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PREVOST X3-45 Multiplex, Maintenance Manual

The PREVOST X3-45 Multiplex Maintenance Manual is a comprehensive guide that provides detailed instructions for maintaining and servicing your bus. This manual covers all aspects of maintenance, ensuring optimal performance and longevity. Download your free copy from manualshive.com to keep your bus running smoothly.

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SECTION 03: FUEL SYSTEM 

 

PA1562 

1

CONTENTS 

1.

 

FUEL SYSTEM WITH DETROIT DIESEL SERIES 60 ENGINE .......................................................... 3

 

1.1

 

D

ESCRIPTION

.................................................................................................................................... 3

 

1.2

 

F

UEL 

V

ALVES

.................................................................................................................................... 3

 

1.3

 

F

UEL 

F

ILTERS

................................................................................................................................... 4

 

1.4

 

R

ACOR 

F

UEL

/W

ATER 

S

EPARATOR 

S

ERVICING

.................................................................................... 4

 

1.5

 

S

PIN

-O

N 

T

YPE 

F

UEL 

F

ILTER 

S

ERVICING 

(P

RIMARY 

&

 

S

ECONDARY

) ..................................................... 5

 

1.6

 

F

UEL 

P

UMP 

I

NSTALLATION

................................................................................................................. 6

 

2.

 

FUEL SYSTEM WITH VOLVO D13 ENGINE ....................................................................................... 7

 

2.1

 

D

ESCRIPTION

.................................................................................................................................... 7

 

2.2

 

F

UEL 

V

ALVES

.................................................................................................................................... 8

 

2.3

 

F

UEL 

F

ILTERS

................................................................................................................................... 8

 

2.3.1

 

Primary Fuel Filter Replacement............................................................................................. 9

 

2.3.2

 

Secondary Fuel Filter Replacement...................................................................................... 10

 

2.4

 

P

RIMING 

T

HE 

F

UEL 

S

YSTEM

............................................................................................................ 10

 

2.5

 

F

UEL 

P

UMP 

R

EMOVAL 

A

ND 

I

NSTALLATION

........................................................................................ 11

 

3.

 

DAVCO FUEL PRO 382...................................................................................................................... 11

 

4.

 

FUEL LINES AND FLEXIBLE HOSES............................................................................................... 13

 

5.

 

PREHEATER FUEL FILTER............................................................................................................... 13

 

6.

 

FUEL TANK......................................................................................................................................... 13

 

6.1

 

T

ANK 

R

EMOVAL

.............................................................................................................................. 13

 

6.2

 

T

ANK 

I

NSTALLATION

........................................................................................................................ 14

 

6.3

 

F

UEL 

T

ANK 

V

ERIFICATION

................................................................................................................ 15

 

6.4

 

P

OLYETHYLENE 

F

UEL 

T

ANK 

R

EPAIR

................................................................................................. 15

 

7.

 

FUEL SPECIFICATIONS .................................................................................................................... 15

 

7.1

 

F

UEL 

T

YPE

..................................................................................................................................... 15

 

7.2

 

B

LENDING

....................................................................................................................................... 16

 

7.3

 

B

IODIESEL 

F

UELS

............................................................................................................................ 16

 

8.

 

AIR CLEANER (DRY TYPE)............................................................................................................... 16

 

8.1

 

P

RE

-C

LEANER 

S

ERVICING

............................................................................................................... 16

 

8.2

 

A

IR 

C

LEANER 

S

ERVICING

................................................................................................................ 16

 

8.3

 

G

ENERAL 

R

ECOMMENDATIONS

........................................................................................................ 17

 

8.4

 

A

IR 

C

LEANER 

R

ESTRICTION 

I

NDICATOR

............................................................................................ 17

 

9.

 

FUEL COOLER – DETROIT DIESEL SERIES 60 ONLY................................................................... 17

 

10.

 

FUEL PEDAL................................................................................................................................... 18

 

10.1

 

F

UEL 

P

EDAL 

A

DJUSTMENT

............................................................................................................... 18

 

10.2

 

P

OTENTIOMETER 

R

EPLACEMENT

..................................................................................................... 18

 

11.

 

SPECIFICATIONS ........................................................................................................................... 19

 

 

Summary of Contents for X3-45 Multiplex

Page 1: ...COACH MANUFACTURER MAINTENANCE MANUAL X3 COACHES PA1562 4th edition...

Page 2: ...PA1562 4th edition Date April 2009 Starting from vehicle 9 9640 Featuring New Bosch alternators on DDEC new Sound System new evaporator compartment motor...

Page 3: ...STENERS 10 5 2 RECOMMENDATIONS FOR REUSE 10 5 3 SIX LOBED SOCKET HEAD 10 ILLUSTRATIONS FIGURE 1 DETROIT DIESEL SERIES 60 5 FIGURE 2 VOLVO D13 ENGINE DATA PLATE 5 FIGURE 3 ALLISON TRANSMISSION 5 FIGURE...

Page 4: ...tions may be used therefore minor illustration difference may exist when compared to actual parts or other publications Prevost occasionally sends Maintenance Information Warranty Bulletins Safety Rec...

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: ...or s attention to unsafe practices which could result in serious personal injury or death WARNING Directs the operator s attention to unsafe practices which could result in serious personal injury or...

Page 7: ...ransmission on the vehicle R H side ZF Fig 3 4 The identification plate shows the transmission serial number part number assembly number and model number Use all three numbers when ordering parts FIGU...

Page 8: ...for fire resistance Certified according to Provincial State and Federal Safety standards Canadian and US BMCSS FMVSS and CMVSS Other applicable certification labels are affixed to the component 4 1 8...

Page 9: ...side The VIN is visible from the outside of the coach Make sure the correct vehicle identification number is given when ordering replacement parts Using the VIN when ordering parts will facilitate pr...

Page 10: ...Section 00 GENERAL INFORMATION PA1562 8 FIGURE 12 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 11: ...the 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 a...

Page 12: ...develops 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...

Page 13: ...Section 00 GENERAL INFORMATION 11 PA1562 FIGURE 16 METRIC US STANDARD CONVERSION TABLE 00005...

Page 14: ...Section 00 General Information PA1562 12 FIGURE 17 CONVERSION CHART 00006...

Page 15: ...itch to the OFF position first Recommendations This procedure should be performed by qualified personnel only Effective Revision 0 Issued with multiplex Revision 1 Modified for Fire Protection System...

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 4 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 4 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: ...20 2 5 OTHER SENSORS 21 2 6 MOTOR CONTROL MODULE MCM 21 2 7 COMMON POWERTRAIN CONTROLLER CPC 21 2 8 DDEC VI DIAGNOSTICS 21 2 8 1 Diagnostic system 21 2 8 2 Check Engine Telltale Light AWL 22 2 8 3 Sto...

Page 32: ...12 NORMAL OIL COOLER POSITION 15 FIGURE 13 VOLVO ENGINE POWER PLANT CRADLE INSTALLATION 16 FIGURE 14 VEHICLE INTERFACE HARNESS GENERAL APPLICATION SHOWN 18 FIGURE 15 DETROIT DIESEL 2007 SERIES 60 ENGI...

Page 33: ...rough the instrument cluster display if equipped The Premium Tech Tool PTT is the preferred tool for performing diagnostic work Using a diagnostic computer or PTT connected to the Serial Communication...

Page 34: ...e Sensor is located on the left or right side of the engine EGR Temperature Sensor The EGR temperature sensor detects exhaust gas temperature for EGR system The sensor modifies a voltage signal from t...

Page 35: ...or has a negative temperature coefficient which means the sensor resistance will decrease as the inlet air temperature increases The Intake Manifold Boost Temperature Sensor is located in the intake m...

Page 36: ...Pressure 8 Air Temperature 2 Crankcase Pressure 9 Humidity Ambient Air Temperature 3 Oil Level Temperature 10 Camshaft Speed 4 EGR Differential Pressure 11 Crankshaft Speed 5 EGR Temperature 12 Oil Pr...

Page 37: ...a or Volvo Trucks North America Web Site under Parts Service purchase engine literature D13F engine FIGURE 2 D13F ENGINE TURBO SIDE TYPICAL 1 EGR Valve 8 Coolant Pump 2 Aftertreatment Fuel Injector 9...

Page 38: ...General Keep the engine oil at the proper level and change it at the recommended intervals Always replace the oil filters at the same time as when the oil is changed 1 3 2 Oil Quality Volvo North Amer...

Page 39: ...frequent oil changes NOTE Use the information in the table below to determine the operating condition and usage applicable to your vehicle Engine Operating Condition Medium Heavy Severe Total Fuel Co...

Page 40: ...already contain a balanced treatment of additives 1 3 8 Oil Consumption Once the engine is stopped check the oil level daily If the engine has just been stopped and it is warm wait approximately five...

Page 41: ...ear protective gloves CAUTION Volvo branded oil filters are designed to provide the proper level of filtration and protection for Volvo engines Filters that do not meet the same stringent requirements...

Page 42: ...ting in order to facilitate reinstallation Plug all openings to prevent dirt from entering the system NOTE No parts within the EECU are serviceable If found defective replace the EECU as a unit First...

Page 43: ...heater cables Also disconnect AFSS cable if applicable Disconnect from engine connector C398 and vehicle interface harness connector located above EECU connectors Also disconnect DPF cable Disconnect...

Page 44: ...located near the cooling fan right angle gearbox Disconnect and remove the air intake duct mounted between the turbocharger outlet and the air cooler inlet Disconnect and remove surge tank hose conne...

Page 45: ...emove bolts B and D Untighten bolts A and C then pivot oil cooler as per figure 12 Install bolts B and D and tighten all bolts 3 Refill cooling system with saved fluid refer to Section 05 COOLANT SYST...

Page 46: ...the front of the engine while two rubber mounts are mounted underneath the engine radiator fan drive mechanism support and the engine alternator support Fig 13 It is recommended that new rubber mounts...

Page 47: ...ication Engine tune up Preventive maintenance Storage Refer to Series 60 DDEC VI Troubleshooting Guide published by Detroit Diesel for more complete information on diagnosis of components and system p...

Page 48: ...e are two major harnesses the Engine Harness EH and the Vehicle Interface Harness VIH The Engine Harness is installed at the Detroit Diesel factory and is delivered connected to all engine sensors the...

Page 49: ...y 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 m...

Page 50: ...EGR 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 temperatur...

Page 51: ...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 52: ...as been detected and that a code has been stored in the MCM memory This light also has a 5 second bulb check when the ignition is first turned on 2 8 3 Stop Engine Warning Light RSL This light also mo...

Page 53: ...gine override switch again Flashing codes provide a four digit number Each fault code is flashed twice in order to help with counting the flashes If there are no active faults or if there are no inact...

Page 54: ...19 PID 84 2113 J1939 Wheel Based Vehicle Speed Signal from Source 3 is erratic 84 13 PID 84 2113 J1939 Wheel Based Vehicle Speed Signal from Source 3 is missing 84 20 PID 84 2113 Vehicle Speed Sensor...

Page 55: ...t Received This Ign Cycle 171 9 PID 171 2131 J1587 Ambient Air Temp Sensor Data Message Stopped Arriving 191 9 SID 231 2615 J1939 ETC1 Message is missing 191 19 SID 231 2132 J1939 Transmission Output...

Page 56: ...2141 J1939 Service Brake Switch Signal from Source 1 is missing 597 19 SID 246 2141 J1939 Service Brake Switch Signal from Source 2 is erratic 597 13 SID 246 2141 J1939 Service Brake Switch Signal fro...

Page 57: ...stent Number of Frames 625 2 SID 248 2151 ECAN ID_1629 Diagnostic Message Reporting Data Not Available 625 14 SID 248 2151 ECAN ID_1629 Diagnostic Message Reporting an Unknown MUID 625 9 SID 248 2151...

Page 58: ...cuit Failed High CEL AWL Lamp 707 4 SID 55 2222 Digital Output 2 10 Circuit Failed Low CEL AWL Lamp 708 3 SID 56 2223 Digital Output 3 12 Circuit Failed High 708 4 SID 56 2223 Digital Output 3 12 Circ...

Page 59: ...Open Circuit 1590 19 SID 155 2615 Adaptive Cruise Control Message Not Received 1590 9 SID 231 2615 Adaptive Cruise Control Device Reporting Error 1624 9 SID 231 2615 J1939 TCO1 Message is missing 1624...

Page 60: ...Positive Torque Error 27 7 PID 27 1111 EGR Valve Stuck Open 27 19 PID 27 1521 Smart Actuator Indicates EGR Position Error 51 4 SID 51 1112 Intake Air Throttle Circuit Failed Low 51 3 SID 51 1112 Inta...

Page 61: ...ow Side Error 168 1 PID 168 1221 Battery Voltage Low 168 0 PID 168 1221 Battery Voltage High 171 4 PID 171 1222 Ambient Temperature Circuit Failed Low 171 3 PID 171 1222 Ambient Temperature Circuit Fa...

Page 62: ...Failed Low 615 3 SID 55 1331 Turbo Compound Valve Circuit Failed High 615 5 SID 55 1331 Turbo Compound Valve Circuit Failed Open 615 4 SID 259 1335 Turbo Brake Sleeve Circuit Failed Low 615 3 SID 259...

Page 63: ...ilsafe Mode Motor On 615 11 SID 155 1453 Smart Remote Actuator 2 Restricted Operability 615 15 SID 155 1453 Smart Remote Actuator 2 Temperature Warning 615 8 SID 155 1453 Smart Remote Actuator 2 Inter...

Page 64: ...e or Spill Control Valve Jammed Closed 652 7 SID 2 1243 Injector Cylinder 2 Nozzle Control Valve or Spill Control Valve Jammed Open or Leakage 652 6 SID 2 1243 Injector Cylinder 2 Needle Control Valve...

Page 65: ...uit Failed Low 677 4 SID 39 1255 Engine Starter Relay Open Circuit 677 14 SID 39 1255 Starter Electronic Fault ECU internal Main 677 7 SID 39 1255 Engine Starter Relay Starter Does Not Engage 677 3 SI...

Page 66: ...ox 1188 4 SID 32 1325 Waste Gate Circuit Failed Low 1188 3 SID 32 1325 Waste Gate Circuit Failed High 1188 5 SID 32 1325 Waste Gate Circuit Failed Open 1188 14 SID 32 1432 Smart Remote Actuator 1 Wast...

Page 67: ...3 SID 273 1515 Charge Air Cooler Outlet Pressure Circuit Failed High 2659 1 SID 277 1515 EGR Flow Target Error Diagnostic Low Flow 2659 0 SID 277 1515 EGR Flow Target Error Diagnostic High Flow 2791 4...

Page 68: ...Temperature Circuit Failed Low 3246 3 SID 320 1532 DPF Oulet Temperature Circuit Failed High 3246 14 SID 320 1532 Abnormal DPF Temperature Rise b 3246 0 SID 320 1532 DPF Outlet Temperature High 3246...

Page 69: ...t Manifold Pressure Difference High Box 3563 1 PID 106 1551 Inlet Manifold Pressure Failed Low 3563 0 PID 106 1551 Inlet Manifold Pressure Failed High 3563 3 PID 106 1551 Inlet Manifold Pressure Sampl...

Page 70: ...Control Valve Amplifier Abnormal Rate of Change 3662 6 SID 365 1614 Injector Cylinder 4 Spill Control Valve Amplifier Valve Shorted Circuit 3663 14 SID 366 1615 Injector Cylinder 5 Spill Control Valve...

Page 71: ...Inlet Differential Pressure Too Low High Box 4226 5 SID 155 1615 Turbocharger Compressor Inlet Differential Pressure Sampling Range Failure 4226 13 SID 155 1454 Turbocharger Compressor Inlet Different...

Page 72: ...ot been added to the crankcase consult with an 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 provid...

Page 73: ...DRAIN PLUG AND OIL FILTERS 01029 5 Clean the 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 un...

Page 74: ...lant 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...

Page 75: ...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 20 Disconnect the oil delivery hose from the val...

Page 76: ...e Fig 25 NOTE Check if any spacer s have been installed between power plant cradle and vehicle rear subframe and if so note position of each washer for reinstallation purposes 36 Using a suitable equi...

Page 77: ...er to Section 03 FUEL SYSTEM 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 2 17 JAKE...

Page 78: ...or is installed in accordance with the manufacturer s specifications It is recommended that the idle count be at 50 or higher with a full throttle count of up to 200 The TPS is self calibrating and th...

Page 79: ...auses 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 the...

Page 80: ...r switch to OFF position H3 40 probable cause no fuel check the 2 breakers on the injector feeding system Contact Detroit Diesel or Pr vost Action Service step 3 see note 2 note 2 see the analog volta...

Page 81: ...ooled No of cylinders 6 Operating range 1200 2100 RPM Maximum RPM 2100 Detroit Diesel Series 60 engine ratings Series 60 engine ratings used in Prevost Car Models are listed in the following tables Th...

Page 82: ...rque specification Engine oil filter Tighten 2 3 of a turn after gasket contact Filters Engine Air Cleaner Filter Make Nelson 70337 N Pr vost number 530197 Engine Coolant Filter Conditioner Make Nalco...

Page 83: ...ING THE FUEL SYSTEM 10 2 5 FUEL PUMP REMOVAL AND INSTALLATION 11 3 DAVCO FUEL PRO 382 11 4 FUEL LINES AND FLEXIBLE HOSES 13 5 PREHEATER FUEL FILTER 13 6 FUEL TANK 13 6 1 TANK REMOVAL 13 6 2 TANK INSTA...

Page 84: ...OFF VALVE VOLVO D13 ENGINE 8 FIGURE 9 MANUAL SHUT OFF VALVE LOCATION WITH DAVCO FUEL PRO 382 VOLVO D13 ENGINE 8 FIGURE 10 FUEL LINE COMPRESSION FITTING 8 FIGURE 11 FUEL FILTERS WITH VOLVO D13 ENGINE...

Page 85: ...alve and the fuel cooler before it returns to the fuel tank One preheater is available 104 000 BTU If the vehicle is equipped with the 104 000 BTU preheater the fuel is drawn from the fuel tank throug...

Page 86: ...ormation on the Davco Fuel Pro 382 fuel filter refer to paragraph 3 1 4 RACOR FUEL WATER SEPARATOR SERVICING MAINTENANCE The Racor fuel water separator should be drained periodically or when the water...

Page 87: ...he maximum pump inlet restriction should not exceed 6 inches of mercury 20 3 kPa and must not exceed 12 inches of mercury 41 kPa with a dirty system At normal operating speeds and with the standard fu...

Page 88: ...fitting Do not use Teflon tape or paste on the fittings 2 Install drive coupling in drive hub of the fuel pump Install a new gasket to the mounting flange of the pump 3 Index the drive coupling with t...

Page 89: ...ery 8 This channel supplies each unit injector 9 with pressurized fuel by a circular groove around each unit injector in the cylinder head The overflow valve 10 controls the fuel supply pressure to th...

Page 90: ...ed on the R H side of engine compartment A manual shut off valve is located at the inlet side of the primary fuel filter or at the inlet side of Davco Fuel Pro 382 fuel filter Shut off valve is design...

Page 91: ...uel filter housing Drain filter 5 Unscrew and remove the separation bowl from the filter cartridge 6 Remove and discard the old gasket from the water separation bowl Clean the bowl thoroughly and then...

Page 92: ...ir pockets from the fuel system 2 4 PRIMING THE FUEL SYSTEM The fuel system will need to be bled if The vehicle has run out of fuel The engine has not been running for an extended period of time Servi...

Page 93: ...FUEL PRO 382 The optional Fuel Pro 382 diesel fuel filter system consists of a permanently mounted fuel processor a replaceable filter element a filter element cover and collar and a fluid filter bas...

Page 94: ...eal 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...

Page 95: ...once a year whichever comes first 6 FUEL TANK X3 45 coaches are equipped with a high density cross link polyethylene fuel tank with a capacity of 208 US gallons 787 liters On all vehicles fuel fillin...

Page 96: ...supported adequately Failure to do so could result in injury as well as damage to the tank 7 From under the vehicle on R H side unscrew the 4 bolts 2 in front 2 in back retaining the tank support to t...

Page 97: ...oil used for high speed diesel engine operation is a very important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust emission levels The U S Environmental P...

Page 98: ...s derived from renewable resources Detroit Diesel highly recommends biodiesel fuels made from soybean or rapeseed oil through the proper transesterification reaction process Other feedstock source of...

Page 99: ...element has been removed from the air cleaner housing the inside surface of the housing must be cleaned with a soft clean cloth 6 Periodically inspect the entire system Dust laden air can pass through...

Page 100: ...rotate the potentiometer clockwise to increase counts or counterclockwise to decrease When correct output is confirmed tighten retaining screws 10 2 POTENTIOMETER REPLACEMENT 1 Disconnect cable harnes...

Page 101: ...98 PROBE WATER SENSOR Prevost number 531391 Primary Fuel Filter Fuel Water Separator With Detroit Diesel Series 60 Engine Make AC Type Spin on Filter No T 915D Prevost number 032700 Element torque 1 2...

Page 102: ...evost Number 530206 Service Part No 7182 8N Prevost number element cartridge 530197 Air Cleaner Restriction Indicator Make Donaldson Model RBX00 2220 Indicates at 20 508 mm of water Prevost number 530...

Page 103: ...AR 2 FIGURE 2 FLEXIBLE COUPLING 3 FIGURE 3 AFTERTREATMENT DEVICE ATD USED WITH DDC S60 ENGINE SHOWN ATD USED WITH VOLVO D13 ENGINE IS SLIGHTLY DIFFERENT 3 FIGURE 4 OPENING DPF COMPARTMENT ACCESS DOOR...

Page 104: ...ing 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 Inspect...

Page 105: ...proactively and the back pressure increases beyond the system limit DDEC VI or EMS will flag the amber warning light on the telltale panel notifying the operator that an ash cleaning is required Clean...

Page 106: ...rod into the receptacle make sure the rod supports the door securely from falling down on to your head or body 4 From under the ATD loosen the water drain pipe clamp to set free the pipe as it will m...

Page 107: ...he DPF from falling when servicing The DPF cartridge weighs between 50 to 54 lbs CAUTION FRAGILE HANDLE WITH CARE Use extreme care when handling DPF cartridge as it could be damaged or destroyed by dr...

Page 108: ...tion grill CAUTION To prevent paint damage and fiberglass overheating caused by hot exhaust gases the diffuser louvered cover must be flush with the roof surface or may not exceed the roof surface mor...

Page 109: ...re that the water drain tube is not clogged Pour a cup of water into the diffuser housing and assure that all the water is drained at once at the other end of the drain tube If tube is clogged remove...

Page 110: ......

Page 111: ...2 1 Thermostat Checking 8 5 COOLANT 8 5 1 COOLANT LEVEL VERIFICATION 8 5 2 COOLANT LEVEL SENSOR 8 5 3 THAWING COOLING SYSTEM 8 5 4 COOLING SYSTEM RECOMMENDATIONS 8 5 5 COOLANT RECOMMENDATIONS FOR DET...

Page 112: ...CHARGE AIR COOLER HOSE CLAMPS DDC S60 7 FIGURE 10 CHARGE AIR COOLER HOSE CLAMPS VOLVO D13 7 FIGURE 11 THERMOSTAT HOUSING DDC S60 ENGINE 7 FIGURE 12 THERMOSTAT HOUSING VOLVO D13 ENGINE 8 FIGURE 13 SURG...

Page 113: ...mal 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 engine war...

Page 114: ...Do not exceed 138 kPa 20 psi Any measurable drop in pressure may indicate a leak Whenever the oil pan is removed the cooling system should be pressure checked as a means of identifying any incipient c...

Page 115: ...rth America Web Site under Parts Service On Volvo web site you will find detailed service procedures for parts replacement repair and maintenance MAINTENANCE Drain flush thoroughly clean and refill th...

Page 116: ...Visual torque check feature When the tip of the screw is extending 6 mm out of the housing the clamp is properly installed and maintains a leak proof connection Since the constant torque clamp automa...

Page 117: ...the cylinder head on the turbo side of the engine Fig 11 At coolant temperature below approximately 182 F 188 F 83 C 86 C the thermostat valves remain closed and block the flow of coolant from the en...

Page 118: ...tat starts to close at 95 C 203 F and is fully closed at approximately 85 C 185 F 5 COOLANT 5 1 COOLANT LEVEL VERIFICATION Coolant level is correct when cold coolant is visible through the surge tank...

Page 119: ...ower Cool P N 23512138 Prestone AF977 bulk 72702 3 78 L 70119 205L 70102 4L Combining suitable water with reliable inhibitors satisfies the first five requirements When freeze protection is required a...

Page 120: ...n may occur in improperly inhibited coolants Cavitation erosion is caused by the implosion of tiny bubbles against localized surfaces of the system Such implosion causes pinpoint pressures high enough...

Page 121: ...leave unwanted deposits in the engine A decal 053487 located on the surge tank provides information on recommended coolants Recommended coolants for Volvo D13 engine Prevost 685241 pre diluted 50 50 m...

Page 122: ...3 engine the regular drain plugs are replaced by quick connect fittings to ease draining and filling of coolant system 6 Open drain cock at bottom of thermostat housing to drain the coolant trapped ab...

Page 123: ...Heating System 8 FLUSHING If the cooling system is contaminated flush the cooling system as follows 1 Drain the coolant from the engine 2 Refill with clean water CAUTION If the engine is hot fill slow...

Page 124: ...ture a radiator tube 6 Continue flushing until only clean water is expelled from the radiator The cylinder block and cylinder head water passages are reverse flushed as follows 1 Remove the thermostat...

Page 125: ...sel Number 23507857 Make Nalco Number DD3000 15 FIGURE 17 COOLANT FILTER VOLVO D13 05145 MAINTENANCE VOLVO D13 ENGINE Replace the coolant filter cartridge after 150 000 miles 240 000 km or one year to...

Page 126: ...prevent accidental starting of the engine 1 Unwrap the drive belt from around the pulley see paragraph MOUNTING THE DRIVE BELT 2 Dismount the drive pulley Gain access to the 6 mounting bolts from beh...

Page 127: ...mparing data from engine coolant temperature charge air temperature Allison transmission oil temperature and small A C High side pressure to a set of calibration data The fan drive clutch is electroma...

Page 128: ...fan clutch does not engage using this procedure then the clutch is faulty or the wiring between the multiplex module and the clutch is faulty Mechanically lock the fan as described in section 13 1 2 1...

Page 129: ...g cracking and proper tension Turn fan through at least 360 of rotation It should turn smoothly with no resistance 13 4 FAN REMOVAL INSTALLATION The fan is bolted to the magnetic clutch To remove the...

Page 130: ...engine 2 Disconnect the fan clutch electrical connector 3 Dismount the fan and lean it against the radiator refer to previous paragraph 4 Disconnect the universal joint shaft FIGURE 27 RIGHT ANGLE GEA...

Page 131: ...NGINE 4 Release the tensioner slowly and let it return to its natural position COOLING FAN DRIVE BELT With Detroit Diesel Series 60 engine Type 14PK2605 Prevost number 550926 With Volvo D13 engine Typ...

Page 132: ...9 205L 70102 4L Coolant Volvo D13 Engine Prevost Number 685241 Texaco CPS 227998 Chevron CPS 2227805 Corrosion Inhibitor and Coolant Stabilizer Detroit Diesel Series 60 Engine Supplier number Detroit...

Page 133: ...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 134: ...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 135: ...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 136: ...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 137: ...5 2 Removing Surface Charge 16 3 5 3 Load Test 16 3 5 4 Testing Battery Cables 17 3 6 BATTERY CHARGING 17 3 6 1 Battery Charging Guide 19 3 6 2 Emergency Jump Starting With Auxiliary Booster Battery 1...

Page 138: ...38 9 1 3 Headlight Adjustment 39 9 1 4 Sealed Beam Unit 40 9 1 5 Front Turn Signal 41 9 1 6 Optional Xenon Headlamp 41 9 2 STOP TAIL DIRECTIONAL BACK UP AND HAZARD WARNING LIGHTS 42 9 2 1 Lamp Removal...

Page 139: ...ES CAN NETWORK LAYOUT 25 FIGURE 17 IO B MODULE REMOVAL 32 FIGURE 18 ALTERNATOR DRIVE BELT 34 FIGURE 19 TWIN BOSCH ALTERNATORS INSTALLATION DDEC SERIES 60 34 FIGURE 20 ALTERNATORS AND ACCESSORIES MOUNT...

Page 140: ...code o Connector code o Diode number code o Resistor number code o Fuse code 1 1 1 Using Wiring Diagrams Three methods are used to work with electric wiring diagrams Situation You have identified the...

Page 141: ...OLORS Each wire in the electrical system has a 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...

Page 142: ...rotecting the A C system are located on the rear electrical junction panel in the rear electrical compartment on L H side of the vehicle This type of circuit breaker deenergizes the circuit without di...

Page 143: ...working on a system inside vehicle make sure to cut electrical power and air supply A component could be supplied with electricity even if the ignition switch is set to the OFF position and or a comp...

Page 144: ...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 145: ...area Do not smoke Avoid prolonged contact with skin and breathing of spray mist Harmful or fatal if swallowed Do not induce vomiting Call physician immediately 2 2 REAR ELECTRICAL COMPARTMENT The rea...

Page 146: ...ke up F61 Reading Lamp LH F80 Power Mux A51 F62 Lavatory night light F81 Alternators excitation resistor F63 Engine Pre heater F85 ZF Trans F64 Spare F86 Spare fuse F65 Power Mux Module RJB F87 Spare...

Page 147: ...ultiplex A41 F35 12 volt accessory outlet F14 Customer F36 HVAC telltale panel F15 R22 F37 Spare fuse F16 Defroster unit F38 Digital Clock F17 Spare F39 Spare fuse F18 Upper Defroster F40 Spare fuse F...

Page 148: ...3 Windshield wipers Solenoids SO3 Door unlock solenoid valve SO5 Door opening solenoid valve SO4 Door unlock solenoid valve SO6 Door closing solenoid valve Diodes D4 Windshield wipers speed 2 D7 Entra...

Page 149: ...ging problems If new cables are required sealed terminal cable replacements should be used to retain the reliability of the original maintenance free connections DANGER All lead acid batteries generat...

Page 150: ...the battery to a charger 3 2 MAIN BATTERY RELAYS Main battery master relays 12V and 24V are provided for this vehicle The relays are located in the rear electrical compartment The 24 volt battery rela...

Page 151: ...tions 3 4 BATTERY RATING Each of the 12 volt batteries used on the vehicle has the following rating Reserve capacity 195 minutes Cold cranking amps 950 0o F 18o C Cold cranking amps 745 20o F 29o C We...

Page 152: ...cables and for evidence of corrosion Correct conditions as required before proceeding with tests 3 5 2 Removing Surface Charge Disconnect cables from the battery and attach alligator clamps to the con...

Page 153: ...t NOTE If it is necessary to extend the voltmeter lead for this test use a 16 AWG or larger wire 3 Check voltage drop between the starter housing and a good ground on the vehicle The reading should be...

Page 154: ...battery should never be charged if the test indicator hydrometer is clear or light yellow If this occurs replace the battery FIGURE 14 ALLIGATOR CLAMPS AND BATTERY 06065 A charge rate between 3 and 50...

Page 155: ...that can supply 30 amperes or more 3 6 2 Emergency Jump Starting With Auxiliary Booster Battery DANGER Off board battery charger with a start boost facility must not be used to jump start the vehicle...

Page 156: ...th 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 wires 3 7 CLEANING AND INSPECTION The external condition of the battery and the battery cables s...

Page 157: ...rging condition it is normal that BAT telltale light illuminates upon starting the engine and stays illuminated for a few seconds This is caused by the normal voltage drop of the battery during starti...

Page 158: ...must be interpreted as if the input or the output is inactive 4 3 CAN NETWORK The CAN network wiring is separated in sections and uses connectors that are not shared with other circuits This allows s...

Page 159: ...ch HVAC overhead compartment fan switch HVAC control unit passenger s section ON OFF Engine ether start switch Radiator fan clutch switch Engine front start enable switch Engine rear start enable swit...

Page 160: ...the vehicle To enter this mode o Activate the dashboard Telltale Light Test switch 3 times within 4 seconds o Push the ON OFF button on the driver s side HVAC control unit 5 times that makes 3 transit...

Page 161: ...ates 3 times at 1 second interval 5 beeps from the back up alarm indicate to go to inside the vehicle 10 SECONDS DELAY Inside the vehicle o Upper section defroster fan motor runs for 5 seconds o 10 se...

Page 162: ...e gray connector on module to see if it is powered 2 Verify that the engine MCM is powered and get the ignition signal a Check reset circuit breaker CB8 Check replace fuse F74 b Check reset circuit br...

Page 163: ...ually up to its closed position and it will lock by itself The door opening button is still functioning No temperature control in the passenger area Passenger temperature display indicates two dashes...

Page 164: ...Probe gray connector on module to see if it is powered Low beam headlights and front flasher on left side not functioning Electric horn not functioning Module A45 is not powered or is faulty 1 Check...

Page 165: ...M The message No Response ModA52 Active indicates a power problem on the module A CAN network problem would show the same message but doesn t produce this symptom 2 Check reset circuit breaker CB5 3 C...

Page 166: ...d fire sensor or defective sensor Cycle the ignition key between the ON and OFF position twice within 3 seconds This will deactivate the fire alarm function This has to be repeated each time the vehic...

Page 167: ...tions will not activate o If the default mode does not activate try to turn the ignition OFF while ensuring that no charger is connected and then restart the vehicle 4 8 1 Available Functions o Startu...

Page 168: ...ll relieve the IO B module see Fig 17 o Reset circuit breaker CB6 This engages the automatic reprogramming o The telltale panel LCD display indicates CAN until the reprogramming is complete Once compl...

Page 169: ...9 and L shaped bracket 1 1 figure 19 Fix the ring bracket using bolt 1a figure 19 and also bolt and nut 1b figure 19 for the ring bracket and L shaped bracket Use some Loctite 262 red 688910 onto the...

Page 170: ...Section 06 ELECTRICAL PA1562 34 FIGURE 18 ALTERNATOR DRIVE BELT 01180 FIGURE 19 TWIN BOSCH ALTERNATORS INSTALLATION DDEC SERIES 60 01077...

Page 171: ...enance Manual Annexed at the end of this section NOTE Use Polyrex EM grease 684922 when repacking the bearings Grease comes in 14 1 oz 400gr cartridges If the alternators needed to be removed reinstal...

Page 172: ...Section 06 ELECTRICAL PA1562 36 FIGURE 21 BOSCH ALTERNATORS MOUNTING TORQUES VOLVO D13 FIGURE 22 TWIN BOSCH ALTERNATORS INSTALLATION VOLVO D13...

Page 173: ...NE ONLY Prior to the installation of the Mitsubishi starter the Flywheel Ring Gear must be examined for excess wear or damage Service Bulletin A1 M1N 1729EN included at the end of Section 06 shows acc...

Page 174: ...m circuit is energized NOTE Pulling the lever rearward while the lights are off will flash the headlights 9 1 2 Maintenance Clean headlights with soap and water and a good glass cleaner whenever dirty...

Page 175: ...enters and the plane on which the vehicle rests not the floor on which the screen rests Fig 26 TABLE 1 VERTICAL BEAM AIM GUIDELINES Headlight centerline Mounting Height Nominal Vertical Aim Aim Inspec...

Page 176: ...headlight screw fixing the headlight assembly then tilt headlight assembly down Fig 24 and 25 3 Remove connector from headlight bulb 4 Remove the bulb by pushing and rotating it out of the socket 5 I...

Page 177: ...its housing then secure using fixing screw NOTE Make sure headlight assembly is properly positioned into its housing before securing using fixing screw 9 1 6 Optional Xenon Headlamp The outer lamps o...

Page 178: ...there is no immediate danger of electric shock even if the warning is disregarded With this safety concept there is no danger to check the ballast with a new bulb There is a very high probability tha...

Page 179: ...tter visibility in foggy weather or to improve the range of vision just ahead of the coach 9 5 1 Bulb Removal and Replacement 1 Pull on the release handle located in the front service compartment near...

Page 180: ...Replacement Proceed as follows to replace a defective bulb 1 Unscrew the two Phillips head screws retaining the lens to the wall and remove it 2 With the light lens removed pull bulb from the lamp whi...

Page 181: ...luorescent tube from light socket 3 Install a new fluorescent tube 4 Lift the hinged cover and replace the two retaining screws Fig 34 Parcel Rack Interior Lighting 1 Open the parcel rack access door...

Page 182: ...A microswitch mounted in the door exterior frame is activated by the door lock mechanism upon locking to energize the circuit This switch is readily serviced by removing the two Phillips head screws...

Page 183: ...20R 12 4 Identification amber 930337 TL 25450Y 12 3 Clearance amber 930337 TL 25450Y 12 4 Front directional hazard marker 562135 3057 32 3W 12 2 Rear directional 560589 1156 32 W 12 4 Stop 560589 1156...

Page 184: ...0MR16 20 W 12 2 EMERGENCY EXIT decal 560601 456 2 W 24 A R LAVATORY OCCUPIED 563108 168 3 W 12 1 WATCH YOUR STEP 561166 1820 1 6 cp 24 2 Aisle 560141 1251 3 W 24 A R Reading 563349 303 6 W 24 A R Fluo...

Page 185: ...uld be between terminal nuts and lead pads of terminals If not possible load value should be 210 amperes Torque specifications Battery cable to post 10 15 Ft lbs 13 20 Nm Battery cover 45 50 Ft lbs 5...

Page 186: ...Section 06 ELECTRICAL PA1562 50 Starter solenoid Make Mitsubishi Electric Corporation MELCO Model Number 1115557 Pull In Voltage 16 volts max...

Page 187: ...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 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...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 194: ...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 195: ...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 196: ...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 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ...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 214: ...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 215: ...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 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ...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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...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 234: ...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 235: ...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 236: ......

Page 237: ...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 238: ...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 239: ...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 240: ...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 241: ...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 242: ...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 243: ...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 244: ...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 245: ...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 246: ...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 247: ...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 248: ...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 249: ...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 250: ...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 251: ...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 252: ...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 253: ...FAULT CODE MANUAL Created on 00 04 25 15 30 1 FAULT CODE MANUAL B7L B7TL B12...

Page 254: ...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 255: ...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 256: ...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 257: ...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 258: ...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 259: ...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 260: ...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 261: ...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 262: ...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 263: ...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 264: ...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 265: ...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 266: ...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 267: ...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 268: ...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 269: ...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 270: ...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 271: ...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 272: ...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 273: ...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 274: ...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 275: ...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 276: ...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 277: ...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 278: ......

Page 279: ...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 280: ...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 281: ...S ON VEHICLES EQUIPPED WITH DETROIT DIESEL ENGINE ONLY 15 5 ALLISON TRANSMISSION REMOVAL 15 6 TRANSMISSION OIL COOLER REMOVAL 16 6 1 TRANSMISSION WITHOUT RETARDER 16 6 1 1 Detroit Diesel Series 60 Eng...

Page 282: ...5 COLD CHECK 5 FIGURE 6 HOT CHECK 5 FIGURE 7 DRAIN PLUG AND FILTERS 13 FIGURE 8 RELEASE BEARING RETAINING CLIP 14 FIGURE 9 ZF OR ALLISON TRANSMISSION BRACKETS 15 FIGURE 10 ENGINE CRANKING POSITION 16...

Page 283: ...n 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 adjust...

Page 284: ...Precautions to be observed before welding for complete procedure 3 MAINTENANCE 3 1 ALLISON TRANSMISSION To gain access to the dipstick open the engine compartment rear doors dipstick is located on the...

Page 285: ...essary to bring the level within the COLD CHECK band 8 Perform a Hot Check at the first opportunity after the normal operating temperature of 160 F 71 C to 200 F 93 C is attained CAUTION DO NOT operat...

Page 286: ...s O L L O 4 Oil Level is LOw 4 or more quarts O L H I 1 Oil Level is HIgh 1 quart CODE CAUSE OF CODE O L H I 2 Oil Level is HIgh 2 quarts O L H I 3 Oil Level is HIgh 3 or more quarts O L fc Oil Level...

Page 287: ...Transmission dealer or distributor before using other fluid types Customers may use TranSynd TES 295 equivalent and extend drain intervals Equivalent TranSynd fluid must meet or exceed TES 295 requir...

Page 288: ...perating period will result in illumination of the CHECK TRANS light on the dashboard telltale panel indicating the increased probability that the service condition will develop into a more serious co...

Page 289: ...rded to indicate a highly deteriorated filter Reset The feature will reset automatically when the main fluid filter has been changed and the pressure drop across the filter no longer exceeds the thres...

Page 290: ...tch es wear enough so that the programming changes O K 4th press One or more of the clutches C1 through C5 have worn enough to change the program L O Display of diagnostic codes d 1 5th press Other co...

Page 291: ...r than one 1 stop per mile 4 General vocation intercity coach with duty cycle less than or equal to one 1 stop per mile and all other vocations not listed in severe vocation TABLE 3 Recommended Fluid...

Page 292: ...nostics enabled 100 concentration of TES 295 Allison approved fluids and Allison High Capacity Filters is required Less than 100 concentration of TES 295 Allison approved fluids are considered a mixtu...

Page 293: ...ng Pushbutton Shift Selector procedure in this section 3 2 ZF AS TRONIC TRANSMISSION All information needed for the removal installation or maintenance of the ZF transmission is included in the docume...

Page 294: ...is closed Refer to figure 8 Remove the Clutch Inspection Cover from the bottom of the transmission The transmission should have been shipped in gear This will allow the installer to rotate the output...

Page 295: ...n 2 Jack up vehicle then place safety supports underneath body CAUTION Only the recommended jacking points must be used as outlined in Section 18 BODY NOTE For more clearance between the tag axle and...

Page 296: ...ey using a suitable adapter fig 10 FIGURE 10 ENGINE CRANKING POSITION 01153 Volvo D13 Engine Only Remove starter motor located on engine L H side Removing the starter motor will allow access to unfast...

Page 297: ...sion hoses from oil cooler Cover hose ends and fittings to prevent fluid contamination Refer to fig 12 WARNING A significant amount of oil may drain from oil lines when they are disconnected 3 Unfaste...

Page 298: ...rrect immediately 3 Loose dirty or improperly adjusted throttle sensor linkage 4 Damaged or loose oil lines 5 Worn or frayed electrical harnesses improper routing 6 Worn or out of phase drive line U j...

Page 299: ...ching screw to turn the converter to gain access to the threaded holes Reinstall the access plug Volvo D13 Engine Only Remove the plug located below starter motor and install cranking tool 88800014 Cr...

Page 300: ...ON CONTROLS Diagnostic codes DTC are numerical indications relating to a malfunction in transmission operation These codes are logged in a list in the TCM memory with the most severe or most recent co...

Page 301: ...diagnostic tool refer to the User Guide o Using the pushbutton shift selector To begin the diagnostic process 1 Bring the vehicle to a stop at a safe location 2 Apply the parking brake To display stor...

Page 302: ...the transmission will still be in D Drive or R Reverse when the clearing procedure is completed N Neutral must be manually selected 9 5 DIAGNOSTIC CODE RESPONSE The following responses are used in the...

Page 303: ...throttle values P063F Auto Configuration Engine Coolant Temp Input Not Present No None P0658 Actuator Supply Voltage 1 HSD1 Low Yes DNS SOL OFF hydraulic default P0659 Actuator Supply Voltage 1 HSD1 H...

Page 304: ...P0842 Transmission Pressure Switch 1 Circuit Low Yes DNS Lock in current range P0843 Transmission Pressure Switch 1 Circuit High Yes DNS Lock in current range P0847 Transmission Pressure Switch 2 Circ...

Page 305: ...L OFF hydraulic default P2686 Actuator Supply Voltage 3 HSD3 High Yes DNS SOL OFF hydraulic default P2714 Pressure Control Solenoid 4 PCS4 Stuck Off Yes DNS RPR P2715 Pressure Control Solenoid 4 PCS4...

Page 306: ...a service point The error number s must be specified when the service point is contacted Calling up error numbers 07107 Switch on ignition Depress N key Hold down key One or more error numbers appear...

Page 307: ...ensor signal Short circuit to positive 32 6 20 142 No splitter group GV sensor signal Short circuit to ground 32 5 20 143 No splitter group GV sensor signal Interruption 32 13 20 144 Splitter group GV...

Page 308: ...it to ground at output stage to Y3 Valve Splitter 38 5 26 35 Interruption at output stage to Y3 Valve Splitter 38 3 26 67 Short circuit to positive at output stage to Y3 Valve Splitter 39 5 27 36 Inte...

Page 309: ...error through ZMP06400 hex 58 7 3A 154 Main transmission gear does not disengage 58 7 3A 155 Main transmission gear does not engage 58 7 3A 156 Wrong gear shifting 59 7 3B 151 Selector cylinder does...

Page 310: ...based vehicle speed signal CCV 231 7 E7 163 Engine does not react on torque intervention 231 14 E7 164 Error on Drivers demand engine percent torque EEC1 231 14 E7 165 Error on Accelerator pedal posit...

Page 311: ...gnal EBC1 231 14 E7 93 Error on ASR engine control active signal EBC1 231 14 E7 94 Error on ASR brake control active signal EBC1 231 14 E7 95 Error on Cruise control active signal CCVS 231 14 E7 96 Er...

Page 312: ...lutch 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 80 1...

Page 313: ...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 314: ...eedle 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 autom...

Page 315: ...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 316: ...int kit tube 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...

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Page 329: ...DQD 6SLFHU ULYHVKDIW 6HUYLFH 0DQXDO 660 XO 6HULHV 8QLYHUVDO RLQWV DQG ULYHVKDIWV...

Page 330: ...e Compatibility 12 Lubrication Procedure for Universal Joints 12 Quick Disconnect Half Round Universal Joints 13 Bearing Plate Full Round Universal Joints 14 Snap Ring Universal Joints 14 Lubrication...

Page 331: ...the vehicle with appropriate weighted support equip ment 7 NEVER remove a driveshaft from a vehicle without keeping the transmission in neutral Spicer 10 Series Driveshaft assemblies can weigh in exc...

Page 332: ...of the driveline from the vehi cle A separated driveline can result in property damage seri ous personal injury or death Failure to torque bolts to specification can cause driveline fail ure which ca...

Page 333: ...bolts can result in driveline fail ure which can result in separation of the driveline from the vehicle A separated driveline can result in property damage serious personal injury or death Damaged cen...

Page 334: ...the vehicle A sepa rated driveline can result in property damage serious per sonal injury or death Incompatible greases that are applied to universal joints and or slip members can result in drivelin...

Page 335: ...veshaft to a qualified driveshaft facility for further inspection and repair 2 Check all end fittings for looseness Grasp the end fitting with both hands and try to move it vertically and horizontally...

Page 336: ...metal or fretting can be removed from yoke cross holes with a fine toothed file and or emery cloth DO NOT deform yoke cross holes by removing excessive metal Raised metal or deformed yoke cross holes...

Page 337: ...e driveline from the vehicle Inspect the bearing caps for any indication of rota tion within the cross holes If rotation is apparent the yoke should be replaced 3 Check the yoke for cross hole alignme...

Page 338: ...loose or fractured 2 If a grease zerk nipple fitting is loose tighten it to required specifications See the Universal Joint Grease Zerk Nipple Fitting and Plug Torque table on page 26 3 If a grease ze...

Page 339: ...ke and is not loose or damaged If any of these situations are evident replacement of the slip member and or seal may be necessary 6 For an inboard and outboard slip yoke assembly design check to be su...

Page 340: ...Disassembly and Reassem bly on page 16 for proper center bearing replace ment procedures Midship End Fitting Please refer to the safety information in the General Safety section and the Midship Nut in...

Page 341: ...at all seals the purging process is complete and the universal joint is properly lubricated City is defined as all applications requiring a mini mum of 90 percent of operation time within city lim its...

Page 342: ...ase Compatibility To help reduce the effects of incompatible greases be sure to thoroughly purge all four bearing seals on each universal joint with the new grease Purge seals until the fresh grease i...

Page 343: ...ns Reference bolt torque speci fications in the above table 5 If the bearings still will not purge complete removal of the universal joint kit is needed to determine the cause of blockage Refer to ori...

Page 344: ...seals Purge old grease thoroughly 2 Install new bolts and torque to specifications in the above table Snap Ring Universal Joints 1 There will occasionally be one or more bearing assembly seals that wi...

Page 345: ...ply grease gun pressure to the grease zerk nip ple fitting until grease appears at the pressure relief hole in the plug 2 Now cover the pressure relief hole with your finger and continue to apply pres...

Page 346: ...pointing up to pre vent interference during disassembly Place an appropriate push rod on the upper bearing assembly and press it through to release the lower bearing assembly Do not distort yoke ears...

Page 347: ...ing an arbor press proceed to Step 3 If using a universal joint installation tool fol low the tool manufacturer s instructions 3 Move one end of the journal cross to cause a trun nion to project throu...

Page 348: ...e 2 With the driveshaft removed see Inspection on page 5 for Bearing Plate Full Round Yoke Inspection disassembly pro cedures Reassembly Bearing Plate Style Please refer to the Universal Joint informa...

Page 349: ...furnished with the universal joint and insert them through the cap screw holes in both the lock strap and or the bearing plate assem bly Thread by hand or with a wrench into the tapped holes in the yo...

Page 350: ...rers instructions and then place the driveshaft in v blocks 3 Mark the counterbore of the coupling shaft end yoke to midship nose with a marking stick paint marker or other legible marking device This...

Page 351: ...card the rubber cushion 10 Using a puller follow the tool manufacturer s instructions to remove the bearing assembly from the midship Discard the center bearing 11 Inspect the midship for wear on the...

Page 352: ...nter bearing bracket If the metal retainer is present remove it and discard 5 Remove and discard the center bearing bracket 6 Remove and discard the rubber cushion Series Nut Nut Washer Head Size Nut...

Page 353: ...ertains to SAE DIN and T Type Companion Flange Flange Yoke Quick Disconnect and Bearing Plate styles 1 Wipe the bearing surface of the midship tube shaft with a fine emery cloth 2 Install a new slinge...

Page 354: ...result the midship nut may not install correctly 1 Visually inspect the midship washer if applicable for flatness corrosion or cracks If the washer is bent corroded or cracked the washer must be repla...

Page 355: ...r surrounding the bearing Refer to the below table Recommended Center Bearing Lubricants 4 Carefully align the new center bearing assembly with the ground surface of the midship tube shaft Physi cally...

Page 356: ...ended wrench turn the grease zerk nipple fitting or plug counter clockwise until it is removed from the journal cross or slip member assembly Discard the grease zerk nipple fitting or plug 2 Check th...

Page 357: ...shafts with fixed centers it is the nominal dimension Cross See Journal Cross Cross Hole A through hole in each lug ear of a yoke used to locate a bearing assembly Deflector See Slinger Driveline An...

Page 358: ...t bearing and a bracket configuration for attachment Pressure Relief Hole A hole in the welch plug of Spicer slip yokes that allows air to escape from the slip member assembly Purge The act of flushin...

Page 359: ...r O D of a tube Tube Yoke An inboard yoke with a piloting hub for attachment to a tube or spline sleeve Tube Shaft A machined element consisting of spline teeth and a piloting hub that attaches to the...

Page 360: ...XVWRPHUV YHQGRUV RU GLVWULEXWRUV SHUPLVVLRQ WR IUHHO FRS UHSURGXFH DQG RU GLVWULEXWH WKLV GRFXPHQW LQ SULQWHG IRUPDW 7 6 1 250 7 21 6 127 17 1 25 6 25 5 6 1 7 6 127 0867 5 0 1 21 23 6 RU DGGLWLRQDO LQ...

Page 361: ...NT WHEEL ALIGNMENT 5 6 2 MAJOR FRONT WHEEL ALIGNMENT 5 6 3 INSPECTION BEFORE ALIGNMENT 5 6 4 TURNING ANGLE ADJUSTMENT 5 6 4 1 R H Turn Adjustment 6 6 4 2 L H Turn Adjustment 6 6 5 HYDRAULIC STOP 6 6 6...

Page 362: ...000 km whichever comes first Fig 2 Tie rod ends and knuckle pins are provided with grease fittings for pressure lubrication These grease fittings should be serviced every 6 250 miles 10 000 km or twi...

Page 363: ...rame Remove the wheels if required refer to Section 13 Wheels Hubs and Tires CAUTION Use only the recommended jacking points as outlined in section 18 Body 2 Exhaust compressed air from the air supply...

Page 364: ...r a bearing which has been in service NOTE If original bearing unit is re fitted and end float is measured at 1 mm with hub not fully tightened to correct torque then the retaining clip within the uni...

Page 365: ...NOTE If steering angle stoppers are changed a special procedure is required for readjusting gearbox steering limiter See paragraph 6 5 Hydraulic Stop in this section 3 Check and adjust the turning ang...

Page 366: ...touches the left stop screw 2 Verify the nearest point of contact of the ball socket body with the air bellows support assembly Measure the distance between those two points 3 The distance between the...

Page 367: ...ht ahead position after taking a turn FIGURE 5 CASTER 10007 Excessive caster results in hard steering around corners A shimmy may also develop when returning to the straight ahead position pulling out...

Page 368: ...rmal operating position Neutralizing the front suspension is extremely important especially if the vehicle has been jacked up in order to mark the tires Otherwise the front wheels will not return to t...

Page 369: ...ed on correctly 4 Power steering system not installed correctly 1 Replace damaged part s adjust power steering system to specified pressure 2 Make sure vehicle is powered on correctly 3 Correctly inst...

Page 370: ...Front Track 84 4 inches 2 145 mm Rated load capacity 16 500 lbs 7 500 kg Torque specifications FIGURE 7 AIR BELLOWS MOUNTING SUPPORT AND AXLE 10030 For more torque specifications see Dana Spicer Main...

Page 371: ...ICATIONS Front Wheel Alignment Minimal Nominal Maximal Camber degrees R H and L H 0 250 0 125 0 375 Caster degrees R H and L H 2 2 75 3 5 Toe in A minus B degrees 0 06 0 08 0 10 NOTE Camber angle chan...

Page 372: ......

Page 373: ...SPICER SPECIALITY AXLE DIVISION place product photo here SERVICE MANUAL GENERAL INFORMATION NDS Axle range...

Page 374: ...lity Axle 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 incurr...

Page 375: ...OR MAINTENANCE 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 COMPONEN...

Page 376: ...NT PERSONAL 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 INSTRUCT...

Page 377: ...onal nature 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...

Page 378: ...lable 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 warra...

Page 379: ......

Page 380: ...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 381: ...SPICER SPECIALITY AXLE DIVISION place product photo here Maintenance Manual NDS axles Lubrication and Maintenance NDS Axle range Issue D BACK RETOUR...

Page 382: ...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 383: ...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 384: ...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 385: ...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 386: ...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 387: ...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 388: ...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 389: ...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 390: ...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 391: ...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 392: ...Page No 12 NDS2 issue A Spicer SpecialityAxle Division Technical Publications Spicer Speciality Axle Division BACK RETOUR...

Page 393: ...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 394: ...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 395: ...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 396: ...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 397: ...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 398: ...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 399: ...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 400: ...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 401: ...SPICER SPECIALITY AXLE DIVISION Maintenance manual Model NDS Hub and brake assembly With Knorr Bremse Disc brake Fitted to offset barrel swivel...

Page 402: ...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 403: ...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 404: ...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 405: ...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 406: ...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 407: ...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 408: ...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 409: ...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 410: ...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 411: ...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 412: ...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 413: ...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 414: ...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 415: ...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 416: ...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 417: ...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 418: ...Page No 18 Manual No NDS8 Spicer Speciality Axle Division Technical Publications Spicer Speciality Axle Division TP1193...

Page 419: ...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 420: ...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 421: ...ALING METHOD 7 2 TAG AXLE 7 2 1 UNLOADING TAG AXLE 7 2 2 RETRACTING TAG AXLE 7 2 3 RETRACTING TAG AXLE FOR REPAIR PURPOSES 8 2 4 GREASE LUBRICATED WHEEL BEARINGS 8 2 5 REMOVAL AND INSTALLATION 8 2 5 1...

Page 422: ...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 423: ...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 424: ...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 425: ...quirements 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 suspe...

Page 426: ...ce with drive axle TAG AXLE ALL VEHICLES Alignment value Minimum value Nominal value Maximum value Parallelism deg 0 02 0 0 02 Total Toe deg 0 18 Toe in 0 0 18 Toe out FIGURE 7 FRONT DRIVE AXLE ALIGNM...

Page 427: ...flat against the wheel hub b Install the tapered dowels at each stud and into the flange of the axle shaft Use a punch or drift and hammer if needed c Install the lock washers and nuts on the studs T...

Page 428: ...facility for re lubrication Front and tag axle hub bearings need to be checked every 30 000 miles 48 000 km NOTE For more information on front and tag axle wheel hub refer to DANA SPICER Maintenance M...

Page 429: ...ut retarder move tag assembly very carefully Pay special attention to the U shaped section as the transmission end components may be easily damaged through a false maneuver 14 Reverse removal procedur...

Page 430: ...d 4 10 1 Optional 4 56 1 Optional 4 88 1 Optional ZF Transmission 3 73 1 Standard 3 42 1 Optional 3 58 1 Optional NOTE The drive axle alignment consists in aligning the axle with reference to the fram...

Page 431: ...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 432: ...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 433: ...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 434: ...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 435: ...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 436: ...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 437: ...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 438: ...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 439: ...Forward and Rear Axle Carrier Diagnostic Flowcharts TP 99125 Issued 12 99 TECHNICAL BULLETIN...

Page 440: ...e diagnostic procedures in this bulletin r Lubrication Maintenance Manual No 1 r Single Reduction Differential Carriers Maintenance Manual No 5 r Single Reduction Rear Differential Carriers Maintenanc...

Page 441: ...the oil screen for contamination Refer to TP 9955 Failure Analysis for Drive Axle Components Check for further carrier damage If none is found repair or replace the oil pump clean or replace the oil...

Page 442: ...he carrier Refer to MM 5L Inspect the main differential bearings for damage Refer to TP 9955 Failure Analysis for Drive Axle Components Repair the carrier or install a remanufactured carrier Refer to...

Page 443: ...e Analysis for Drive Axle Components Inspect the main differential bearings for damage Refer to TP 9955 Failure Analysis for Drive Axle Components Visually inspect the carrier in the axle housing Remo...

Page 444: ...ge Refer to TP 9955 Failure Analysis for Drive Axle Components Install the carrier Refer to MM 5L Test drive the vehicle Return the vehicle to service Remove the main differential and ring gear from t...

Page 445: ...he carrier from the axle housing Repair the carrier or install a remanufactured carrier Refer to MM 5L Fill the carrier with the correct amount of the specified lubricant Refer to MM 1 Clean the seal...

Page 446: ...e axle housing Remove the carrier from the axle housing Repair the carrier or install a remanufactured carrier Refer to MM 5 Drain and inspect the lubricant Refer to MM 1 Remove the carrier from the a...

Page 447: ...the axle housing Remove the carrier from the axle housing Repair the carrier or install a remanufactured carrier Refer to MM 5 Drain and inspect the lubricant Refer to MM 1 Check the drive pinion end...

Page 448: ...ect the carrier in the axle housing Remove the carrier from the axle housing Repair the carrier or install a remanufactured carrier Refer to MM 5 Fill the carrier with the correct amount of the specif...

Page 449: ...carrier to housing joint for leaks No Remove the carrier from the axle Refer to MM 5 or 5L Drain and inspect the lubricant Refer to MM 1 Replace the leaking seal with a unitized seal Joint leaking No...

Page 450: ...he 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 disco...

Page 451: ...LTER DRYER PURGE TANK 8 8 AIR LINES 8 8 1 COPPER PIPING 8 8 2 FLEXIBLE HOSES 9 8 3 NYLON TUBING 9 8 4 AIR LINE OPERATING TEST 9 8 5 AIR LINE LEAKAGE TEST 9 8 6 MAINTENANCE 9 9 PRESSURE REGULATING VALV...

Page 452: ...Air Disc Brakes 18 27 1 4 Pad Removal 18 27 1 5 Checking Pad Wear 18 27 1 6 Important Pad and Rotor Measurements 19 27 1 7 Checking Caliper Guidance and Seal Condition 19 27 1 8 Checking the Tappet Bo...

Page 453: ...GURE 14 BRAKE PEDAL ADJUSTMENT 13 FIGURE 15 DELCO SWITCH 13 FIGURE 16 BENDIX SWITCH 13 FIGURE 17 R 12 13 FIGURE 18 R 14 14 FIGURE 19 QR 1 14 FIGURE 20 SR 7 14 FIGURE 21 PR 4 14 FIGURE 22 LP 3 15 FIGUR...

Page 454: ...ND AIR SYSTEM PA1562 4 FIGURE 45 ABS MODULATOR VALVE 28 FIGURE 46 ABS SENSOR LOCATION 28 FIGURE 47 SPRING CLIP 29 FIGURE 48 HOSE FITTINGS 29 FIGURE 49 HOSE FITTING 29 FIGURE 50 HOSE FITTING 29 FIGURE...

Page 455: ...Furthermore the brake application or release which is speed up by 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...

Page 456: ...Accessory Air Tank The accessory air tank is installed close to the front axle and is provided with a bottom drain valve Fig 1 2 Purge the reservoir by it s drain valve every 12 500 miles 20 000 km o...

Page 457: ...mpartment close to R H side of door frame Fig 4 These two air system emergency fill valves are fitted with the same valve stems as standard tires and can be filled by any standard external air supply...

Page 458: ...dirt compressor oil and other contaminants that can damage the system Change cartridge every 100 000 miles 160 000 km or once every two years whichever comes first The air dryer may be purged for mai...

Page 459: ...a soapy solution to check for air leakage No leakage is permitted Leakage can sometimes be corrected by tightening the connection If this fails to correct the leakage new fittings nylon tubing copper...

Page 460: ...side of the engine on the rear of the engine gear case Fig 9 Its function is to provide and maintain air under pressure to operate devices in brake and air systems This air compressor also drives the...

Page 461: ...pump The air is taken from the air intake manifold and entered in the top of the compressor The compressed air is pushed into the discharge line located on side of the compressor which sends air to t...

Page 462: ...ol valve is used with the optional parking brake overrule system In the case of self application of spring brakes due to a pressure drop the brakes can be released by holding down this control valve M...

Page 463: ...itches are not serviceable items if found defective the complete unit must be replaced FIGURE 15 DELCO SWITCH 12139 FIGURE 16 BENDIX SWITCH 12140 16 PARKING BRAKE ALARM SWITCH Refer to the appropriate...

Page 464: ...service and spring forces Maintenance and repair information on the spring brake valve is supplied in the applicable booklet annexed to this section under reference number SD 03 9043 FIGURE 20 SR 7 1...

Page 465: ...FIGURE 23 DC 4 12134 23 EMERGENCY DOOR OPENING VALVES Two emergency door opening three way valves are installed on coaches One is in the front service compartment readily accessible The other one is...

Page 466: ...ent refer to subsequent headings in this section for more details Ensure all fasteners are tight refer to Specifications for recommended tightening torques 27 AIR BRAKES 27 1 DISC BRAKES Knorr Bremse...

Page 467: ...a long feeler gauge long enough to measure across entire tappet surface between the tappet and the backing plate of the pad measure clearance at both tappets Clearance should range between 0 020 and 0...

Page 468: ...d not exceed 2 mm 5 64 FIGURE 30 CALIPER AXIAL MOVEMENT 12132 The pad thickness can be seen but would require removal of the tire and rim An indicator of the pad wear condition is available by inspect...

Page 469: ...ge ments 4 7 across a distance of 1 3 16 inch 30 mm when the pads are removed The sleeve 5 is sealed using the boot 9 and the cap 10 b The rubber components 9 and 10 should show no damage The position...

Page 470: ...per to full inboard position and install inside pad WARNING It is recommended to change all pads on an axle at the same time FIGURE 37 PAD INSTALLATION 12111 27 1 10 Adjusting the Running Clearance a...

Page 471: ...time There is no inner or outer pad since all pads are the same Worn pads should be replaced in the same position FIGURE 39 BRAKE PAD CHECK 12117 27 1 13 Torque specifications For proper caliper maint...

Page 472: ...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 473: ...e If restricted clean or replace element or faulty line Check compressor head or discharge line for carbonization or restriction Clean or replace as necessary If discharge valves leak pull head and co...

Page 474: ...ted warranty returns or claims For more information on this policy refer to Bendix Pr vost product notification annexed at the end of Section 12 of Maintenance Manual 30 BRAKE AIR CHAMBER If this vehi...

Page 475: ...g 4 To manually reset the emergency parking brake turn the nut counterclockwise Rein stall access plugs on the spring chambers and release stud tools in their storage places 30 3 BRAKE CHAMBER REMOVAL...

Page 476: ...re stability and permit steering control of vehicle during hard braking and to minimize its stopping distance whatever the road conditions are On slippery roads and generally in emergency situations o...

Page 477: ...ABS consists of 4 sensors and 4 modulator valves 4S 4M CAUTION Even with ESP equipped vehicles the driver remains responsible for ensuring vehicle stability during operation DANGER ESP may reduce the...

Page 478: ...magnetic flux picked up by the coil producing an alternating voltage the frequency of which is proportional to wheel speed When wheel speed decreases magnetic flux decreases proportion ately Conseque...

Page 479: ...e sensor to its adjusted position Fig 47 FIGURE 47 SPRING CLIP 12161 Maintenance The spring clip requires no specific maintnance 32 FITTING TIGHTENING TORQUES 45 Flare and Inverted Flare Tighten assem...

Page 480: ...cated in the following chart Piping diameter inches Number of additional turns required following hand tightening 1 4 3 8 1 2 2 5 8 3 4 3 FIGURE 51 HOSE FITTING 12056 Pipe Tightening All connections m...

Page 481: ...Meritor Wabco Model SS636 Capacity at 1250 rpm 37 4 cfm 1 059 m3 min Pr vost number Air Dryer Make Haldex Model AT 87192 Pr vost number 70303498 Desiccant cartridge Pr vost number 3097369 Flip Flop Co...

Page 482: ...Pa Pr vost number 641137 Shuttle Type Double Check Valve Make Bendix Westinghouse Model DC 4 Pr vost number 641015 Low Pressure Indicators Make Bendix Westinghouse Model LP 3 Contact close 66 psi 455...

Page 483: ...hambers Make Knorr Bremse Type 14 Pr vost number 642087 Tag Axle Brake Chambers Make Knorr Bremse Type 16 Pr vost number 642086 Brake Lining All Axles Make Knorr Bremse Pr vost number 611049 Pr vost n...

Page 484: ......

Page 485: ...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 486: ...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 487: ...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 488: ...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 489: ...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 490: ...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 491: ...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 492: ...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 493: ...System Saver 636 Twin Cylinder Air Compressor for Mack E TechTM Engines Maintenance Manual MM 0204 Issued 08 02...

Page 494: ......

Page 495: ...ol and Notes Access Product and Service Information on Our Website Enter meritorwabco com in your browser s address box for quick access to our website At our home page click on literature to access o...

Page 496: ...ce Intervals Cylinder Head Visual Inspection 3 Section 2 Troubleshooting 5 Section 3 Compressor Replacement Compressor Replacement Information 9 Compressor Removal Compressor Installation 10 Cylinder...

Page 497: ...ne or other malfunction NOTE This compressor has NO through drive capabilities for hydraulic power steering pumps Description The Meritor WABCO System Saver 636 twin cylinder air compressor provides a...

Page 498: ...ssure is increased causing the compressor s discharge valves to open 3 Unloading Air passes from the cylinders to the inlet chambers of the cylinder head via a port controlled by sliding leaf valves W...

Page 499: ...ressor can detect minor problems see legend for examples of these problems This check should be part of the vehicle preventive maintenance program Figure 1 5 Figure 1 5 1 Check water ports for leakage...

Page 500: ...Notes Copyright 2002 Maintenance Manual MM 0204 Page 4 ArvinMeritor Inc Issued 08 02...

Page 501: ...compressor inlet Verify engine air cleaner is functioning properly Replace if necessary Repair compressor air inlet kinks or excessive bends Check vehicle specifications to ensure air and coolant lin...

Page 502: ...eck for air dryer malfunction Refer to air dryer manufacturer s service instructions Chafed or worn discharge line Replace faulty sections of discharge line Loose or leaking air line connections Verif...

Page 503: ...amage including worn or damaged unloader piston O ring porosity in unloader piston bore loose or leaking seal at unloader piston bore Replace compressor cylinder head assembly Compressor head gasket f...

Page 504: ...Notes Copyright 2002 Maintenance Manual MM 0204 Page 8 ArvinMeritor Inc Issued 08 02...

Page 505: ...for additional information The front of the Meritor WABCO System Saver 636 air compressor is mounted to the engine Before you remove the compressor make sure you have a replacement gasket to install w...

Page 506: ...onnect all air and water lines leading to the compressor Tighten per Mack specifications 8 Add engine coolant to the cooling system Use the coolant recommended by the engine manufacturer Visually insp...

Page 507: ...e bushings and that the unloader hole allows air pressure communication from the cylinder head to the crankcase Figure 3 5 3 Place the inlet valves over the guide pins provided ensuring that the pads...

Page 508: ...ning Sequence 7 Follow the steps listed in Compressor Installation to reinstall the compressor and test for leaks Figure 3 7 1 Tighten bolts in sequence shown Figure 3 8 1 Tighten bolts in sequence sh...

Page 509: ...plumbing leakage must be checked and if necessary repaired See air system leakage test procedures which follow If the compressor fails to unload verify proper governor operation Air System Leakage Te...

Page 510: ...n effect at the time the publication was approved for printing and is subject to change without notice or liability Meritor WABCO reserves the right to revise the information presented or discontinue...

Page 511: ...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 512: ...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 513: ...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 514: ...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 515: ...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 516: ...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 517: ...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 518: ...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 519: ...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 520: ...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 521: ...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 522: ...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 523: ...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 524: ...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 525: ...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 526: ...16 BW2158 Honeywell Commercial Vehicle Systems Company 4 2001 Printed in USA...

Page 527: ...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 528: ...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 529: ...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 530: ......

Page 531: ...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 532: ...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 533: ...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 534: ...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 535: ...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 536: ...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 537: ...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 538: ......

Page 539: ...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 540: ...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 541: ...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 542: ...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 543: ...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 544: ...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 545: ...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 546: ......

Page 547: ...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 548: ...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 549: ...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 550: ...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 551: ...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 552: ...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 553: ......

Page 554: ...8 main local global operation trouble m e n u search search shooting BW1431 AlliedSignalTruckBrakeSystemsCo 1 1999 PrintedinU S A...

Page 555: ...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 556: ...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 557: ...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 558: ...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 559: ...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 560: ...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 561: ...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 562: ...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 563: ...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 564: ...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 565: ...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 566: ......

Page 567: ...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 568: ...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 569: ...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 570: ...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 571: ...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 572: ...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 573: ...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 574: ...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 575: ...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 576: ...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 577: ...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 578: ...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 579: ...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 580: ...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 581: ...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 582: ...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 583: ...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 584: ...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 585: ...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 586: ...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 587: ...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 588: ...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 589: ...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 590: ...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 591: ...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 592: ...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 593: ...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 594: ...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 595: ...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 596: ...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 597: ...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 598: ...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 599: ...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 600: ...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 601: ...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 602: ...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 603: ...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 604: ...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 605: ...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 606: ...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 607: ...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 608: ...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 609: ...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 610: ...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 611: ...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 612: ...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 613: ...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 614: ...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 615: ...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 616: ...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 617: ...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 618: ...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 619: ...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 620: ...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 621: ...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 622: ...48 REVISED 5 31 05 BW2429 2005 Bendix Commercial Vehicle Systems LLC All Rights Reserved 5 05 Printed in U S A...

Page 623: ...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 624: ...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 625: ...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 626: ...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 627: ...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 628: ...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 629: ...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 630: ...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 631: ...Maintenance Manual MM 0112 Anti Lock Braking System ABS for Trucks Tractors and Buses Revised 07 05 For E Version ECUs 12 Volt Systems...

Page 632: ...oid serious personal injury and damage to components Hazard Alert Messages and Torque Symbols WARNING A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious...

Page 633: ...Tractor ABS Only 21 Pro Link Plus Diagnostics 22 J1939 Datalink Verification Pro Link Plus 23 System Information TOOLBOX Software 29 Tire Size Range Testing Components 30 Valve Tests 32 Dynamometer T...

Page 634: ...osure to non asbestos fiber dust a cancer and lung disease hazard Material Safety Data Sheets are available from ArvinMeritor Hazard Summary Most recently manufactured brake linings do not contain asb...

Page 635: ...es and controls braking during wheel lock situations The system improves vehicle stability and control by reducing wheel lock during braking The ECU receives and processes signals from the wheel speed...

Page 636: ...ator valves Figure 1 4 6S 4M 6 wheel speed sensors 4 modulator valves 6S 6M 6 wheel speed sensors 6 modulator valves Typical illustrations in this manual use the 4S 4M configuration as a sample Layout...

Page 637: ...er ABS lamp The ABS indicator lamp works as follows Ignition ON Normal Operation ABS lamp comes on at ignition momentarily for a bulb check then goes out System is OK After servicing ABS ABS lamp does...

Page 638: ...after 2 5 seconds after fault is detected Trailer ABS fault occurred during operation and the fault was corrected None Multiple Trailers Dollies Single Trailer ABS lamp is off comes on then goes off 1...

Page 639: ...and E version units including D and E Basic and is available for front or rear axle installation Single Trailer to Multiples ABS lamp is on and stays on when a new trailer with no new fault is added...

Page 640: ...one by one then together diagonally as follows 4M channel valve cycle order 1 2 3 4 6M channel valve cycle order 1 2 3 4 5 6 ABS Valve Packages The front ABS valve package combines a quick release va...

Page 641: ...ting location Steering axle sensors are installed in the steering knuckle or in a bolted on bracket Drive axle sensors are mounted in a block attached to the axle housing or in a bolted on bracket Che...

Page 642: ...ystem Components The ECU is the brain of the ABS system It receives information from the sensors and sends signals to the ABS valves ECUs are available for cab or frame mounted applications Basic and...

Page 643: ...ns in Windows 98 Me 2000 or XP Internet Explorer version 3 02 or higher must be installed RS232 to J1708 convertor box is required Figure 1 14 Not recommended Approved for use with TOOLBOX as of July...

Page 644: ...de improved traction If ATC turns itself on and off drivers do not have to select this feature If drive wheels spin during acceleration the ATC indicator lamp comes on indicating ATC is active It goes...

Page 645: ...and Mud Switch A deep snow and mud option switch is included with ATC This function increases available traction on extra soft surfaces like snow mud or gravel by slightly increasing the permissible...

Page 646: ...ssure to the drive axle brakes and may modulate the trailer brakes to slow the vehicle down Like ATC RSC works automatically The driver does not have to select this feature RSC uses many of the same c...

Page 647: ...light but the ATC RSC lamp will stay lit briefly after the ABS lamp goes out Figure 2 6 NOTE Active mode means RSC is installed and will become active if it is needed TOOLBOX Software can also be used...

Page 648: ...nk Plus with MPC and Meritor WABCO applications card version 2 0 or higher Refer to the information in this section OEM Diagnostic Displays Refer to the vehicle operator s manual Information about TOO...

Page 649: ...rivers to an ABS tractor fault and it is used during diagnostics to display the blink code Blink Code A series of blinks or flashes that describe a particular ABS system fault or condition Blink Code...

Page 650: ...nected No recognizable active faults in the ABS No action required Inspect wiring Inspect bulb Make necessary repairs Continue with blink code diagnostics Go to Step II Continue with blink code diagno...

Page 651: ...is turned off 1st Digit 2 3 2 3 5 1 1 2 3 4 2nd Digit Pause 1 5 s Pause 1 5 s Pause 1 5 s Pause 4 s Light ON Off Stored Faults Displays all stored faults once last fault stored is displayed first Blin...

Page 652: ...M ID SYSTEM ID System Configuration Code 2 4S 4M System 1002022a S Seconds Condition Reason Action ABS indicator lamp does not come on at ignition Loose or burned out bulb Check bulb Check connections...

Page 653: ...axle curb side 1 6 Left rear additional axle driver s side 1 7 System function2 1 J1939 datalink 2 ATC valve 3 Retarder relay third brake 4 ABS indicator lamp 5 ATC configuration 6 RSC valve 8 ECU 1 L...

Page 654: ...correct J1939 data link connection Verify correct sensor adjustment Refer to the sensor adjustment information in this section Refer to the wiring diagram in Appendix II 7 2 Check ATC valve valve cabl...

Page 655: ...nnector 5 Refer to the Pro Link Plus manual for complete diagnostic instructions Pro Link Plus Screens This information provides basic screen explanations for the Pro Link Plus with an MPC and Meritor...

Page 656: ...will be followed by the system configuration code A 4S 4M two blinks system is identified here The system configuration code will continue during the entire test 2 Activate the J1939 engine torque red...

Page 657: ...aults and road speed is read and updated continuously The status of ABS switches and lamps as well as other data may also be observed from this screen TOOLBOX Software Display Select Display from the...

Page 658: ...railer Brake Valve RSC Valve RSC Data Select RSC Data from the pull down menu for RSC status information Figure 3 13 For RSC Control Status NA RSC is not an option OFF RSC is installed but is not curr...

Page 659: ...ensure the correct valve is cycling This is also helpful in verifying correct operation installation and wiring Figure 3 15 Figure 3 15 Select all valves from the menu to cycle all available ABS valv...

Page 660: ...e retarder Figure 3 20 Figure 3 20 Select Disable ATC from the pull down menu to send a command to the ECU to disable automatic traction control ATC will remain disabled until the enable command is se...

Page 661: ...as not recognized a retarder relay Where the ECU has recognized a J1939 datalink The ECU is capable of supporting ABS and ATC switches NOTE Yes indicates the ECU is capable of supporting these options...

Page 662: ...ff states of the ABS tractor lamp Follow the screen prompts 1 On 2 Off to change the status of the lamp on the instrument panel ABS Trailer Lamp Monitors the commanded on off states of the ABS trailer...

Page 663: ...esting the ABS system do not damage the connector terminals Voltage Check Measure voltage at the pins indicated in Table F Voltage must be between 9 5 and 14 0 volts The ignition must be turned ON for...

Page 664: ...gnition OFF 2 To measure resistance at the sensor connector disconnect the ECU connector from the ECU To measure resistance at the sensor connector disconnect the sensor from the sensor extension cabl...

Page 665: ...ckage Troubleshooting information RSC Valve Measure resistance across the two electrical terminals on the RSC valve to ensure 7 0 to 14 0 ohms Figure 3 28 If the resistance is greater than 14 0 ohms c...

Page 666: ...stem configuration code begins ATC has been disabled The ATC lamp comes on and stays on while ATC is disabled ATC will remain disabled until the vehicle ignition is cycled After testing ATC will autom...

Page 667: ...0 F 40 to 150 C Lubricants approved for use on Meritor WABCO sensors and spring clips are as follows Figure 4 1 Mobilith SHC 220 Mobil TEK 662 Roy Dean Products Staburags NBU 30 PTM Kluber Lubrication...

Page 668: ...also be replaced To remove the sensor from the rear axle WARNING Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not...

Page 669: ...Complete the installation per the vehicle manufacturer s manual ABS Modulator Valve Removal 1 Turn the ignition switch to the OFF position Apply the parking brake WARNING Park the vehicle on a level s...

Page 670: ...ng brake WARNING Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jack...

Page 671: ...ir lines from Port 1 air supply Port 2 air discharge and Port 3 treadle of the RSC valve Figure 4 6 Figure 4 6 7 Remove the two mounting capscrews and nuts Remove the RSC valve Installation 1 Install...

Page 672: ...replacement O rings with the grease provided 5 Plug any unused ports on the replacement valve s 6 Attach the ABS modulator valve s to the relay or quick release valve Use a 6 mm Allen wrench to tighte...

Page 673: ...eeding the air from the appropriate supply tank 5 Disconnect the wiring from the ATC valve 6 Disconnect the supply air line from the adapter and the treadle air line from the ATC valve 7 Use a 5 mm Al...

Page 674: ...nnect the treadle air line to the control port on the ATC valve 5 Attach the wiring connector to the ATC valve Hand tighten only 6 Remove the blocks and stands 7 Test the installation Checking the Ins...

Page 675: ...THREE ABS TRAILER ABS ATC VALVE PACKAGE INSTALLATION REAR STANDARD OR BASIC 4S 4M ABS VALVE PACKAGE INSTALLATION FRONT 1003364e LAMPS VALVE PACKAGE INSTALLATION REAR 6S 4M ABS AIR LINES ELEC LINES LAM...

Page 676: ...C LAMPS UPTOTHREE ABS TRAILER ABS ATC LAMPS ATC VALVE VALVE PACKAGE INSTALLATION FRONT 4005321b 4S 4M ABS ATC RSC VALVE PACKAGE INSTALLATION REAR AIR LINES ELECTRICAL LINES LAMPS TRACTOR PROTECTION VA...

Page 677: ...1 BASIC ECU CAB MOUNTED 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 1 2 3 4 5 6 7 8 9 10 11 13 14 15 14 BASIC 4004024a Figure 6 2 UNIVERSAL ECU CAB MOUNTED 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 678: ...RIGHT FRONT SENSOR LEFT REAR SENSOR LEFT FRONT SENSOR RIGHT REAR SENSOR TP 1 4 3 6 2 5 IV GND OV IV GND OV 10 13 11 14 12 15 17 18 IV GND OV IV GND OV 8 9 DIF VALVE 1 4 3 6 2 5 7 TP 8 9 TP TP 16 AWG 1...

Page 679: ...T VALVE OUTLET VALVE RIGHT FRONT ABS VALVE LEFT FRONT ABS VALVE LEFT REAR ABS VALVE RIGHT REAR ABS VALVE RIGHT FRONT SENSOR LEFT REAR SENSOR LEFT FRONT SENSOR RIGHT REAR SENSOR TP 1 4 3 6 2 5 ATC SWIT...

Page 680: ...LVE LEFT REAR ABS VALVE RIGHT REAR ABS VALVE RIGHT FRONT SENSOR LEFT REAR SENSOR LEFT FRONT SENSOR RIGHT REAR SENSOR TP 1 4 3 6 2 5 IV GND OV IV GND OV 10 13 11 14 12 15 17 18 IV GND OV IV GND OV 8 9...

Page 681: ...AD SWITCH OUTLET COMMON INLET ABS VALVE LEFT 3RD 6S 6M ONLY 6S 4M AND 6S 6M ONLY GND 11 2 10 3 9 4 8 5 7 6 ABS VALVE RIGHT FRONT ABS VALVE LEFT FRONT INLET COMMON OUTLET OUTLET COMMON INLET SENSOR LEF...

Page 682: ...Dirt buildup inside relay valve Inspect repair lines brakes If the condition is not corrected Replace the relay valve Valves don t cycle at power up OR Indicator lamp comes on blink code or diagnosti...

Page 683: ...not present at the next power up the ECU records a fault This can occur if an ECU is moved from one truck to another and one or more of the memorized components are not available on the new truck If t...

Page 684: ...cannot be conducted if there are active faults present These must be repaired before proceeding with the reconfiguration Observe the ABS and ATC lamps The ATC lamp comes on and stays on A complete ATC...

Page 685: ...will light only if ATC is connected System ID A system reconfiguration is illustrated below IGNITION ON Light ON Continues until power is turned off SWITCH 1s Pause 4 s Pause 4 s Pause 4 s Pause 4 s...

Page 686: ...d in USA Copyright Revised 07 05 ArvinMeritor Inc Maintenance Manual MM 0112 Meritor WABCO Vehicle Control Systems 2135 West Maple Road Troy MI 48084 7121 USA 800 535 5560 meritorwabco com 2005 16579...

Page 687: ...code is also displayed on the Main Screen of TOOLBOX Software and on the Program ID screen of the Pro Link There are two ways to perform J1922 datalink verification one using TOOLBOX Software and the...

Page 688: ...e ATC lamp will not come on B ABS lamp will come on and blink eight times If the lamp does not blink eight times there are faults that must be cleared before you continue with this test The eight quic...

Page 689: ...WHEEL STRAIGHTNESS TEST 5 6 WHEEL STUDS 6 6 1 DRIVE AXLE STUDS 6 6 2 FRONT AND TAG AXLE STUDS 6 7 HUB MOUNTED WHEELS 7 7 1 CARE OF WHEELS 7 8 FRONT AND TAG AXLE WHEEL HUBS 7 8 1 HUB BEARING INSPECTIO...

Page 690: ...ENCE 3 FIGURE 3 DIAL GAUGE INSTALLATION 6 FIGURE 4 STUD MOUNTED WHEELS 6 FIGURE 5 HUB MOUNTED WHEELS 7 FIGURE 6 WARNING REFLECTORS LOCATION 9 FIGURE 7 SPARE WHEEL COMPARTMENT 9 FIGURE 8 SPARE WHEEL AN...

Page 691: ...to the proper torque In the case of a new vehicle or after a wheel installation stud nuts should be tightened every 100 miles 160 km for the first 500 miles 800 km to allow setting in of clamping sur...

Page 692: ...a 3 DUAL WHEELS 3 1 OUTER WHEEL REMOVAL Same as described in Single Wheel Removal procedure described previously 3 2 INNER WHEEL 1 Remove outer wheel 2 Unscrew inner cap nuts 3 Remove inner wheel 3 3...

Page 693: ...ar from wheel surface with a good quality tar remover 2 Spray Alcoa Cleaner Pr vost 683529 evenly on cool outer surface of wheel Let work 15 20 minutes keep wet by spraying more Cleaner if necessary 3...

Page 694: ...ide 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 whee...

Page 695: ...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 696: ...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 Re...

Page 697: ...ease handle located in the front service compartment Although the bumper is heavy sprung hinges permit one person operation When closing bumper compartment make sure bumper is securely installed WARNI...

Page 698: ...ened in compartment 11 TIRE MAINTENANCE The most critical factor in tire maintenance is proper inflation Fig 9 No tire is impervious to loss of air pressure To avoid the hazards of under inflation alw...

Page 699: ...ng even for a short distance causes tires to heat up and air pressure to increase Check inflation pressure on all tires including the spare tire using an accurate tire gauge NOTE The recommended tire...

Page 700: ...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 701: ...AT MAXIMUM LOAD cold NOTE Vehicle is delivered with the specific inflation pressure certification plate according to the tire selection WARNING Special tire selection may lower maximum allowable spee...

Page 702: ......

Page 703: ...ms wheels understand the safety information contained in this manual Do not let your employees service rims wheels unless they are thoroughly trained and completely understand this safety information...

Page 704: ...g with abrasives abrasive brushes steel wool scouring pads or strong chemicals acids or alkaline Dura Bright Surface Treated Wheels are warranted against a Filiform corrosion worm or hair like lines g...

Page 705: ...ats are spherical 27 5 5 Single and wide base wheel stud located ball seat mounting 27 5 6 Dualed wheels stud located ball seat mounting 28 5 7 Dualed wheels steel inner aluminum outer stud located ba...

Page 706: ...ny wheel assembly without proper training Proper equipment is important Be sure you have the recommended tools and equipment on hand and use them according to manufacturer s instructions Tubeless whee...

Page 707: ...ted ball seat mounting 8 750 in bolt circle 6 495 in hub bore 1 219 in bolt hole diameter Lug nut covers 150 Hub covers N A 1 17 5x6 75 15 DC 5070 32 5 55 4 72 125 TR553C 005533 663170 0 2 3 4 Stud 59...

Page 708: ...12 300 70 3 5 2 38 130 TR553E outset 005535 TR555E inset 005555 833650 0 1 2 9 39874 39874 24 22 5x13 00 15 DC 11 000 74 6 42 5 3 130 TR552 005520 833640 0 1 39874 39874 25 22 5x14 00 15 DC 12 800 68...

Page 709: ...ub bore 21 5mm bolt hole diameter use two piece flange nuts Lug nut covers N A Hub covers N A 41 17 5x6 00 15 DC 4000 1814 27 0 12 2 5 0 127 4 25 108 130 896 TR554C 664800 0 1 Do not exceed maximum wh...

Page 710: ...of wheel damage can be hidden beneath the tire so whenever a tire is removed thoroughly examine the complete wheel Remove all grease and road dirt Use a wire brush or steel wool to remove rubber from...

Page 711: ...l on an Alcoa wheel may indicate that the wheel has been exposed to excessive heat as shown in picture to the left or discoloration of the wheel as shown in pic ture to the right Inspect all axle end...

Page 712: ...short leg across both rim flanges of the wheel as shown above Repeat this process at four equidistant points around the wheel The short leg should touch both rim flanges at each point If a distance gr...

Page 713: ...of 040 inches or less is acceptable Tire wear 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...

Page 714: ...racks emanating from bolt hole to bolt hole Causes are undersized diameter of wheel support surface see specifications on next page support surface not flat incorrect attachment parts see Section 5 2...

Page 715: ...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 can corrode severely Bead seat and valve stem corrosion often are c...

Page 716: ...b piloted wheels Remove damaged wheels from service For hub piloted normally if you see a wal lowed out bolt hole this would indicate the wheel ran loose Damaged ball seat contact area Pounding of nut...

Page 717: ...the wheel from service Bead Seat area 3 11 Loss of air may be caused by cracks in the bead seat areas around the rim Remove the wheel from service if damaged Bead seat cracks are normally caused by ov...

Page 718: ...warranty period THESE GAUGES ARE TO BE USED FOR RIM FLANGE WEAR ONLY THEY ARE NOT A BEAD SEAT ANGLE OR DIAMETER TOOL UNACCEPTABLE To obtain a gauge s at no charge and information on free training on...

Page 719: ...below If the flange cuts or appears close to being sharp enough to cut the rubber on the sharpness indicator gauge the edge can be removed per the edge removal procedures below If the rub ber is not c...

Page 720: ...hod of remov ing 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 721: ...ny power tools have edges that are sharp or may become hot during use Some power tools produce excessive noise when used Metal filings can be sharp and when projected by the action of power tools can...

Page 722: ...or OSHA safety wall charts and procedures 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 damaged wheels c...

Page 723: ...er and a mild detergent with assistance of a commerical high pressure power washer if available Always dilute the detergent according to the manufacturer s recommendation never use the detergent strai...

Page 724: ...protect the wheel contact surfaces from marring 2 Always use a rubber leather faced or plastic mallet 3 Inspect the wheel for damage Do not use a damaged or severely corroded wheel see Section 3 4 Cl...

Page 725: ...d separate violently This violent separation can cause serious injury or death Always contain the tire wheel assembly in an inflation cage during inflation WARNING Recommendations for mounting tubeles...

Page 726: ...and remount the tire Mounting tires on non symmetrical drop well wheels 4 3 Alcoa wheels often contain a symmetrical drop well with a narrow ledge on both sides of the rim This feature allows mounting...

Page 727: ...adial Approved for both radial Approved and bias tires Rim Widths and bias tires Rim Widths Recommendations for demounting tubeless tires 4 5 WARNING An aluminum wheel can be structurally weakened by...

Page 728: ...ance 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 flanges hooking stop on the tool over...

Page 729: ...hield prior to tightening the cap nuts The wrench end will mar the wheel around the cap nuts if it is not smooth 3 Keep all component contact surfaces smooth and clean Dirt or projections on mounting...

Page 730: ...N 39708 M20x1 5 RH threads WARNING 2 piece 33mm hex head flange nut Mounts dualed wheels with 32mmboltholestowheelcentering hubs Right hand threads used on both sides of vehicle P N 4307 32 M22x1 5 RH...

Page 731: ...ull thread First full thread Single and wide base wheel stud located ball seat mounting 5 5 Front wheels are mounted as singles and require 1 8 45 7mm minimum stud standout Most vehi cles have 1 1 8 i...

Page 732: ...ed wheels stud located ball seat mounting 5 6 Rear wheels are most frequently mounted as duals Each inner aluminum wheel is attached by 10 inner cap nuts Alcoa recommends use of inner cap nuts 5978R 5...

Page 733: ...nts Match mounted dual wheels should be put on the vehicles with the valve stems 180 apart Disc Mate wheel spacers are recommended for use with Alcoa Dura Bright surface treated wheels to protect the...

Page 734: ...ge 26 Alcoa Aluminum Wheel Disc Mate when used WARNING Incorrect inner cap nuts used with steel wheels can bottom out on the unthreaded portion of the stud before the wheels are properly seated Improp...

Page 735: ...should not be applied to the cap nut seat or to the cap nut to wheel contact surface Oiled seats can lead to over torquing which can stretch studs causing failure of studs Failed studs can cause the...

Page 736: ...rosol 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 right side of the vehicle have...

Page 737: ...s Most frequently these are M22x1 5 Generally the same diameter stud is used to mount either single or dualed wheels Studs on both sides of the vehicle are right hand threads thereby eliminating the n...

Page 738: ...orqued flange nuts allow wheels to run loose and fatigue studs or lose nuts Overtorquing can stretch studs causing them to fail with loss to torque and may cause pre mature fatigue Both under and over...

Page 739: ...o the recommended torque following the proper sequence shown below for your type wheel After 5 50 miles of operation torque should be rechecked unless your documented fleet practices determine otherwi...

Page 740: ...g 26 for proper hardware assemblies The following are examples of incorrect wheel assemblies Incorrect use of ball seat cap nut on hub piloted system Do not use ball seat cap nuts with hub piloted whe...

Page 741: ...hould be inspected to be sure 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...

Page 742: ...e stems Metal valve stem caps are recommended instead of plastic It is recommended that valve stems with O rings or grom mets be replaced at every tire change When replacing valve stems it is recommen...

Page 743: ...er November 2002 have Alcoa wheel part numbers ending with DB earlier wheels have part numbers ending in a 4 or 7 with bead seat diameters measured in 0 5 inch increments Not all Alcoa wheels are avai...

Page 744: ...g Chart or any other poster 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 Inst...

Page 745: ...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 746: ...esettable 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 the trajectory 5 Current charts or rim man...

Page 747: ...mployer shall establish a safe operating procedure for servicing single piece rim wheels and shall assure that employees are instructed in and follow that procedure The procedure shall include at leas...

Page 748: ...ional Offices The address and telephone number of the nearest OSHA office can be obtained by looking in the local telephone directory under U S Government U S Department of Labor Occupational Safety a...

Page 749: ...between the brake drum and wheel and or between two wheels to protect against corrosion DISC WHEEL A one piece forged or two piece welded assembly of a disc and a rim DROP CENTER The well or center p...

Page 750: ...ted wheel PSI Abbreviation 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 lin...

Page 751: ...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 outs...

Page 752: ...9 48 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 inch 9 1 9 Conversion Tables...

Page 753: ...limeters 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 2046 Pounds Foot pounds to Newt...

Page 754: ...Alcoa Wheel Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright 2009 Alcoa Wheel Products All Rights Reserved Form E37 13584 Printed in USA 05 06 30M...

Page 755: ...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 756: ...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 757: ...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 758: ...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 759: ...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 760: ......

Page 761: ...oval And Installation 6 6 1 3 Maintenance 7 6 2 WITH VOLVO D13 ENGINE 7 6 2 1 Description 7 6 2 2 Removal And Installation 7 7 STEERING COLUMN 8 7 1 REMOVAL 8 8 STEERING WHEEL 8 8 1 REMOVAL 8 8 2 INST...

Page 762: ...RE 9 STEERING COLUMN COVERS 8 FIGURE 10 REMOVING THE HORN PAD 9 FIGURE 11 STEERING HARNESS HORN WIRE 9 FIGURE 12 LOCKING THE CLOCKSPRING IN PLACE 9 FIGURE 13 CLOCKSPRING INSTALLATION 10 FIGURE 14 PROP...

Page 763: ...components are added to transmit increase and regulate steering control forces These elements are 1 Steering stabilizer damper 2 A vane type hydraulic pump and 3 Hydraulic reservoir and hoses The stee...

Page 764: ...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 wheel to the steering arms Hy...

Page 765: ...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 766: ...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 Service Manual NOTE For v...

Page 767: ...pump and fuel lines Position a container to catch any fuel that might drain from the pump or lines Remove the fuel pump NOTE Only unfasten the bolts marked with arrows FIGURE 5 FUEL PUMP REMOVAL CAUT...

Page 768: ...e compartment The upper steering column U joint and the steering slip joint are accessible from the front driver s area To access these joints proceed as follows FIGURE 9 STEERING COLUMN COVERS 14040...

Page 769: ...e to lock it in place Fig 12 FIGURE 12 LOCKING THE CLOCKSPRING IN PLACE NOTE The clockspring mechanism permits a certain number of turns in each direction At the moment of reinstalling the steering wh...

Page 770: ...lic Stop CAUTION Reduce or shut off the power steering hydraulic pressure before the boss on the axle touches the stop screw If not the components of the front axle will be damaged refer to ZF SERVOCO...

Page 771: ...2 INSTALLATION 1 Position pitman arm on sector gear shaft with reference marks aligned 2 Install fixing nut Pr vost 661050 Tighten nut to 470 570 lbf ft 637 773 Nm NOTE Use a new nut if the previousl...

Page 772: ...hicle will be seriously impaired Whenever a steering linkage part is repaired replaced or adjusted steering geometry and front wheel alignment must be checked and necessary corrections made Refer to s...

Page 773: ...3 Remove the retaining spring and finally the filter cartridge element FIGURE 19 POWER STEERING FLUID RESERVOIR 14018A 12 2 STEERING STABILIZER CYLINDER DAMPER The steering damper is located on R H si...

Page 774: ...en service brakes are applied wheel locking will oppose the effect of steering geometry which tends to make the front wheels rotate in opposite directions Persisting in turning or maintaining the stee...

Page 775: ...Section 14 STEERING PA1562 15 14 TORQUE SPECIFICATIONS FIGURE 21 DRAG LINK COMPONENTS 14038 FIGURE 22 TIE ROD END 14036 FIGURE 23 FRONT AXLE COMPONENTS 14045...

Page 776: ...Stabilizer damper Fixing Nuts Fig 23 T1 100 120 135 165 Steering Top Lever Nuts Fig 23 T2 150 200 205 275 Steering Damper Mounting Support Nuts Fig 23 T3 65 70 90 95 15 SPECIFICATIONS Power Steering G...

Page 777: ...Prevost number 661009 Gasket Supplier number 23516100 Gasket Prevost number 510488 Power Steering Reservoir Make Nelson Muffler Oil capacity 4 US qts 3 7 liters Supplier number 91410A Prevost number 6...

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Page 879: ...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 880: ......

Page 881: ...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 882: ...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 883: ...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 884: ...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 885: ...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 886: ...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 887: ...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 888: ...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 889: ...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 890: ...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 891: ...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 892: ...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 893: ...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 894: ...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 895: ...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 896: ...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 897: ...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 898: ...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 899: ...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 900: ...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 901: ...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 902: ...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 903: ...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 904: ...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 905: ...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 906: ...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 907: ...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 908: ...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 909: ...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 910: ...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 911: ...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 912: ...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 913: ...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 914: ...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 915: ...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 916: ...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 917: ...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 918: ...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 919: ...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 920: ...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 921: ...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 922: ...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 923: ...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 924: ...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 925: ...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 926: ...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 927: ...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 928: ...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...

Page 929: ...TRW Automotive Commercial Steering Systems Power Steering Pump Service Manual PS SERIES Die Cut...

Page 930: ...weight approx 7 2 lbs 4 Flow control valve compatible with TAS steering gear Made in the USA Three inlet port locations Two outlet port locations Three displacements available in a single housing size...

Page 931: ...reveals evidence of abnormal wear or damage to the PS pump or if you encounter circumstances not covered in the Manual STOP CONSULT THE VEHICLE MANUFACTURER S SERVICE MANUAL AND WARRANTY DO NOT TRY T...

Page 932: ...eseal Repair Disassembly 17 Inspection 23 Assembly 25 Internal Damage Repair by reference Input shaft Replacement 31 Needle Bearing Removal 32 Section 4 Reinstallation Reinstallation 34 Filling and Ai...

Page 933: ...ion Introduction 6 General Design Operation 7 Oil Flow Illustration 8 Approved Hydraulic Fluids 8 Torque Chart 9 Pump Specification Numbers 9 Service Parts List 10 Exploded View 11 Part Number Breakdo...

Page 934: ...ploded view is on a fold out page so you can see it while reading through the procedures Item numbers on the exploded view correspond with item numbers used throughout the Service Manual As you gain e...

Page 935: ...line to take the oil supplied by the pump to the steering gear All excess bypass oil is diverted internally in the pump housing back to the inlet of the pumping element Other systems may have a third...

Page 936: ...oss of fluid which could result in a loss of power steering assist Oil Flow Illustration Mack EO K2 Engine Oil Mobil ATF 210 Mobil Super 10W 40 Motor Oil Texaco 10W 40 Texaco TL 1833 Power Steering Fl...

Page 937: ...aximum 50 N M Suction port inlet 74 lbf ft maximum 100 N M Torque Chart Specification Numbers The PS power steering pump TRW part number serial number and customer part number are stamped on a machine...

Page 938: ...t 11 tooth 086128 28 Input shaft woodruf key 086129 Seal Kit includes following parts SK000131 8 O ring 032845 11 O ring 032844 12 Backup ring 032846 19 O ring 032843 20 O ring 032842 23 Shaft seal 03...

Page 939: ...ly 7 Spring 8 O ring 9 Plug 10 Spring 11 O ring 12 Backup ring 13 Top plate 14 Cam ring 15 Vanes 16 Rotor 17 Bottom plate 18 Locating pins 19 O ring 20 O ring 21 Cover 22 Needle bearing 23 Shaft seal...

Page 940: ...tation R clockwise rotation L counterclockwise rotation Shaft type 1 11 tooth 16 32 spline 2 625 dia woodruf key 3 7 8 B Flange tapered shaft Housing cover Standard Cover Outlet Inlet Housing Orientat...

Page 941: ...Initial Installation Section 2 Initial Installation Installation 14 Maintenance Tips 15...

Page 942: ...turer s specification 4 Position either a gasket or o ring dependent on the application which will seal the pump face to the mounting surface 5 Engage the input shaft 6 Tighten the mounting bolts to m...

Page 943: ...empt to weld any broken steering component Replace the component with original equipment only Do not cold straighten hot straighten or bend any steering system component Always clean off around the re...

Page 944: ...Initial Installation Section 3 Reseal Repair Disassembly 17 Inspection 23 Assembly 25 Internal Damage Repair by reference Input Shaft Replacement 31 Needle Bearing Removal 32...

Page 945: ...blow dry them only Because they are flammable be extremely careful when using any solvents Even a small explosion or fire could cause injury or death Wear eye protection and be sure to comply with OS...

Page 946: ...ug 9 and o ring 8 Discard the o ring Remove valve spool assembly 4 Remove the valve spool assembly 6 by hand or by pushing with a small rod through the orifice 3 on the opposite end of the spool cavit...

Page 947: ...ing 1 from the cover 21 using a twisting motion Remove housing 8 Remove the spring 10 Remove spring Marker solvent proof 9 16 Socket Wear eye protection The spring 10 will make the housing jump and ma...

Page 948: ...arefully being prepared for the vanes to slip from their slots in the rotor 13 Remove the locating pins 18 Make marks on the outside of the cover not on the sealing surface to remind you from which ho...

Page 949: ...move o rings 18 Check the input shaft 28 for damaged splines and unusual wear around the shaft seal area Check retaining rings 25 for damage The ball bearing 26 should exhibit free rolling operation I...

Page 950: ...ceed to step 22 22 Remove the relief valve seat assembly 6E from the valve spool assembly 6 by placing the spool in a collet if necessary Remove relief valve seat assem bly 23 Remove the shims 6D make...

Page 951: ...Inspect the cover 21 for nicks in o ring seal grooves Make sure the seal drain hole is open and the seal bore is free of nicks and other damage Make sure the surface on which the bottom plate rests i...

Page 952: ...normal wear patterns 7 Check the input shaft 28 for damaged splines and unusual wear or grooves around the shaft seal area Grooves you can detect with your fingernail necessi tate replacement of the i...

Page 953: ...diameter of the shaft seal 23 with the special grease provided and press it into the cover with the lettered side facing toward the needle bearing The installed seal should be flush with or just belo...

Page 954: ...ge the shaft into the seal by hand until the ball bearing contacts the cover Use a 7 8 socket or other appropriate tool to press the shaft and bearing into the cover until it bottoms 6 Reverse the cov...

Page 955: ...y should be aligned Install cam ring Install rotor and vanes Install top plate 12 Install the top plate 13 with the pin holes down The locating pins 18 must be engaged in the pin holes not the pockets...

Page 956: ...ate Seat it at the bottom of the groove Install backup ring 17 Grease the sealing areas of the housing 1 Grease housing sealing areas 18 Place the spring 10 on the top plate 13 Position spring 16 Grea...

Page 957: ...ring 6B and poppet 6C blunt end first into the spool 6A Install shims 6D onto the relief valve seat assembly 6E Make sure to install the same number of shims as were removed Assembly valve spool assem...

Page 958: ...all o ring 26 Lightly grease the o ring 8 and plug 9 threads Install into housing and torque to 20 lbf ft 27 N M Install plug o ring 1 1 4 Socket Torque wrench 27 Install the woodruf key into the new...

Page 959: ...ove the second retaining ring 25 and replace it in the same groove in the new input shaft sheared edge out Press shaft from bearing Retaining ring pliers Press 3 Press the new input shaft 28 into the...

Page 960: ...ring 22 Inspect needle bearing 3 Put the cover in a clean press with the flange side up Press the needle bearing 22 into the cover lettered side toward the pressing tool until flush with the inside su...

Page 961: ...Section 4 Reinstallation Reinstallation 34 Filling and Air Bleeding the System 35 Maintenance Tips 36 Reinstallation...

Page 962: ...tion the new gasket or o ring whichever was removed which will seal the pump face to the mounting surface 5 Engage the input shaft 6 Tighten the mounting bolts to manufacturer s specifications 7 Unplu...

Page 963: ...check the fluid level in the reservoir Refill as required 3 Start the engine again Steer the vehicle from full left to full right several times Add fluid as neces sary to the full line on the dip sti...

Page 964: ...empt to weld any broken steering component Replace the component with original equipment only Do not cold straighten hot straighten or bend any steering system component Always clean off around the re...

Page 965: ...Glossary Section 5 Glossary Glossary 39...

Page 966: ...over and housing Erosion Gradual wearing away or deteriorat ing Full Turn Axle contacts axle stop Grooves A long narrow furrow cut in a surface Input Port Opening in the pump through which fluid is re...

Page 967: ......

Page 968: ...TRW Automotive Commercial Steering Systems 800 Heath Street Lafayette IN 47904 Tel 765 423 5377 Fax 765 429 1868 www trucksteering com TRW Inc 2006 TRW1312 Rev 3 06...

Page 969: ...JUSTMENT 13 3 4 PITMAN ARM REMOVAL 13 3 5 PITMAN ARM INSTALLATION 14 3 6 DRAG LINK 14 3 6 1 Adjustment 14 3 7 BELL CRANK AND IDLER ARM 14 3 7 1 Bell Crank and Idler Arm Removal 14 3 7 2 Bell crank or...

Page 970: ...SUSPENSION 29 4 1 AIR SPRINGS 30 4 1 1 Inspection 30 4 1 2 Removal 30 4 1 3 Installation 30 4 2 SHOCK ABSORBERS 31 4 2 1 Inspection 31 4 2 2 Removal 32 4 2 3 Installation 32 4 3 RADIUS RODS 32 4 3 1 I...

Page 971: ...FIGURE 6 TYPICAL RADIUS ROD SETUP 8 FIGURE 7 RADIUS ROD BUSHING REMOVAL 9 FIGURE 8 RADIUS ROD BUSHING INSTALLATION 9 FIGURE 9 RADIUS ROD INSTALLATION 9 FIGURE 10 I BEAM FRONT AXLE SWAY BAR 10 FIGURE 1...

Page 972: ...E SUSPENSION 29 FIGURE 39 AIR SPRING 30 FIGURE 40 SHOCK ABSORBER 32 FIGURE 41 TYPICAL SHOCK ABSORBER SETUP 32 FIGURE 42 TYPICAL RADIUS ROD SETUP 32 FIGURE 43 RADIUS ROD BUSHING REMOVAL 33 FIGURE 44 RA...

Page 973: ...ON FIGURE 1 FRONT SUSPENSION COMPONENTS 16096 FIGURE 2 DETAILS OF FRONT SUSPENSION 16110 2 1 AIR SPRINGS The air springs are made from a special compound rubber molded to the proper contour and dimens...

Page 974: ...pring upper nut and then the two lower nuts Remove air spring 2 1 3 Installation 1 Compress air spring as necessary then aligning studs with their holes position air spring between both the lower and...

Page 975: ...a vise CAUTION Do not clamp the reservoir tube or the dust tube 2 Rotate the dust tube Notice any binding condition may be compared with new unit Binding condition indicates a scored rod Units with s...

Page 976: ...provided on the front axle suspension three longitudinal and one transversal Refer to figures 1 2 and 6 for details These rods transmit both braking and driving forces from the axles to the vehicle b...

Page 977: ...adius rod end until it extends equally on both sides of the rod 5 It is also possible to proceed differently Place radius rod bushing on a plane surface Spray a light coat of water on the inner and ou...

Page 978: ...0 4 Install a cotter pin on each nut and bend 3 INDEPENDENT FRONT SUSPENSION IFS 3 1 STEERING LINKAGE Turning motion of the steering wheel is transferred by the steering gear and steering linkage to t...

Page 979: ...nder paragraph 3 16 Front End Alignment in this supplement To check steering maximum turning angle proceed with the following method 1 Check if front tires rub against the frame or if the steering gea...

Page 980: ...Section 16 SUSPENSION PA1562 12 FIGURE 12 LOCATION OF CLAMPS 16168 FIGURE 13 CLAMP POSITIONING 16169 FIGURE 14 CLAMP POSITIONING 16170...

Page 981: ...izontal axis Fig 17 3 Locate centerline of vehicle then install relay rod in boss at steering bell crank and idler arm Align center of relay rod with centerline of vehicle FIGURE 17 PITMAN ARM ALIGNME...

Page 982: ...ailure Drag link end sockets are equipped with lubrication fittings and should be lubricated as directed in Lubrication Fittings in this section 3 6 1 Adjustment It should not be necessary to alter th...

Page 983: ...or idler arm eye Fig 21 NOTE Install grease seal according to figure 21 Grease must be able to exit the bell crank or idler arm mechanism For grease seal installation use tool Pr vost 110683 3 Install...

Page 984: ...hammer to loosen end assemblies 3 Remove stud nuts and washers then remove studs 4 Position relay rod studs into bell crank and idler arm then tap stud ends with a brass hammer to seat tapered surface...

Page 985: ...ligned with stud binding will result 3 10 STEERING ARMS The left and right wheel steering arms are secured to a swivel at one end and to a tie rod at the other end 3 10 1 Removal 1 Remove wheel as dir...

Page 986: ...o 2 Shell Retinax LX or equivalent 4 Swivel Assembly Refer to DANA SPICER MAINTENANCE MANUAL NDS AXLES Lubrication and Maintenance annexed at the end of Section 10 5 Idler Arm and Crank bell Lubricate...

Page 987: ...oad 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 988: ...ball 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...

Page 989: ...e difference between the two dimensions is greater than 0 060 1 5 mm then the ball joint should be replaced FIGURE 28 UPPER A ARM CENTRAL BALL JOINT 16116 3 16 FRONT END ALIGNMENT Proper front end ali...

Page 990: ...at the bottom B Fig 30 Front Axle Caster The inclination of the king pin from vertical in the fore and aft direction C Fig 30 3 16 2 Front End Inspection Before checking front end alignment make the f...

Page 991: ...wear and steering instability with a tendency to wander Toe In Check 1 Check the camber adjustment and adjust if necessary 2 Hoist the front of the vehicle and spin the wheels marking the centerline o...

Page 992: ...62 24 FIGURE 30 FRONT END ALIGNMENT DIAGRAM 16134 ALIGNMENT SPECS See Figure 30 Minimal Nominal Maximal A WHEEL CAMBER 0 0 0 150 0 35 B KING PIN INCLINATION 8 not adjustable C CASTER 2 35 2 6 2 85 D E...

Page 993: ...not apply more than 10 psi 69 kPa air pressure to the unmounted air spring 3 17 2 Removal NOTE Front air springs can be removed without removing the entire suspension assembly 1 Safely support vehicle...

Page 994: ...supply connected to the accessory tank fill valve or to the emergency fill valve 6 Check operation of bellows and with the primary air system at normal operating pressure 95 125 psi 655 860 kPa coat...

Page 995: ...on shock absorber pin Fig 33 4 Install washer and rubber joint on shock absorber mounting stud lower side 5 Install the shock absorber as shown in figure 32 with the mounting stud protruding through...

Page 996: ...Section 16 SUSPENSION PA1562 28 FIGURE 34 SWAY BAR FRONT SUSPENSION 16138B FIGURE 35 SWAY BAR REAR SUSPENSION 16144...

Page 997: ...9 4 REAR SUSPENSION For a description of all these systems refer to the appropriate heading in this section FIGURE 36 REAR SUSPENSION COMPONENTS 16167 FIGURE 37 DETAILS OF REAR SUSPENSION 16106 FIGURE...

Page 998: ...emoval 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 give...

Page 999: ...ightening of all shock absorber pins 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 CAU...

Page 1000: ...hings on shock absorbers upper and lower 3 Place the inner washers with washer convex side facing the shock absorber rubber bushing on each shock absorber pin Fig 41 4 Install the shock absorber eyes...

Page 1001: ...REMOVAL 16011 2 Place a flat steel disc slightly smaller than the outside diameter of the bushing Fig 43 3 Using an arbor press or a suitable driving tool press or drive the old bushing out of the rod...

Page 1002: ...air tank support These connections allow the valves to apportion air pressure in the springs to the vehicle load maintaining normal ride height Immediate response height control valves increase or de...

Page 1003: ...ar air spring clearance 1 With the vehicle at normal operating air pressure 100 125 psi 689 860 kPa measure air spring clearance This clearance should be 11 292 6 mm NOTE The measurement should be tak...

Page 1004: ...and Air System for complete information It provides a means for braking operating controls and accessories and suspension An air system schematic diagram is annexed at the end of this section for bett...

Page 1005: ...Section 16 SUSPENSION PA1562 37 FIGURE 49 IFS AIR TANKS LOCATION 24034 FIGURE 50 I BEAM FRONT SUSPENSION AIR TANKS LOCATION 24035...

Page 1006: ...d with a bottom drain valve It is recommended to purge them with all other tanks every 12 500 miles 20 000 km or once a year whichever comes first 7 2 EMERGENCY FILL VALVES The vehicle is equipped wit...

Page 1007: ...lowering the front suspension UP FRONT HIGH BUOY Only the bellows control solenoid valve is energized so the air coming from the kneeling air tank is routed through air control valves and up to front...

Page 1008: ...kwise until the desired outlet pressure is reached 4 To avoid minor readjustment after making a change in pressure setting always approach the desired pressure from a lower pressure When reducing from...

Page 1009: ...s air to close the passage between both the delivery and supply ports A relay valve opens and provides air springs until the suspension reaches the normal ride height 11 2 MAINTENANCE Refer to the air...

Page 1010: ...bers Make Sachs Color Black Type NUV45X230HA Ext Diam 75 mm Collapsed length 14 88 378 mm Extended length 23 86 606 mm Supplier number 481700000206 Pr vost number 630254 Drive and tag axle shock absor...

Page 1011: ...sett 90 psi 621 kPa Supplier number R74G 4AT RMN Pr vost number 641352 14 TORQUE SPECIFICATIONS 1 Shock absorber pin 500 550 lbf ft 680 750 Nm 2 Shock absorber pin nut 70 80 lbf ft 95 110 Nm 3 Radius...

Page 1012: ......

Page 1013: ...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 1014: ...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 1015: ...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 1016: ...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 1017: ...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 1018: ...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 1019: ...RIPTION 16 7 ZONE 1 16 7 1 FRONT BUMPER 16 7 2 FRONT CREST 17 7 3 HEADLIGHTS 17 7 4 REAR VIEW MIRRORS RAMCO 18 7 4 1 Adjustment 18 7 4 2 Disassembly 18 7 4 3 Assembly 18 7 4 4 Replacement of Mirror Gl...

Page 1020: ...Door Lower Panel 42 11 1 2 Door Upper Panel 43 11 2 BAGGAGE COMPARTMENT FLOOR 44 11 2 1 Repair of Mantex Urethane Covering 44 11 2 2 Baggage Compartment Floor Installation 45 11 3 EVAPORATOR COMPARTM...

Page 1021: ...DOOR WIPER CONTROL PANEL 20 FIGURE 16 ENTRANCE DOOR OPERATING BUTTONS 21 FIGURE 17 COACH ENTRANCE DOOR 21 FIGURE 18 ENTRANCE DOOR CONTROL SWITCH 21 FIGURE 19 INTERIOR UNLATCH AIR VALVE 22 FIGURE 20 E...

Page 1022: ...LICATION OF SIKA 221 GRAY 61 FIGURE 47 JACKING POINTS ON FRAME 69 FIGURE 48 FRONT END JACKING POINTS 69 FIGURE 49 REAR END JACKING POINTS 69 FIGURE 50 JACKING POINTS ON IND SUSPENSION 69 FIGURE 51 JAC...

Page 1023: ...partment 5 Fuel filler door 6 Condenser compartment 7 Entrance door control switch 8 Entrance door 9 Engine compartment rear doors 10 Rear view mirrors 11 Spare wheel compartment 12 Front electrical a...

Page 1024: ...ng 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 environm...

Page 1025: ...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 1026: ...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 1027: ...sing 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 4...

Page 1028: ...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 1029: ...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 1030: ...clean with solvent Grind or file the damaged area to form a V at the broken or cracked portion Sides of V should have a shallow pitch for maximum bonding area NOTE Roughening the surface improves adhe...

Page 1031: ...apping hole approximately 1 to 1 25 40 mm all around Remove all dirt grease and paint from area to ensure good bonding surface Feather the cleaned area all around Fig 2 FIGURE 2 FIBERGLASS REPAIR 1808...

Page 1032: ...cold Park vehicle in the shade whenever possible 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 1033: ...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 1034: ...ch zone is then sub divided into components Refer to the appropriate zone then component for complete procedure FIGURE 7 X3 COACHES ZONING 18623 7 ZONE 1 FIGURE 8 ZONE 1 18624 7 1 FRONT BUMPER The fro...

Page 1035: ...URE 9 FRONT BUMPER RELEASE HANDLE 18613 FIGURE 10 FRONT BUMPER 18614 FIGURE 11 FRONT BUMPER REMOVAL 18565 7 2 FRONT CREST Use a Chix cloth and anti silicone to clean the surface where the crest will b...

Page 1036: ...between the cup halves 7 4 4 Replacement of Mirror Glass Remove the broken glass Position new glass in mirror head and press to lock the Velcro in place 7 4 5 Heated Remote Controlled Rear View Mirror...

Page 1037: ...ld wipers 7 6 WINDSHIELD For the removal or installation of windshield you will need A rope A plastic spatula to lift the rubber seal lip A metal rod or screwdriver to clean the seal groove A filler i...

Page 1038: ...h excess length at the filler extremity Every 6 inches or so it is important to compress the filler due to its tendency to contract during drying process When filler insertion is almost complete cut f...

Page 1039: ...alve circuit should be used only in emergencies or when the door control system does not function properly Refer to the air system schematic diagram annexed at the end of section 12 Brakes and to page...

Page 1040: ...is completely closed or opened The door cylinder must stop the door on opening Screw or unscrew rod end to adjust if necessary To adjust opening and closing cycle speed on damper Fig 21 1 Remove the d...

Page 1041: ...rod end with bear ing to the upper hinge See figure 22 3 Support the door with a wooden block and a hydraulic jack 4 Loosen the horizontal bolts retaining the door to the hinges Adjust the door horizo...

Page 1042: ...e replace control relay DOOR WILL NOT OPEN FROM EXTERIOR SWITCH Switch malfunction Replace switch Switch malfunction Replace switch DOOR WILL NOT CLOSE FROM EXTERIOR SWITCH Solenoid failure Check volt...

Page 1043: ...x months Key hole Damper pins Hinges Low viscosity oil Every six months 7 7 7 Entrance Door Body Panel and Window Window For the removal of entrance door window you will need Pneumatic Zip gun type to...

Page 1044: ...oor lock and interior lighting Using the Zip Gun cut Sika bead located inch 7 8 mm from each body panel edge NOTE Wear ear plugs during this operation Separate body panel from door Using a razor sharp...

Page 1045: ...window There must be a gap of 4 2mm between window and body panel Apply some masking tape 1mm from window edge and body panel Fill the gap between window and body panel with Sika 255 Smooth down the...

Page 1046: ...during this operation Separate body panel from door Using a razor sharp window scraper remove from door frame Sika bead and double face self adhesive tape residue Clean door frame using anti silicone...

Page 1047: ...groove and fix power window wiper NOTE Anti friction side must be on glass side From inside the door apply some Sika 252 at the corners of window wiper Apply some 680066 glue inside finishing panel gr...

Page 1048: ...river s Window Gutter Dry fit the gutter on the vehicle If required straighten up gutter using a hammer and a wooden block Apply anti silicone inside right angle Apply Sika 205 inside right angle Appl...

Page 1049: ...raper Olfa knife Face shield From inside of vehicle cut Sika bead around window perimeter using a Zip gun while another person hold the window from the outside NOTE Wear ear plugs during this operatio...

Page 1050: ...ndow height if necessary R H side Once the window is centered apply some masking tape on bottom of window to mark off the position Peel the back from double face self adhesive tape Apply some Sika 255...

Page 1051: ...using window cleaner Apply Sika Aktivator onto gluing area making sure to avoid Sika adhesive if it is not cured yet Apply anti silicone onto molding Apply Sika 205 Clean gutter using anti silicone To...

Page 1052: ...ishing joint Apply masking tape on each side of vertical molding Apply Sika 252 to fill the gap between molding and windows Smooth down the joint with finger If required clean surfaces using Sika 208...

Page 1053: ...when needed The single glazed windows are made of tinted tempered safety glass while the double glazed windows are made of tinted tempered safety glass outside and clear tempered glass inside For fix...

Page 1054: ...Sika perform the following steps o Clean using anti silicone o Remove from structure old primer using a sander 120 150 grit o Clean again using anti silicone o Apply 206 G P primer Reactivate 206 G P...

Page 1055: ...both locks on the window simultaneously The tension required to release the window should not exceed twenty pounds 9 kg of force The release bar mechanism itself has been designed such as no adjustmen...

Page 1056: ...esents a possible hazard when improperly reattached to a hidden tapping plate itself often damaged whenever the hinge is damaged The tapping plate is permanently laminated between the inner and outer...

Page 1057: ...frame with SIKA 205 7 Apply rubber adhesive SIKA 221 under the hatch frame surface 8 Install the frame in place and fix it with rivets 9 Remove excess adhesive and clean all around 9 ZONE 3 FIGURE 29...

Page 1058: ...mechanism 4 Fig 30 and the striker pin 1 Open the doors to access the striker pin 2 Slightly loosen the striker pin 3 Using a hammer adjust the striker pin to center it in the door latch mechanism 4 T...

Page 1059: ...epending on the 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...

Page 1060: ...p gun type tool Razor sharp window scraper or putty knife Open damaged compartment door and unfasten rub rail fixing bolts Remove rub rail Unfasten bolts and disconnect cable if necessary in order to...

Page 1061: ...dow scraper remove any Sika bead or self adhesive tape residue left on the door frame Upper Panel Preparation and Installation Use a Chix cloth and anti silicone to remove any dust or residue from doo...

Page 1062: ...door and adjust height using the catch plates Tighten cylinder blocks fixing screws 11 2 BAGGAGE COMPARTMENT FLOOR 11 2 1 Repair of Mantex Urethane Covering Minor Repair Use Dupont IMRON paint Apply u...

Page 1063: ...Compartment Floor Installation Preparation and Installation Clean baggage compartment support structure using anti silicone Glue spacers 790392 about 16 inch apart Rear baggage compartment without WC...

Page 1064: ...structure Evenly distribute and install conforming weights 6 to 8 80 to 100 lbs total onto panel for at least 4 hours Make sure panel does not move Finishing Joints In the case of lateral finishing j...

Page 1065: ...L Rear baggage compartment without WCL Remove masking tape Smooth down joints using soapy water 11 3 EVAPORATOR COMPARTMENT DOOR 1 Open the evaporator door 2 Loosen the screws fixing the hinge to hing...

Page 1066: ...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 the do...

Page 1067: ...E 39 ZONE 6 18629 12 1 FRONT FENDER Front fender may be removed using the following procedure Remove the nuts on the inside of the fender Remove the fender from the vehicle To reinstall reverse the pr...

Page 1068: ...to remove rivet heads C Grind tig weld spots at each end of side panel D Safely support or temporary fix side panel Warning Panel weights over 200 pounds E Insert a flat screwdriver between the side...

Page 1069: ...using anti silicone until all clothes come clean See PR000001 section A B Use the belt sander grit coarse Use a new paper on each vehicle side panel C Clean using anti silicone until all clothes come...

Page 1070: ...minutes After 2 hours Reactivate surface with Sika 205 Before applying any other product If surface seems dusty greasy or with finger marks start operation again SECTION 3 SIDE PANEL INSTALLATION A Us...

Page 1071: ...tion Bead must be continuous for the whole perimeter A Install side panel onto support jig Section A A Section B B B Position side panel in front of vehicle structure C Perform final adjustment to mak...

Page 1072: ...imum 3 30 Remove pulling equipment A Remove protective film from double face self adhesive tape 3 40 B Compress top and bottom section of side panel A Cut excess of side panel Make sure that cut is pa...

Page 1073: ...step 2 00 4 10 Prepare air intake panel as for side panel Refer to step 2 05 4 15 Install foam tape 1 8 X onto structure as shown in picture 4 20 Install foam tape 1 16 X onto air intake panel pleat 4...

Page 1074: ...a 205 reaches as far as the corner See PR000001 section B C Apply Sika 252 black at the junction of both tubing Smooth down the joint 5 00 D Remove protective tape 13 2 SIDE CREST FIGURE 41 SIDE CREST...

Page 1075: ...Section 18 BODY PA1562 57 14 BODY PANEL AND WINDOW SPACING FIGURE 42 BODY PANEL AND WINDOW SPACING 18631...

Page 1076: ...ic simply unclip from the frame The Tourismo 2 and Silhouette seats have 3 armrests The aisle and center armrests can be folded up and down manually while the window armrest is fixed 15 1 ROTATING SEA...

Page 1077: ...sulting fumes could be hazardous in the confines of the coach and the solvent could be detrimental to the foam padding of the seats 15 3 3 Cleaning With Covers in Place The most effective and economic...

Page 1078: ...rows of seats so that repair is not as noticeable 3 Clean plywood using a scraper NOTE Make sure that no staples are sticking out beyond surface Adjacent plywood sheets must be leveled 4 Fill up hole...

Page 1079: ...Section 18 BODY PA1562 61 FIGURE 45 TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 46 APPLICATION OF SIKA 221 GRAY18641...

Page 1080: ...to prevent reaching condensation point Mechanically preheat working area heat lamp or heat gun or wait until vehicle reaches room temperature PREPARATION OF TARABUS FLOOR COVERING 1 Sand under step us...

Page 1081: ...to Section B Section D Sika Primer 215 1 Apply 2 Allow drying For a smooth surface aluminum stainless steel fiberglass gelcoat side etc 2 minutes Minimum time For a porous surface fiberglass non gelco...

Page 1082: ...ng position step nosing then press Drill and fix using screws 7 Clean top of step nosing using Sika 205 refer to Section B 8 Apply some Sika 221 onto white safety strip spread with a spatula to cover...

Page 1083: ...eating time 5 minutes 2 Before welding visually ensure that a 1 to 1 5 mm gap exists between white safety strip and Tarabus floor covering Use a knife if this is not the case NOTE There should be no e...

Page 1084: ...iller bead to make the joint then cut 6 Take position with welding torch The proper position is with a slight slope to the rear 7 Once the welding torch is ready insert the filler bead into the nozzle...

Page 1085: ...procedure for turning the torch off must absolutely be followed If this step is not taken the element may burn 11 Set temperature potentiometer to 0 position Fan will evacuate residual heat Leave the...

Page 1086: ...ning and at the end of repair 5 Perform steps indicated in paragraphs 9 10 and 11 17 VEHICLE JACKING POINTS The vehicle can be lifted by applying pressure under body jacking points or front end and dr...

Page 1087: ...suspension components FIGURE 53 JACKING POINTS ON TAG AXLE 11029 WARNING The jacking points on the tag axle must be used for raising the tag axle only Several kinds of hydraulic jacks can be used Only...

Page 1088: ...r Use only a solid link tow bar and a safety chain to tow the vehicle If required connect an auxiliary air supply to the vehicle so brakes can be operated while towing CAUTION To prevent damage to the...

Page 1089: ...to the transmission Plug axle tube to prevent oil loss Refer to Arvin Meritor Maintenance Manual no 5 annexed at the end of Section 11 Rear axle in this manual for correct procedure CAUTION Transmissi...

Page 1090: ...25 mm Supplier number 241 P Pr vost number 641209 Manifold solenoid Manufacturer Norgren Type 4 ports 1 8 NPT Voltage 24 VDC Power consumption 6 watts Maximum pressure 150 psi 1035 kPa Pr vost number...

Page 1091: ...nual No 7018081 02 Rel Jun 1999 Copyright Isringhausen 1999 Read and understand this manual before servicing this seat Isringhausen Seat Model 6800 338 Bus Seat Model 6800 338 Premium LX Service Manua...

Page 1092: ...ensure your safety the safety of others and the safe operation of the equipment fully inspect and test the equipment to ensure that the repair or service has been properly performed and the equipment...

Page 1093: ...TMENT VALVE SUSPENSION 10 subject page HEIGHTADJUSTMENT HANDLE 11 HEIGHTADJUSTMENT CYLINDER AND CAM 11 HORIZONTALADJUSTMENT SLIDE SET 12 QUICK AIR RELEASE VALVE AND HANDLE 12 QUICK AIR RELEASE VALVE S...

Page 1094: ...Indicates a potential personal safety hazard SIGNAL WORDS DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates an potentiall...

Page 1095: ...cam is defective Replace height adj cam 11 stay adjusted Height adj cylinder is defective Replace height adj cylinder 11 Height adj valve is defective Replace height adj valve 10 Horizontal slide will...

Page 1096: ...should be easy to move and hold the seat in the adjusted position when released 6 Seat tilt adjustment Control should be easy to move and hold the seat in position when released 7 Lower and upper lumb...

Page 1097: ...REMIUM LX Air supply Critical fastener torque Air supply to seat must 90 to 145 p s i Suspension to riser torque to 14 8 18 4 lb ft 20 25 N m Seat rails to suspension torque to 14 8 18 4 lb ft 20 25 N...

Page 1098: ...cle must be in a safe parked position or seat removed from vehicle Removal Mark and disconnect air lines Remove fasteners Pry one side of seat frame away from backrest Remove backrest Installation Put...

Page 1099: ...ver bar and snap bottom of clip in place Install push fasteners and cable ties Backrest assembly Set up Backrest must be removed from seat see Backrest Removal Premium XL remove upholstery and backres...

Page 1100: ...nect air lines Covers LH and RH Set up Vehicle must be in a safe parked position or seat removed from vehicle Removal Control cover Remove backrest adjustment handle Remove tilt adjustment handle for...

Page 1101: ...parked position or seat removed from vehicle Removal Slide cushion assembly forward Pry lever handle up to release cushion stop lift cushion off of glides Installation Put seat cushion assembly on gl...

Page 1102: ...ers and remove lever Installation Align locator button of lever with hole in seat pan Fasten lever to seat pan with screw and washer Push handle on torque to 7 4 8 1 lb ft 10 11 N m Height adjustment...

Page 1103: ...n place be sure it snaps in place Install cam and screw Install handle Height adjustment cylinder and cam Set up Vehicle must be in a safe parked position or seat removed from vehicle Seat cushion mus...

Page 1104: ...stallation Move horizontal adjustment forward or back to allow access to fasteners Install mounting fasteners torque to 14 8 18 4 lb ft 20 25 N m Quick air release valve and handle LH and RH Set up Se...

Page 1105: ...Connect air line Removal riser Remove riser to floor fasteners and remove riser Installation riser Put riser in place and install fasteners torque to manufactures specification 13 Manual No 7018081 0...

Page 1106: ...le handle end Removal Mark and remove air lines Remove fasteners Remove seat frame Installation Fasten seat frame to static spacer rails with bolts and nuts Torque fasteners to 14 8 18 4 lb ft 20 25 N...

Page 1107: ...must be in a safe parked position or seat removed from vehicle Removal Pull handle off Installation Push handle on Tilt handle Set up Vehicle must be in a safe parked position or seat removed from ve...

Page 1108: ...g fasteners Connect air line torque to 44 2 62 lb in 5 7 N m do not over tighten Boot Boot adapter plate ICP bar and tethers Set up Vehicle must be in a safe parked position or seat removed from vehic...

Page 1109: ...d secure with plug Route cable through control body and fasten to control handle with pin Fasten control handle to control body with pin Fasten control and bracket to frame with screws Adjustable shoc...

Page 1110: ...remove air lines from valve Remove valve fastener and remove valve Installation Fasten valve to frame with screw Connect air lines Headrest Set up Vehicle must be in a safe parked position or seat rem...

Page 1111: ...19 Manual No 7018081 02 Rel Jun 1999 Copyright Isringhausen 1999 PARTS MODEL 6800 338 BUS MODEL 6800 338 PREMIUM LX...

Page 1112: ...KIT 19 95486 03 HEIGHTADJUSTMENT CYLINDER KIT 20 920266 05 HEIGHTADJUSTMENT HANDLE KIT LH 20 920266 06 HEIGHTADJUSTMENT HANDLE KIT RH 21 98976 07 HEIGHTADJUSTMENT VALVE KIT LH 22 98875 07 HEIGHTADJUST...

Page 1113: ...t Kit C 024 Backrest Asm 17518 00 860739 D 008 Seat Pan Asm 14663 04 860742 E 059 Seat Frame Asm 02371 02 861099 F 016 Static Spacer 18191P 861083 G Swivel Asm H Isolator Asm J 006 Slide Set 17491 860...

Page 1114: ...C2 Backrest Foam 00849 864741 C3 Kit Air Lumbar Bag 95622 01 860494 C4 Uph Backrest C5 Uph Rod Long See C27 C7 Fitting 47278 C8 Clip Lumbar Bag Attach See C3 C18 Filler Foam Back 13797 C20 Air Lumbar...

Page 1115: ......

Page 1116: ......

Page 1117: ...LLUS NO DESCRIPTION ISRI P N CUSTOMER P N D1 Seat Pan 17832P 860743 D2 Seat Foam 00425 860744 D3 Uph Clip See D15 D5 Uph Rod Long See D16 D10 Hog Ring See D16 D11 Sew Strip Front See D16 D12 Sew Strip...

Page 1118: ......

Page 1119: ......

Page 1120: ...95773 01 860753 E9 Bushing Hdw Kit H S 95847 01 860754 E13 Tooth Plate Kit 914209 05 E14 Swivel Bolt Clip Kit 914204 02 860757 E50 Cover Seat Frame Rear See E1 E51 Hose Lumbar Upper Rubber See E4 E52...

Page 1121: ...Latch H S Rear 35865J E84 Pin Pivot Latch 40647N E85 Ring Retaining 60020 E86 Guide H S 42962 E88 Spring Tension See E7 E89 Lever H S Front 43012D 860588 E90 Spring Tension See E7 E91 Spring Tension...

Page 1122: ...CUSTOMER P N E142 Washer Flat A8 4 See E3 E143 Sleeve Push On PU4 46097 02 E144 Sleeve Push On PU3 44713 02 E145 Ring Retaining 60045 E147 Hose PU3 AL Supply See E3 E149 Valve AL MV IPS5 See E4 E150...

Page 1123: ......

Page 1124: ......

Page 1125: ......

Page 1126: ......

Page 1127: ......

Page 1128: ......

Page 1129: ...Car Customer P N 860758 Specification 90 60 slide stroke double locking bar handle up ILLUS NO DESCRIPTION ISRI P N CUSTOMER P N J1 Handle Slide See J8 J2 Slide Slave LH 23908 J3 Slide Master RH 2390...

Page 1130: ......

Page 1131: ...ee K12 K51 Washer Split Lock B8 See K12 K53 Bumper Cone Shape See K12 K56 Bushing Flange See K2 K59 Nut Hex Crimp Lock M10 See K2 K61 Spring Air See K6 K66 Washer Flat A6 4 See K6 K67 Screw Air Spring...

Page 1132: ...U3 44713 01 K159 Ring Retaining Shock Upr See K5 K160 Washer Shock Lwr See K5 K161 Cable Adjustable Shock See K19 K162 Plug See K19 or K20 K163 Bracket Cable Handle Mtg See K20 K164 Housing Adjustable...

Page 1133: ......

Page 1134: ......

Page 1135: ...92625 01 Description Boot Kit Susp Air AL ISRI Illus No M 001 Customer Prevost Car Customer P N Specification ILLUS NO DESCRIPTION ISRI P N CUSTOMER P N M1 Boot 00169 M2 Boot Button Small See M4 M3 B...

Page 1136: ......

Page 1137: ...rade Isopropyl Alcohol To Minimize Fine or Hairline Scratches Plastic Polishes applied and removed per manufacturer instructions Suggested Polishes Mirror Glaze Clear Plastic Polish Cleaner Detailer b...

Page 1138: ......

Page 1139: ......

Page 1140: ......

Page 1141: ......

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Page 1143: ...FRIGERANT 13 6 2 1 Procurement 13 6 2 2 Precautions in Handling Refrigerant 13 6 2 3 Treatment in Case of Injury 13 6 2 4 Precautions in Handling Refrigerant Lines 15 6 2 5 Auxiliary System Refrigeran...

Page 1144: ...ompressor is inoperable 34 8 2 3 Evacuating System Before Adding Refrigerant Auxiliary System 35 8 3 OIL ADDITION 35 8 4 COMPRESSOR OIL CONTAMINATION 35 8 5 OIL RETURN OPERATION 35 9 HEATING SYSTEM 37...

Page 1145: ...EMENT DDC S60 ENGINE 20 FIGURE 20 BELTS ARRANGEMENT VOLVO D13 ENGINE 20 FIGURE 21 IDLER PULLEY INSTALLATION ON VOLVO D13 ENGINE 20 FIGURE 22 BELT PLAY 20 FIGURE 23 COMPRESSOR ALIGNMENT 21 FIGURE 24 CO...

Page 1146: ...ng system One additional air register is located in the driver s area but supplied by the passengers air ducting system It is installed in the stepwell for step de icing FIGURE 1 DRIVER S AIR CIRCULAT...

Page 1147: ...dashboard panel Fig 5 The driver s HVAC section piping is paralleled with the passengers HVAC section piping Both sections use the same refrigerant and coolant and are linked to the same condenser an...

Page 1148: ...00 125 257 88 130 266 77 135 275 68 140 284 60 145 293 53 150 302 47 3 2 PASSENGERS SECTION OPERATION The R H portion of the HVAC control unit enables the selection of the temperature in the passenger...

Page 1149: ...the fans also controls the A C system 4 HVAC UNIT MAINTENANCE No special maintenance is required on the passengers driver s and auxiliary HVAC units with the exception of cleaning their respective coi...

Page 1150: ...oor steps Slide out the recirculating air and fresh air filters To clean filters back flush with water then dry with air every 12 500 miles 20 000 km or once a year which ever comes first Fig 12 13 NO...

Page 1151: ...complete understanding of the HVAC components circuitry read and understand section 06 ELECTRICAL of this manual under Troubleshooting And Testing The Multiplex Vehicles and Test Mode For Switches An...

Page 1152: ...he outside temperature is above 50 F 10 C when there is less demand for heating Note To test a working pump it is possible to keep it active even if the outside temperature is above 50 F 10 C See para...

Page 1153: ...tment to lock unlock the door HVAC condenser fans not functioning in speed 1 Circuit breaker CB7 was manually tripped and not reset Seized bearing Brush problem Bad wiring Check reset circuit breaker...

Page 1154: ...n air conditioning capacity of 2 tons 6 1 A C CYCLE Refrigeration may be defined as the transfer of heat from a place where it is not wanted to a place where it is unobjectionable Components required...

Page 1155: ...valve and safety plug from damage It is a good practice to replace the cap after each use of the cylinder for the same reason If the cylinder is exposed to the sun s radiant heat pressure increase re...

Page 1156: ...Section 22 HEATING AND AIR CONDITIONING PA1562 14 FIGURE 16 REFRIGERANT CIRCUIT CENTRAL AND AUXILIARY SYSTEMS 22313_1...

Page 1157: ...gs and seats must be in perfect condition The slightest burr or piece of dirt may cause a leak 8 O rings should be coated with refrigeration oil and installed on the line before the line is inserted i...

Page 1158: ...accelerate procedure lightly open compressor suction valve until pressure reaches this value 6 4 ADDING REFRIGERANT VAPOR STATE Use the suction service valve on the compressor to add a small quantity...

Page 1159: ...vacuum pump off and see if the vacuum holds This is to check the setup for leaks 4 Midseat the system service valves 5 Open the vacuum pump and the thermistor valves Start the pump and evacuate to a s...

Page 1160: ...f valves 3 to 4 turns 4 Open the lower receiver valve by turning out all the way 5 Backseat the upper receiver valve by turning out all the way 6 Remove the cover cap from the service fitting in the t...

Page 1161: ...lean 6 7 3 Clean out After Major Compressor Failure 1 Reclaim the refrigerant into a refrigerant bottle through a filter dryer to filter out contaminants 2 Remove the failed compressor and repair it i...

Page 1162: ...ts as explained in Section 12 NOTE Both belts must always be replaced simultaneously to ensure an equal distribution of load on each of them FIGURE 18 AIR PRESSURE REGULATOR 12200 FIGURE 19 BELTS ARRA...

Page 1163: ...etween each extremity of straight edge 1 Fig 24 and drive belt If they are different loosen the pillow block compressor bolts and with a hammer knock compressor pillow block to slide it in order to ob...

Page 1164: ...d properly liquid drainback during shutdown Broken Suction Valves Symptom Loss of unit capacity at all temperatures Compressor unable to pull extremely low vacuum with suction service valve frontseate...

Page 1165: ...SSEMBLY 7 4 CONDENSER The central A C system condenser coil is hinge mounted on the R H side of the vehicle on the A C condenser door Fig 29 The condenser coil for vehicles equipped with an auxiliary...

Page 1166: ...lation from the rest of the system 7 6 FILTER 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 mo...

Page 1167: ...bubbles indicates a shortage of refrigerant or restriction in line Moisture is one of the main causes of chemical instability or contamination in air conditioning systems If moisture is present it ca...

Page 1168: ...stated previously 6 Add a small quantity of refrigerant R 134a to the low side of the system Check for leaks Return the system to normal operation FIGURE 31 REFRIGERANT SOLENOID VALVE 22044 7 8 EXPAN...

Page 1169: ...if allowed to return in the suction line A vapor is said to be superheated when its temperature is higher than the saturation temperature corresponding to its pressure The amount of the superheat is...

Page 1170: ...49 F 40 F 9 F 9 4 C 4 4 C 5 C Average of low and high swing is 49 F 9 4 C NOTE The low swing of the superheat should be a minimum of 4 F 2 2 C higher at the remote bulb and have an average of 8 to 12...

Page 1171: ...valves together The cage must fit properly before tightening the body flange Tighten bolts evenly 5 Check for leaks Safety Instructions 1 Make sure the valve is installed with the flow arrow on the v...

Page 1172: ...at Adjustment Power assembly failure or partial loss of charge Replace power assembly or replace valve Air filter screen clogged Clean or replace air filter screen Plugged lines Clean repair or replac...

Page 1173: ...required Compressor vibrates Check and tighten compressor mounting bolts and belt tension Low refrigerant level Check for refrigerant leaks and add refrigerant if required Suction pressure rises fast...

Page 1174: ...Example for an exterior temperature of 100 F Exterior temperature 100 F 30 F 130 F Refer to paragraph 10 11 Temperature Pressure Note the corresponding pressure for a temperature of 130 F 199 8 psi R...

Page 1175: ...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 1176: ...ame so that the top of the cone is approximately level or within one half inch above the plate 2 Probe end of suction test tube around all joints valves etc When a leak has been found at a soldered jo...

Page 1177: ...mount of oil Evaporator Condenser Filter Dryer 50 cm 1 7 ozs 30 cm 1 0 ozs 10 cm 0 3 ozs The amount of oil recovered with the refrigerant recovery should be added at the same time 25 ml of oil lb of r...

Page 1178: ...Section 22 HEATING AND AIR CONDITIONING PA1562 36 FIGURE 36 CENTRAL HEATING SYSTEM COMPONENTS 22325...

Page 1179: ...red tab to close the valve WARNING Before proceeding with the following steps check that coolant has cooled down 3 Loosen hose clamp install an appropriate container to recover coolant and disconnect...

Page 1180: ...he water recirculating pump should be energized to assist in circulating coolant through the heating system To perform this operation start the engine switch on the HVAC control unit both driver and p...

Page 1181: ...t that might interfere with its operation No other maintenance is needed unless a malfunction occurs FIGURE 41 DRIVER S HOT WATER PNEUMATIC VALVE ASSEMBLY 22240 9 5 2 Pneumatic Water Valve Disassembly...

Page 1182: ...compartment is designed so that the pilot solenoid valve which is part of the assembly opens and closes a port which directs air pressure to the actuator casing thereby allowing the hot water to enter...

Page 1183: ...2 A pilot solenoid valve replacement seal kit is available 871390 FIGURE 44 PNEUMATIC WATER VALVE 22330 9 6 5 Valve Troubleshooting PROBLEM PROCEDURE Valve fails to close 1 Check electrical supply wi...

Page 1184: ...er to recover the residual coolant in the line 5 Remove the two clamps holding the pump motor to its mounting bracket Remove the pump with the motor as an assembly 9 7 2 Disassembly 1 Separate the hou...

Page 1185: ...43 FIGURE 46 WATER RECIRCULATING PUMP CENTRAL A C 22282 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 8 Dr...

Page 1186: ...e preheater is located inside engine compartment and is accessible through engine compartment R H side door refer to figure 47 This Auxiliary Preheating System is used for preheating and retaining the...

Page 1187: ...pens and fuel is sprayed into the combustion chamber At the same time the electronic ignition unit produces high voltage 8000 V and the mixture of fuel and air in the combustion chamber is ignited by...

Page 1188: ...tton to set the time of day 3 Wait 5 seconds The time of day is stored time of week flashes 4 Press 8 or 9 button to set the correct day of week 5 Wait 5 seconds The day of week is stored Viewing the...

Page 1189: ...ystem using coded light signals the equipment on indicator operation indicator flashes Refer to the following table Failure Symptom Probable Cause Check and Correct 1X Flash F 01 No combustion after c...

Page 1190: ...coil 12X Flashes F 12 Heater lock out 3 repeated faults flame outs or 5 repeated start attempts Reinitialize control unit by switching heater on and disconnecting power 9 8 5 Troubleshooting and Maint...

Page 1191: ...63586 Condenser fan motors Make EBMPAPST Type AXIAL BRUSHLESS Voltage 24 V DC Qty 4 Prevost number 563461 Evaporator air filter Central system Make Permatron Corp Type Polypropylene Prevost number 874...

Page 1192: ...1750 rpm Nominal Minimum speed for lubrification 400 rpm Nominal horsepower 15 Oil pressure at 1750 rpm 15 to 30 psi 103 207 kPa Oil capacity 1 13 U S gal 4 3 liters Weight 142 lbs 64 5 kg Approved oi...

Page 1193: ...Model BX100 Prevost number with two BOSH Alternators 506864 Condenser coil Auxiliary system Make Valeo Prevost number Condenser coil Central system Make Carrier Transicold Aluminum Prevost number 8706...

Page 1194: ...Central system Make Burkert Type 3 WAY Voltage 24 V DC Prevost number 871381 Seal kit Water Side 871389 Seal kit Actuator Side 871388 Seal kit Pilot Solenoid Valve 871390 Driver s hot water pneumatic...

Page 1195: ...alve Central system Make Alco Model TCLE 5 1 2 Prevost number 950320 Preheating system Make WEBASTO Model THERMO 300 Capacity 104 000 Btu h 30 kW Heating medium Coolant Rated voltage 24 V DC Operating...

Page 1196: ......

Page 1197: ...Compressor 62 11052 Rev A WORKSHOP MANUAL for MODEL 05G TWIN PORT COMPRESSOR R...

Page 1198: ...WORKSHOP MANUAL COMPRESSOR MODEL 05G TWIN PORT...

Page 1199: ...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 1200: ...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 1201: ...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 1202: ...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 1203: ...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 1204: ...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 1205: ...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 1206: ...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 1207: ...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 1208: ...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 1209: ...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 1210: ...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 1211: ...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 1212: ...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 1213: ...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 1214: ...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 1215: ...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 1216: ...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 1217: ...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 1218: ...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 1219: ...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 1220: ...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 1221: ...Compressor 62 11053 Rev B SERVICE PARTS LIST for MODEL 05G TWIN PORT COMPRESSOR 1 2 3 4 5 6 R...

Page 1222: ...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 1223: ...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 1224: ...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 1225: ...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 1226: ...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 1227: ...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 1228: ...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 1229: ...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 1230: ...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 1231: ...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 1232: ...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 1233: ...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 1234: ...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 1235: ...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 1236: ...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 1237: ...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 1238: ...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 1239: ...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 1240: ...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 1241: ...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 1242: ...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 1243: ...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 1244: ...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 1245: ...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 1246: ...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 1247: ...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 1248: ...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 1249: ......

Page 1250: ......

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Page 1253: ...3...

Page 1254: ...4...

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Page 1256: ...6...

Page 1257: ...7...

Page 1258: ...8...

Page 1259: ...9...

Page 1260: ......

Page 1261: ...BACK UP CAMERA AND MONITOR 10 3 HUBODOMETER 12 3 1 DESCRIPTION 12 3 2 OPERATION 13 3 3 REMOVAL 13 3 4 INSTALLATION 13 4 COLD STARTING AID ETHER 13 4 1 PREVENTIVE MAINTENANCE 13 4 2 TROUBLESHOOTING IF...

Page 1262: ...21 8 1 GENERAL DESCRIPTION 21 8 2 WASHER FLUID REFILLING 21 8 3 WASHER NOZZLES ADJUSTMENT 21 9 WINDSHIELD WIPERS AND WASHERS 22 9 1 GENERAL DESCRIPTION 22 9 2 WIPER ARM 23 9 2 1 Wiper Arms Positionin...

Page 1263: ...IGURE 19 ENGINE 13 FIGURE 20 COLD STARTING AID 14 FIGURE 21 DESTINATION SIGN ELECTRONIC 15 FIGURE 22 LAVATORY 15 FIGURE 23 VENTILATION FAN INSTALLATION 16 FIGURE 24 DOOR LOCK 16 FIGURE 25 F W TANK SER...

Page 1264: ...ns for AM FM radio satellite radio karaoke wireless microphone DVD scenic view and back up camera system and GPS Navigation System module may be featured FIGURE 1 AUDIO VIDEO PANEL Each service module...

Page 1265: ...Section 23 ACCESSORIES PA1562 5 FIGURE 2 AUDIO VIDEO CONNECTIONS...

Page 1266: ...F position Remove the dashboard cover Disconnect the electrical cable connectors from radio and unfasten back plate securing nuts screws To separate the radio from its support insert the removal tool...

Page 1267: ...t DC COMPATIBILITY This DVD player can play the following disc formats DVD CD VCD DVCD MP3 CD R CD RW SYSTEM FUNCTIONS Video output system system MULTI NTSC or PAL switchable 1 L R audio output 1 L R...

Page 1268: ...E 23083 1 6 1 Removal 1 Place the ignition switch in the OFF position 2 Remove the mounting screws at mounting flange 3 Disconnect wiring 1 6 2 Installation 1 Reconnect wiring 2 Align mounting flange...

Page 1269: ...ILE DVD PLAYER DV1500 FIGURE 15 PANASONIC DV1500 1 11 DRIVER S SPEAKERS The driver s speakers are mounted one on each side This arrangement provides the driver with clear stereo sound Controls for the...

Page 1270: ...when backing up The camera is automatically activated when the transmission is put in reverse gear and the ignition switch is ON BUTTON DESCRIPTION 1 STANDBY On Off switch 2 UP This key has 3 functio...

Page 1271: ...ied with the keys UP and DOWN POSSIBLE SETTINGS LANGUAGE ENGLISH GERMAN ENG DEUT SCREEN FORMAT NOR 4 3 picture format 4 3 WIDE picture format 16 9 FULL picture format 16 9 middle enlarge USER LANGUE E...

Page 1272: ...ide camera The connection is to be made at the INDICATOR ORANGE Control wire for switching on the reversing camera The connection is to be made at the reversing light 3 HUBODOMETER 3 1 DESCRIPTION An...

Page 1273: ...l cutout valve Atomizer The control rocker switch is located on the dashboard This switch is provided with a locking mechanism to avoid accidental use when engine is running To activate the ether star...

Page 1274: ...fuel is not discharged from tube remove tube and blow out or replace If fuel is discharged connect tube to thermal cutout valve and disconnect other tube 4 Actuate the solenoid valve If fuel is not d...

Page 1275: ...is located over the windshield An indicator light on the dashboard will illuminate to inform the driver when the lavatory is occupied A night light is permanently lit in the lavatory when the ignition...

Page 1276: ...nce should be determined according to vehicle mileage and operating conditions However it is recommended to check this item every 50 000 miles 80 000 km or once a year whichever comes first Remove fan...

Page 1277: ...3 Remove switch through this opening taking care to disconnect electric wires 6 8 FRESH WATER TANK One panel allows access to the fresh water tank It is located behind the toilet mirror Remove the ta...

Page 1278: ...Section 23 ACCESSORIES PA1562 18 FIGURE 26 FUNCTIONING OF LAVATORY 23051...

Page 1279: ...y turning clockwise until lock snaps into position NOTE The dispenser requires priming when extremely viscous lotion soaps are used Remove piston and spout cover and supply tube assembly Pump water in...

Page 1280: ...sump tank overflow cock when the tank is full CAUTION In cold weather add 2 gallons 9 liters of antifreeze e g ethylene glycol in the toilet before filling main tank 6 12 3 Auxiliary sump Tank Draini...

Page 1281: ...e front electrical and service compartment However this system shares the same telltale light than the windshield washer low level sensor refer to Operator s manual for operation Each pressing of this...

Page 1282: ...o restriction to the flow of washer liquid Check that wiper arms have the proper sweep position and the washer nozzles are aimed so that spray is within the proper wiper pattern The windshield wipers...

Page 1283: ...Do not attempt to manually move the wiper arms to make wiper blade sweep adjustments as damage to the wiper linkage or motor may occur If it is necessary to adjust the sweep of blades remove the arms...

Page 1284: ...nt The windshield wiper motor is located at lower front of the vehicle behind the defroster panel Refer to figure 34 for motor location WARNING Park vehicle safely apply parking brake stop engine and...

Page 1285: ...tions A Add proper fluid B Store coach or parts in heated area then purge system with low temperature solution C Remove with compressed air if severely clogged replace items D Replace section E Realig...

Page 1286: ...nstruments Safety Features and Equipment and also Appendix G 10 1 TIRE VALVE INSTALLATION Use as required a small rod to hold the valve in place when tightening Steel Wheels All wheels a Install Beru...

Page 1287: ...o extension piece Prevost 651079 Aluminum wheels former Stud Mounted wheels All wheels a Remove Alcoa valve b Install Beru valve Torque valve to 102lb in 22 c no extension piece Prevost 651082 CAUTION...

Page 1288: ...ty of the preheating system if so equipped The system operation is fully automatic and does not require assistance from the operator however if required the system can be manually activated by the ope...

Page 1289: ...ify that that the extinguisher pressure gauge pointer is in the green arc at room temperature o Verify that distribution piping and nozzles are intact and unobstructed and that nozzle blow off caps ar...

Page 1290: ...Section 23 ACCESSORIES PA1562 30 FIGURE 40 FIRE EXTINGUISHER INSTALLATION FIGURE 41 NOZZLE BRACKETS IDENTIFICATION AND INSTALLATION...

Page 1291: ...er 901317 DASHBOARD RADIO XM Power source 12 volts Prevost number 901316 MOBILE DVD PLAYER Power source 12 volts Prevost number 901198 SPEAKER standard Model Dual Cone Impedance 4 ohms Prevost number...

Page 1292: ...umber 901054 VIDEO DISTRIBUTION AMPLIFIER Power source 24V Prevost number 901117 TV MONITOR Type 10 4 LCD Power source 24V Prevost number 901130 HUBODOMETER US model miles Make Stemco Prevost number 6...

Page 1293: ...ke Furnas Type Resettable Time 0 2 to 180 seconds Pr vost number 900348 FLUSH PUMP Make RULE 2000 Model number 12 24 V Power source 24 volts DC Capacity 1450 GPH Pr vost number 900960 AIR HORN Make Al...

Page 1294: ......

Page 1295: ...DASHBOARD RADIO OPERATING INSTRUCTIONS Beginning with vehicle A 1493 February 2009 MANUEL D UTILISATION DE LA RADIO DU TABLEAU DE BORD D butant avec le v hicule A 1493 F vrier 2009...

Page 1296: ...s Storing Radio Stations 8 Presets Selecting a Stored Radio Station 8 Scan Mode 8 Using the Weather Band 9 Satellite Radio Service Optional Feature 9 CD Mode 10 Switching to CD Mode 10 Eject a CD 10 C...

Page 1297: ...Adjusting Bass Up and Down 16 Adjusting Treble Up and Down 16 Adjusting Balance Left and Right 16 Adjusting Fader Front and Back 16 Adjusting Mid Medium Frequency Range Up and Down Optional Feature 1...

Page 1298: ...ation 30 Mise en marche mise l arr t sourdine et pause du syst me audio 30 Mode radio 30 S lection de bandes FM et AM 30 Recherche en mode radio 30 Syntonisation manuelle 30 Pr r glages m morisation d...

Page 1299: ...vance rapide sur un iPod 38 Activation des plages d un iPod dans un ordre al atoire 38 R p tition de plage sur le iPod 38 Balayage sur le iPod 38 Mode AUX Caract ristiques en option 39 R glages audio...

Page 1300: ...heure 44 Format 12 ou 24 heures 44 R glage de l horloge 44 Mise en marche et arr t de l alarme Caract ristiques en option 45 Programmation de l alarme Caract ristiques en option 45 Code antivol 46 En...

Page 1301: ......

Page 1302: ...n unsafe practice that could result in serious personal injury or death A danger advisory banner is in white type on a black background with a black border WARNING Warning indicates an unsafe practice...

Page 1303: ...eard When possible use the Steering wheel controls It is a feature to make it both easy and safe to handle the radio while driving Introduction The following instructions explain the general functions...

Page 1304: ...on Radio Push and release Recall Preset Station Radio Push and hold Store Preset Station 3 Preset 3 Button Radio Push and release Recall Preset Station Radio Push and hold Store Preset Station 4 Prese...

Page 1305: ...adio Cancel ongoing Traffic or News message 12 CD Aux Mode Select CD USB Switch between sources other than radio 13 Up Button Radio Manual tuning up 14 Fast Forward Button Radio Seek CD USB Push and r...

Page 1306: ...orward 21 Previous Button Radio Push and release Seek Radio Push and hold Manual tune down CD USB Push and release Select previous track CD USB Push and hold Fast reverse 22 YES Button Bluetooth Phone...

Page 1307: ...PWR Button General Turns the Radio On and Off 32 Seek Buttons Radio Seek CD USB Next or previous track 33 Mute Pause Button General Mute or Pause the source of audio 34 Aux Button Not used for Base r...

Page 1308: ...only CD USB Displays other source than radio 43 Preset Number Radio Displays preset number 44 Phone Connected General Indicates that the phone is connected 45 Bluetooth On General Indicates that the...

Page 1309: ...radio as the play mode turn the radio on and press the RADIO 10 button The radio will then be active on the last used radio band AM FM etc To switch between the bands AM FM1 FM2 use the RADIO 10 butt...

Page 1310: ...o select one of the preset stations perform the following 1 Push the RADIO 10 button to select the required band AM FM1 FM2 FM3 Mid radio only Weather or Satellite radio Mid radio only 2 Push and rele...

Page 1311: ...satellite radio compatible XM and Sirius are satellite radio services that offer more than 100 channels of digital quality audio programming and can be heard uninterrupted across the contiguous Unite...

Page 1312: ...g wheel controls Push and release the 21 or 20 button to move to the previous or next track respectively Fast Reverse or Fast Forward of a CD Fast forwarding or reversing a CD can be performed in one...

Page 1313: ...WN 17 buttons to choose between All and Folder 5 Push OK 14 button to enter the desired repeat mode Changing to Another Folder on a CD Optional Feature If the content of the CD is stored in folders it...

Page 1314: ...12 button until USB shows on the display OR 2 Connect a USB device Disconnecting a USB Device No special preparations are needed to disconnect the USB device When USB device is removed the radio will...

Page 1315: ...e is stored in folders By default Repeat All is active To change the repeat setting do the following 1 Push MENU 15 button 2 Push UP 13 or DOWN 17 buttons until REPEAT is displayed 3 Push OK 14 button...

Page 1316: ...iPod Mode There are two ways to switch to iPod mode 1 Push the CD AUX 12 button until iPod shows on the display OR 2 Connect an iPod device Disconnecting an iPod Device No special preparations are ne...

Page 1317: ...r the random sub menu 4 Push UP 13 or DOWN 17 buttons to choose between All and Folder 5 Push OK 14 button to enter the desired random mode Repeat a Track on an iPod There are two possible Repeat sett...

Page 1318: ...sted up and down by using ESC 16 or OK 14 buttons respectively Adjusting Treble Up and Down The audio systems treble can be adjusted by pressing the AUDIO 18 button until TREBLE shows on the display T...

Page 1319: ...K 14 button to enter the advanced sub menu 4 Push UP 13 or DOWN 17 buttons until SPEAKERS is displayed 5 Push OK 14 button to change between 2CH and 4CH Activate Speed Dependant Volume ASC Optional Fe...

Page 1320: ...nd a phone as well as to add a phone to the radio phone list 1 Push MENU 15 button 2 Push UP 13 or DOWN 17 buttons until HANDS FREE is displayed 3 Push OK 14 button to enter the hands free sub menu 4...

Page 1321: ...om the phone list in the radio 1 Push MENU 15 button 2 Push UP 13 or DOWN 17 buttons until HANDS FREE is displayed 3 Push OK 14 button to enter the hands free sub menu 4 Push UP 13 or DOWN 17 buttons...

Page 1322: ...s Setting the Clock Normally the time is set automatically by the trucks system The option to manually set the time will then not be available To set the clock manually do the following 1 Push MENU 15...

Page 1323: ...nction with only one vehicle The Guard feature prohibits operation of the radio anywhere else The Guard is automatic and no manual handling is normally needed In Case of Malfunction If by some reason...

Page 1324: ...set Guard On or Off The user will be requested for the Anti Theft Code to deactivate or activate Guard The display will then show CODE 0000 with the first digit blinking To enter the code do the foll...

Page 1325: ...ar phones that do not support this standard may still work To see if your phone supports BlueTooth Hands Free Profile 1 5 visit the BlueTooth organization homepage at https www bluetooth org tpg listi...

Page 1326: ...situ es sur le volant Cette caract ristique rend la conduite plus s curitaire et facilite la commande de la radio Introduction Les instructions suivantes expliquent le fonctionnement des mod les de ra...

Page 1327: ...l e 2 Bouton Pr r glage n 2 Radio Appuyer et rel cher Rappel de la station pr r gl e Radio Appuyer et maintenir enfonc M morisation de la station pr r gl e 3 Bouton Pr r glage n 3 Radio Appuyer et rel...

Page 1328: ...rmation Trafic Nouvelles Radio Trafic en marche ou l arr t Radio Annule message continu de Trafic ou Nouvelles 12 Mode CD Aux CD USB Choisir entre les sources non radio 13 Bouton vers le haut Radio Sy...

Page 1329: ...rapide 21 Bouton pr c dent Radio Appuyer et rel cher Recherche Radio Appuyer et maintenir enfonc Syntonisation manuelle vers le bas CD USB Appuyer et rel cher Choisir plage pr c dente CD USB Appuyer...

Page 1330: ...e en marche et arr t de la radio 32 Boutons SEEK recherche Radio Recherche CD USB Plage suivante ou pr c dente 33 Bouton sourdine pause G n ralit s Sourdine ou pause de la source audio 34 Bouton AUX F...

Page 1331: ...o Nombre pr r gl 44 T l phone connect G n ralit s Indique qu un t l phone Bluetooth est connect 45 Bluetooth en marche G n ralit s Indique que la fonction Bluetooth est activ e 46 Information sur la c...

Page 1332: ...e radio allumer la radio et appuyer sur le bouton RADIO 10 La bande de fr quence de la radio sera alors la derni re utilis e AM FM etc Pour passer d une bande une autre AM FM1 FM2 utiliser le bouton R...

Page 1333: ...glages s lection d une station radio m moris e Pour choisir l une des stations pr r gl es il faut 1 Appuyer sur le bouton RADIO 10 pour choisir la bande n cessaire AM FM1 FM2 FM3 en option m t o ou r...

Page 1334: ...ces de radio par satellite offrant plus de 100 canaux de programmation audio de qualit num rique La transmission est sans interruption aux tats Unis continentaux Le service de radiodiffusion par satel...

Page 1335: ...r et rel cher le bouton 21 or 20 pour passer la plage pr c dente ou la suivante Recul rapide ou avance rapide d un CD Le recul ou l avance rapide se r alise de deux mani res avec un CD 1 Maintenir enf...

Page 1336: ...3 ou le 17 pour choisir entre All tous Track plage et Folder fichier 5 Appuyer sur le bouton OK 14 pour activer le mode de r p tition souhait Changement de fichier sur un CD Caract ristiques en option...

Page 1337: ...e bouton CD AUX 12 jusqu ce que USB s affiche OU 2 connecter un appareil USB D connexion d un appareil USB Aucune pr paration sp ciale n est n cessaire pour d brancher un appareil USB Une fois l appar...

Page 1338: ...dans des fichiers Par d faut Repeat All r p tition pour tous est activ Pour changer le r glage de r p tition il faut 1 Appuyer sur le bouton MENU 15 2 Appuyer sur le bouton 13 ou le 17 jusqu ce que R...

Page 1339: ...vent verrouill es Une fois le iPod connect la radio ses commandes se retrouvent verrouill es S lection du mode iPod Il existe deux fa ons de passer au mode iPod 1 Appuyer sur le bouton CD AUX 12 jusqu...

Page 1340: ...on MENU 15 2 Appuyer sur le bouton 13 ou le 17 jusqu ce que RANDOM s affiche 3 Entrer le sous menu du r glage al atoire en appuyant sur le bouton OK 14 4 Appuyer sur le bouton 13 ou le 17 pour choisir...

Page 1341: ...he Le niveau des graves du syst me audio peut tre mont en tournant le bouton 7 dans le sens horaire et baiss en tournant le bouton 7 dans le sens antihoraire Il est aussi possible d ajuster les graves...

Page 1342: ...audio en mode de 2 ou de 4 haut parleurs il faut 1 Appuyer sur le bouton MENU 15 2 Appuyer sur le bouton 13 ou le 17 jusqu ce que ADVANCE s affiche 3 Appuyer sur le bouton OK 14 pour entrer le sous me...

Page 1343: ...Free mains libres s affiche 3 Appuyer sur le bouton OK 14 pour entrer le sous menu Mains libres 4 Appuyer sur le bouton OK 14 pour activer Bluetooth Lorsque Bluetooth est actif l ic ne 45 s affiche A...

Page 1344: ...le sous menu Mains libres 4 Appuyer sur le bouton 13 ou le 17 jusqu ce que Edit Phone modification de t l phone s affiche 5 Appuyer sur le bouton OK 14 pour entrer le sous menu Modification de t l ph...

Page 1345: ...re de transf rer les appels t l phoniques afin de les recevoir et de les entendre par le truchement d un t l phone actif au lieu de par la radio 1 Pour transf rer un appel du v hicule un t l phone act...

Page 1346: ...entrer le sous menu Horloge 4 Appuyer sur le bouton 13 ou le 17 jusqu ce que 12 24 HR s affiche 5 Appuyer sur le bouton OK 14 pour passer l une de ces options 12H ou 24H R glage de l horloge Normaleme...

Page 1347: ...l il faut 1 Appuyer sur le bouton MENU 15 2 Appuyer sur le bouton 13 ou le 17 jusqu ce que WAKE UP ALARM r veil par alarme s affiche 3 Appuyer sur le bouton OK 14 pour entrer le sous menu R veil par a...

Page 1348: ...60 minutes avant de pouvoir faire trois nouveaux essais D sactivation de l antivol Il est possible de d sactiver l antivol mais cela est vivement d conseill Pour d sactiver la fonction antivol il faut...

Page 1349: ...t Pour savoir si votre t l phone est compatible avec le profil Mains libres BlueTooth 1 5 veuillez consulter la page d accueil BlueTooth https www bluetooth org tpg listings cfm et trouver les sp cifi...

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Page 1387: ...MANUAL NUMBER 160339 REVISION 09SEPT04 PAGE 1 OPERATION MAINTENANCE MANUAL Manual Number 160339 Revision 09SEPT04...

Page 1388: ...ection Panel 6 Optical Fire Detector 7 Linear Thermal Detector 8 End of Line Device 8 Manual Activation Switch 9 Cone Nozzle 9 Fire Extinguisher 10 Component Locations 11 Electrical Interconnections 1...

Page 1389: ...arm signal to the Protection Panel located in the operator s area The Protection Panel immediately turns on the fire ALARM lamp and sounds the audio alarm After a 15 second time delay the engine is au...

Page 1390: ...rbside engine comp MANUAL ACTIVATION SWITCH operator s area PROTECTION PANEL operator s area VEHICLE BATTERIES EXTINGUISHER aft luggage comp FIGURE 1 SYSTEM BLOCK DIAGRAM OPTICAL FIRE DETECTOR 2 aft s...

Page 1391: ...extinguisher discharge will occur immediately If the operator presses and releases the DELAY ENGINE STOP switch once the engine shutdown and extinguisher discharge will be delayed by an additional 15...

Page 1392: ...ng the TEST RESET switch tests the Protection Panel s lamps and audio alarm The ALARM SILENCE switch will disable the audio alarm When a fire detector automatically detects a fire the fire ALARM lamp...

Page 1393: ...pan fire fueled by diesel The fire sensor is immune to false alarms from sunlight flashlights lightning vehicle headlights incandescent lights 100W at 2 inches and welding arcs 30 inches Each fire se...

Page 1394: ...e cable is not resettable however If the wire alarms to a fire the wire must be replaced or the damaged section cut out and a new section added prior to returning the system to service The added secti...

Page 1395: ...sing the red FIRE button for more than half a second After the Manual Activation Switch has been activated the Protection Panel will blink the fire ALARM indicator until power has been cycled to the s...

Page 1396: ...d cylinder The Extinguisher is installed vertically in the bottle mounting bracket CAUTION THE EXTINGUISHER WILL NOT FUNCTION AS INTENDED IF ORIENTED INCORRECTLY WARNING THE ANTI RECOIL PLUG SHALL BE...

Page 1397: ...NT LOCATIONS The major system components consist of a Protection Panel 2 Optical Fire Detectors 1 Linear Thermal Detector 1 End of Line Device a Manual Activation Switch a Fire Extinguisher and 4 Cone...

Page 1398: ...Manual Activation Switch Extinguisher and first Optical Fire Detector Additional Optical Fire Detectors and Linear Thermal Detector are connected to the preceding detector using interconnect harness...

Page 1399: ...IL PLUG SHALL BE INSTALLED ON THE VALVE OUTLET PORT AT ALL TIMES EXCEPT WHEN THE EXTINGUISHER IS CONNECTED TO THE DISTRIBUTION PIPING OR WHILE THE EXTINGUISHER IS BEING FILLED d Loosen the mounting cl...

Page 1400: ...ion piping d Connect system power by replacing the system fuse located in the battery compartment and verify the red fire ALARM lamp on the Protection Panel is NOT on NOTE The fire TROUBLE lamp will b...

Page 1401: ...face is on solid green Verify nothing is blocking the detector s field of view Verify the windows on the face of the detector are free of excess contamination dirt oil grease etc if necessary clean us...

Page 1402: ...the fire extinguisher rebuilt by a qualified fire protection equipment company familiar with Kidde Dual Spectrum equipment Rebuild shall include squib valve seals and dry chemical replacement At time...

Page 1403: ...s described in the system reset portion of this manual Protection Panel green SYSTEM OK lamp off yellow fire TROUBLE lamp on red fire ALARM lamp on blinking and audible alarm on System manually discha...

Page 1404: ...as described in the system reset portion of this manual Extinguisher cold Let extinguishers warm up to room temperature about 70 F and recheck the gauge If the pointer is then within the green arc no...

Page 1405: ...eal P N 421317 2 Optical Fire Detector P N 420010 Linear Thermal Detector LTD 20ft P N 420413 20 End of Line Device EOL P N 420241 Vertical Fire Extinguisher 22lb BC Gauge Right P N 408876 1232 Exting...

Page 1406: ......

Page 1407: ...4 313 03 01 Date of preparation February 25 2004 SECTION 2 COMPOSITION AND INFORMATION ON INGREDIENTS CHEMICAL NAME CAS N w w OSHA PEL mg m3 ACGIH TLV mg m3 TOXICITY DATA Potassium bicarbonate 298 14...

Page 1408: ...Acute Transient cough shortness of breath irritation of airways Chronic This product is not known to cause chronic illness Medical conditions generally aggravated by exposure Asthma emphysema bronchi...

Page 1409: ...ls which are listed hazardous wastes It does not exhibit the hazardous characteristics of ignitability corrosivity or reactivity and is not formulated with contaminants as determined by the toxicity c...

Page 1410: ......

Page 1411: ...tion 2 2 1 2 Leaks 2 2 1 3 Service life 2 2 2 LUBRICANT AND COOLANT SPECIFICATIONS 6 2 3 PART NUMBER SPECIFICATIONS 7 2 4 LUBRICATION AND SERVICING SCHEDULE 7 ILLUSTRATIONS FIGURE 1 LUBRICATION AND SE...

Page 1412: ...erforms at its best safest and longest Also unscheduled maintenance will be minimized since inspection should expose potential problems before they become major ones 2 1 FLEXIBLE HOSE MAINTENANCE The...

Page 1413: ...ended that all hoses in this vehicle be replaced during major overhaul and or after a maximum of five service years Quality of replacement hose assemblies should always be equal to or superior to thos...

Page 1414: ...Section 24 LUBRICATION PA1562 4 FIGURE 1 LUBRICATION AND SERVICING POINTS ON INDEPENDENT FRONT SUSPENSION VEHICLES 24031_1...

Page 1415: ...Section 24 LUBRICATION PA1562 5 FIGURE 2 LUBRICATION AND SERVICING POINTS ON I BEAM AXLE FRONT SUSPENSION VEHICLES 24030_1...

Page 1416: ...Multigrade gear oil meeting MIL L 2105 D 85W140 If temperature drops below 10 F 12 C 80W90 should be used Below 15 F 26 C 75W90 should be used In extreme conditions or for better performance full synt...

Page 1417: ...rge element filter DDC Series 60 550629 P12 Engine coolant maintenance element filter DDC Series 60 550630 P13 Engine coolant filter cartridge Volvo D13 20458771 P14 HVAC driver s air filter 871147 87...

Page 1418: ......

Page 1419: ...o D13 Engine oil and filter change heavy 4 operation condition 17 A P2 Volvo D13 Valves injectors initial adjust 12 Volvo D13 Valves injectors check adjust 24 Volvo D13 Drive belts 36 Volvo D13 Aftert...

Page 1420: ...Section 07 Transmission for fluid and filter change 16 I P16 Allison transmission filled with TranSynd or TES295 synthetic fluid only no mixture 6 with Prognostics mode disabled Refer to TABLE 2 in Se...

Page 1421: ...on each universal joint and slip joint 34 6 K 11 REAR AXLE Differential check oil level add if necessary 35 E Differential change oil clean breathers 35 E Differential change oil clean breathers with...

Page 1422: ...6 K Bell crank grease fitting 41 6 K Steering damper cylinder grease one fitting at rod end 39 6 K Steering knuckle pins grease two fittings per knuckle 9 6 K Power steering reservoir replace oil and...

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