPS2 R 134a 1 4 12 00334 03 Switch Pressure UPS1 R 134a 1 5 40 00249 01 Fitting Tee Male Branch 1 4 FPT x 1 4 FPT x 1 4 MPT...

Page 1173: ...l 36 VDC 2 3 12 00334 02 Switch Pressure UPS2 R 134a 1 4 12 00334 03 Switch Pressure UPS1 R 134a 1 5 40 00249 01 Fitting Tee Male Branch 1 4 FPT x 1 4 FPT x 1 4 MPT 1 6 40 00243 01 Fitting Tee Street...

Page 1174: ...00 5 17 40324 00 5 18 17 40408 02 9 17 40409 00 9 17 40417 00 9 20 21 17 40417 02 21 17 40418 00 9 17 44002 00 7 17 44004 06 6 13 17 44005 00 1 17 44008 00 5 17 44011 00 2 3 17 44012 00 12 17 44013 0...

Page 1175: ...50 00226 09 16 50 00226 18 16 50 00226 19 17 50 00226 41 16 17 50 00226 50 16 17 50 00226 501 16 50 00226 65 17 50 00226 66 17 50 01108 00 18 50 01110 00 18 50 01110 01 18 50 01114 00 18 50 01115 00...

Page 1176: ...ansicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 357 7223 Fax 1 706 355 5435 Central America and Mexico Ejercito Nacional No 418 Piso 9 Torre Yumal Col Chapultepec Morales 11570 Mexico D F Tel...

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Page 1178: ......

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Page 1182: ...4...

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Page 1189: ...ALVE QUICK TEST 5 5 AIR HORN VALVE 5 5 1 AIR HORN VALVE MAINTENANCE 5 6 HEADLIGHTS CLEANING SYSTEM 5 6 1 GENERAL DESCRIPTION 5 6 2 WASHER FLUID REFILLING 6 6 3 WASHER NOZZLES ADJUSTMENT 6 7 WINDSHIELD...

Page 1190: ...FIGURE 6 TUBING AND FITTINGS 6 FIGURE 7 WASHER NOZZLES ADJUSTMENT 6 FIGURE 8 WINDSHIELD WIPER INSTALLATION 7 FIGURE 9 MULTIFUNCTION LEVER 7 FIGURE 10 WINSHIELD WASHER RESERVOIR 7 FIGURE 11 WINDSHIELD...

Page 1191: ...ner on hubodometer face or on plastic hubcaps Do not weld on hubodometer 2 3 REMOVAL To remove the unit remove the two lock nuts and washers securing it to the wheel hub and pull the unit off the stud...

Page 1192: ...of ignition as this fuel is extremely flammable Avoid breathing vapors and contacting fuel with skin Never smoke during test FIGURE 3 COLD STARTING AID 23048 1 Check cylinder for hand tightness and f...

Page 1193: ...isconnect tube at thermal cutout valve as in step 2 and repeat step 3 No fuel should be discharged 5 AIR HORN VALVE The air horn valve is located in the front service compartment and the air horn valv...

Page 1194: ...0377 with the reference line shown on the front view detail As seen on the side view position the end of the adjustment tool to a distance of high beam and 1 low beam from the top of the headlight for...

Page 1195: ...front service compartment fig 10 This unit pumps the washer liquid to the spray nozzles where it is dispersed across the windshield 7 2 WIPER ARM Check operation of the wipers for proper blade sweep a...

Page 1196: ...MOTOR 7 3 1 Windshield Wiper Motor Replacement The windshield wiper motor is located at lower front of the vehicle behind the defroster panel Refer to figure 8 for motor location WARNING Park vehicle...

Page 1197: ...air if severely clogged replace items D Replace section E Realign tubing and or refit Trim end to ensure proper fit or re place INADEQUATE SPRAYING A Tubing failure A Replace tubing SLOW OPERATION A I...

Page 1198: ...lb in 9 5 b no extension piece Prevost 681083 Front axle and tag axle wheels with 365 tires a Remove Alcoa valve b Install Beru valve Torque valve to 102lb in 22 c no extension piece Prevost 651080 Al...

Page 1199: ...ve b Install Beru valve Torque valve to 102lb in 22 c no extension piece Prevost 651082 8 2 BERU SENSORS INSTALLATION IMPORTANT NOTE Beru sensors have a limited lifespan 5 years on average Install sen...

Page 1200: ...TIONS HUBODOMETER US model miles Make Stemco Prevost number 650002 HUBODOMETER Canada model km Make Stemco Prevost number 650117 AIR HORN Make Allied Signal Inc Prevost number 640093 AIR HORN VALVE Ma...

Page 1201: ...2 LUBRICATION AND SERVICE SCHEDULE 2 2 1 FLEXIBLE HOSE MAINTENANCE 3 2 1 1 Pre Starting Inspection 3 2 1 2 Leaks 3 2 1 3 Service life 3 2 2 WALK AROUND INSPECTION 4 2 3 LUBRICANT AND COOLANT SPECIFIC...

Page 1202: ...recommendations 1 1 FIRST SERVICE ON NEW VEHICLE Perform the following maintenance procedures after the first 3 000 miles 4 800 km of operation unless otherwise specified Once initial maintenance is...

Page 1203: ...corrective action immediately Leaks are not only potentially detrimental to machine operation but can also result in added expenses caused by the need to replace lost fluids WARNING Personal injury an...

Page 1204: ...k Allison transmission oil level can be checked from push button shift selector Add if necessary 29 Check power steering reservoir fluid level Add if necessary 21 Check coolant surge tank fluid level...

Page 1205: ...Section 24 LUBRICATION PA1564 5 FIGURE 1 LUBRICATION AND SERVICING POINTS ON INDEPENDENT FRONT SUSPENSION VEHICLES 24036_1...

Page 1206: ...80W90 should be used Below 15 F 26 C 75W90 should be used In extreme conditions or for better performance full synthetic gear oil can be used F Differential Oil Full Synthetic Multigrade gear oil meet...

Page 1207: ...fuel filter 510794 P8 Engine coolant precharge element filter 550629 P9 Engine coolant maintenance element filter 550630 P10 HVAC driver s air filter 871147 871144 P11 HVAC cabin air filter 871383 P12...

Page 1208: ...LUBRICATION AND SERVICING SCHEDULE For lubrication and servicing schedule refer to table A IMPORTANT NOTE Refer to the manufacturers documentation included in this maintenance manual for specific manu...

Page 1209: ...Repair instruction 142 219 in Section 01 Engine change oil and filters 17 12 A P1 03 FUEL Change primary secondary fuel filters 17 12 P5 P7 05 COOLING Cooling fan gearbox check oil level add if neces...

Page 1210: ...ed with transmission retarder 24 09 PROPELLER SHAFT Grease one fitting on each universal joint and slip joint 34 6 K 11 REAR AXLE Differential check oil level add if necessary 35 6 E Differential chan...

Page 1211: ...K Bell crank grease fitting 41 6 K Steering damper cylinder grease one fitting at rod end 6 K Steering knuckle pins grease two fittings per knuckle 9 6 K Power steering reservoir replace oil and filte...

Page 1212: ......

Page 1213: ...NT 8 5 PINION 9 5 1 PINION AND KEYLESS BUSHING POSITIONING 9 5 2 FRONT SLIDE OUT SHAFT PINION REPLACEMENT 9 5 3 REAR SLIDE OUT SHAFT PINION REPLACEMENT 10 5 4 KEYLESS BUSHING 10 5 4 1 Installation 10...

Page 1214: ...15 5 SLIDE OUT LIMIT SENSORS 25 15 5 1 Maintenance and adjustment 25 16 SLIDE OUT EXTERIOR FINISHING PANELS WINDOWS 26 16 1 FACE PANEL REMOVAL 26 16 2 FACE PANEL INSTALLATION 26 16 3 SIDE PANELS REMO...

Page 1215: ...RIVE MOTOR GEARBOX ASSEMBLY MOUNTING BOLTS 13 FIGURE 19 CLAMPING HUB POSITION ON GEARBOX SHAFT 14 FIGURE 20 JAW COUPLING 14 FIGURE 21 SLIDE OUT LEVEL ADJUSTEMENT 15 FIGURE 22 SLIDE OUT LEVELING 16 FIG...

Page 1216: ...G WINDOW RUBBER BUMPER INSTALLATION 31 FIGURE 62 SIDE BUMPERS 32 FIGURE 63 MASKING TAPE APPLICATION 32 FIGURE 64 SIKA 255 APPLICATION 32 FIGURE 65 AWNING WINDOW SIKA AKTIVATOR 32 FIGURE 66 AWNING WIND...

Page 1217: ...ide structure keys figure 1 2 FIGURE 1 FRONT SLIDE OUT 1 1 1 Maintenance Check that the inner stopper screws are tight and that no damage or deformation has taken place for both the side and the upper...

Page 1218: ...astic in limit stoppers add or remove shims as required between the stopper and the extrusion 4 Using the manual override procedure section 18 move the slide out up to its full in position 5 Using a s...

Page 1219: ...the pin produces excessive knocking when it engages with releasing of the parking brake reduce air cylinder speed by adjusting the air flow regulator on the pneumatic control panel FIGURE 29 item 11...

Page 1220: ...heads reduce plastic thickness Do not torque higher than specified 4 3 REAR SLIDE OUT RACK REPLACEMENT 1 Using the slide out handheld control or the manual override procedure section 18 if using the...

Page 1221: ...e out shaft pinion replacement check the following conditions The locking collars located on the side of the pinion being replaced are disengaged The drive motor gearbox assembly is removed see sectio...

Page 1222: ...hten the keyless bushing use a special open end wrench to retain the yellow part and another wrench to tighten the black part Figure 20 shows how to tighten the keyless bushing When tightening make su...

Page 1223: ...Section 26 XLII SLIDE OUT PA1564 11...

Page 1224: ...Section 26 XLII SLIDE OUT PA1564 12 FIGURE 16 KEYLESS BUSHING INSTALLATION INSTRUCTION...

Page 1225: ...ews 5 Re connect the electric cable connector 7 SPEED REDUCTION GEARBOX The speed reduction gearbox used is a helical worm gear type This gearbox has a 2 stage 740 1 ratio and the output shafts are se...

Page 1226: ...haft to align the keyways 9 Tighten clamping screws to a torque of 18 lbf ft FIGURE 20 JAW COUPLING 9 FLANGE BEARING There are two different types of flange bearing on the slide out mechanism FIGURE 1...

Page 1227: ...side the vehicle when it is retracted The slide out is slightly tilted When retracting the upper in limit stoppers touch first the vehicle structure followed by the lower in limit stoppers Tilt adjust...

Page 1228: ...n contact with the support plate Make sure screws 1 2 3 4 are in contact with the support plate 8 Loosen retaining screw A B 9 Using a crisscross pattern tighten progressively 3 rounds the retaining s...

Page 1229: ...body extrusion and can be removed through the end cap FIGURE 24 6 Adjust the flat bar position to align the weldnuts with the rail mounting holes 7 Temporarily tighten the bolts 8 Adjust the rail posi...

Page 1230: ...ng of the seal and the other for deflating of the seal When one of the solenoids is activated seal deflating valve for example the valve will keep its state even if the solenoid is deactivated The inf...

Page 1231: ...the Prevost maintenance manual INFLATABLE SEAL CIRCUIT The efficiency of the seal could be affected by impurities such as white powder in the pneumatic control valve It is recommended to inspect the i...

Page 1232: ...aling device for both retracted and extended slide out position and a wiper seal as a secondary sealing device which is used to wipe water out and to ensure sealing during slide out movement INFLATABL...

Page 1233: ...wiper seal and the exterior panels and glasses 14 3 3 Seal assembly installation NOTE This procedure is to install the inflatable seal assembly on the structure CAUTION Always apply product in the sam...

Page 1234: ...out are accessible from outside figure 7 4 Using a knife cut the sealant between the extrusion and the roof figure 7 Unscrew and remove the central exterior extrusion screws and the two end extrusion...

Page 1235: ...ss compartment The other interconnections are located on the pneumatic panel and the electrical panel in the front service compartment All the interconnections are shown on the electrical diagrams of...

Page 1236: ...black connector To disconnect the black connector slide downwards the red latch Turn the ignition key to the ON position This engages the automatic reprogramming The slide out telltale light will turn...

Page 1237: ...he in limit stoppers are perfectly adjusted see section 1 2 2 1 Retract the slide out to its full IN position with the in limit stoppers in contact with their bearing surface 2 Loosen the in limit sen...

Page 1238: ...ng supports and clean them before re using Check where adhesive sealant and double face adhesive tape are on the structure and the panel back side in order to be able to stick the new panel in the sam...

Page 1239: ...efer to the MTH side panel installation procedure described in section 18 BODY 1 Protect adjacent surfaces with appropriate material 2 Refer to figure 41 for 1 16x1 4 double face adhesive tape locatio...

Page 1240: ...city never use a buffer or other sanding method to remove it 16 6 TOP AND BOTTOM PANEL INSTALLATION NOTE The top and bottom panels are made of aluminum sheets and need aluminum rivet For surface clean...

Page 1241: ...mical adhesives 16 7 WINDOWS REMOVAL 1 Remove the slide out 2 If needed remove the exterior extrusion as described in section 1 3 CAUTION Be careful not to damage the adjacent surfaces 3 With a knife...

Page 1242: ...SEAL INSTALLATION FIGURE 52 FACE FIXED WINDOWS 3 16 X 1 2 DOUBLE FACE ADHESIVE TAPE INSTALLATION FIGURE 53 SIDE FIXED WINDOW X DOUBLE FACE ADHESIVE TAPE INSTALLATION FIGURE 54 FACE FIXED WINDOW AND HA...

Page 1243: ...high 7 Install the windows on the slide out structure see FIGURE 59 or FIGURE 60 8 Press the jigs on the windows and wait for the adhesive to dry 90 minutes minimum 9 After drying apply Sika 221 as a...

Page 1244: ...APPLICATION 6 Apply Sika Aktivator as per FIGURE 65 7 Apply Sika 255 as per FIGURE 66 triangular bead 10mm width X 10mm high FIGURE 65 AWNING WINDOW SIKA AKTIVATOR FIGURE 66 AWNING WINDOW SIKA 255 APP...

Page 1245: ...riate cleaner abrasives and primers Clean surfaces with anti silicone 2 Apply Sika Aktivator on sliding window as per FIGURE 71 3 Apply Sika Aktivator on the structure as per FIGURE 72 4 Apply Sika 25...

Page 1246: ...QUENCE FIGURE 75 SLIDING WINDOW SEAL THE UPPER CORNERS FIGURE 76 SEAL 16 11 FINISHING JOINT The following procedure applies to section 16 11 1 up to 16 11 4 For surface cleaning and preparation tools...

Page 1247: ...d the structural member FIGURE 77 Apply Sika 221 between the top of face window and the structural member FIGURE 78 16 11 2 Slide out side Apply Sika 221 between the top of side window and the structu...

Page 1248: ...security pin cavity FIGURE 85 16 11 4 Top of Slide out Apply Sika 221 between edge of top panel and structural member FIGURE 86 17 WELDING PRECAUTION CAUTION Prior to arc welding on the vehicle refer...

Page 1249: ...a vacuum or pressure build up inside the vehicle FRONT SERVICE COMPARTMENT SLIDE OUT CONTROL PANEL INSIDE ENGINE R H SIDE ACCESS COMPARTMENT FIGURE 87 COMPARTMENTS LOCATION FIGURE 88 VEC CIRCUIT BREAK...

Page 1250: ...turning the shut off valve handle counterclockwise Check the pressure gage on the inflatable seal regulator to see if the pressure is increasing to 10 psi FIGURE 93 0 psi SEAL DEFLATED 10 psi SEAL IN...

Page 1251: ...he drive mechanism and cause damage to the reduction gearbox 7 Finally the inflatable seal can be re inflated by turning the shut off valve handle counterclockwise Check the pressure gage on the infla...

Page 1252: ...2 Check that the slide out is straight when completely extended and that it leans against all inner stoppers 3 Make sure the vehicle upper member is parallel with the front slide out structure If not...

Page 1253: ...system from the CECM Press the enter key If applicable the MCD shows the device ID the fault messages or fault codes recorded When more than one fault is recorded an arrow pointing down appears on the...

Page 1254: ...of the vacuum generator B Faulty vacuum generator connection to the vacuum generator open seal deflating valve solenoid open circuit C I O B module output defective in limit sensor shorted to ground...

Page 1255: ...ut moves out slightly when vehicle is traveling A Lower in limit stoppers are not leaning against the structure at the moment when the in limit sensor detects the magnet A Adjust the sensor position i...

Page 1256: ...e or adjust acetal plastic block proper position Top of slide out not flush with vehicle body A Broken or misadjusted leveling or retaining screw B Faulty upper in limit stopper A Check and replace sc...

Page 1257: ...unction E Excessive load in the slide out F Slide out not centered in the structure opening A Always deflate the seal when manually retracting or extending the slide out B Check the pressure transduce...

Page 1258: ...onnected Faulty pressure transducer Connection or wiring harness open Check replace vacuum transducer Check reconnect the connector SESo1 Fix wiring harness 5 SldO Vacuum Sensor Shorted High Pressure...

Page 1259: ...Low Solenoid or wiring harness shorted to ground Fix solenoid or wiring harness Open Circuit Solenoid is broken or open Bad connection on solenoid or bloc valve Wiring harness is cut Check fix soleno...

Page 1260: ...tch or wiring harness 18 SldO Close Sw Shorted High Switch or wiring harness shorted to 12v or 24v Fix switch or wiring harness 19 SldO Limit In Se Shorted High Sensor or wiring harness shorted to 12v...

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