Download Print this page

Hino 600 Workshop Manual

Table of Contents

Advertisement

Quick Links

Download this manual

This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.

Applicable for HINO 238, 258LP, 268, 338 series, equipped with J08E-VB and J08E-VC engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures.

As for maintenance items, refer to the Driver's / Owner's Manual.

All information and specifications in this manual are based upon the latest product information available at the time of printing.

Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.

Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys-

tems in these vehicles.

Chassis Workshop Manual

J08E-VB, VC Engine Workshop Manual

Trouble Shooting Workshop Manual

MENU

FOREWORD

Manual Name

Pub. No.

S1-UNAE11A 2/2

S5-UJ08E11A

S7-UNAE11A 1/3

S7-UNAE11A 2/3

S7-UNAE11A 3/3

Table of Contents

Advertisement

Chapters

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the 600 and is the answer not in the manual?

Questions and answers

Summary of Contents for Hino 600

Page 1 All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice. Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys- tems in these vehicles.
Page 2 CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL NO. S1-UNAE11A 1/2 (U.S.A.), S1-CNAE11A 1/2 (CANADA) MODELS HINO 238, 258LP, 268, 338, 358 CHAPTER Production Model NE8J, NF8J, NJ8J, NV8J Code...
Page 3 INDEX: CHASSIS GROUP 1/4 GENERAL INTRODUCTION CLUTCH EQUIPMENT CLUTCH MAIN UNIT WORKSHOP CLUTCH CONTROL MANUAL TRANSMISSION EQUIPMENT TRANSMISSION MAIN UNIT TRANSFER MAIN UNIT AUTOMATIC TRANSMISSION PTO (POWER TAKE-OFF) TRANSMISSION / TRANSFER CONTROL PROPELLER SHAFT EQUIPMENT PROPELLER SHAFT DIFFERENTIAL EQUIPMENT DIFFERENTIAL CARRIER BRAKE EQUIPMENT SERVICE BRAKE...
Page 4 INDEX: CHASSIS GROUP 2/4 ES START (EASY & SMOOTH START) SYSTEM EXHAUST BRAKE RETARDER BRAKE PARKING BRAKE STEERING EQUIPMENT STEERING UNIT POWER STEERING AXLE EQUIPMENT FRONT AXLE REAR AXLE WHEEL & TIRE SUSPENSION EQUIPMENT SUSPENSION CHASSIS EQUIPMENT CHASSIS FRAME COUPLER (5TH WHEEL) PINTLE HOOK...
Page 5 INDEX: CHASSIS GROUP 3/4 CAB EQUIPMENT ELECTRICAL EQUIPMENT ELECTRIC WIRE HYBRID SYSTEM...
Page 6 INDEX: CHASSIS GROUP 4/4 ENGINE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS...
Page 7: Table Of Contents
METRIC INFORMATION .......GN02-21 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS ...GN02-23 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS ....GN02-23 RECOMMENDED LUBRICANTS ....GN02-25 VEHICLE LIFT AND SUPPORT LOCATIONS......GN02-27 INFORMATION DISPLAY ......GN02-29 SYMPTOM SIMULATION ......GN02-34 GLOSSARY ...........GN02-36 GLOSSARY OF SAE AND HINO TERMS ..GN02-39...
Page 8: General Introduction
Improper or incomplete work can cause a malfunction of the vehicle which may result in personal injury and/or property damage. If you have any question about performing mainte- nance, please consult your Hino dealer. WARNING When working on your vehicle, observe the following general precautions to prevent death, personal injury and/or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chapter.
Page 9 GENERAL INTRODUCTION (CHASSIS) GN02–3 TOWING • When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No.
Page 10 GN02–4 GENERAL INTRODUCTION (CHASSIS) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset with- out diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to satisfy requirements in §...
Page 11: Identification Information
GENERAL INTRODUCTION (CHASSIS) GN02–5 IDENTIFICATION INFORMATION EN00Z00020200001 VEHICLE IDENTIFICATION NUMBER • VEHICLE IDENTIFICATION NUMBER (VIN) is comprised of 17 digits and letters. The VIN label is affixed to the left pillar of the cab. These numbers are used for identification purposes when you have a vehicle registered or inspected. Please quote these numbers when ordering spare parts or reporting technical matter to receive prompt service attention.
Page 12 GN02–6 GENERAL INTRODUCTION (CHASSIS) See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page. P.S. (PRODUCTION SERIES) AND VEHICLE COMPONENTS PRODUC- TRANS- TRANSMISSION RATIO REAR SER- PARK- MODEL TION CODE MIS- CLUTCH SUSPEN- AXLE VICE (CLASS) SION SIZE SION BRAKE BRAKE SERIES 1st 2nd 3rd 4th 5th 6th Rev.
Page 13 GENERAL INTRODUCTION (CHASSIS) GN02–7 PRODUC- TRANS- TRANSMISSION RATIO REAR SER- PARK- MODEL TION CODE MIS- CLUTCH SUSPEN- AXLE VICE (CLASS) SIZE SION SION BRAKE BRAKE SERIES 1st 2nd 3rd 4th 5th 6th Rev. MODEL SERIES SERIES RS17-145 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS19-145 RS17-145 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49...
Page 14 GN02–8 GENERAL INTRODUCTION (CHASSIS) PRODUC- TRANS- TRANSMISSION RATIO REAR SER- PARK- MODEL TION CODE MIS- CLUTCH SUSPEN- AXLE VICE (CLASS) SIZE SION SION BRAKE BRAKE SERIES 1st 2nd 3rd 4th 5th 6th Rev. MODEL SERIES SERIES RS21-145 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09 RS23-160 RS21-145 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03...
Page 15 GENERAL INTRODUCTION (CHASSIS) GN02–9 SHTS00Z000200007...
Page 16 OWNER' S MANUAL) INCORPORATED INTO THIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT. (B)THE USE OF THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE. MFD BY:HINO MOTORS, LTD. DATE OF MANUFACTURE 03/2009 SHTS00Z000200010 ENGINE SERIAL NUMBERS.
Page 17 GENERAL INTRODUCTION (CHASSIS) GN02–11 VEHICLE EMISSION CONTROL INFORMATION • The Vehicle Emission Control Information is affixed to the side of the left door. The name of manufacturer, production year and month, and emission applicable to medium and heavy trucks in conformity with label U.S.
Page 18: How To Use
GN02–12 GENERAL INTRODUCTION (CHASSIS) HOW TO USE THIS WORKSHOP MANUAL EN00Z00020200002 This workshop manual is designed as a guide for servicing the vehicle. An INDEX is provided on the first page of each chapter. TROUBLESHOOTING is dealt with in each chapter. When beginning operations, refer to the TROUBLESHOOTING section for a guide to appropriate diagnosis.
Page 19 GENERAL INTRODUCTION (CHASSIS) GN02–13 MAIN CYLINDER EXAMPLE: SHTS00Z000200014 Clevis Return spring Lock nut Body Push rod Hose joint Boot O-ring Retainer ring Soft washer Thrust washer Bolt Piston Tightening torque Unit: Nm {kgfcm, lbfft} 2.5-4.4 {25-45, 1.8-3.2} In some cases, illustrations may be of parts which differ in some nonessen- tial way from the parts found on your particular vehicle.
Page 20 GN02–14 GENERAL INTRODUCTION (CHASSIS) SHTS00Z000200015C...
Page 21: Precautions
"LOCK" posi- tion. In this case, use HINO DX Ⅱ to clear the DTC (P204F and P068A), to turn off the MIL and to conduct DPR regeneration manually.
Page 22 GN02–16 GENERAL INTRODUCTION (CHASSIS) HANDLING OF CONNECTOR To remove a connector, hold the connector (indicated by an arrow in the figure) to pull it out. Never pull the harness. To remove a connector with lock, release the lock then pull it out. To connect a connector with lock, insert it until it clicks.
Page 23 GENERAL INTRODUCTION (CHASSIS) GN02–17 PRECAUTIONS FOR ELECTRIC WELDING PRECAUTION FOR ELECTRIC WELDING Electrical components such as the alternator and tachograph are directly connected to the battery and one end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical components, etc.
Page 24: Sealant On The Tapered Screw For Piping
GN02–18 GENERAL INTRODUCTION (CHASSIS) SEALANT ON THE TAPERED SCREW FOR PIPING EN00Z00020200003 To the tapered thread of the air pipe joint is applied the sealant "LOC-TITE #575". Follow the procedure below to remove/attach the piping. REMOVAL The sealant (LOCTITE #575) has a high sealing capability. The return torque of taper joint is about 1.5 times as high as the initial tightening torque.
Page 25: Nylon Tube Replacement Method
NOTICE Caulking joint Since the function and quality of nylon tubes and joints are guaran- teed as tube and joint sets, the use of parts other than Hino Genuine Parts must be avoided. SHTS00Z000200023 ONE-TOUCH JOINT NYLON TUBE INSERTION LENGTH...
Page 26 GN02–20 GENERAL INTRODUCTION (CHASSIS) • Before inserting the tube, mark the insertion length on the tube with a white-out pen or similar implement, in accordance with the dimen- sions, "ONE-TOUCH JOINT NYLON TUBE INSERTION LENGTH." Then insert the tube firmly in place as far as the marked point. INSTALLATION OF A CAULKING JOINT •...
Page 27: Metric Information
GN02–21 METRIC INFORMATION EN00Z00021200001 METRIC FASTENERS Most threaded fasteners on the Hino trucks series are metric. Be careful not to mix them up with threaded fasteners using the inch system. Mismatched or incorrect bolts, nuts and screws can cause dam- age or malfunction, resulting in personal injury and/or property damage.
Page 28 GN02–22 GENERAL INTRODUCTION (CHASSIS) DECIMAL AND METRIC EQUIVALENTS Fractions Decimal In. Metric mm. Fractions Decimal In. Metric mm. 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 17/32 0.53125 13.494 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64...
Page 29: Specified Torque For Standard Bolts And Nuts
GENERAL INTRODUCTION (CHASSIS) GN02–23 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS EN00Z00023200001 Unit: Nm {kgfcm, lbfft.} Class Representation No Mark Diameter 4.4-6.6 7.2-10.8 9.5-13.5 {45-67, 3.3-4.8} {74-110, 5.4-7.9} {94-140, 6.8-10.1} 18.0-26.0 23.5-34.5 11.5-16.5 {114-172, 8.3-12.4} {179-269, 13.0-19.4} {237-355, 17.2-25.6} 22.0-32.0 34.5-51.5 46.0-68.0 {221-331, 16.0-23.9}...
Page 30 GN02–24 GENERAL INTRODUCTION (CHASSIS) With new flange (w/o grooves) Unit: Nm {kgfcm, lbfft.} Class 8.8T 10.9T Shape Diameter 21.7-40.3 27.3-50.7 {221-411, 16.0-29.7} {278-517, 20.1-37.4} 24.5-45.5 32.7-60.3 {250-464, 18.1-33.6} {333-615, 24.1-44.5} 44.1-81.9 57.4-106.6 {450-835, 32.5-60.4} {585-1087, 42.3-78.6} 91-169 {928-1723, 67.1-124.6} — 104-156* {106-1590, 76.7-115.1}...
Page 31: Recommended Lubricants
GENERAL INTRODUCTION (CHASSIS) GN02–25 RECOMMENDED LUBRICANTS EN00Z0002H600001 LUBRICANTS POSITONS VISCOSITY RECOMENDATIONS (SAE) Engine oil A.P.I.: CJ-4 Cylinder Block JASO: DH-2 ACEA: E–6, E-9 LUBRICANTS POSITONS ATMOSPHERIC TEMP. S.A.E. No Heavy duty engine oil Above 10F (–12C) MIL-L-2104D, API-CD, or Cat Above 10F (–12C) TO-4 EATON Fuller...
Page 32 GN02–26 GENERAL INTRODUCTION (CHASSIS) LUBRICANTS POSITONS POWER STEERING FLUID (ATF DEXRON 2 or 3) Integral Power Steering Gear BRAKE AND CLUTCH FLUID (DOT-3) or (DOT-4) Brake & Clutch WHEEL BEARING GREASE (MIL-G-10924B/18709A) (N.L.G.I.'s No.2 LITHIUM- Propeller Shaft Universal Joint and Slip Joint SOAP) Clutch Disc Hub Spline T/M Main Drive Shaft Spline...
Page 33: Vehicle Lift And Support Locations
GENERAL INTRODUCTION (CHASSIS) GN02–27 VEHICLE LIFT AND SUPPORT LOCATIONS EN00Z0002A200001 NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP As a rule, vehicle must be in an unloaded condition and never jack up or lift up the vehicle with things of heavy weight. If removing any things of heavy weight like the engine and transmis- sion, the center of gravity of the vehicle moves.
Page 34 GN02–28 GENERAL INTRODUCTION (CHASSIS) Front Rear Leaf suspension Air suspension Garage jack position Air spring Front Center of front axle beam Rear Center of rear axle housing Oil jack position Support position Safety stand If necessary, remove the front bumper. SHTS00Z000200034...
Page 35: Information Display
GENERAL INTRODUCTION (CHASSIS) GN02–29 INFORMATION DISPLAY EN00Z0002A200002 INFORMATION DISPLAY ITEMS • Information display shows following items. Ordinary display Trip meter, voltage, date, fuel consumption, average speed and engine or vehicle maintenance information etc. Warning display The warning display is automatically displayed and shows messages. NOTICE •...
Page 36 GN02–30 GENERAL INTRODUCTION (CHASSIS) (Starter key ON) The system remembers last display at each function. Push down "MODE " button Push button "SET/RESET" at the same time Push up "SELECT " button Other : Those displays are broken in automatically Normal display item Returns to last display automatically Operation menu...
Page 37 GENERAL INTRODUCTION (CHASSIS) GN02–31 WARNING DISPLAY Warning display Display Warning Display remarks Engine control system has malfunction. This is important and must be addressed immediately. DPR cleaner needs to be manually regenerated. NOTICE • The display shows DPR MANUAL REGENERATE REQUIRED with the buzzer sound when DPR cleaner needs to be manually regen- erated.
Page 38 599999 599000 • But, especially in the case of "DPR", push and hold "MODE" and Disable "SET/RESET" button at the same time for more than 20sec. to reset. (Following to the low, use only at an authorized Hino SHTS00Z000200049 dealer.)
Page 39 GENERAL INTRODUCTION (CHASSIS) GN02–33 AVAILABLE SETTING ITEMS • Engine oil • T/M oil • Diff oil • Coolant • Fuel filter • Belt • • Turbo • Starter • Alternator • Radiator • Battery • Air dryer • Customize1 • Customize2 •...
Page 40: Symptom Simulation
GN02–34 GENERAL INTRODUCTION (CHASSIS) SYMPTOM SIMULATION EN00Z0002A200003 HINT The most difficult case in troubleshooting is when no problem symp- toms occur. In such a case, a thorough problem analysis must be car- ried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out.
Page 41 GENERAL INTRODUCTION (CHASSIS) GN02–35 WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE • Never sprinkle water directly into the engine compartment. Indi- rectly change the temperature and humidity by spraying water onto the front of the radiator.
Page 42: Glossary
GN02–36 GENERAL INTRODUCTION (CHASSIS) GLOSSARY DEFINITION OF ABBREVIATION IN THIS MANUAL LIST OF ABBREVIATION SAE TERMS ABBREVIATIONS Air conditioner Anti-lock Brake System Accessory Automated Manual Type After Turbo catalyst Automatic Transmission Fluid Crank Angle Controller Area Network CD-ROM Compact Disc Read Only Memory Central Processing Unit Decibel Direct Current...
Page 43 GENERAL INTRODUCTION (CHASSIS) GN02–37 SAE TERMS ABBREVIATIONS Front Underrun Protector Ground Gross Vehicle Weight High HINO DX Ⅱ Hino Diagnostic eXplorer Ⅱ HVAC Heating, Ventilating and Air-Conditioning unit I.S.C. Idle Speed Control Integrated Circuits Identification Intelligent Power Device Idle Stop...
Page 44 GN02–38 GENERAL INTRODUCTION (CHASSIS) SAE TERMS ABBREVIATIONS Physical Vapor Deposit Power QE code Quick Response Code Rear axle Right Hand Selective Catalytic Reduction Switch Transmission...
Page 45: Glossary Of Sae And Hino Terms
GENERAL INTRODUCTION (CHASSIS) GN02–39 GLOSSARY OF SAE AND HINO TERMS EN00Z00020200005 This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as well as their HINO equivalents. HINO TERMS SAE TERMS ABBREVIATIONS ( )--ABBREVIATIONS...
Page 46 GN02–40 GENERAL INTRODUCTION (CHASSIS) HINO TERMS SAE TERMS ABBREVIATIONS ( )--ABBREVIATIONS EXHAUST BACK PRESSURE REGULATOR EBPR Valve Exhaust control valve Valve ENGINE CONTROL Engine control ENGINE COOLANT TEMPERATURE Coolant Temperature ENGINE COOLANT TEMPERATURE Water Temperature ENGINE FUEL TEMPERATURE Fuel temperature...
Page 47 GENERAL INTRODUCTION (CHASSIS) GN02–41 HINO TERMS SAE TERMS ABBREVIATIONS ( )--ABBREVIATIONS PCV Valve POS CRANKCASE VENTILATION Valve PCV Valve PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve PARK/NEUTRAL POSITION Neutral position PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch RAIL FUEL PRESSURE...
Page 48 CLUTCH MAIN UNIT (EATON 1401) CL02–1 C LUTCH MAIN UNIT (EATON 1401) C L 0 2 CL02-001 CLUTCH ASSEMBLY (EATON SAS1401)........CL02-2 DATA AND SPECIFICATIONS ......CL02-2 DESCRIPTION ..........CL02-2 TROUBLESHOOTING ........CL02-3 SPECIAL TOOL ..........CL02-5 COMPONENT LOCATOR.........CL02-6 OVERHAUL ............CL02-7 CLUTCH ASSEMBLY (EATON SOLO1401) ....... CL02-14 DATA AND SPECIFICATIONS ......CL02-14 COMPONENT LOCATOR.......CL02-14 OVERHAUL ............CL02-15...
Page 49: Clutch Assembly (Eaton Sas1401)
CL02–2 CLUTCH MAIN UNIT (EATON 1401) CLUTCH ASSEMBLY (EATON SAS1401) DATA AND SPECIFICATIONS EN02Z0202I200001 CLUTCH FACING Unit: mm {in.} Material Sintered metal (Ceramic metal) Type Dry single plate with damper spring Inside diameter 222 {8.8} Outside diameter 350 {13.8} Thickness 11.5 {0.45} DESCRIPTION EN02Z0202C100001...
Page 50: Troubleshooting
CLUTCH MAIN UNIT (EATON 1401) CL02–3 TROUBLESHOOTING EN02Z0202F300001 Symptom Possible cause Remedy/Prevention Clutch dragging. Clutch disc distorted or warped. Replace clutch disc. Transmission input shaft worn. Replace input shaft and check clutch hub for excessive wear. If worn, replace disc. Check flywheel housing alignment.
Page 51 CL02–4 CLUTCH MAIN UNIT (EATON 1401) Symptom Possible cause Remedy/Prevention Noisy clutch. Release bearing worn or dried. Replace release bearing. Pilot bearing worn or dried. Replace pilot bearing. Clutch disc distorted or warped. Replace clutch disc. Flywheel housing misalignment. Replace flywheel housing. Transmission input shaft or clutch disc Clean and lubricate or replace.
Page 52: Special Tool
CLUTCH MAIN UNIT (EATON 1401) CL02–5 SPECIAL TOOL EN02Z0202K100001 Prior to starting a clutch overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks CLUTCH PILOT BEARING S0965-01970 PULLER S0942-01442 SLIDING HAMMER S0966-21410 CLUTCH ALIGNING ARBOR S0940-91200 CRANKING TOOL...
Page 53: Component Locator
CL02–6 CLUTCH MAIN UNIT (EATON 1401) COMPONENT LOCATOR EN02Z0202D100001 SHTS02Z020200006 Clutch cover Adjusting screw Clutch disc Bolt Tightening torque Unit: Nm {kgfcm, lbfft} 50-64 {510-655, 37-47}...
Page 54: Overhaul
CLUTCH MAIN UNIT (EATON 1401) CL02–7 OVERHAUL EN02Z0202H200001 IMPORTANT POINT - DISMOUNTING REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO PREVENT DAMAGE TO THE BEARING AND DISCS. 1.Remove the transmission INSTALL TWO WOODEN SPACERS 1"-1-1/2" THICK BETWEEN RELEASE BEARING AND COVER ASSEMBLY. REMOVE THE CLUTCH FROM THE FLYWHEEL.
Page 55 CL02–8 CLUTCH MAIN UNIT (EATON 1401) Release yoke fingers Check release yoke fingers SHTS02Z020200011 Splines on the input shaft NOTICE Check splines on the Any wear on the splines will prevent the newly installed driven discs input shaft from sliding freely, thus causing poor release (clutch drag). Select a disc out of the new installation and slide it full length on the transmis- sion splines.
Page 56 CLUTCH MAIN UNIT (EATON 1401) CL02–9 IMPORTANT POINT - MOUNTING Insert 2 guide studs INSERT TWO (2) 3/8" x 16 UNC x 3" (76 MM) LONG GUIDE STUDS INTO THE TWO UPPER MOUNTING HOLES OF THE FLYWHEEL. Guide studs SHTS02Z020200014 INSTALL THE DISC BY INSERTING THE ALIGNING TOOL THROUGH THE DISC SPLINES AND THEN INTO THE PILOT BEARING.
Page 57 CL02–10 CLUTCH MAIN UNIT (EATON 1401) REMOVE THE ALIGNING TOOL. Remove aligning tool SHTS02Z020200017 SHIFT THE TRANSMISSION INTO GEAR. Shift into gear Shift transmission into gear SHTS02Z020200018 POSITION THE TRANSMISSION SO THAT IT IS BOTH SQUARE TO AND ALIGNED WITH THE ENGINE. Align the transmission to the engine SHTS02Z020200019...
Page 58 CLUTCH MAIN UNIT (EATON 1401) CL02–11 WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE BEARING HOUSING INTO THEIR FINAL POSITION.
Page 59 CL02–12 CLUTCH MAIN UNIT (EATON 1401) ARRANGE THE KWIK-ADJUSTER Crank Set SST the crank pulley. pulley SST: Cranking Tool (S0940-91200) Torque wrench SHTS02Z020200023 Turn the crank pulley till the Kwik-Adjuster matches the inspection hole. Kwik-adjuster SHTS02Z020200024 ADJUSTING PROCEDURES Adjust the release bearing position; •...
Page 60 CLUTCH MAIN UNIT (EATON 1401) CL02–13 ADJUST THE RELEASE BEARING POSITION Set 1.75" (44 mm) dimension: With pedal down, turn adjusting ring to obtain approximately 1.75" (44 mm). Turning the adjusting ring clock- wise moves the release bearing toward the transmission. Turning the adjusting ring counterclockwise moves the release bearing toward the Pedal Pedal...
Page 61: Clutch Assembly (Eaton Solo1401)
CL02–14 CLUTCH MAIN UNIT (EATON 1401) CLUTCH ASSEMBLY (EATON SOLO1401) DATA AND SPECIFICATIONS EN02Z0202I200002 CLUTCH FACING Unit: mm {in.} Material Sintered metal (Ceramic metal) Type Dry single plate with damper spring Inside diameter 222 {8.8} Outside diameter 350 {13.8} Thickness 11.5 {0.45} Adjustment-Free COMPONENT LOCATOR EN02Z0202D100002...
Page 62: Overhaul
CLUTCH MAIN UNIT (EATON 1401) CL02–15 OVERHAUL EN02Z0202H200002 IMPORTANT POINT - DISMOUNTING REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO PREVENT DAMAGE TO THE BEARING AND DISCS. NOTICE Remove the transmission If a SOLO Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (3/8"...
Page 63 CL02–16 CLUTCH MAIN UNIT (EATON 1401) Using a suitable tapping rod, install the pilot bearing. NOTICE After installing the pilot bearing, ensure that it rotates smoothly. CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY WORN COMPONENTS. SHTS02Z020200034 Cross-shafts and bushings NOTICE Check cross-shaftsand Excessive wear at these points can cause a side loading condition.
Page 64 CLUTCH MAIN UNIT (EATON 1401) CL02–17 Smooth area of input shaft Mating surfaces NOTICE Inspect the mating surfaces of both the transmission bell housing and the flywheel housing. Any appreciable wear on either housing will cause misalignment. Most wear will occur between the 3 and 8 o'clock positions.
Page 65 CL02–18 CLUTCH MAIN UNIT (EATON 1401) Remove the four (4) gold colored shipping bolts in a criss-cross pat- tern. NOTICE Save these four (4) bolts for future use in case you need to remove, then reinstall the SOLO Clutch. REMOVE THE ALIGNING TOOL. Remove aligning tool SHTS02Z020200042 SHIFT THE TRANSMISSION INTO GEAR.
Page 66 CLUTCH MAIN UNIT (EATON 1401) CL02–19 WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE BEARING HOUSING INTO THEIR FINAL POSITION.
Page 67 CL02–20 CLUTCH MAIN UNIT (EATON 1401) IMPORTANT POINT-SET-UP ADJUST LINKAGE Remove the return spring. Loosen the lock nut and turn the push rod counterclockwise until the release bearing contacts the release lever plate or release lever. Push rod Master cylinder SHTS02Z020200046 Fully press the pedal up to 5 times to move the release bearing slightly closer to the transmission and gain free-play in the cab.
Page 68 CLUTCH MAIN UNIT (EATON 1401) CL02–21 IMPORTANT POINT-CHECK WEAR INDICATOR REMOVE THE COVER OF INSPECTION HOLE AT THE BOTTOM OF THE CLUTCH HOUSING. CHECK WEAR INDICATOR • Reflects clutch wear and indicates when it is time to replace clutch. • When replacing clutch, should change clutch disc together with clutch cover.
Page 69: Inspection And Repair
CL02–22 CLUTCH MAIN UNIT (EATON 1401) INSPECTION AND REPAIR EN02Z0202H300001 EATON SAS1401 and SOLO1401 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Clutch facing thickness 11.43 8.26 Replace disc Measure {0.45} {0.33} assembly. Clutch disc misalignment 0-0.38 0.38 Replace.
Page 70 CLUTCH MAIN UNIT (EATON 1401) CL02–23 Inspection item Standard Limit Remedy Inspection procedure Flywheel friction surface — Grind limit Regrind the fric- Visual check scoring or heat cracking 1.0 {0.039} tion surface or Deflection replace, if neces- limit sary. 0.04 NOTICE {0.00157} Do not grind the...
Page 71 CL02–24 CLUTCH MAIN UNIT (EATON 1401) LUBRICATION (EATON SAS1401 and SOLO1401) RELEASE BEARING The cast iron bearing housing will be equipped with either a standard grease fitting or a lube tube extension. If a lube tube is not present, it is necessary to remove the inspection cover to gain access to the grease fitting.
Page 72 CLUTCH MAIN UNIT (EATON 1402) CL02–1 C LUTCH MAIN UNIT (EATON 1402) C L 0 2 CL02-002 CLUTCH ASSEMBLY (EATON SAS1402)........CL02-2 DATA AND SPECIFICATIONS ......CL02-2 DESCRIPTION ..........CL02-2 TROUBLESHOOTING ........CL02-3 SPECIAL TOOL ..........CL02-5 COMPONENT LOCATOR.........CL02-6 OVERHAUL ............CL02-7 CLUTCH ASSEMBLY (EATON SOLO1402) ....... CL02-16 DATA AND SPECIFICATIONS ......CL02-16 COMPONENT LOCATOR.......CL02-16 OVERHAUL ............CL02-17...
Page 73: Clutch Assembly (Eaton Sas1402)
CL02–2 CLUTCH MAIN UNIT (EATON 1402) CLUTCH ASSEMBLY (EATON SAS1402) DATA AND SPECIFICATIONS EN02Z0202I200001 CLUTCH FACING Unit: mm {in.} Material Sintered metal (Ceramic metal) Type Dry two plate with damper spring Inside diameter 222 {8.8} Outside diameter 350 {13.8} Thickness 11.5 {0.45} DESCRIPTION EN02Z0202C100001...
Page 74: Troubleshooting
CLUTCH MAIN UNIT (EATON 1402) CL02–3 TROUBLESHOOTING EN02Z0202F300001 Symptom Possible cause Remedy/Prevention Clutch dragging. Clutch disc distorted or warped. Replace clutch disc. Transmission input shaft worn. Replace input shaft and check clutch hub for excessive wear. If worn, replace disc. Check flywheel housing alignment.
Page 75 CL02–4 CLUTCH MAIN UNIT (EATON 1402) Symptom Possible cause Remedy/Prevention Noisy clutch. Release bearing worn or dried. Replace release bearing. Pilot bearing worn or dried. Replace pilot bearing. Clutch disc distorted or warped. Replace clutch disc. Flywheel housing misalignment. Replace flywheel housing. Transmission input shaft or clutch disc Clean and lubricate or replace.
Page 76: Special Tool
CLUTCH MAIN UNIT (EATON 1402) CL02–5 SPECIAL TOOL EN02Z0202K100001 Prior to starting a clutch overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks CLUTCH PILOT BEARING S0965-01970 PULLER S0942-01442 SLIDING HAMMER S0966-21420 CLUTCH ALIGNING ARBOR S0940-91200 CRANKING TOOL...
Page 77: Component Locator
CL02–6 CLUTCH MAIN UNIT (EATON 1402) COMPONENT LOCATOR EN02Z0202D100001 SHTS02Z020200006 Clutch cover Adjusting screw Clutch disc Bolt Intermediate plate Tightening torque Unit: Nm {kgfcm, lbfft} 50-64 {510-655, 37-47}...
Page 78: Overhaul
CLUTCH MAIN UNIT (EATON 1402) CL02–7 OVERHAUL EN02Z0202H200001 IMPORTANT POINT - DISMOUNTING REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO PREVENT DAMAGE TO THE BEARING AND DISCS. Remove the INSTALL TWO WOODEN SPACERS 1"-1-1/2" THICK BETWEEN transmission RELEASE BEARING AND COVER ASSEMBLY. REMOVE THE CLUTCH FROM THE FLYWHEEL.
Page 79 CL02–8 CLUTCH MAIN UNIT (EATON 1402) Release yoke fingers Check release yoke fingers SAPH02Z080200002 Splines on the input shaft NOTICE Check splines on the Any wear on the splines will prevent the newly installed driven discs input shaft from sliding freely, thus causing poor release (clutch drag). Select a disc out of the new installation and slide it full length on the transmis- sion splines.
Page 80 CLUTCH MAIN UNIT (EATON 1402) CL02–9 IMPORTANT POINT - MOUNTING Insert 2 guide studs INSERT TWO (2) 3/8" x 16 UNC x 3" (76 MM) LONG GUIDE STUDS INTO THE TWO UPPER MOUNTING HOLES OF THE FLYWHEEL. Guide studs SHTS02Z020200014 INSTALL THE FRONT DISC BY INSERTING THE ALIGNING TOOL THROUGH THE DISC SPLINES AND THEN INTO THE PILOT BEARING.
Page 81 CL02–10 CLUTCH MAIN UNIT (EATON 1402) REMOVE THE ALIGNING TOOL AND INSTALL IT THROUGH THE SPLINES OF THE REAR DISC, AND INSERT THE ALIGNING TOOL THROUGH THE FRONT DISC AND ALSO THE PILOT BEARING. NOTICE Make sure the side of the disc marked "Pressure Plate Side" is facing Buttons the pressure plate.
Page 82 CLUTCH MAIN UNIT (EATON 1402) CL02–11 INSTALL LOCKWASHER AND SIX (6) 3/8" x 16 UNC MOUNTING BOLTS HAND TIGHTEN. Remove the two (2) guide studs and replace with the remaining mounting bolts with lockwasher. Using a torque wrench, progressively tighten the eight (8) mounting bolts using the following criss-cross pat- tern.
Page 83 CL02–12 CLUTCH MAIN UNIT (EATON 1402) Top view Access hole Roll pin Clutch cover SHTS02Z020200022 Side view Flywheel Roll pin (Qty.4) Access hole 0.20"-0.30" (0.5-0.8mm) Clutch cover SHTS02Z020200023 SHIFT THE TRANSMISSION INTO GEAR. Shift into gear Shift transmission into gear SHTS02Z020200024 10.
Page 84 CLUTCH MAIN UNIT (EATON 1402) CL02–13 11. WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE BEARING HOUSING INTO THEIR FINAL POSITION.
Page 85 CL02–14 CLUTCH MAIN UNIT (EATON 1402) ARRANGE THE KWIK-ADJUSTER Set SST the crank pulley. Crank pulley SST: Cranking Tool (S0940-91200) Torque wrench SHTS02Z020200029 Turn the crank pulley till the Kwik-Adjuster matches the inspection hole. Kwik-adjuster SHTS02Z020200030 ADJUSTING PROCEDURES Adjust the release bearing position; •...
Page 86 CLUTCH MAIN UNIT (EATON 1402) CL02–15 ADJUST THE RELEASE BEARING POSITION Set 0.75" (19 mm) dimension: With pedal down, turn adjusting ring to obtain approximately 0.75" (19 mm). Turning the adjusting ring clock- wise moves the release bearing toward the transmission. Turning the Pedal Pedal adjusting ring counterclockwise moves the release bearing toward the...
Page 87: Clutch Assembly (Eaton Solo1402)
CL02–16 CLUTCH MAIN UNIT (EATON 1402) CLUTCH ASSEMBLY (EATON SOLO1402) DATA AND SPECIFICATIONS EN02Z0202I200002 CLUTCH FACING Unit: mm {in.} Material Sintered metal (Ceramic metal) Type Dry two plate with damper spring Inside diameter 222 {8.8} Outside diameter 350 {13.8} Thickness 11.5 {0.45} Adjustment-Free COMPONENT LOCATOR EN02Z0202D100002...
Page 88: Overhaul
CLUTCH MAIN UNIT (EATON 1402) CL02–17 OVERHAUL EN02Z0202H200002 IMPORTANT POINT - DISMOUNTING REMOVE THE TRANSMISSION, SUPPORTING ITS WEIGHT TO PREVENT DAMAGE TO THE BEARING AND DISCS. NOTICE Remove the transmission If a SOLO Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (3/8"...
Page 89 CL02–18 CLUTCH MAIN UNIT (EATON 1402) Using a suitable tapping rod, install the pilot bearing. NOTICE After installing the pilot bearing, ensure that it rotates smoothly. SHTS02Z020200040 CHECK THE FOLLOWING ITEMS FOR WEAR REPLACE ANY WORN COMPONENTS: Check cross-shafts Cross-shafts and bushings and bushings NOTICE Excessive wear at these points can cause a side loading condition.
Page 90 CLUTCH MAIN UNIT (EATON 1402) CL02–19 Smooth area of input shaft Mating surfaces NOTICE Inspect the mating surfaces of both the transmission bell housing and the flywheel housing. Any appreciable wear on either housing will cause misalignment. Most wear will occur between the 3 and 8 o'clock positions.
Page 91 CL02–20 CLUTCH MAIN UNIT (EATON 1402) INSTALL THE INTERMEDIATE PLATE ASSEMBLY OVER THE TWO (2) GUIDE STUDS AND SLIDE IT FORWARD UNTIL IT TOUCHES THE FLYWHEEL. NOTICE Make sure the side marked "Pressure Plate Side" is facing the pres- sure plate (the drive straps must face the pressure plate). Place intermediate plate properly orientated...
Page 92 CLUTCH MAIN UNIT (EATON 1402) CL02–21 WITH THE ALIGNING TOOL STILL IN PLACE, SLIDE THE COVER ASSEMBLY OVER BOTH THE ALIGNING TOOL AND THE TWO (2) GUIDE STUDS UNTIL IT RESTS AGAINST THE INTERMEDIATE PLATE ASSEMBLY. Slide cover assembly over aligning tool and guide studs SHTS02Z020200018 INSTALL LOCKWASHER AND SIX (6) 3/8"...
Page 93 CL02–22 CLUTCH MAIN UNIT (EATON 1402) REMOVE THE FOUR (4) GOLD COLORED SHIPPING BOLTS IN A CRISS-CROSS PATTERN. NOTICE Save these four (4) bolts for future use in case you need to remove, then reinstall the SOLO Clutch. Remove the 4 shipping bolts SHTS02Z020200047 REMOVE THE ALIGNING TOOL.
Page 94 CLUTCH MAIN UNIT (EATON 1402) CL02–23 Top view Access hole Roll pin Clutch cover SHTS02Z020200050 Side view Flywheel Roll Pin (Qty.4) Access hole 0.20"-0.30" (0.5-0.8mm) Clutch cover SHTS02Z020200051 10. SHIFT THE TRANSMISSION INTO GEAR. Shift into gear Shift transmission into gear SHTS02Z020200052 11.
Page 95 CL02–24 CLUTCH MAIN UNIT (EATON 1402) 12. WHILE MOVING THE TRANSMISSION FORWARD, ROTATE THE OUTPUT SHAFT OF THE TRANSMISSION UNTIL THE SPLINES OF BOTH THE INPUT SHAFT AND THE DISC(S) MESH WITH EACH OTHER. WHILE PERFORMING THIS TASK, YOU MUST ALSO ENSURE THAT THE YOKE FINGERS REMAIN IN THE UP POSITION UNTIL THEY CAN BE ROTATED OVER THE RELEASE BEARING HOUSING INTO THEIR FINAL POSITION.
Page 96 CLUTCH MAIN UNIT (EATON 1402) CL02–25 13. INSTALL THE TRANSMISSION MOUNTING BOLTS AND TORQUE TO THE PROPER SPECIFICATION. Tightening Torque: 37.5-48.5 Nm{382-494 kgfcm, 28-35 lbfft} IMPORTANT POINT-SET-UP ADJUST LINKAGE Adjust the clutch linkage until the yoke fingers contact the release bearing (zero free-play in the cab).
Page 97 CL02–26 CLUTCH MAIN UNIT (EATON 1402) IMPORTANT POINT-CHECK WEAR INDICATOR REMOVE THE COVER OF INSPECTION HOLE AT THE BOTTOM OF THE CLUTCH HOUSING. CHECK WEAR INDICATOR • Reflects clutch wear and indicates when it is time to replace clutch. • When replacing clutch, should change clutch disc together with clutch cover.
Page 98: Inspection And Repair
CLUTCH MAIN UNIT (EATON 1402) CL02–27 INSPECTION AND REPAIR EN02Z0202H300001 EATON SAS1402 and SOLO1402 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Clutch facing thickness 11.43 8.26 Replace disc Measure {0.45} {0.33} assembly. Clutch disc misalignment 0-0.38 0.38 Replace.
Page 99 CL02–28 CLUTCH MAIN UNIT (EATON 1402) Inspection item Standard Limit Remedy Inspection procedure Flywheel friction surface — Grind limit Regrind the fric- Visual check scoring or heat cracking 1.0 {0.039} tion surface or Deflection replace, if neces- limit sary. 0.04 NOTICE {0.00157} Do not grind the...
Page 100 CLUTCH MAIN UNIT (EATON 1402) CL02–29 LUBRICATION (EATON SAS1402 and SOLO1402) RELEASE BEARING The cast iron bearing housing will be equipped with either a standard grease fitting or a lube tube extension. If a lube tube is not present, it is necessary to remove the inspection cover to gain access to the grease fitting.
Page 101 CLUTCH CONTROL CL03–1 C LUTCH CONTROL C L 0 3 CL03-001 CLUTCH CONTROL UNIT......CL03-2 DESCRIPTION ..........CL03-2 INSPECTION AND ADJUSTMENT ....CL03-3 CLUTCH PEDAL AND RELEASE UNIT... CL03-6 COMPONENT LOCATOR.........CL03-6 OVERHAUL ............CL03-7 INSPECTION AND REPAIR ......CL03-9 CLUTCH MASTER CYLINDER ....CL03-10 COMPONENT LOCATOR.......CL03-10 OVERHAUL ............CL03-11 INSPECTION AND REPAIR ......CL03-11...
Page 102: Clutch Control Unit
CL03–2 CLUTCH CONTROL CLUTCH CONTROL UNIT DESCRIPTION EN02Z0203C100001 CLUTCH RELEASE UNIT SHTS02Z020300001 Clutch master cylinder Clutch pedal Reservoir tank Pedal bracket...
Page 103: Inspection And Adjustment
CLUTCH CONTROL CL03–3 INSPECTION AND ADJUSTMENT EN02Z0203H300001 AIR BLEEDING BLEED THE AIR FROM HYDRAULIC LINE. NOTICE • Do not mix the clutch fluid with different types or brands. • Be careful not to spill clutch fluid from the reservoir tank or from the air bleeder during air bleeding.
Page 104 Depress the clutch pedal fully and measure the push rod stroke. If the stroke is less than standard, re-bleed the hydraulic system. Standard: Model Standard HINO 238 (NE), 258 (NE, NJ), 268 More than 22.5 mm {0.886 in.} (NE, NF, NJ), 338 (NF, NV), 358 (NH) SHTS02Z020300006...
Page 105 Push the pedal until the beginning of clutch resistance is felt. Assembly Standard: Model Standard Limit HINO 238 (NE), 258 (NE, NJ), 44-59 mm 268 (NE, NF, NJ), 338 (NF, NV), 35 mm {1.38 in.} {1.73-2.32 in.} 358 (NH) NOTICE For adjustment of clutch, refer to the chapter "CLUTCH MAIN UNIT".
Page 106: Clutch Pedal And Release Unit
CL03–6 CLUTCH CONTROL CLUTCH PEDAL AND RELEASE UNIT COMPONENT LOCATOR EN02Z0203D100001 SHTS02Z020300011 Reservoir tank Pedal pad Master cylinder Switch (For cruise control) Return spring Switch (For clutch on start) Clutch pedal Pedal shaft Bracket Pedal bracket Tightening torque Unit: Nm {kgfcm, lbfft} 41.5-61.5 {424-627, 30-46} 18-26 {184-265, 14-19}...
Page 107: Overhaul
CLUTCH CONTROL CL03–7 OVERHAUL EN02Z0203H200001 IMPORTANT POINTS - DISMOUNTING REMOVE THE PEDAL UNIT ASSEMBLY. Remove the 10 bolts and 2 nuts and dismount the pedal bracket assembly from the vehicle. NOTICE Be careful not to damage the vehicle. SHTS02Z020300012 REMOVE THE CLUTCH PEDAL. Remove the clip, and tap the pedal shaft lightly to remove the clutch pedal using a brass bar and a hammer.
Page 108 CL03–8 CLUTCH CONTROL INSTALL THE SWITCH FOR CRUISE CONTROL AND CLUTCH ON START. Install the switch bushing into the switch bracket. SHTS02Z020300015 Push the switch into the switch bushing until the switch pounds the buffer, then fix the switch by turning if clockwise. NOTICE Check that the switch body does not contact the buffer and also that the switch rightly functions.
Page 109: Inspection And Repair
CLUTCH CONTROL CL03–9 INSPECTION AND REPAIR EN02Z0203H300002 Inspection item Standard Limit Remedy Inspection procedure Release bearing improper — — Replace release Visual check rotation bearing, if necessary. Release fork and release — — Replace the Visual check hub: parts, Wear and damage if necessary.
Page 110: Clutch Master Cylinder
CL03–10 CLUTCH CONTROL CLUTCH MASTER CYLINDER COMPONENT LOCATOR EN02Z0203D100002 SHTS02Z020300021 Clevis Clamp Lock nut Reservoir cap Push rod Gasket Boot Oil reservoir strainer Retainer ring Reservoir tank Piston Stopper bolt Return spring O-ring Body Tightening torque Unit: Nm {kgfcm, lbfft} 11.5-16.9 {118-172, 8.5-12.4} 2.4-4.4 {24-45, 1.8-3.2}...
Page 111: Overhaul
CLUTCH CONTROL CL03–11 OVERHAUL EN02Z0203H200002 IMPORTANT POINT - DISMOUNTING REMOVE THE MASTER CYLINDER. NOTICE • Before removing the master cylinder, drain the clutch fluid from the hydraulic line. • Place a small drain pan under the master cylinder to catch the hydraulic fluid.
Page 112 TRANSMISSION MAIN UNIT (EATON FS 5406/6406) TR02–1 T RANSMISSION MAIN UNIT T R 0 2 (EATON FS 5406/6406) TR02-001 TRANSMISSION ASSEMBLY....TR02-2 DATA AND SPECIFICATION......TR02-2 DISMOUNTING AND MOUNTING ....TR02-3...
Page 113: Transmission Assembly
TR02–2 TRANSMISSION MAIN UNIT (EATON FS 5406/6406) TRANSMISSION ASSEMBLY DATA AND SPECIFICATION EN03Z0302I200001 Six forward speeds, one reverse Type 1, 2, 3, 4, 5, 6th Synchromesh, Reverse, Constant mesh 9.01 5.27 3.22 Gear ratios 2.04 1.36 1.00 Reverse 8.63 Number of teeth: input shaft 1st gear 2nd gear 3rd gear...
Page 114 TRANSMISSION MAIN UNIT (EATON FS 5406/6406) TR02–3 DISMOUNTING AND MOUNTING EN03Z0302H100001 IMPORTANT POINTS-DISMOUNTING ! WARNING Do not work on the transmission while it is hot. This can result in per- sonal injury. BLOCK THE WHEELS DRAIN THE TRANSMISSION OIL DISCONNECT THE PROPELLER SHAFT DISCONNECT THE ELECTRIC HARNESS AND OTHER ATTACH- MENTS.
Page 115 TR02–4 TRANSMISSION MAIN UNIT (EATON FS 5406/6406) IMPORTANT POINTS-MOUNTING APPLY HEAT-RESISTANT GREASE TO THE INPUT SHAFT SPLINE. Grease: Refer to RECOMMENED LUBRICATION in the chapter "CLUTCH MAIN UNIT." SHTS03Z030200003 INSTALL THE TRANSMISSION. Jack up the transmission until the input shaft spline and the clutch disc spline align.
Page 116 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR04–1 A UTOMATIC TRANSMISSION T R 0 4 (ALLISON 2200RDS, 2500RDS, 2200HS) TR04-001 AUTOMATIC TRANSMISSION ASSEMBLY ..........TR04-2 TROUBLESHOOTING ........TR04-2 SPECIAL TOOL ..........TR04-2 DISMOUNTING AND MOUNTING ....TR04-2...
Page 117 TR04–2 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) AUTOMATIC TRANSMISSION ASSEMBLY TROUBLESHOOTING EN03Z0304F300001 NOTICE When diagnosing transmission problems, refer to the Allison Shop Manual or troubleshooting procedures for detailed information on items that could be causing the problem. SPECIAL TOOL EN03Z0304K100001 Prior to removal and installing of automatic transmission, it is necessary to have this special tool.
Page 118 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR04–3 REMOVE THE PROPELLER SHAFTS. Disconnect the yoke from the propeller spider and remove the center bearing holder. Move the forward end of the propeller shaft out of the way. SHTS03Z030400004 DISCONNECT THE ELECTRICAL HARNESS FROM THE REAR OF THE TRANSMISSION.
Page 119 TR04–4 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) REMOVE THE SUPPORT OF THE OIL LEVER GAUGE FROM THE ENGINE CYLINDER BLOCK. Rear view Side view SHTS03Z030400008 REMOVE INSPECTION COVER FROM THE BOTTOM FRONT SIDE OF THE FLYWHEEL HOUSING. SHTS03Z030400009 REMOVE THE SIX COUPLING BOLTS FROM THE FLYWHEEL. Turn the flywheel manually to match the attaching bolt to the slot on the inspection opening at the bottom front side of the flywheel hous- ing.
Page 120 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR04–5 11. POSITION A TRANSMISSION JACK UNDER THE TRANSMISSION AND SECURE THE TRANSMISSION TO THE JACK WITH A SAFETY CHAIN OR WIRE CABLE. 12. REMOVE THE REMAINING CONVERTER HOUSING FROM THE FLYWHEEL HOUSING ATTACHING BOLTS. 13.
Page 121 TR04–6 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) IMPORTANT POINTS - MOUNTING TIGHTEN THE FLEX PLATE, SPACER COUPLING AND WEAR PLATE. Tightening Torque: 78.5-87.5 Nm {801-893 kgfcm, 58-64.5 lbfft} NOTICE Before tightening, face the chamfered outer rim of the wear plate to the flex plate.
Page 122 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR04–7 SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTO THE SPACER COUPLING OF THE TRANSMISSION ASSEMBLY. ROTATE THE TORQUE CONVERTER SO THAT THE GUIDE FACES DOWNWARD. SST: Spacer coupling guide (S0965-71370) SHTS03Z030400016 ROTATE THE ENGINE TO ALIGN THE FITTING HOLE OF THE ENGINE FLYWHEEL AND SPACER COUPLING WITH THE INSPECTION HOLE ON THE FRONT OF THE FLYWHEEL HOUS- ING.
Page 123 TR04–8 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) 11. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLYWHEEL AND THE SPACER COUPLING THROUGH THE INSPECTION HOLE. IN ORDER TO TIGHTEN THE BOLTS, TURN THE RING GEAR WITH A SCREW DRIVER THROUGH THE TIMING ADJUSTMENT HOLE ON THE UPPER PART OF THE FLYWHEEL HOUSING.
Page 124 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS) TR04–9 15. INSTALL THE SUPPORT OF THE OIL LEVEL GAUGE TO THE ENGINE CYLINDER BLOCK. Rear view Side view SHTS03Z030400008 Cover Plate SHTS03Z030400022 16. INSTALL THE PROPELLER SHAFT YOKE TO THE TRANSMIS- SION YOKE. Tightening Torque: 61-81 Nm {622-826 kgfcm, 45-60 lbfft} 17.
Page 125 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR04–1 A UTOMATIC TRANSMISSION (ALLISON 3000RDS, T R 0 4 3500RDS) TR04-002 AUTOMATIC TRANSMISSION ASSEMBLY ..........TR04-2 TROUBLESHOOTING ........TR04-2 SPECIAL TOOL ..........TR04-2 DISMOUNTING AND MOUNTING ....TR04-2...
Page 126 TR04–2 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) AUTOMATIC TRANSMISSION ASSEMBLY TROUBLESHOOTING EN03Z0304F300001 NOTICE When diagnosing transmission problems, refer to the Allison Shop Manual or troubleshooting procedures for detailed information on items that could be causing the problem. SPECIAL TOOL EN03Z0304K100001 Prior to removal and installing of automatic transmission, it is necessary to have this special tool. Illustration Part number Tool name...
Page 127 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR04–3 REMOVE THE CONNECTORS OF MAIN CONNECTOR, SPEED SENSOR AND CONVERTER TURBINE SENSOR. Speed sensor Main Converter turbine sensor connector SHTS03Z030400004C DISCONNECT THE OIL COOLER LINES AT THE TRANSMISSION. SHTS03Z030400005 REMOVE THE SUPPORT OF THE OIL LEVEL GAUGE FROM THE ENGINE CYLINDER BLOCK.
Page 128 TR04–4 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) REMOVE THE SIX COUPLING BOLTS FROM THE FLYWHEEL. Turn the flywheel manually to match the attaching bolt to the slot on the inspection opening at the bottom front side of the flywheel hous- ing. Remove the coupling bolts one by one.
Page 129 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR04–5 IMPORTANT POINTS - MOUNTING TIGHTEN THE FLEX PLATE, SPACER COUPLING AND WEAR PLATE. Tightening Torque: 64-85 Nm {653-867 kgfcm, 48-62 lbfft} NOTICE Before tightening, face the chamfered outer rim of the wear plate to the flex plate.
Page 130 TR04–6 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTO THE SPACER COUPLING OF THE TRANSMISSION ASSEMBLY. ROTATE THE TORQUE CONVERTER SO THAT THE GUIDE FACES DOWNWARD. SST: Spacer coupling guide (S0965-71370) SHTS03Z030400016 ROTATE THE ENGINE TO ALIGN THE FITTING HOLE OF THE ENGINE FLYWHEEL AND SPACER COUPLING WITH THE INSPECTION HOLE ON THE FRONT OF THE FLYWHEEL HOUS- ING.
Page 131 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) TR04–7 12. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLYWHEEL AND THE SPACER COUPLING THROUGH THE INSPECTION HOLE. IN ORDER TO TIGHTEN THE BOLTS, TURN THE RING GEAR WITH A SCREW DRIVER THROUGH THE TIMING ADJUSTMENT HOLE ON THE UPPER PART OF THE FLYWHEEL HOUSING.
Page 132 TR04–8 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS) 19. INSTALL THE SUPPORT OF THE OIL LEVEL GAUGE TO THE ENGINE CYLINDER BLOCK. 20. REMOVE THE CAP OF THE OIL FILLER TUBE AND POUR AUTO- MATIC TRANSMISSION FLUID INTO THE TUBE. Automatic transmission fluid: Refer to RECOMMENDED LUBRICANTS LIST in the chapter “GENERAL INTRODUCTION (CHASSIS).”...
Page 133 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) TR06–1 T RANSMISSION/TRANSFER CONTROL T R 0 6 (EATON MANUAL TRANSMISSION) TR06-001 TRANSMISSION CONTROL UNIT ... TR06-2 TROUBLESHOOTING ........TR06-2 COMPONENT LOCATOR........ TR06-3 OVERHAUL ............. TR06-4...
Page 134: Transmission Control Unit
TR06–2 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) TRANSMISSION CONTROL UNIT TROUBLESHOOTING EN03Z0306F300001 MANUAL TRANSMISSION Symptom Possible cause Remedy/Prevention Unable to shift the gear or very diffi- Damaged shift lever assembly Replace shift lever. cult to shift when the engine is Damaged broken transmission Replace.
Page 135: Component Locator
TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) TR06–3 COMPONENT LOCATOR EN03Z0306D100001 MANUAL TRANSMISSION CONTROL SHTS03Z030600001 Knob Isolator Shift lever Stub lever Boot Tightening torque Unit: Nm {kgfcm, lbfft} 14-16 {143-163, 10-11.8}...
Page 136: Overhaul
TR06–4 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) OVERHAUL EN03Z0306H200001 IMPORTANT POINT - ASSEMBLY MANUAL TRANSMISSION CONTROL When you connect the shift lever and the stub lever, tighten the nut with the isolator steadily. Tightening Torque: 14-16 Nm {143-163 kgfcm, 10-11.8 lbfft} Check the shift and select stroke.
Page 137 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) TR06–1 T RANSMISSION/TRANSFER CONTROL T R 0 6 (ALLISON AUTOMATIC TRANSMISSION) TR06-002 TRANSMISSION CONTROL UNIT ... TR06-2 TROUBLESHOOTING ........TR06-2 COMPONENT LOCATOR........ TR06-2 OVERHAUL ............. TR06-4...
Page 138 TR06–2 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) TRANSMISSION CONTROL UNIT TROUBLESHOOTING EN03Z0306F300001 AUTOMATIC TRANSMISSION Allison 2200RDS, 2200HS, 2500RDS, 3000RDS, 3500RDS auto-transmission problem, refer to the Allison shop manual or troubleshooting procedures for detailed information on items that could be causing the problem. COMPONENT LOCATOR EN03Z0306D100001 AUTOMATIC TRANSMISSION CONTROL...
Page 139 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) TR06–3 [Allison 3000RDS,3500RDS button-type] SAPH03Z030600002 Selector assembly...
Page 140 TR06–4 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) OVERHAUL EN03Z0306H200001 IMPORTANT POINT - ASSEMBLY AUTOMATIC TRANSMISSION CONTROL [Allison 2200RDS, 2200HS, 2500RDS MODEL] Before installation the cable, check the shift cable for wear and dam- age, if necessary, replace the parts. SAPH03Z030600004 When you install the shift cable, it should not bent sharply. Any loop- ing should have a radius of more than 150 mm (5.91 in.).
Page 141 PROPELLER SHAFT (SPL 100, 140) PP02–1 P ROPELLER SHAFT (SPL 100, 140) P P 0 2 PP02-001 PROPELLER SHAFT ASSEMBLY ... PP02-2 DATA AND SPECIFICATIONS ......PP02-2 DESCRIPTION ..........PP02-2 TROUBLESHOOTING ........PP02-3 COMPONENT LOCATOR........ PP02-3 OVERHAUL ............. PP02-5...
Page 142: Propeller Shaft Assembly
PP02–2 PROPELLER SHAFT (SPL 100, 140) PROPELLER SHAFT ASSEMBLY DATA AND SPECIFICATIONS EN04Z0402I200001 Manufacturer Spicer Type Tubular shaft type Universal joint All metal, round bearing type with needle roller bearing DESCRIPTION EN04Z0402C100001 SHTS04Z040200001 Bearing assembly Washer Cross assembly Snap ring Slip yoke assembly Yoke shaft assembly Clamp...
Page 143: Troubleshooting
Tightening torque Unit: Nm {kgfcm, lbfft} 61-81 {625-825, 45-60} 128-156 {1,300-1,600, 95-115} ! WARNING Never allow grease and oil to adhere stamped straps, stamped strap bolts and bold holes. The grease and/or oil which adhere to the stamped retainer bolts, stamped straps, stamped strap bolts, damaged bearing retainers or used inferior grade bolts can cause driveline failure, which can result in separation of driveline from the vehicle.
Page 144 Tightening torque Unit: Nm {kgfcm, lbfft} 143-169 {1,457-1,723, 105-125} 128-156 {1,300-1,600, 95-115} ! WARNING Never allow grease and oil to adhere stamped straps, stamped strap bolts and bold holes. The grease and/or oil which adhere to the stamped retainer bolts, stamped straps, stamped strap bolts, damaged bearing retainers or used inferior grade bolts can cause driveline failure, which can result in separation of driveline from the vehicle.
Page 145: Overhaul
PROPELLER SHAFT (SPL 100, 140) PP02–5 OVERHAUL EN04Z0402H200001 IMPORTANT POINT - DISMOUNTING DISCONNECT THE PROPELLER SHAFT FROM THE ALL CON- NECTING POINTS. Park the vehicle on level ground, apply the parking brake and apply wheel stoppers at the front or rear tires. Make aligning marks on all bearing positions, spline positions, shaft locations and all bearing retainers.
Page 146 PP02–6 PROPELLER SHAFT (SPL 100, 140) Remove the bearing retainers or stamped straps and bolts at rear end. Discard bolts. Discard stamped straps (if applicable). ! WARNING • Bearing retainers CAN be reused if there is no damage. If dam- aged, replace.
Page 147 PROPELLER SHAFT (SPL 100, 140) PP02–7 IMPORTANT POINTS - DISASSEMBLY DISASSEMBLE THE UNIVERSAL JOINT ASSEMBLY (SNAP RING STYLE). Using snap-ring pliers, remove all snap rings. If snap rings are severely corroded or out-of-round, snap rings must be replaced. ! WARNING DO NOT reuse severely corroded or out-of-round snap rings.
Page 148 PP02–8 PROPELLER SHAFT (SPL 100, 140) Grip the bearing cup in bench vise. Strike the yoke ear with a soft- faced hammer until bearing is removed. SHTS04Z040200015 Place the yoke in the arbor press with remaining bearing cup face down. Using a push rod, press on the end of journal cross trunnion. Continue to press down on journal cross trunnion until the shoulder of the journal cross makes contact with the inside of yoke ear.
Page 149 PROPELLER SHAFT (SPL 100, 140) PP02–9 DISASSEMBLE THE UNIVERSAL JOINT ASSEMBLY (SPRING TAB STYLE) Remove and discard spring tabs and bolts. ! WARNING DO NOT reuse spring tabs, spring tab bolts or use inferior grade bolts. Reuse of spring tabs, spring tab bolts and use of inferior grade bolts, can cause driveline failure, which can result in separation of driveline from the vehicle.
Page 150 PP02–10 PROPELLER SHAFT (SPL 100, 140) The bearing cup is not designed to drop out of the yoke. It will be nec- essary to use a soft-faced hammer to tap the partially pressed-out bearing cup from side to side, to "walk" the bearing cup out of the yoke ear.
Page 151 PROPELLER SHAFT (SPL 100, 140) PP02–11 REMOVE THE MEMBER BOOT ! CAUTION Seal can style slip member assemblies are NOT serviceable. If seal can or seal is damaged, replacement of the complete driveshaft assembly is necessary. Remove and discard both boot clamps. Clamps may be separated using a chisel to disengage locking hooks.
Page 152 PP02–12 PROPELLER SHAFT (SPL 100, 140) Mark the counterbore of end yoke to midship "nose" with marking stick, paint marker or other legible marking device. This assures proper reassembly of the center bearing end yoke in its original phased position. ! WARNING Reassembly of a driveline out of original phase can cause vibration and failure of the driveline and attaching components.
Page 153 PROPELLER SHAFT (SPL 100, 140) PP02–13 Inspect midship for wear on the bearing diameter. If the midship is damaged from a seized bearing, replacement of the entire coupling shaft is necessary. ! WARNING Failure to replace damaged driveline components can cause driveline failure, which can result in separation of driveline from vehicle.
Page 154 PP02–14 PROPELLER SHAFT (SPL 100, 140) Move one end of the journal cross to cause a trunnion to project through the cross hole beyond the outer machined face of the yoke ear. Take one bearing cup assembly and position an installation height tool on the end of the bearing cup assembly.
Page 155 PROPELLER SHAFT (SPL 100, 140) PP02–15 ASSEMBLE THE UNIVERSAL JOINT ASSEMBLY (SNAP RING STYLE). Using a high quality N.L.G.I.*, E. P. Grade 2 lubricating grease, wipe each bearing cup assembly with grease. Fill all cavities between the needle rollers. Also apply a liberal coating of grease on the bottom of each bearing cup assembly and on the lip of the seal.
Page 156 PP02–16 PROPELLER SHAFT (SPL 100, 140) Place a push rod that is smaller than the diameter of the bearing cup assembly under the bearing cup assembly and continue pressing into the yoke cross hole until it is far enough to install a snap ring. Remove yoke from arbor press.
Page 157 PROPELLER SHAFT (SPL 100, 140) PP02–17 (17) Flex the journal cross to make sure it moves freely in bearings. If the joint is stiff, place a plate on the yoke ear and hit the plate with a ham- mer to seat the bearing cup assemblies. ! WARNING When using hammer, TO PREVENT eye injury, always wear safety glasses when performing maintenance or service.
Page 158 PP02–18 PROPELLER SHAFT (SPL 100, 140) Measure and place a mark 2.25 inches (55-60mm) from yoke shaft shoulder with a marking stick, paint marker or other legible marking device. Position a clamp on each end of the new boot. Slide the boot onto the grease-free yoke shaft shoulder.
Page 159 PROPELLER SHAFT (SPL 100, 140) PP02–19 Before installing the new center bearing assembly, be sure to fill the entire cavity around the bearing with waterproof lubricant. (See photo 131, above.) Enough lubricant must be applied to fill the cavity to the extreme edge of the slinger surrounding the bearing.
Page 160 PP02–20 PROPELLER SHAFT (SPL 100, 140) IMPORTANT POINT - MOUNTING CONNECT THE PROPELLER SHAFT TO THE ALL CONNECTING POINTS. Position support straps to make sure that the driveshaft will be prop- erly supported at the slip member, behind the center bearing end fit- tings and in front of center bearing, with support straps.
Page 161 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–1 D IFFERENTIAL CARRIER D F 0 2 (MERITOR RS17.19.21&23) DF02-001 DIFFERENTIAL CARRIER ASSEMBLY... DF02-2 DATA AND SPECIFICATIONS ......DF02-2 DESCRIPTION ..........DF02-4 TROUBLESHOOTING ........DF02-7 SPECIAL TOOL ..........DF02-8 COMPONENT LOCATOR......DF02-10 OVERHAUL ........... DF02-14 INSPECTION AND REPAIR ......
Page 162: Differential Carrier Assembly
DATA AND SPECIFICATIONS EN05Z0502I200001 CAPACITY MODEL AXLE MODEL GEAR RATIOS U.S. Pints Liters 3.07, 3.90, 4.11, 4.88, HINO 238 (NE8J), HINO 258 (NE8J, NJ8J) RS17-145 33.6 15.9 5.13, 5.29 3.73, 3.90, 4.11, 4.88, HINO 268 (NE8J, NJ8J) RS19-145 33.2 15.7 5.13, 5.29, 5.57...
Page 163 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–3 Single-Reduction Differential carrier with Differential Lock SHTS05Z050200002 TAPERED ROLLER BEARINGS HOUSING CARRIER TAPERED ROLLER BEARING STRAIGHT ROLLER BEARING HYPOID DRIVE PINION AND RING GEAR TAPERED ROLLER BEARING DIFFERENTIAL LOCK ASSEMBLY BEVEL DIFFERENTIAL GEARS...
Page 164: Description
DF02–4 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DESCRIPTION EN05Z0502D100001 Single-Reduction Differential Carrier SHTS05Z050200003 Nut —Drive Pinion* Carrier Washer — Drive Pinion* Adjusting Ring Input Yoke* or Flange* Cotter Pin — Adjusting Ring Deflector Jam Nut* — Thrust Screw* POSE seal Thrust Screw* Triple Lip (Main) Seal Snap Ring Bearing Cone —...
Page 165 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–5 SHTS05Z050200004 Side Gears — Differential Spider — Differential Thrust Washers — Differential Pinion Bolts* or Rivets* — Ring Gear and Case Half Pinions — Differential Ring Gear (Pinion Drive Gear) Differential — Side Gears Case Half — Flange Thrust Washers —...
Page 166 DF02–6 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Differential lock assembly SHTS05Z050200005 SENSOR SWITCH AIR CYLINDER TUBE SHIFT FORK SCREW-IN DIFFERENTIAL LOCK SHIFT SHAFT SPRING PISTON O-RING SHIFT SHAFT PISTON SPRING RETAINING PIN SHIFT COLLAR FLAT WASHER, OR SILASTIC AS REQUIRED SHIFT FORK ROLL PINS *Some Meritor carriers do not have these described parts.
Page 167: Troubleshooting
DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–7 TROUBLESHOOTING EN05Z0502F300001 Symptom Possible cause Remedy/Prevention Abnormal noise (Bearing system) Worn or damaged pinion bearings Replace bearings. Worn or damaged differential side Replace bearings. bearings Loose pinion bearings Adjust bearing preload. Loose differential side bearings Adjust bearing preload.
Page 168: Special Tool
DF02–8 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) SPECIAL TOOL EN05Z0502K100001 Prior to starting a differential carrier overhaul, it is necessary to have these special tools. SPX Kent-Moore part number J-3409-D SHTS05Z050200006 PLATES 8' LONG X 3/4" THICK X 1-1/4" WIDE WITH 23-1/2" CENTER TO CENTER OF PIPE A TONGUE TO FIT SLOT IN BAR WELD PLATES TO HANDLE 7"...
Page 169 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–9 HOW TO MAKE A YOKE BAR Measure dimensions A and B of the yoke you are servicing. YOKE SHTS05Z050200007 Calculate dimensions C and D of the yoke bar by adding 0.125-0.250- inch to dimensions A and B of the yoke. ! WARNING Wear safe clothing and eye protection when you use welding equip- ment.
Page 170: Component Locator
DF02–10 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) COMPONENT LOCATOR EN05Z0502D100002 SHTS05Z050200009...
Page 171 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–11 Fastener Thread Size Torque Value lb-ft (Nm) Capscrew, Axle Shaft .31-24 18-24 (24-33) .50-13 85-115 (115-156) Nut, Axle Shaft Stud Plain Nut 50-75 (68-102) .44-20 75-115 (102-156) .50-20 110-165 (149-224) .56-18 150-230 (203-312) .62-18 Lock Nut 40-65 (54-88) .44-20...
Page 172 DF02–12 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Fastener Thread Size Torque Value lb-ft (Nm) Capscrew, Carrier to Housing .44-14 50-75 (68-102) .50-13 75-115 (102-156) .56-12 110-165 (149-224) .62-11 150-230 (203-312) .75-10 270-400 (366-542) M12 x 1.75 74-89 (100-120) M16 x 2 181-221 (245-300) Jam Nut, Thrust Screw .75-16...
Page 173 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–13 TORQUE VALUES FOR FASTENERS GENERAL INFORMATION The torque values on page DF02-11–12 are for fasteners that have a light application of oil on the threads. • If the fasteners are dry: Increase the torque values by 10%. •...
Page 174: Overhaul
DF02–14 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) OVERHAUL EN05Z0502H200001 BEFORE YOU BEGIN This manual provides instructions for the Meritor RS-Series axles. Before you begin procedures: Read and understand all instructions and procedures before you begin to service components. Read and observe all Caution and Warning safety alerts that precede instructions or procedures you will perform.
Page 175 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–15 IMPORTANT POINTS - DISMOUNTING ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving.
Page 176 DF02–16 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Brass Drift Method ! WARNING Do not strike the round driving lugs on the flange of an axle shaft. Pieces can break off and cause serious personal injury. a. Hold a 1-1/2-inch diameter brass drift or brass hammer against the center of the axle shaft, inside the round driving lugs.
Page 177 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–17 CARRIER FROM THE AXLE Place a hydraulic roller jack under the differential carrier to support the assembly. Remove all but the top two carrier to housing capscrews or stud nuts and washers. Loosen the top two carrier-to-housing fasteners and leave attached to the assembly.
Page 178 DF02–18 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) IMPORTANT POINTS - DISASSEMBLY DIFFERENTIAL AND RING GEAR FROM THE CARRIER NOTICE Before working on the differential carrier, inspect the hypoid gear set for damage. If inspection shows no damage, the same gear set can be used again.
Page 179 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–19 Remove the cotter keys, pins or lock plates, if equipped, that hold the bearing adjusting rings in position. Use a small drift and hammer to remove pins. Each lock plate is held in position by two capscrews. REMOVING COTTER KEY REMOVING LOCK PLATE SHTS05Z050200023...
Page 180 DF02–20 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DISASSEMBLY OF DIFFERENTIAL AND RING GEAR ASSEMBLY ! WARNING Observe all warnings and cautions provided by the press manufac- turer to avoid damage to components and serious personal injury. If the match marks on the case halves of the differential assembly are not visible, mark each case half with a center punch and hammer.
Page 181 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–21 If the differential bearings need to be replaced, use a bearing puller or press to remove the bearing cones from the case halves. PULLER PRESS SHTS05Z050200031 REMOVAL OF DRIVE PINION AND BEARING CAGE FROM THE CARRIER Fasten a flange bar to the input yoke or flange.
Page 182 DF02–22 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Remove the drive pinion, bearing cage and shims from the carrier. Do not use a pry bar. • If the bearing cage is tight in the carrier: Hit the bearing cage at several points around the flange area with a leather, plastic or rubber mallet.
Page 183 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–23 If the pinion bearings need to be replaced, remove the inner and outer bearing cups from the inside of cage. Use a press and sleeve, bearing BEARING puller or a small drift hammer. The type of tool used depends on the DRIVER design of the bearing cage.
Page 184 DF02–24 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) BEARING PULLER SPIGOT BEARING SHTS05Z050200043 (10) If the spigot bearings are a two-piece assembly, remove the inner race from the pinion with a bearing puller. Remove the outer race and roller assembly from the carrier with a drift or a press. Remove outer race and roller assembly from carrier.
Page 185 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–25 Gear Set Match Number NOTICE Meritor's drive pinions and ring gears are only available as matched sets. Each gear in a set has an alpha-numeric match number. Match Number Drive Pinion Loca- Ring Gear Location tion At the end of the On the front face or...
Page 186 DF02–26 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Place the drive pinion in a press with the gear head or teeth toward the bottom. Press the inner bearing cone on the shaft of the drive pinion until the cone is flat against the gear head. Use a sleeve of the correct size against the bearing inner race.
Page 187 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–27 Place the drive pinion and the tube of the staking tool in a press with the spigot bearing toward the top. When using a staking tool and press, apply 6,614 lb (3,000 kg) force on a 0.375-inch (10 mm) ball. Calculate the force required on the tool as follows.
Page 188 DF02–28 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Apply two stripes of temperature indicating liquid on the pinion stem from the top to the bottom. Apply a green stripe to indicate 400F (205C) and a blue stripe to indicate 500F (260C). ! CAUTION You must use the heat shield when you heat the pinion stem.
Page 189 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–29 Place the staking tool over the bearing race. Cut a 1-inch (25 mm) piece from the green plastigage strip and place in between the punch and the staking tool. You do not need to use the plastigage for every stake.
Page 190 DF02–30 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) ADJUSTMENT OF PINION BEARING PRELOAD BY PRESS METHOD If a press is not available, or the press does not have a pressure gauge, use the yoke or flange method to adjust pinion bearing pre- load. Refer to DF02-31. NOTICE Do not read starting torque.
Page 191 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–31 Use the following procedure to calculate the bearing preload or torque. • Pounds Pulled x Radius (inches) = lb-in Preload —Preload x 0.113 = Nm Preload • Kilograms Pulled x Radius (cm) = kgcm lb-in Preload —Preload x 0.098 = Nm Preload Example •...
Page 192 DF02–32 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Install the drive pinion and cage assembly into the carrier. Do not install shims under the bearing cage. Install the bearing cage-to-carrier capscrews. Washers are not required at this time. Hand-tighten the capscrews. SHTS05Z050200061 Fasten a yoke or flange bar to the input yoke or flange. The bar will hold the drive pinion in position when the nut is tightened.
Page 193 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–33 c. Press the seal into the bearing cage. The seal flange must be flat against the top of the bearing cage. Use a sleeve or seal driver of the correct size that fits against the metal seal flange. The diame- ter of the sleeve or driver must be larger than the flange diameter.
Page 194 DF02–34 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) ADJUSTMENT OF SHIM PACK THICKNESS FOR A NEW DRIVE PINION NOTICE Use this procedure if you'll install a new drive pinion and ring gear set, or if you have to adjust the depth of the drive pinion. Use a micrometer to measure the thickness of the shim pack that was removed from under the pinion cage.
Page 195 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–35 Example Inches Old Shim Pack Thickness. Old PC 0.030-0.002 = 0.028+0.005 = 0.033 0.760-0.050 = 0.710+0.130 = 0.840 Number, PC +2 inches (+0.05 mm) Standard Shim Pack Thickness. New PC Number, PC +5 inches (+0.13 mm) New Shim Pack Thickness Old Shim Pack Thickness Old PC 0.030+0.002 = 0.032+0.005 = 0.037...
Page 196 DF02–36 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Install the drive pinion and bearing cage into the carrier. If necessary, use a rubber, plastic or leather mallet to hit the assembly into position. DRIVE PINION AND BEARING CAGE SHIMS CARRIER SHTS05Z050200072 Install the bearing cage-to-carrier capscrews and washers. Tighten the capscrews to the correct torque value.
Page 197 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–37 Install the drive pinion nut and washer on the input pinion shaft and against the yoke collar. Tighten the nut against yoke collar to torque specifications. Refer to page DF02-12. Use flange or yoke bar. SHTS05Z050200075 11.
Page 198 DF02–38 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Use a 0.010-inch (0.25 mm) shim to check for clearance between the entire seal flange circumference and the bearing cage. • If the 0.010-inch (0.25 mm) shim slides between the seal flange and bearing cage: Correctly position the seal driver and drive the seal into the bore until the 0.010-inch (0.25 mm) shim cannot slide between the seal flange and bearing cage at any point around the seal flange.
Page 199 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–39 Inspect the yoke seal surface for grooves. • If you find grooves on the yoke: Use calipers to measure the groove diameters. If any groove diameter measures less than the dimensions shown in figure, replace the yoke. ! CAUTION Do not install a POSE seal after you install a unitized pinion seal.
Page 200 DF02–40 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Align the ring gear and the flange case half fastener holes. Rotate the ring gear as necessary. NOTICE If rivets were used to hold the ring gear to the flange case half, replace them with bolts, nuts and washers. Install the bolts, nuts and washers that hold the ring gear to the flange case half.
Page 201 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–41 (12) Install the spider or cross, differential pinions and thrust washers into the flange case half. SPIDER, PINION AND THRUST WASHERS SHTS05Z050200085 (13) Install the second side gear and thrust washer over the spider and dif- ferential pinions.
Page 202 DF02–42 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) 14. DIFFERENTIAL GEARS ROTATING RESISTANCE CHECK Make an inspection tool using an axle shaft that matches the spline size of the differential side gear. Cut the shaft to approximately 12- inches (304.8 mm). Weld a nut onto the end of the shaft. APPROXIMATELY 12"...
Page 203 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–43 Install the bearing cups over the bearing cones that are assembled on the case halves. Safely lift the differential and ring gear assembly and install it into the carrier. The bearing cups must be flat against the bores between the carrier legs.
Page 204 DF02–44 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) 16. ADJUST DIFFERENTIAL BEARING PRELOAD Differential Bearing All Carrier Models 15-35 lb-in Preload (1.7-3.9 Nm) Expansion between RS-145 and RS-160 0.002-0.009-inch bearing caps carrier models (0.05-0.229 mm) 17. METHOD 1 Attach a dial indicator onto the carrier mounting flange so that the plunger or pointer is against the ring gear back surface.
Page 205 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–45 18. METHOD 2 Hand-tighten both adjusting rings against the differential bearings. Use a micrometer to measure distance X or Y between the opposite surfaces of the bearing caps. Record the measurement. Tighten each bearing adjusting ring one notch. Measure distance X or Y again.
Page 206 DF02–46 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) 20. RING GEAR BACKLASH ADJUSTMENT Ring Gear Pitch Range of Backlash Backlash Setting for Diameter Setting New Gear Sets Less than 17-inches 0.008-0.018-inch 0.012-inch (0.30 mm) (431.8 mm) (0.20-0.46 mm) Greater than 0.010-0.020-inch 0.015-inch (0.38 mm) inches (431.8 mm) (0.25-0.51 mm) Measure outer diameter for approximate pitch...
Page 207 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–47 21. CHECK GEAR SET TOOTH CONTACT PATTERNS (BACKLASH) Some Meritor carriers have a generoid hypoid gear set. The tooth contact patterns for each type of gear set are different. Check the part numbers to determine what type of gear set is in the carrier.Refer to figure for the location of part numbers.
Page 208 DF02–48 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Look at the contact patterns on the ring gear teeth. Compare the pat- terns to figures. The location of good hand-rolled contact patterns for new conven- tional and generoid gear sets is toward the toe of the gear tooth and in the center between the top and bottom of the tooth.
Page 209 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–49 Change the thickness of the shim pack under the bearing cage to move the contact patterns between the top and bottom of the gear teeth. Use the following procedure. a. Remove the drive pinion and bearing cage from the carrier. Refer to Drive Pinion and Bearing Cage from the Carrier on page DF02- •...
Page 210 DF02–50 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) 22. ADJUST THE THRUST SCREW Rotate the carrier in the repair stand until the back surface of ring gear is toward the top. Install the jam nut on the thrust screw, if equipped, one half the dis- tance between both ends.
Page 211 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–51 23. INSTALLATION OF DIFFERENTIAL CARRIER INTO AXLE HOUS- ! WARNING When you apply some silicone gasket materials, a small amount of acid vapor is present. To prevent serious personal injury, ensure that the work area is well-ventilated. Read the manufacturer's instructions before using a silicone gasket material, then carefully follow the instructions.
Page 212 DF02–52 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Use a hydraulic roller jack or a lifting tool to install the carrier into the axle housing. Install nuts and washers or capscrews and washers, if equipped, in the four corner locations around the carrier and axle housing. Hand- tighten the fasteners.
Page 213 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–53 Install solid tapered dowels over each stud and into the flange of the axle shaft. Use a punch or a drift and hammer, if necessary. Install the Grade 8 nuts and hardened washers on the stud. Lock washers are an acceptable alternative.
Page 214 DF02–54 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) INSPECTION AND REPAIR EN05Z0502H300001 CLEAN AND INSPECT YOKES ! CAUTION Do not install a press on shaft excluder or POSE seal after installa- tion of a unitized pinion seal. The use of a POSE seal will prevent correct seating of the unitized pinion seal on the yoke and will result in lubricant leakage at the seal.
Page 215 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–55 DRY PARTS AFTER CLEANING Parts must be dried immediately after cleaning and washing. Dry the parts using soft, clean paper or cloth rags. ! CAUTION Damage to bearings can result when they are rotated and dried with compressed air.
Page 216 DF02–56 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) • There are bright wear marks on the outer surface of the roller cage. WEAR MARKS SHTS05Z050200128 • There is damage on the rollers and on the surfaces of the cup and cone inner race that touch the rollers. ETCHING AND PITTING SHTS05Z050200129 •...
Page 217 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–57 Inspect hypoid pinions and gears for wear and damage. Replace gears that are worn or damaged. ! CAUTION A thrust washer, differential side gear and pinion gear are machined DIFFERENTIAL as a matched set. When you replace any of these parts, you must CASE HALVES install a new matched set.
Page 218 DF02–58 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) FASTENERS REMOVING FASTENERS SECURED WITH ADHESIVE If it is difficult to remove fasteners secured with Dri-Loc, Meritor adhesive or Loctite 277 adhesive, use the following procedure. When you remove fasteners secured with adhesive, slowly heat the fastener to 350F (177C).
Page 219 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–59 APPLYING ADHESIVE AND SILICONE GASKET MATE- RIAL MERITOR SPECIFICATION 2297-T-4180 ADHESIVE IN DIFFEREN- TIAL BEARING BORES NOTICE Use Meritor specification 2297-T-4180 adhesive for all axles. Clean the oil and dirt from outer diameters of bearing cups and bear- ing bores in the carrier and bearing caps.
Page 220 DF02–60 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Use a tool with a flat blade, if required, to remove all old gasket mate- rial from surfaces. Use a cleaning solvent to clean the surfaces where you will apply sili- cone gasket material. Remove all oil, grease, dirt and moisture with- out damaging the mating surfaces.
Page 221 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–61 CARRIER-TO-HOUSING JOINT REPAIR Remove the carrier from the housing. Refer to page DF02-15. Remove all debris from inside the housing. Use a rotary tool with a ScotchBrite pad to clean all silicone residue from the housing and carrier faces. Surfaces must be clean, dry and free of foreign matter.
Page 222 DF02–62 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) INSTALLING TIGHT FIT YOKES AND POSE SEAL INSTALLATION Apply the same lubricant used in the axle housing to the hub of the yoke or flange. Inspect and verify that the lips of the POSE seal and the outer retainer of the triple-lip seal or main seal are clean and free from dirt and particles that may cause lubricant leakage between the seals.
Page 223 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–63 DRIVER-CONTROLLED MAIN DIF- FERENTIAL LOCK OVERHAUL EN05Z0502H200002 IMPORTANT POINTS - DISMOUNTING ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving.
Page 224 DF02–64 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) IMPORTANT POINTS-DISASSEMBLY SCREW-IN STYLE DIFFERENTIAL LOCK CYLINDER Use the following manual engaging method to lockout the screw-in DCDL assembly. Follow Steps 1-5 of Axle Setup for DCDL Disassembly in this section. Remove the manual engaging capscrew from the storage hole in the carrier casting, next to the cylinder.
Page 225 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) DF02–65 IMPORTANT POINTS-ASSEMBLY SCREW-IN STYLE DIFFERENTIAL LOCK ASSEMBLY INTO CAR- RIER Install the differential shift assembly after the differential carrier is assembled and the gear and bearing adjustments are completed. Install the shift spring and fork into the correct position in the carrier case.
Page 226 DF02–66 DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23) Differential Lock Assembly Cover Plates NOTICE For carriers without the differential lock or air shift, assemble the sen- sor switch plug and cover plate as follows. Apply Loctite518 liquid adhesive to the plate threads. NOTICE •...
Page 227 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–1 B RAKE EQUIPMENT B R 0 1 (MODELS WITH HYDRAULIC BRAKE) BR01-001 SERVICE BRAKE ASSEMBLY....BR01-2 DESCRIPTION ..........BR01-2 DIAGRAM ............BR01-3 TROUBLESHOOTING ........BR01-5 BRAKE SYSTEM AIR BLEEDING....BR01-9 POWER STEERING SYSTEM AIR BLEEDING..........BR01-11 BRAKE TEST ..........
Page 228: Service Brake Assembly
The ABS modulator maintains the appropriate braking force based on the control sig- nals. Hydraulic disc brake Model: HINO 238, 258, 268 (NE8J) and 258 (NF8J), 338 Four-Piston fixed mount Caliper. NOTICE Above components were made by the following manufacturer's;...
Page 229: Diagram
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–3 DIAGRAM EN0680101J100001 MODEL: HINO238(NE8J), 258(NE8J/NF8J), 268(NE8J) AND 338(NF8J) HYDRAULIC BRAKE (E version) : POWER STEERING FLUID LINE : ELECTRICAL CIRCUIT : OIL PIPE : OIL HOSE : AIR PIPE : NYLON TUBE CIRCUIT OF CIRCUIT OF EXHAUST BRAKE AIR SUSPENSION,...
Page 230 BR01–4 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) Hydro-Max booster and master cylinder Air dryer Stop light switch Air tank Flow switch Magnetic valve Pressure switch Exhaust brake Power steering oil reservoir Magnetic valve Power steering pump Air horn (if so equipped) Power steering gear Air suspension protection valve Backup pump &...
Page 231: Troubleshooting
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–5 TROUBLESHOOTING EN0680101F300001 Symptom Possible cause Remedy/Prevention No response upon working the Insufficient seal of master cylinder sec- Replace master cylinder assembly. pedal or there is the feeling of step- ondary cup ping on sponge (Air trapped in the brake lines) Insufficient air bleeding Bleed air from brake line.
Page 232 BR01–6 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) Symptom Possible cause Remedy/Prevention Brake drags or does not release Improper return of master cylinder pis- Replace master cylinder assembly. Clogging of brake system Replace the pipe, hose, etc. Constricted master cylinder reservoir Clean vent passage in reservoir cap.
Page 233 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–7 Symptom Possible cause Remedy/Prevention Brake squeal Improper pad material or glazed pad Replace pad. Pad back plate contact with rotor Replace pad. Deformation or wear of rotor Repair or replace. Intrusion of foreign matter between Clean the surface of pad or replace.
Page 234 BR01–8 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) Symptom Possible cause Remedy/Prevention Power steering pump is noisy Insufficient power steering fluid Refill proper level. Air trapped in the power steering fluid Bleed air from power steering system. Contamination in the power steering Replace power steering pump and fluid fluid.
Page 235: Brake System Air Bleeding
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–9 BRAKE SYSTEM AIR BLEEDING EN0680101F300002 PREPARATION Apply the parking brake and block the wheels. Turn the starter switch to "LOCK" position and disconnect the battery terminals. NOTICE The starter switch must remain at "LOCK" position for the entire bleeding procedure.
Page 236 BR01–10 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) (11) Check the travel of the brake pedal. If a firm resistance is felt the man- ual bleeding procedure is complete. (12) Check the fluid level in reservoir and fill if required. Replace reservoir cap and dispose of used brake fluid.
Page 237: Power Steering System Air Bleeding
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–11 POWER STEERING SYSTEM AIR BLEED- EN0680101H200001 FILL THE OIL RESERVOIR WITH POWER STEERING FLUID. NOTICE • Use only specified fluid. • Do not overfill the oil reservoir. • Replace old fluid with new fluid after overhauling power steering gear unit or power steering pump.
Page 238: Brake Test
BR01–12 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) CHECK THE BRAKE OPERATION. Release the parking brake. Turn the starter switch to "ON" position (engine is not running). The brake pressure warning light and buzzer should come on. Depress the brake pedal, and the backup pump should start. Start the engine and depress the brake pedal.
Page 239 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) BR01–1 B RAKE EQUIPMENT B R 0 1 (MODELS WITH FULL AIR BRAKE) BR01-002 SERVICE BRAKE ASSEMBLY....BR01-2 DESCRIPTION ..........BR01-2 DATA AND SPECIFICATIONS ......BR01-3 DIAGRAM ............BR01-4 TROUBLESHOOTING ........BR01-5...
Page 240: Service Brake Assembly
BR01–2 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) SERVICE BRAKE ASSEMBLY DESCRIPTION EN0680201C100001 Type of service brake Full air, S-cam brake (Q-plus) with automatic adjuster. Air charging system Air charging is from piston type air compressor and air flow is directed and controlled by a pressure regulator, the necessary valves, and lines as required.
Page 241: Data And Specifications
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) BR01–3 DATA AND SPECIFICATIONS EN0680201I200001 Model  specification Parts name Maker Front axle wheel brake MERITOR 15 x 4 Q-Plus Cam Brake with Cast Spider, auto- matic slack adjuster (Slack length: 5.5, type: handed) Drum: 15 in.
Page 242: Diagram
BR01–4 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) DIAGRAM EN0680201J100001 MODEL: HINO 258, 268 (NJ8J), 338 (NV8J), AND 358 (NH8J) FULL AIR BRAKE CAB SIDE CHASSIS SIDE CIRCUIT OF CAB AIR CIRCUIT OF SUSPENSION CIRCUIT OF AIR HORN DIFFERENTIAL LOCK...
Page 243: Troubleshooting
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) BR01–5 TROUBLESHOOTING EN0680201F300001 Symptom Possible cause Remedy/Prevention Not enough braking (Wheel brake Lining is wet with grease or oil Replace lining. and drum) Improper contact of drum and lining Correct. Improper lining material or hardening Replace lining.
Page 244 BR01–6 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) Symptom Possible cause Remedy/Prevention Brake squeal (Wheel brake and Improper lining material or glazed lin- Replace lining. drum) Loose lining rivet Replace or tighten the rivet further. Lining rivet in contact with drum Replace lining and rivet.
Page 245 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–1 S ERVICE BRAKE (HYDRAULIC BRAKE) B R 0 2 BR02-001 HYDRAULIC BRAKE ........BR02-2 INSPECTION AND ADJUSTMENT ....BR02-2 HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER CYLINDER .......BR02-5 DATA AND SPECIFICATIONS ......BR02-5 DESCRIPTION ..........BR02-5 PRINCIPLE OF OPERATION ......BR02-7 COMPONENT LOCATOR........
Page 246: Hydraulic Brake
BR02–2 SERVICE BRAKE (HYDRAULIC BRAKE) HYDRAULIC BRAKE INSPECTION AND ADJUSTMENT EN1680102H600001 REMAINING THICKNESS OF PAD Inspect the pad thickness. If the pad thickness is less than the service limit or if it is foreseen that it may be worn to the service limit before the next inspection, replace it with a new one.
Page 247 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–3 BRAKE FLUID When the brake fluid is used for a long time, water may get into the brake fluid and its boiling point may become low, thereby causing a possibility of vapor lock which is very dangerous. Replace old brake fluid with fresh brake fluid (Use DOT3 or DOT4 brake fluid) every 36,000 miles (60,000 km) or 12 months.
Page 248 BR02–4 SERVICE BRAKE (HYDRAULIC BRAKE) BRAKE PRESSURE WARNING LIGHT Check for brake pressure warning light failure. If the brake pressure warning light does not turn on when the starter switch is turned to the ON position, the light has burned out. Replace any burned out light with a new one.
Page 249: Hydro-Max Hydraulic Brake Booster And Master Cylinder
SERVICE BRAKE (HYDRAULIC BRAKE) BR02–5 HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER CYLINDER DATA AND SPECIFICATIONS EN1680102I200001 Manufacturer BOSCH Type HYDRO-MAX II and master cylinder Master cylinder diameter 50.80 mm {2.00 in} DESCRIPTION EN1680102D100001 SAPH168010200004...
Page 250 BR02–6 SERVICE BRAKE (HYDRAULIC BRAKE) SAPH168010200005 Reservoir cap with diaphragm Check valve seat Differential pressure switch Check ball Tube seat Hydro-Max booster assembly Master cylinder assembly Check ball retainer Flow switch Adapter O-ring Face seal Flow piston Backup pump Flow piston spring Backup pump relay NOTICE The above parts can be replaced if necessary.
Page 251: Principle Of Operation
SERVICE BRAKE (HYDRAULIC BRAKE) BR02–7 PRINCIPLE OF OPERATION EN1680102C100001 HYDRO-MAX BOOSTER During normal system operation, fluid flow from a hydraulic power source (the power steering pump) enters the inlet port of the Hydro-Max booster, flows through the power piston, around the throttle valve and through the flow switch, exiting through the outlet port.
Page 252 BR02–8 SERVICE BRAKE (HYDRAULIC BRAKE) SAPH168010200006 NOTICE This illustration is a representative model for operation reference.
Page 253: Component Locator
SERVICE BRAKE (HYDRAULIC BRAKE) BR02–9 COMPONENT LOCATOR EN1680102D100002 SAPH168010200007 Brake hose Stop light switch Brake hose clip Stop light switch cover Brake pipe bracket Return spring Brake pipe Bushing Sub harness Brake pedal Harness clamp Collar Hydro-Max booster and master cylinder Pedal pad Retainer Power steering fluid reservoir...
Page 254: Hydro-Max Booster
BR02–10 SERVICE BRAKE (HYDRAULIC BRAKE) HYDRO-MAX BOOSTER OVERHAUL EN1680102H200001 IMPORTANT POINT-DISMOUNTING ! CAUTION The Hydro-Max booster and the master cylinder use two distinctly dif- ferent incompatible hydraulic fluids. They must not be mixed. Using the incorrect fluid will permanently damage the seals and can cause malfunctioning brakes.
Page 255 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–11 REMOVE THE HYDRO-MAX BOOSTER Remove the stop light switch cover. Stop light switch cover Stop light switch Remove the clevis pin to disconnect the brake pedal, stop light switch and push rod. Remove the Hydro-Max booster tightening nuts. Move the master cylinder forward to allow for the Hydro-Max booster removal and support it in that position.
Page 256 BR02–12 SERVICE BRAKE (HYDRAULIC BRAKE) IMPORTANT POINTS-ASSEMBLY O-ring INSTALL THE INLET CHECK VALVE Install the check ball to inlet port. Check valve seat Lubricate and install the O-ring in the inlet check seat. Check ball Install the inlet check valve seat. SAPH168010200015 INSTALL THE FLOW SWITCH ASSEMBLY Install the flow spring and piston.
Page 257 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–13 IMPORTANT POINTS-MOUNTING Stop light switch cover INSTALL THE HYDRO-MAX BOOSTER Install the Hydro-Max booster and tighten the nuts. Tightening Torque: 33.9-40.7 Nm {346-415 kgcm, 25-30 lbfft} Install the clevis pin to connect the brake pedal, stop light switch and Brake pedal push rod.
Page 258 BR02–14 SERVICE BRAKE (HYDRAULIC BRAKE) Connect hydraulic hose and tighten the clamp. Tighten the clamp until dimension L = 4-5 mm (0.16-0.19 in.). SAPH168010200022 CONNECT THE HARNESS CONNECTORS AND HARNESS Install the sub harness to the backup pump terminal. Connect the connectors of differential pressure switch, flow switch, backup pump sub harness and relay.
Page 259 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–15 BRAKE PEDAL HEIGHT Check that the pedal height H from the floor is within the stan- dard dimension. Standard: 162.5-172.5 mm {6.4-6.7 in} Flooe panel SAPH168010200024...
Page 260: Master Cylinder
BR02–16 SERVICE BRAKE (HYDRAULIC BRAKE) MASTER CYLINDER OVERHAUL EN1680102H200002 IMPORTANT POINTS-DISMOUNTING ! WARNING If the brake pressure warning light continues to light up after the engine has started, the vehicle should not be operated for safety rea- sons. During normal driving a longer stopping distance is required so extreme caution should be taken as there is a risk of personal injury or property damage.
Page 261 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–17 IMPORTANT POINTS-ASSEMBLY INSTALL THE PRESSURE DIFFERENTIAL SWITCH Tightening Torque: 1.1-1.7 Nm {11-17 kgfcm, 9.7-15 lbfin.} Pressure differential switch SAPH168010200027 INSTALL THE TUBE SEAT If the tube seat was removed, install the new parts. Press the tube seat by using a tube nut. Make sure the seat is completely inserted in the bottom.
Page 262: Pressure Tests
BR02–18 SERVICE BRAKE (HYDRAULIC BRAKE) PRESSURE TESTS EN1680102H600002 CHECK THE BRAKE LINE PRESSURE To measure the brake line pressure, install a 0 to 13,800 kPa {140 kgf/ , 2,000 lbf/in } gauge to the brake caliper. Depress the brake pedal while the engine is not running. The backup pump should start and produce pressure approximately 5,515 kPa {56 kgf/cm , 800 lbf/in...
Page 263: Abs Modulator
SERVICE BRAKE (HYDRAULIC BRAKE) BR02–19 ABS MODULATOR DATA AND SPECIFICATIONS EN1680102I200002 Manufacturer MERITOR WABCO Type Hydraulic ABS modulator DESCRIPTION EN1680102D100003 E version Modulator valve SAPH168010200031 NOTICE For removal and installation of ABS MODULATOR. refer to chapter "BRAKE CONTROL (ABS: HYDRAULIC) (E ver- sion)"...
Page 264: Wheel Brake (Type: 4 Piston)
0.125" (3.2 mm) Brake Fluid High-Performance Brake Fluid DOT 3 or DOT 4 Rotor Rotor Diameter 15.38" (390.7 mm) Thickness (New) 1.54" (39.1 mm) Thickness (Discard) 1.42" (36.1 mm) Vehicle Model HINO 238, 258, 268, 338 (NE8J, NF8J): Front, Rear...
Page 265: Description
SERVICE BRAKE (HYDRAULIC BRAKE) BR02–21 DESCRIPTION EN1680102D100004 Spring bolt Lining assembly Piston button head bolt Seal Dust piston Lining Dust boot Piston boot spacer seal Piston Caliper housing SAPH168010200032 TORQUE SPECIFICATIONS Description Specification ABS Sensor Bolts — 5/16-18 9-12 lb-ft (12.2-16.3 Nm) Brake Hose Hold Down Clamp Bolt —...
Page 266: Troubleshooting
BR02–22 SERVICE BRAKE (HYDRAULIC BRAKE) TROUBLESHOOTING EN1680102F300001 Symptom Possible cause Remedy/Prevention Excessive Pedal Effort Pads worn below minimum thickness Install new pads. Faded, overheated condition, glazed Replace the rotor and/or reface pads if pads, blued or heat-checked rotors sufficient lining remains. Grease, oil and/or brake fluid on linings Install new pads in the axle sets.
Page 267 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–23 Symptom Possible cause Remedy/Prevention No Braking Effect or Excessive Reservoir fluid level low Check for causes of fluid leak, repair Pedal Travel as required and refill the reservoir. Bleed the system as needed. Air in the hydraulic system Bleed the system.
Page 268 BR02–24 SERVICE BRAKE (HYDRAULIC BRAKE) REMOVAL ! WARNING To prevent serious personal injury, always wear safe eye protection when you perform vehicle maintenance or service. BRAKE PADS Visually inspect all brake pads. Replace pads when the remaining lin- ing reaches 1/8-inch (3.175 mm) thickness. •...
Page 269 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–25 BRAKE CALIPER ! 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. Jacks can slip and fall over.
Page 270 BR02–26 SERVICE BRAKE (HYDRAULIC BRAKE) SUPPORT Remove the caliper from vehicle as described in Brake Caliper in this section. Remove the splash shield if installed from the support. Remove the hub and rotor assembly according to vehicle manufac- turer's recommended service procedure. Remove the ABS sensor.
Page 271 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–27 Place a block of wood (7-5/8 x 3-1/2 x 2-9/16-inches thick) between the caliper pistons. Use a C-clamp to hold the block of wood against the pistons on one side of the caliper. ! WARNING Wood When you use compressed air to remove the pistons form the caliper block...
Page 272 BR02–28 SERVICE BRAKE (HYDRAULIC BRAKE) (11) Remove the piston seals with a non-metallic device and discard them. Do not knock, scratch or otherwise scar piston bores or seal grooves. NOTICE Do not hone the caliper bores. Pistons are not available for honed cal- iper bores.
Page 273 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–29 ASSEMBLY ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. BRAKE CALIPER NOTICE When using compressed air, use air lines that are completely free of oil and moisture.
Page 274 BR02–30 SERVICE BRAKE (HYDRAULIC BRAKE) Install the piston boots over the projecting ends of the pistons and press the ring side of the boots into the boot bore. An old bearing cup equal to the boot ring size helps install the boots. Make sure the pis- ton boot bead is seated back against the shoulder of the projecting end of the piston.
Page 275 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–31 INSTALLATION ROTOR NOTICE Do not resurface a new replacement rotor. To install, reverse the removal processes, making sure that the mat- ing surfaces of the hub or spoke wheel and rotor are clean and free of rust build-up.
Page 276 BR02–32 SERVICE BRAKE (HYDRAULIC BRAKE) BRAKE PADS Inspect the rotor for scoring, warping, cracks, bluing, heat spots or other damage or defects and minimum thickness. Repair or replace if necessary. Inspect the disc brake calipers for leakage, damage or defects to pis- ton boots, seals or pistons.
Page 277 SERVICE BRAKE (HYDRAULIC BRAKE) BR02–33 INSPECT PARTS ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. CALIPER Clean the area around the brake hose. Use brake parts cleaner. Inspect the heat shields (previous style only) for wear and damage. Replace worn or damaged shields.
Page 278 BR02–34 SERVICE BRAKE (HYDRAULIC BRAKE) Open the outer bleeder screw and purge the air and tighten the bleeder screw to 9-12 lb-ft (12.2-16.3 Nm). Now again open the inner bleeder screw and purge the air and tighten the bleeder screw to 9-12 lb-ft (12.2-16.3 Nm). Repeat this procedure for all other brakes in the sequence specified in step 2.
Page 279 SERVICE BRAKE (FULL AIR BRAKE) BR02–1 S ERVICE BRAKE (FULL AIR BRAKE) B R 0 2 BR02-002 AIR DRYER AND RESERVOIR SYSTEM BRAKE CHAMBER (REAR) ....BR02-46 (MODEL: BENDIX AD-IS)......BR02-2 DATA AND SPECIFICATIONS....... BR02-46 DESCRIPTION ..........BR02-47 DESCRIPTION ..........BR02-2 COMPONENT LOCATOR ......
Page 280: Air Dryer And Reservoir System (Model: Bendix Ad-Is)
BR02–2 SERVICE BRAKE (FULL AIR BRAKE) AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD- DESCRIPTION EN0680202C100001 SHTS068020200001 TABLE 1 - PORT DESIGNATIONS Air Connection Port ID Function/Connection 1 IN Inlet Port (air in). 21 PRI Delivery Port out (to Primary reservoir) 22 SEC Delivery Port out (to Secondary reservoir) 24 AUX 1...
Page 281 SERVICE BRAKE (FULL AIR BRAKE) BR02–3 SHTS068020200002 The function of the pressure protection valves is to protect each reservoir from a pressure loss in the other reservoir or a pres- sure loss in an air accessory. Each of the pressure protection valves in the AD-IS air dryer and reservoir system may have different pressure settings, but these are factory set and must not be changed or adjusted.
Page 282 BR02–4 SERVICE BRAKE (FULL AIR BRAKE) SHTS068020200003 AD-IS AIR DRYER AND RESERVOIR SYSTEM OPERATION: GENERAL (Refer to Figure 2) The AD-IS air dryer and reservoir system is designed to receive compressed air from the vehicle air compressor, clean and dry the air, deliver air to the vehicle's primary reservoir, secondary reservoir and accessories, and control the compressor/ dryer charge cycle.
Page 283 SERVICE BRAKE (FULL AIR BRAKE) BR02–5 CHARGE CYCLE (Refer to Figure 2) When the compressor is loaded (compressing air) compressed air flows through the compressor discharge line to the inlet (1/ IN) port of the air dryer body. The compressed air often includes contaminates such as oil, oil vapor, water and water vapor. Traveling through the discharge line and into the air dryer, the temperature of the compressed air falls, causing some of the contaminants to condense and drop to the bottom of the air dryer and reservoir system purge valve assembly, ready to be expelled at the next purge cycle.
Page 284: Preventive Maintenance
BR02–6 SERVICE BRAKE (FULL AIR BRAKE) PREVENTIVE MAINTENANCE Important: Review the warranty policy before performing any intrusive maintenance procedures. An extended warranty may be voided if intrusive maintenance is performed during this period. Purge valve maintenance is permissible during the warranty period only when using a genuine Bendix purge valve kit.
Page 285 SERVICE BRAKE (FULL AIR BRAKE) BR02–7 OPERATION & LEAKAGE TESTS (ALSO SEE VIDEO BW2327) Check all lines and fittings leading to and from the air dryer and reservoir system for leakage and integrity. Repair any leaks found. Build up system pressure to governor cut-out and note that the AD-IS air dryer and reservoir system purges with an audible escape of air.
Page 286 BR02–8 SERVICE BRAKE (FULL AIR BRAKE) REBUILDING THE AD-IS AIR DRYER AND RESERVOIR SYSTEM GENERAL SAFETY GUIDELINES ! WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH: When working on or around a vehicle, the following general precautions should be observed at all times. Park the vehicle on a level surface, apply the parking brakes, and always block the wheels.
Page 287 SERVICE BRAKE (FULL AIR BRAKE) BR02–9 SHTS068020200006 Do not attempt to install, remove, disassemble or assemble a component until you have read and thoroughly understand the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools. If the work is being performed on the vehicle's air brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle.
Page 288 BR02–10 SERVICE BRAKE (FULL AIR BRAKE) GENERAL When rebuilding or replacing components of the air dryer and reservoir system use only genuine Bendix parts. For ease in ser- vicing, the AD-IS air dryer and reservoir system has been designed so that any of the following maintenance kits can be installed without removing the air dryer and reservoir system from the vehicle.
Page 289 SERVICE BRAKE (FULL AIR BRAKE) BR02–11 ROADSIDE INSPECTION In the event of a roadside inspection the system behavior will be as follows: When the system is charged to governor cut-out, and then one reservoir drain valve is opened, initially both reservoir gauges will fall, however, the AD-IS air dryer and reser- voir system primary and secondary pressure protection valves will close at pressures above 70 psi, protecting the remaining brake circuit from further loss of pressure.
Page 290 BR02–12 SERVICE BRAKE (FULL AIR BRAKE) DELIVERY CHECK VALVE CLEANING PROCEDURE (Note: This is only required if system pressure does not build after temporary bypass is completed.) See Figure 7 throughout this procedure. Depressurize the air brake system following the general safety precautions outlined elsewhere in this document.
Page 291: Ad-Is Air Dryer Reservoir System Troubleshooting Chart
SERVICE BRAKE (FULL AIR BRAKE) BR02–13 AD-IS AIR DRYER RESERVOIR SYSTEM TROUBLESHOOTING CHART EN0680202F300001 SYMPTOMS CAUSE REMEDY Dryer is constantly "cycling" A. Excessive system Test for excessive system leakage. or purging leakage Allowable leakage observed at dash gauge: Single vehicle - 1 psi/minute. Tractor trailer - 3 psi/minute.
Page 292 BR02–14 SERVICE BRAKE (FULL AIR BRAKE) SYMPTOMS CAUSE REMEDY Water in vehicle reservoirs. A. Maximum air dryer inlet Check for excessive carbon build up in compressor temperature is exceeded discharge line. Replace if required. Make certain due to improper discharge that discharge line length is at least 6 ft.
Page 293 SERVICE BRAKE (FULL AIR BRAKE) BR02–15 SYMPTOMS CAUSE REMEDY Constant exhaust of air at A. Air dryer purge valve leak- With compressor loaded, apply soap solution on air dryer purge valve ing excessively. purge valve exhaust, to test for excessive leakage. exhaust or unable to build Repair or replace purge valve as necessary.
Page 294 BR02–16 SERVICE BRAKE (FULL AIR BRAKE) SYMPTOMS CAUSE REMEDY "Pinging" noise excessive A. Single cylinder compres- A slight "pinging" sound may be heard during sys- during compressor loaded sor with high pulse cycles. tem build up when a single cylinder compressor is cycle.
Page 295: Check Valve
SERVICE BRAKE (FULL AIR BRAKE) BR02–17 CHECK VALVE DATA AND SPECIFICATIONS EN0680202I200001 Type Spring type, wafer type valve DESCRIPTION EN0680202C100002 INLET OUTLET SPRING INLET OUTLET WAFER-TYPE CHECK VALVE SHTS068020200008...
Page 296: Inspection And Repair
BR02–18 SERVICE BRAKE (FULL AIR BRAKE) INSPECTION AND REPAIR EN0680202H300001 PREVENTATIVE MAINTENANCE Every 6 months, 1,800 operating hours or every 50,000 miles inspect all parts. Replace any check valves leaking or showing signs of wear or deteri- oration. Check for proper operation. OPERATION &...
Page 297 SERVICE BRAKE (FULL AIR BRAKE) BR02–19 Do not attempt to install, remove, disassemble or assemble a compo- nent until you have read and thoroughly understand the recom- mended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools. Use only genuine Bendix replacement parts, components, and kits.
Page 298: Brake Pedal
BR02–20 SERVICE BRAKE (FULL AIR BRAKE) BRAKE PEDAL OVERHAUL EN0680202H200001 IMPORTANT POINTS-DISMOUNTING DISCONNECT THE NYLON TUBE FROM THE BRAKE VALVE AND CLUTCH PIPE FROM THE MASTER CYLINDER REMOVE THE CLUTCH MASTER CYLINDER AND DISCONNECT THE STEERING SHAFT REMOVE THE PEDAL BRACKET ASSEMBLY Loosen the bolts and remove the pedal bracket assembly.
Page 299 SERVICE BRAKE (FULL AIR BRAKE) BR02–21 IMPORTANT POINTS-MOUNTING INSTALL THE BRAKE VALVE ASSEMBLY Install the brake valve assembly with the 4 nuts. Tightening Torque: 18-26 Nm{184-265 kgfcm, 13-19 lbfft} CONNECT THE PUSH ROD JOINT TO THE BRAKE PEDAL LEVER NOTICE A: The boot has to be securely fit into the groove of the push rod.
Page 300 BR02–22 SERVICE BRAKE (FULL AIR BRAKE) If the pedal play is out of the standard value, loosen the lock nut and turn the push rod to adjust the pedal play to the standard value. NOTICE If you have loosened the push rod lock nut for the adjustment, retighten it securely.
Page 301: Brake Valve
SERVICE BRAKE (FULL AIR BRAKE) BR02–23 BRAKE VALVE DATA AND SPECIFICATIONS EN0680202I200002 Type Dual pistons and valves with a plunger type pedal DESCRIPTION EN0680202C100003 UPPER BODY DEL - 1 SUP - 1 LOWER BODY SUP - 2 BODY ATTACHING SCREWS DEL -2 EXHAUST COVER ATTACHING SCREWS...
Page 302: Component Locator
BR02–24 SERVICE BRAKE (FULL AIR BRAKE) COMPONENT LOCATOR EN0680202D100001 LOWER BODY UPPER BODY BODY ATTACHING SCREWS (QTY. 4) EXHAUST COVER ATTACHING SCREWS (QTY. 4) SHTS068020200018 Screw Relay piston spring Exhaust diaphragm Primary piston Washer Graduating spring Exhaust cover Washer Inlet valve Primary piston spring seat nut Seal ring Spring seat...
Page 303: Inspection And Repair
Apply 2 to 4 drops of oil between plunger and mounting plate - do not over oil! Every year, or 100,000 miles, or 3,600 operating hours: Disassemble: clean parts with mineral spirits, replace all rubber parts, or any part worn or damaged. Check for proper operation before plac- ing vehicle in service.
Page 304 BR02–26 SERVICE BRAKE (FULL AIR BRAKE) REMOVAL Chock the vehicle wheels or park the vehicle by mechanical means. (Block and hold vehicle by means other than air brakes.) Drain all air system reservoirs. Identify and disconnect all supply and delivery lines at the brake valve. Remove the brake valve and treadle assembly from the vehicle by removing the three cap screws on the outer bolt circle of the mounting plate.
Page 305 SERVICE BRAKE (FULL AIR BRAKE) BR02–27 ASSEMBLY Prior to reassembling, lubricate all o-rings, o-ring grooves, piston bores, and metal to metal moving surfaces with Dow Corning 55 o- ring lubricant (Bendix piece number 291126). IMPORTANT All torques specified in this manual are assembly torques and can be expected to fall off, after assembly is accomplished.
Page 306 BR02–28 SERVICE BRAKE (FULL AIR BRAKE) IMPORTANT: MAINTENANCE PRECAUTIONS When working on or around a vehicle, the following general precau- tions should be observed: Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Stop the engine when working around the vehicle.
Page 307: Relay Valve
SERVICE BRAKE (FULL AIR BRAKE) BR02–29 RELAY VALVE DATA AND SPECIFICATIONS EN0680202I200003 Type Diaphragm type with double check valve combined Pressure difference between signal and outlet pressure 29.4 kPa {0.3 kgf/cm , 4.26 lbf/in DESCRIPTION EN0680202C100004 BALANCE/QUICK EXHAUST PORT (ANTI-COMPOUND) EXHAUST COVER EXHAUST SEAT...
Page 308 BR02–30 SERVICE BRAKE (FULL AIR BRAKE) Every 12 months or 100,000 miles or 3,600 operating hours: disas- semble valve, clean parts with mineral spirits. Replace all rubber parts and any part worn or damaged. Check for proper operation before placing vehicle in service.
Page 309 SERVICE BRAKE (FULL AIR BRAKE) BR02–31 Remove the piston and o-ring from the body. While depressing the exhaust cover, remove the retaining ring and slowly relax the spring beneath the exhaust cover. Remove the exhaust cover assembly and o-rings. Remove the inlet/exhaust valve return spring from the body. Remove the inlet/exhaust valve from the body.
Page 310 BR02–32 SERVICE BRAKE (FULL AIR BRAKE) (14) Test the valves as outlined in the Operational and Leakage Test on page BR02-30 before returning the valve to service. INSTALLATION Clean air lines. Inspect all lines and/or hoses for damage and replace as necessary. Install valve and tighten mounting bolts.
Page 311: Spring Brake Modulating Valve
SERVICE BRAKE (FULL AIR BRAKE) BR02–33 SPRING BRAKE MODULATING VALVE DESCRIPTION EN0680202C100005 PARK CONTROL (FROM DASH VALVE) BALANCE PORT SUPPLY PORT DELIVERY EXHAUST SHTS068020200020...
Page 312: Component Locator
BR02–34 SERVICE BRAKE (FULL AIR BRAKE) COMPONENT LOCATOR EN0680202D100002 MAIN PISTON DOUBLE CHECK VALVE CONTROL PISTON O-RING SPRING GUIDE CHECK VALVE UPPER BODY COVER RETAINING RING O-RING PARK CONTROL PORT O-RING SPACER IN-LINE SINGLE MAIN PISTON CHECK VALVE SPRING BALANCE PORT SPRING STATIC PISTON O-RING...
Page 313: Inspection And Repair
SERVICE BRAKE (FULL AIR BRAKE) BR02–35 INSPECTION AND REPAIR EN0680202H200004 PREVENTIVE MAINTENANCE The SR-7 valve should be inspected every 6 months or 1500 operating hours, whichever comes first, for proper operation. Should the SR-7 valve not meet the elements of the opera- tional tests noted in this document, further investigation and ser- vice of the valve may be required.
Page 314 BR02–36 SERVICE BRAKE (FULL AIR BRAKE) WARNING! PLEASE READ AND FOLLOW THESE INSTRUC- TIONS TO AVOID PERSONAL INJURY OR DEATH: When working on or around a vehicle, the following general precau- tions should be observed at all times. Park the vehicle on a level surface, apply the parking brakes, and always block the wheels.
Page 315: Spring Brake Control Valve
SERVICE BRAKE (FULL AIR BRAKE) BR02–37 SPRING BRAKE CONTROL VALVE DESCRIPTION EN0680202C100006 SUPPLY DELIVERY EXHAUST COVER BUTTON Ports: Port Embossed I.D. Primary Reservoir Supply Supply 11 Secondary Reservoir Supply Supply 12 Delivery Delivery 21 Exhaust Exhaust 3 SHTS068020200022...
Page 316: Component Locator
BR02–38 SERVICE BRAKE (FULL AIR BRAKE) COMPONENT LOCATOR EN0680202D100003 BUTTON SCREW COVER CHECK VALVE SEAT GUIDE SPOOL BODY PLUNGER STEM PLUNGER INDEX TABS SHTS068020200023...
Page 317: Inspection And Repair
Every 3 months; 25,000 miles; or 900 operating hours; or during the vehicle chassis lubrication interval, make the visual inspections noted in "SERVICE CHECKS." Every 12 months; 100,000 miles; or 3,600 operating hours, perform "OPERATIONAL AND LEAKAGE TESTS." SERVICE CHECKS Remove any accumulated contaminants.
Page 318 BR02–40 SERVICE BRAKE (FULL AIR BRAKE) INSTALLATION Install the PP-DC in its location on the dashboard. Using the mounting hardware saved in "REMOVAL," secure the valve to the vehicle. Reconnect all air lines to the valve using the identification made in "REMOVAL."...
Page 319 SERVICE BRAKE (FULL AIR BRAKE) BR02–41 NOTICE Before placing the vehicle back into service, perform the "leakage and operational tests" in this manual. If the PP-DC fails to function as described, or if leakage is excessive, repair the valve or replace it at the nearest authorized Bendix Commercial Vehicle Systems parts outlet.
Page 320: Brake Chamber (Front)
BR02–42 SERVICE BRAKE (FULL AIR BRAKE) BRAKE CHAMBER (FRONT) DATA AND SPECIFICATIONS EN0680202I200004 P/N Series 1420 Model Size Stroke 2.25" Part Number 1420001 Wt. (Lbs.) 7.55 4.16 3.41 6.92 4.75 5/8"-11UNC 5/8"-18UNF Inlets 3/8"-NPTF X-Min. (in the caged position) 8.00" DESCRIPTION EN0680202C100007 SHTS068020200024...
Page 321: Component Locator
SERVICE BRAKE (FULL AIR BRAKE) BR02–43 COMPONENT LOCATOR EN0680202D100004 SHTS068020200025 Kit - NP Chamber (b) Kit - Center Hole Shield Kit - Nuts & Bolts NP Chamber Assembly Clamp Band Assembly Kit - Nuts & Washers Diaphragm Hex Nut - Yoke Kit - Push-Rod Assembly (b) Pressure Cap (2-inlets/steel) (a) Return Spring...
Page 322: Overhaul
BR02–44 SERVICE BRAKE (FULL AIR BRAKE) OVERHAUL EN0680202H200006 IMPORTANT POINT-DISMOUNTING Brake chamber DISMOUNTING OF THE BRAKE CHAMBER Threaded clevis Before dismounting, apply aligning mark to the chamber, clamp and chamber cover. Apply a position mark "R" or "L" to identify the side where the cham- ber was installed.
Page 323: Inspection And Repair
SERVICE BRAKE (FULL AIR BRAKE) BR02–45 IMPORTANT POINT-MOUNTING INSTALLING THE BRAKE CHAMBER The chamber must be mounted on the side a s marked when dis- mounting. NOTICE • See the position mark ("R" or "L") which was applied when dis- mounting.
Page 324: Brake Chamber (Rear)
BR02–46 SERVICE BRAKE (FULL AIR BRAKE) BRAKE CHAMBER (REAR) DATA AND SPECIFICATIONS EN0680202I200005 Type Diaphragm type P/N Series 3430 Model TR3030 Size 3030 Stroke 2.50" P/N Combination 3430051 P/N Single/Piggyback 3430001 P/N Piggyback Plus Kit 3430008 Wt.Combination (Lbs.) 20.0 Wt. Single (Lbs.) 11.6 9.04 6.66...
Page 325: Description
SERVICE BRAKE (FULL AIR BRAKE) BR02–47 DESCRIPTION EN0680202C100008 SHTS068020200031...
Page 326: Component Locator
BR02–48 SERVICE BRAKE (FULL AIR BRAKE) COMPONENT LOCATOR EN0680202D100005 Center Hole Shield Permits visual inspection of stroke alert but prevents entry of contaminants SHTS068020200032 Kit-NP Chamber (b) NP Chamber Assembly Kit-Nuts & Bolts Kit-Nuts & Washers Clamp Band Assembly Hex Nut - Yoke Diaphragm Kit-Weatherseal Plug...
Page 327: Inspection And Repair
SERVICE BRAKE (FULL AIR BRAKE) BR02–49 INSPECTION AND REPAIR EN0680202H300003 ! CAUTION The MGM Brakes Tamper Resistant spring brake chambers are an important part of your braking system. While they do not require scheduled servicing, it is good preventative maintenance to make the following routine inspections while they are in the shop for regular servicing of other components or at a minimum of every 50,000 miles.
Page 328 BR02–50 SERVICE BRAKE (FULL AIR BRAKE) Inspect the YOKE ASSEMBLY being sure YOKE PIN is installed and locked into place with a COTTER PIN. Replace any damaged, worn or missing parts. MGM Brakes recommends the YOKE LOCKNUT be tightened to 25-50 Lbs.-Ft. torque. (Not Shown) On units equipped with a DUST BOOT, check the BOOT for damage and replace as necessary.
Page 329 SERVICE BRAKE (FULL AIR BRAKE) BR02–51 IMPORTANT If the bolt does not lock into the piston in less than 1/2 inch out- ward movement, repeat 1. (4) and (5) until you are sure it does lock. Holding the bolt locked into the piston, install the flat washer and the release nut on the end of the release-bolt, and turn down the nut against the flat washer until finger tight.
Page 330 BR02–52 SERVICE BRAKE (FULL AIR BRAKE) Using a 15/16 inch wrench, unscrew hex nuts on mounting bolts and cautiously remove the old chamber from the mounting bracket. Cut the service push-rod to proper length. Remove the hex nut and the flat washers on the mounting bolts of the new chamber, clean the face of the mounting bracket and install the chamber on the bracket with close attention given to positioning the chamber air inlet ports for correct alignment to the vehicle lines.
Page 331 SERVICE BRAKE (FULL AIR BRAKE) BR02–53 securely in place will void the MGM Brakes Warranty without remedy. IMPORTANT: If chamber is fitted with an external breather tube be sure both ends of the connector tube are engaged a minimum of 1/2 inch into each of the flexible elbows.
Page 332 BR02–54 SERVICE BRAKE (FULL AIR BRAKE) Make sure the spring chamber of the removed actuator is fully released (power spring caged) and the service brake push-rod is fully retracted to zero stroke position (i.e., brake fully released). Measure and record the "X" and "Y" dimensions. "X"...
Page 333 SERVICE BRAKE (FULL AIR BRAKE) BR02–55 On all MGM Brakes models fitted with external breather tubes, dis- connect the tube and elbow from the service chamber housing. Apply Adhesive Here 1/2-inch Minimum Engagement 1/2-inch Diameter Hole SHTS068020200045 Using a 9/16 inch wrench or socket, remove the clamp nuts on the service clamp ring.
Page 334 BR02–56 SERVICE BRAKE (FULL AIR BRAKE) Make sure the new single (piggyback) spring brake is fully released as outlined in Section 2 on page BR02-50 of this manual. Position the diaphragm in the bottom recess of the chamber and, with very close attention taken to assure all mating parts are aligned straight and the air lines are positioned to mate with the vehicle air supply lines, replace the service clamp ring.
Page 335 SERVICE BRAKE (FULL AIR BRAKE) BR02–57 (12) Replace the end cap properly. Operating these units without the END CAP securely in place will void the MGM Brakes Warranty without remedy. REMOVAL AND INSTALLATION INSTRUCTIONS FOR "SERVICE BRAKE DIAPHRAGM" Follow all instructions given in Section 5 of this manual and install the new diaphragm in Step 5-(5).
Page 336 BR02–58 SERVICE BRAKE (FULL AIR BRAKE) CAM BRAKE ADJUSTMENT - ALL MODELS SPRING BRAKE AND SERVICE BRAKE ACTUATORS. NOTICE The last half of an air chamber stroke is less efficient than the first half. Therefore, the following adjustments are recommended for maxi- mum efficiency when using manually adjusted slack adjusters.
Page 337 SERVICE BRAKE (FULL AIR BRAKE) BR02–59 RECOMMENDED SPRING BRAKE ACTUATOR DISARMING PRO- CEDURE ! WARNING • This procedure must be strictly adhered to. never attempt to remove the spring chamber clamp ring from a double diaphragm actuator or the spring chamber retaining ring from a piston actu- ator.
Page 338: Protection Valve
BR02–60 SERVICE BRAKE (FULL AIR BRAKE) PROTECTION VALVE DATA AND SPECIFICATIONS EN0680202I200006 Type Spring type Operating pressure Close 70 PSI DESCRIPTION EN0680202C100009 SPRING PISTON VALVE INLET PORT DELIVERY PORT PR-4 SHTS068020200051...
Page 339: Inspection
SERVICE BRAKE (FULL AIR BRAKE) BR02–61 INSPECTION EN0680202H200007 PREVENTIVE MAINTENANCE Every 3 months, 900 operating hours or 25,000 miles, whichever if first, it is recommended that the operation and leakage checks described in this manual be performed. OPERATING CHECKS Provide a pressure gauge and drain valve at the supply side and delivery side of the pressure protection valve being checked.
Page 340 BR02–62 SERVICE BRAKE (FULL AIR BRAKE) WHEN WORKING ON OR AROUND A VEHICLE, THE FOLLOW- ING GENERAL PRECAUTIONS SHOULD BE OBSERVED AT ALL TIMES: ! WARNING Please read and follow these instructions to avoid personal injury or death. Park the vehicle on a level surface, apply the parking brakes, and always block the wheels.
Page 341: Wheel Brake
SERVICE BRAKE (FULL AIR BRAKE) BR02–63 WHEEL BRAKE DATA AND SPECIFICATIONS EN0680202I200007 Drum brake with internally expanding, leading-trailing Type shoes operated by camshaft and automatic slack adjuster in all wheels. Front 15 x 4 in. (381 x 102 mm), 16.5 x 5 in. (419 x 127 mm) Brake drum inside diameter x lining width Rear...
Page 342: Description
BR02–64 SERVICE BRAKE (FULL AIR BRAKE) DESCRIPTION EN0680202C100010 HOLD DOWN CLIP (2) CAM BRACKET MOUNTING (4) PUSH ROD LOCK NUT (1) (some models) 0.500"-13 thread 0.625"-18 thread 0.250"-28 thread Grade 8 = 90-120 lb-ft (122-163 N·m) 25-50 lb-ft (34-68 N·m) 105-135 lb-in (12-15 N·m) Grade 5 = 65-100 lb-ft (88-136 N·m) 0.500"-20 thread...
Page 343: Component Locator
SERVICE BRAKE (FULL AIR BRAKE) BR02–65 COMPONENT LOCATOR EN0680202D100006 FRONT 13 14 SHTS068020200053 Shoe and Lining Assembly Cast spider — brake Spring — shoe retaining Seal — chamber bracket Bushing — anchor pin Bracket — camshaft and chamber Anchor Pin — brake shoe Capscrew —...
Page 344 BR02–66 SERVICE BRAKE (FULL AIR BRAKE) SHTS068020200054...
Page 345: Overhaul
SERVICE BRAKE (FULL AIR BRAKE) BR02–67 OVERHAUL EN0680202H200008 ! WARNING • ArvinMeritor Automatic Slack Adjusters (ASA's) should not need to be manually adjusted in service. ASA's should not have to be adjusted to correct excessive pushrod stroke. The excessive stroke may be an indication that a problem exists with the foun- dation brake, ASA, brake actuator or other system components.
Page 346 BR02–68 SERVICE BRAKE (FULL AIR BRAKE) ! WARNING • Some brake linings contain asbestos fibers, a cancer and lung disease hazard. Some brake linings contain non-asbestos fibers, whose long-term effects to health are unknown. You must use caution when you handle both asbestos and non-asbestos mate- rials.
Page 347 SERVICE BRAKE (FULL AIR BRAKE) BR02–69 b. Use a wrench to turn the manual adjusting nut COUNTER- CLOCKWISE until the brake shoes are fully retracted, and the lin- ing clears the drum. ! WARNING When you remove a clevis pin that has a spring, hold the spring with pliers.
Page 348 BR02–70 SERVICE BRAKE (FULL AIR BRAKE) Check Cam-to-Bushing Radial Free Play and Axial End Play Before you remove the automatic slack adjuster and camshaft, move the camshaft as shown in figure. Use a feeler gauge to verify that the cam-to-bushing radial free play and axial end play are within specifi- cation.
Page 349 SERVICE BRAKE (FULL AIR BRAKE) BR02–71 IMPORTANT POINTS-ASSEMBLY Automatic Slack Adjuster a. If the slack adjuster has a "quick connect" clevis, check the gap between the clevis and the collar. • If the gap exceeds 0.060-inch (1.52 mm): Replace the clevis with a one-piece threaded clevis.
Page 350 BR02–72 SERVICE BRAKE (FULL AIR BRAKE) Automatic Slack Adjuster Grease Specifications Components Meritor NLGI Grade Grease Type Outside Temperature Specification Automatic Slack Adjuster O-616-A Clay Base Down to -40F (-40C) O-692 1 and 2 Lithium Base Down to -40F (-40C) O-645 Synthetic Oil, Clay Down to -65F (-54C)
Page 351 SERVICE BRAKE (FULL AIR BRAKE) BR02–73 ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. SEAL SEAL SPIDER CAMSHAFT BRACKET SHTS068020200065 ! WARNING Do not use the straight-center bar shoe return spring with the Q Plus camshaft.
Page 352 BR02–74 SERVICE BRAKE (FULL AIR BRAKE) Automatic Slack Adjuster onto the Camshaft a. Check the camshaft and bushings and seals for wear and corro- sion. Turn the camshaft by hand to check for smooth operation. Repair or replace parts as required. b.
Page 353 SERVICE BRAKE (FULL AIR BRAKE) BR02–75 ! CAUTION You must disengage a pull pawl or remove a conventional pawl before rotating the manual adjusting nut, or you will damage the pawl teeth. A damaged pawl will not allow the slack adjuster to automatically adjust brake clearance.
Page 354 BR02–76 SERVICE BRAKE (FULL AIR BRAKE) ! WARNING • Meritor provides a slack adjuster template for truck and tractor, trailer, and coach drum brakes. These templates are not inter- changeable. You must use the correct template when you install the clevis. •...
Page 355 SERVICE BRAKE (FULL AIR BRAKE) BR02–77 d. Verify that thread engagement between the clevis and push rod is 1/2-5/8-inch (12.7-15.9 mm). MINIMUM 1/2" e. Verify that the push rod does not extend through the clevis more than 1/8-inch (12.7 mm). •...
Page 356 BR02–78 SERVICE BRAKE (FULL AIR BRAKE) b. Rotate the lower brake shoe forward. Install a new brake shoe return spring with the open end of the spring hooks toward the camshaft. SHTS068020200075 c. Pull each brake shoe away from the camshaft to enable you to install the camshaft roller and roller retainer.
Page 357 SERVICE BRAKE (FULL AIR BRAKE) BR02–79 Cam Brake Grease Specifications Components Meritor NLGI Grade Grease Type Outside Temperature Specification • Retainer Clips O-616-A Clay Base Down to -40F (-40C) • Anchor Pins O-617-A Lithium 12-Hydroxy Refer to the grease manufac- •...
Page 358 BR02–80 SERVICE BRAKE (FULL AIR BRAKE) ADJUST THE BRAKES When you perform preventive maintenance procedures on an in-ser- vice brake, check both the free stroke and adjusted chamber stroke. Refer to Commercial Vehicle Safety Alliance (CVSA) Guidelines to Measure Push Rod Travel (Adjusted Chamber Stroke) in this section. Free stroke sets the clearance between the linings and drum.
Page 359 SERVICE BRAKE (FULL AIR BRAKE) BR02–81 Re-engage the pull pawl by removing the screwdriver or equiva- lent tool. The pull pawl will re-engage automatically. Disengage pull pawl • If the slack adjuster has a conventional pawl: Install the pawl or remove assembly into the housing.
Page 360 BR02–82 SERVICE BRAKE (FULL AIR BRAKE) "Standard Stroke" Clamp-Type Brake Chamber Data Type Outside Diameter Brake Adjustment Limit (inches) (inches) 4-1/2 1-1/4 5-1/4 1-3/8 5-4/16 1-3/8 As short as possible 6-3/8 1-3/4 without lining to drum 6-25/32 1-3/4 contact 7-7/32 1-3/4 8-3/32 2-1/4...
Page 361 SERVICE BRAKE (FULL AIR BRAKE) BR02–83 Combination Friction Linings ! CAUTION When you install combination friction linings, you must install the pri- mary lining on the primary brake shoe. If you install combination fric- tion linings incorrectly, damage to components will result. Carefully follow instructions included with the replacement linings.
Page 362: Inspection And Repair
BR02–84 SERVICE BRAKE (FULL AIR BRAKE) Both wheel ends of each axle must have the same linings and drums. All four wheel ends of tandem axles also must have the same linings TANDEM AXLES FRONT AXLE and drums. It is not necessary for the front axle brakes to be the same as the rear driving axle brakes.
Page 363 SERVICE BRAKE (FULL AIR BRAKE) BR02–85 NOTICE If you remove cotter pins from a slack adjuster during maintenance and service procedures, Meritor recommends that you install clevis pin retainer clips at assembly. Inspect clevis pin retainer clips or cotter pins for wear or damage. Replace worn or damaged retainer clips or cotter pins.
Page 364: Automatic Slack Adjuster
BR02–86 SERVICE BRAKE (FULL AIR BRAKE) AUTOMATIC SLACK ADJUSTER DESCRIPTION EN0680202C100011 PUSH LARGE CLEVIS LARGE CLEVIS PIN CLEVIS RETAINER CLIP BRAKE AIR CHAMBER SMALL CLEVIS PIN RETAINER CLIP SMALL CLEVIS PIN ACTUATOR ROD BOOT COLLAR BOOT RETAINING CLAMP HOUSING PISTON ROLLER (PIN) RETAINING RING ACTUATOR PISTON...
Page 365: Diagnostics
SERVICE BRAKE (FULL AIR BRAKE) BR02–87 DIAGNOSTICS EN0680202F300002 Symptom Possible Causes Corrective Actions Adjusted stroke is too long. The slack adjuster part number is Check with WD or OEM. No adjustment. incorrect. Use correct template or BSAP setting The clevis angle is incorrect. to install clevis correctly.
Page 366: Component Locator
BR02–88 SERVICE BRAKE (FULL AIR BRAKE) COMPONENT LOCATOR EN0680202D100007 BOOT RETAINING BOOT CLAMP SMALL CLEVIS PIN ACTUATOR ROD PISTON RETAINING LARGE RING ACTUATOR CLEVIS PIN ROLLER (PIN) ASSEMBLY RETAINER CLIP ACTUATOR PISTON ACTUATOR (ADJUSTING SLEEVE) SMALL LARGE CLEVIS PIN CLEVIS PIN RETAINER CLIP HOUSING...
Page 367 SERVICE BRAKE (FULL AIR BRAKE) BR02–89 "QUICK CONNECT" CLEVIS Some models of Meritor's automatic slack adjuster have a "Quick CLEVIS Connect" clevis. • A "Quick Connect" clevis is a three-piece assembly that cannot be separated after it is assembled. • The collar has a threaded hole for the push rod.
Page 368: Overhaul
BR02–90 SERVICE BRAKE (FULL AIR BRAKE) OVERHAUL EN0680202H200009 ! WARNING • ArvinMeritor Automatic Slack Adjusters (ASA's) should not need to be manually adjusted in service. ASA's should not have to be adjusted to correct excessive pushrod stroke. The excessive stroke may be an indication that a problem exists with the foun- dation brake, ASA, brake actuator or other system components.
Page 369 SERVICE BRAKE (FULL AIR BRAKE) BR02–91 Use a wrench to turn the manual adjusting nut in the direction shown in figure. Move the slack adjuster away from the clevis. Remove the snap ring and washers from the camshaft. Remove the slack adjuster from the camshaft.
Page 370 BR02–92 SERVICE BRAKE (FULL AIR BRAKE) NOTICE Steps (11) through (21) apply only to automatic slack adjusters manu- factured BEFORE January 1993. The gear set and seals are not ser- viceable on automatic slack adjusters manufactured AFTER January 1993. Refer to the exploded views on pages (2) and (3) of this manual for more information.
Page 371 SERVICE BRAKE (FULL AIR BRAKE) BR02–93 IMPORTANT POINTS-INSPECTION PREPARE PARTS FOR ASSEMBLY ! WARNING • To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. • Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emul- sion-type cleaners and petroleum-based cleaners.
Page 372 BR02–94 SERVICE BRAKE (FULL AIR BRAKE) AUTOMATIC SLACK ADJUSTERS ! CAUTION Always replace used clevis pin retainer clips with new ones when ser- vicing the automatic slack adjuster or chamber. Do not reuse clevis pin retainer clips after removing them. Discard used clips. When removed for maintenance or service, clevis pin retainer clips can be bent or "gapped apart"...
Page 373 SERVICE BRAKE (FULL AIR BRAKE) BR02–95 Expand the retaining ring coil. Install one end of the coil into the groove in the outer diameter of the gear. Work around the gear and press the coil into the groove. SHTS068020200102 Repeat Steps 7 and 8 for the opposite side of the gear. (10) Install the worm into the bore.
Page 374 BR02–96 SERVICE BRAKE (FULL AIR BRAKE) (13) If you removed the pin, install it into the rod and piston. (14) Install the actuator rod and piston assembly into the actuator (adjust- ing sleeve). (15) Slide the piston retaining ring over the rod. PISTON (16) Extend the coils of the ring.
Page 375 SERVICE BRAKE (FULL AIR BRAKE) BR02–97 (28) As you turn the adjusting nut in the direction shown in figure, read the torque scale and rotate the gear 360 degrees (22 turns of the wrench). 22 TURNS ROTATE GEAR 360º SHTS068020200108 (29) The torque value must remain less than 25 lb-in (2.83 Nm) during the complete 360-degree rotation of the gear.
Page 376: Installing The Slack Adjuster
BR02–98 SERVICE BRAKE (FULL AIR BRAKE) INSTALLING SLACK ADJUSTER ONTO THE CAMSHAFT EN0680202H200010 INSTALLATION ! WARNING • To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. • Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands.
Page 377 SERVICE BRAKE (FULL AIR BRAKE) BR02–99 If the automatic slack adjuster gear has a 10-tooth spline, apply anti- seize compound to the slack adjuster and cam splines. Use Meritor specified O-637, Southwest SA 8249496 or equivalent lubricants. NOTICE Install the slack adjuster so that you can remove a conventional pawl or disengage a pull pawl when you adjust the brake.
Page 378: Check & Adjustment
BR02–100 SERVICE BRAKE (FULL AIR BRAKE) CHECK & ADJUSTMENT EN0680202H200011 CHECK BRAKE CHAMBER PUSH ROD STROKE AND ADJUST THE CLEVIS POSITION ! WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. NOTICE You cannot adjust the clevis position on a chamber push rod that is equipped with a welded clevis.
Page 379 SERVICE BRAKE (FULL AIR BRAKE) BR02–101 MEASURE THE SLACK ADJUSTER NOTICE For long stroke chambers, use the BSAP method to measure the auto- matic slack adjuster. Use the correct Meritor automatic slack adjuster template to measure the length of the slack adjuster. The marks by the holes in the small end of the template indicate the length of the slack adjuster.
Page 380 BR02–102 SERVICE BRAKE (FULL AIR BRAKE) Check for these specifications: • Thread engagement between the clevis and the push rod must be at MINIMUM 1/2" least 1/2-inch (12.7 mm). • The push rod must not extend through the clevis more than 1/8-inch (3.18 mm).
Page 381 SERVICE BRAKE (FULL AIR BRAKE) BR02–103 Measure the distance from the center of the large clevis pin to the bot- tom of the air chamber while the brake is released. Refer to "X" in MEASURE “ FREE STROKE ” figure. “...
Page 382 BR02–104 SERVICE BRAKE (FULL AIR BRAKE) COMMERCIAL VEHICLE SAFETY ALLIANCE (CVSA) GUIDELINES TO MEASURE PUSH ROD TRAVEL (ADJUSTED CHAMBER STROKE) Use the following procedures to check in-service push rod travel (adjusted chamber stroke) on truck or tractor air brakes with automatic slack adjust- ers.
Page 383 SERVICE BRAKE (FULL AIR BRAKE) BR02–105 COMMERCIAL VEHICLE SAFETY ALLIANCE (CVSA) NORTH AMERICAN OUT-OF-SERVICE CRITERIA REF- ERENCE CHARTS NOTICE A brake found at the adjustment limit is not a violation. "Standard Stroke" Clamp-Type Brake Chamber Data Type Outside Diameter Brake Adjustment Limit (inches) (inches) 4-1/2 1-1/4...
Page 384 BR02–106 SERVICE BRAKE (FULL AIR BRAKE) LUBRICANTS Conventional Automatic Slack Adjuster Grease Specifications Components Meritor NLGI Grade Grease Type Outside Temperature Specification Automatic Slack Adjuster O-616-A Clay Base Down to -40F (-40C) O-692 1 and 2 Lithium Base Down to -40F (-40C) O-645 Synthetic Oil, Clay Down to -65F (-54C)
Page 385 ABS (ABS : HYDRAULIC (E VERSION)) BR03–1 A BS (ABS : HYDRAULIC (E VERSION)) B R 0 3 BR03-001 ABS ............BR03-2 OVERVIEW............BR03-2 COMPOSITION AND OPERATION ....BR03-3 FUNCTION ............BR03-6 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS ........BR03-7 OVERVIEW AND FUNCTION......
Page 386: Abs
BR03–2 ABS (ABS : HYDRAULIC (E VERSION)) OVERVIEW EN0680103C100001 ABS is a system that makes effective use of the friction between the tires and the road surface to maintain vehicle stability while the brakes are being applied and for stopping the vehicle. Applying the brakes forcefully on a slippery road surface can cause the wheels to be locked, due to excessive braking force.
Page 387: Composition And Operation
ABS (ABS : HYDRAULIC (E VERSION)) BR03–3 COMPOSITION AND OPERATION EN0680103C100002 The ABS system is comprised of sensor rings mounted on the wheels, the ABS ECU, which receives signals from the wheel sensors that monitor the rotational speed of the wheels and outputs control signals to maintain the appropriate braking force;...
Page 388 BR03–4 ABS (ABS : HYDRAULIC (E VERSION)) ABS CONTROL FLOWCHART Input signals ABS ECU Output signals Front right pres- Front right sure maintenance wheel sensor solenoid valve Front right pres- Front left sure reduction wheel sensor solenoid valve Front left pres- Rear right ABS ECU sure maintenance...
Page 389 ABS (ABS : HYDRAULIC (E VERSION)) BR03–5 BASIC PRINCIPLE Based on its relationship with the slip ratio, which is determined from the wheels' rotational speed and the vehicle's speed, ABS controls the brake force so that it will be most effective. When the driver applies the brakes, the rotation of the wheels is controlled and the vehicle speed drops.
Page 390: Function
BR03–6 ABS (ABS : HYDRAULIC (E VERSION)) FUNCTION EN0680103C100003 FAIL-SAFE FUNCTION This ABS system is equipped with a fail-safe function that causes the ABS warning light on the instrument panel to light and to restore the normal (non-ABS) brake system, should an ABS malfunction occur. Note that the ABS system consists of two independent circuits.
Page 391: Precautions When Driving Vehicles Equipped With Abs
ABS must be ately at your nearest Hino service dealer. inspected. OTHER CHECKPOINTS REGARDING HANDLING 1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS modulator, harnesses, or connectors.
Page 392: Overview And Function
BR03–8 ABS (ABS : HYDRAULIC (E VERSION)) OVERVIEW AND FUNCTION EN0680103C100004 ABS ECU (INTEGRATED WITH ABS MODULATOR) Based on pulse signals from the wheel sensors, the ABS ECU mounted in the vehicle calculates and evaluates the slip ratio and the acceleration/ deceleration speed of the wheels.
Page 393 ABS (ABS : HYDRAULIC (E VERSION)) BR03–9 SAPH068010300009...
Page 394 BR03–10 ABS (ABS : HYDRAULIC (E VERSION)) Operation During Normal Braking (ABS is not operating) • Since there is no control signal input from the ABS ECU, the pressure maintenance solenoid valve port A is open, and the pressure reduc- tion solenoid valve port B is closed.
Page 395 ABS (ABS : HYDRAULIC (E VERSION)) BR03–11 During ABS Braking a. Pressure Reduction Mode • When the wheels are about to lock, the pressure maintenance sole- noid valve port A closes and the pressure reduction solenoid valve port B opens according to control signals from the ABS ECU. Accord- ingly, the wheel cylinder brake fluid is fed through the pressure reduc- tion solenoid valve port B to the reservoir, reducing the wheel cylinder fluid pressure.
Page 396 BR03–12 ABS (ABS : HYDRAULIC (E VERSION)) b. During Pressure Maintenance • When the wheel cylinder fluid pressure is reduced or increased to the required fluid pressure, the pressure maintenance solenoid valve port A and the pressure reduction solenoid valve port B simultaneously close according to control signals from the ABS ECU.
Page 397 ABS (ABS : HYDRAULIC (E VERSION)) BR03–13 c. During Pressure Increase • When the wheel cylinder fluid pressure needs to increase rapidly, the pressure maintenance solenoid valve port A opens and the pressure reduction solenoid valve port B closes according to control signals from the ABS ECU.
Page 398 BR03–14 ABS (ABS : HYDRAULIC (E VERSION)) WHEEL SENSOR These sensors are mounted facing the sensor rings on each wheel on the front and rear axles. The wheel sensors are electromagnetic sensors consisting of a permanent magnet core with a coil of wire wrapped around it. The frequency of the pulse signals generated by magnetic inductance between the sensors and the sensor rings they face is proportional to the rotational speed of the wheels.
Page 399 ABS (ABS : HYDRAULIC (E VERSION)) BR03–15 CLAMPING BUSHING The wheel sensors are held in place through friction by clamping bushings that are inserted into the mounting brackets. If they are assembled properly (the clamping bushings should be pushed in to place so that the stoppers on the clamping bushings come in contact with the holder), the clamping bushings serve to eliminate the need to adjust the clearance between the wheel sensors and sensor rings.
Page 400 In the event that the wire harness should become cut, have it replaced by an authorized Hino dealer. SAPH068010300018 ABS WIRE HARNESSES Front axle ABS wire harness •...
Page 401 ABS (ABS : HYDRAULIC (E VERSION)) BR03–17 Rear axle ABS wire harness • The wheel sensor wire harness is arranged so that the left and right wheel sensor wire harnesses are near each other. Therefore, special care should be taken not to make incorrect connections if the har- nesses have been removed for inspection or repairs.
Page 402 BR03–18 ABS (ABS : HYDRAULIC (E VERSION)) HANDLING WIRE HARNESSES • The various sensors, valves, relays and wire harness connections to the ABS ECU employ multipolar harness connectors suitable for use with the weak currents used by electronic circuitry. Be very careful when handling them.
Page 403 Installation of certain electronic and radio equipment can also cause the ABS ECU to malfunction. All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment, please contact your Hino service representa- tive. Quick battery charge •...
Page 404 ABS (ABS : FULL AIR) BR03–1 A BS (ABS : FULL AIR) B R 0 3 BR03-002 ABS ............BR03-2 OVERVIEW............BR03-2 COMPOSITION AND OPERATION ....BR03-3 FUNCTION ............BR03-6 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS ........BR03-7 OVERVIEW AND FUNCTION......BR03-8 INSPECTION (FRONT WHEEL BRAKE) ..
Page 405: Abs
BR03–2 ABS (ABS : FULL AIR) OVERVIEW EN0680203C100001 ABS is a system that makes effective use of the friction between the tires and the road surface to maintain vehicle stability while the brakes are being applied and for stopping the vehicle. Applying the brakes forcefully on a slippery road surface can cause the wheels to be locked, due to excessive braking force.
Page 406: Composition And Operation
ABS (ABS : FULL AIR) BR03–3 COMPOSITION AND OPERATION EN0680203C100002 The ABS system is comprised of sensor rings mounted on the wheels. The ABS ECU, which receives signals from the wheel sensors that monitor the rotational speed of the wheels and outputs control signals to maintain the appropriate braking force;...
Page 407 BR03–4 ABS (ABS : FULL AIR) ABS CONTROL FLOWCHART Input signals ABS ECU Output signals Front left wheel sensor ABS control valve for front left wheel Front right wheel sensor ABS control valve for front right wheel Rear left wheel sensor ABS control valve for rear left wheel Rear right wheel sensor...
Page 408 ABS (ABS : FULL AIR) BR03–5 BASIC PRINCIPLE Based on its relationship with the slip ratio, which is determined from the wheels' rotational speed and the vehicle's speed, ABS controls the brake force so that it will be most effective. When the driver applies the brakes, the rotation of the wheels is controlled and the vehicle speed drops.
Page 409: Function
BR03–6 ABS (ABS : FULL AIR) FUNCTION EN0680203C100003 FAIL-SAFE FUNCTION This ABS system is equipped with a fail-safe function that causes the ABS warning light on the instrument panel to light and to restore the normal (non-ABS) brake system, should an ABS malfunction occur. Note that the ABS system consists of two independent circuits.
Page 410: Precautions When Driving Vehicles Equipped With Abs
If the warning light fails to go on, have your vehicle inspected and serviced immedi- out after the engine is restarted and the ately at your nearest HIno service dealer. speed indicated above is reached, or if it lights frequency while the vehicle...
Page 411: Overview And Function
BR03–8 ABS (ABS : FULL AIR) OVERVIEW AND FUNCTION EN0680203C100004 ABS ECU Based on pulse signals from the wheel sensors, the ABS ECU mounted in the vehicle calculates and evaluates the slip ratio and the acceleration/ deceleration speed of the wheels. Based on the results, it sends signals to the ABS control valves as necessary, causing them to operate and apply the brakes to maintain the slippage of the wheels within the optimal range.
Page 412 ABS (ABS : FULL AIR) BR03–9 SHTS068020300010 Operation Pressure increase a. PRESSURE INCREASE MODE • When the driver steps on the brake pedal, air from the relay valve enters through inlet port (6), pushes open diaphragm (5), passes through outlet port (9), and flows into the brake chamber. At this point, solenoid coil (1) is not energized, so solenoid valve (3) is closed and pilot chamber (14) is open to the atmosphere.
Page 413 BR03–10 ABS (ABS : FULL AIR) b. PRESSURE REDUCTION MODE Pressure reduction • When solenoid coil (1) is energized, solenoid valve (3) opens and air also flows into pilot chamber (14). It pushes down on diaphragm (5), shutting off chambers (7) and (8). At the same time, solenoid coil (2) is also energized.
Page 414 ABS (ABS : FULL AIR) BR03–11 WHEEL SENSORS These sensors are mounted, facing the sensor rings on each wheel on the front and rear axles. The wheel sensors are electromagnet sensors consisting of a permanent magnet core with a coil of wire wrapped around it. The frequency of the pulse signals generated by magnetic inductance between the sensors and the sensor rings they face is proportional to the rotational speed of the wheels.
Page 415 BR03–12 ABS (ABS : FULL AIR) WHEEL SENSOR HARNESSES Each wheel sensor wire harness employs a two-conductor twisted wire cable. Its function is to protect the wheel sensor signals, which are vital to the proper operation of the ABS system, from electromagnetic interference. Under no circumstances should any part of the wheel sensor wire har- nesses be cut or connected to any other wire.
Page 416: Inspection (Front Wheel Brake)
ABS (ABS : FULL AIR) BR03–13 INSPECTION (FRONT WHEEL BRAKE) EN0680203H300001 INSPECTION OF ONLY WHEEL SENSOR With a tester, measure the resistance of wheel sensor. Standard: 900-2,000  When the measured value is out of the basic standard, change the wheel sensor as it might be considered presumably to be abnormal.
Page 417 BR03–14 ABS (ABS : FULL AIR) MOUNTING THE WHEEL HUB AND BRAKE DRUM Refer to CHAPTER, FRONT AXLE. NOTICE If the wheel sensors are mounted, hammering on the wheel hubs and the like on that axle could cause internal damage to the wheel sen- sors.
Page 418: Inspection (Rear Wheel Brake)
ABS (ABS : FULL AIR) BR03–15 INSPECTION (REAR WHEEL BRAKE) EN0680203H300002 INSPECTION OF ONLY WHEEL SENSOR With a tester, measure the resistance of wheel sensor. Standard: 900-2,000  When the measured value is out of the basic standard, change the wheel sensor as it might be considered presumably to be abnormal.
Page 419 BR03–16 ABS (ABS : FULL AIR) MOUNTING THE SENSOR RING Place the sensor ring on the wheel hub and use the dolly block and a press to evenly pressure mount it. NOTICE Warming up the sensor ring with hot water will make it easier to pres- sure mount it.
Page 420 ABS (ABS : FULL AIR) BR03–17 SHTS068020300032...
Page 421 BR03–18 ABS (ABS : FULL AIR) Rear axle chassis harness • The rear axle chassis harnesses is arranged so that the left and right wheel sensor harnesses are near each other. Therefore, special care should be taken not to make incorrect connections if the harnesses have been removed for inspection or repairs.
Page 422 ABS (ABS : FULL AIR) BR03–19 HANDLING WIRE HARNESSES • The various sensors, valves, relays and wire harness connections to the ABS ECU employ multipolar harness connectors suitable for use with the weak currents used by electronic circuitry. Be very careful when handling them.
Page 423 Installation of certain electronic and radio equipment can also cause the ABS ECU to malfunction. All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment, please contact your Hino service representa- tive. Quick battery charge •...
Page 424 EXHAUST BRAKE BR05–1 E XHAUST BRAKE B R 0 5 BR05-001 EXHAUST BRAKE SYSTEM ....BR05-2 SYSTEM DIAGRAM ........BR05-2 TROUBLESHOOTING ........BR05-3 ADJUSTMENT..........BR05-3 BRAKE CYLINDER........BR05-5 DATA AND SPECIFICATIONS ......BR05-5 DESCRIPTION ..........BR05-5...
Page 425: Exhaust Brake System
BR05–2 EXHAUST BRAKE EXHAUST BRAKE SYSTEM SYSTEM DIAGRAM EN06Z0805J100001 Manual transmission Fine line : Electric line Thick line : Air line Dotted line : In case of manual transmission Automatic transmission and ultrashift transmission No. 2, 10 and 12 circuit are less. Three is No. 3 instead of this with automatic transmission and UltraShift transmission. (One point chain line) SHTS06Z080500001 ABS exhaust cut relay...
Page 426: Troubleshooting
ADJUST THE OUTPUT VOLTAGE OF THE ACCELERATOR PEDAL STROKE SENSOR. a. Use HINO DX Ⅱ to check the output voltage of the accelerator pedal stroke sensor. In case the output voltage does not conform to the standard, shift the mounting position of the sensor in the direction of rotation (at the long hole of the sensor) for adjustment or replace the sensor with new one.
Page 427 BR05–4 EXHAUST BRAKE CLUTCH SWITCH ADJUSTMENT (MANUAL TRANSMIS- SION) The clutch switch should not be knocked against. With the clutch pedal release, the clearance between the plastic bush and the clutch switch's tip should be 0.5-1.5 mm {0.020-0.059 in.}. Assembly standard: 0.5-1.5 mm {0.020-0.059 in.} SHTS06Z080500004...
Page 428: Brake Cylinder
EXHAUST BRAKE BR05–5 BRAKE CYLINDER DATA AND SPECIFICATIONS EN06Z0805I200001 Type Butterfly valve DESCRIPTION EN06Z0805C100001 SHTS06Z080500005 Control cylinder Body Plate Seal ring Plate Lever Valve Shaft Clevis Bush...
Page 429 PARKING BRAKE (BOSCH 12") BR07–1 P ARKING BRAKE (BOSCH 12") B R 0 7 BR07-001 PARKING BRAKE ASSEMBLY ....BR07-2 DATA AND SPECIFICATIONS ......BR07-2 DESCRIPTION ..........BR07-2 TROUBLESHOOTING ........BR07-3 COMPONENT LOCATOR........ BR07-4 OVERHAUL ............. BR07-6 INSPECTION AND REPAIR ......BR07-20 ADJUSTMENT..........
Page 430: Parking Brake Assembly
BR07–2 PARKING BRAKE (BOSCH 12") PARKING BRAKE ASSEMBLY DATA AND SPECIFICATIONS EN06Z0807I200001 Parking brake type Duplex Cam mechanical brake, internal expanding acting type Parking brake control type Lever type control with control cable Drum inside diameter 304.8 mm {12.0 in.} Brake lining Width 76.2 mm {3.0 in} DESCRIPTION...
Page 431: Troubleshooting
PARKING BRAKE (BOSCH 12") BR07–3 TROUBLESHOOTING EN06Z0807F300001 Symptom Possible cause Remedy/Prevention Light force or lack of resistance Shoe cage under-adjusted(*1) Adjust shoes per cage adjustment pro- when applying brake lever (on man- cedure. ual apply systems) Worn or deformed actuation compo- Inspect and replace per Anchor Screw, nents (lever, cam lugs shoe ends) Lever and Cam.
Page 432: Component Locator
BR07–4 PARKING BRAKE (BOSCH 12") COMPONENT LOCATOR EN06Z0807D100001 PARKING BRAKE LEVER SHTS06Z080700002 Parking brake lever Parking brake switch Knob Bolt Brake lever bracket Knob cover Clevis Bolt Tightening torque Unit: Nm {kgfcm, lbfft} 42-62 {430-630, 31-46} 1.1-1.9 {12-19, 0.9-1.4}...
Page 433 PARKING BRAKE (BOSCH 12") BR07–5 PARKING BRAKE SHTS06Z080700003...
Page 434: Overhaul
BR07–6 PARKING BRAKE (BOSCH 12") Brake drum Adjuster nut Parking brake assembly Lever return spring Companion flange Lower return spring End yoke Upper return spring Backing plate Hold-down bracket Brake shoe Hold-down spring Lever Auto adjuster lever Cam plate Adjuster cable Adjuster screw Auto adjuster spring Tightening torque...
Page 435 PARKING BRAKE (BOSCH 12") BR07–7 Remove both shoe-return springs. Use pliers, vice-grips, or a heavy duty brake spring tool as shown in Figure 2. SHTS06Z080700005 Remove both shoe hold-down springs. Use a brake shoe spring tool as shown in Figure 3. HINT Detach the parking brake apply cable and lever return spring from the end of the lever to allow easier access to the spring on the lever side.
Page 436 BR07–8 PARKING BRAKE (BOSCH 12") INSTALLING THE SHOES ! WARNING • Failure to correctly assemble the Adjuster Cable may result in reduced brake performance that could cause personal injury or property damage. • Torque all fasteners to the manufacturer’s recommended torque using a torque wrench.
Page 437 PARKING BRAKE (BOSCH 12") BR07–9 If the lever has been removed, reinstall lever and associated compo- nents per the ANCHOR SCREW, LEVER, AND CAM REPLACE- MENT section in the manual. SHTS06Z080700008 (10) Route the adjuster cable around the adjuster cable guide, under the shoe hold down spring, and attach to the adjuster lever as shown in Figure 6.
Page 438 BR07–10 PARKING BRAKE (BOSCH 12") (14) Lower the vehicle and test the brake for proper function before return- ing the vehicle for service use. If necessary, make adjustments per the vehicle manufacturer's service manual. SHTS06Z080700009...
Page 439 PARKING BRAKE (BOSCH 12") BR07–11 SHOE CAGE ADJUSTMENT PROCEDURES ADJUSTMENT WITH DRUM OFF - PRIMARY PROCEDURE Use a 12 inch caliper, or inside micrometer, to measure the inside diameter of the drum. Subtract 0.025 inches from the drum inside diameter measurement. Set the measurement caliper to this value, and lock the set screw.
Page 440 BR07–12 PARKING BRAKE (BOSCH 12") ADJUSTMENT WITH DRUM INSTALLED - ALTERNATE PROCE- DURE With the engine off, the battery disconnected, and the tires blocked to prevent vehicle movement, place transmission in neutral and fully release the parking brake. Check to see if the drum can be rotated back and forth by hand.
Page 441 PARKING BRAKE (BOSCH 12") BR07–13 DISENGAGING ADJUSTER LEVER FROM ADJUSTER STAR- WHEEL TO ALLOW RETRACTING THE BRAKE SHOES (LOOSEN BRAKE) NOTICE Some vehicles may not have enough clearance behind the park brake to have direct access through the access slot to the adjuster lever. In these cases, an adjuster lever tool can be made from 3/32 inch diame- ter welding filler rod.
Page 442 BR07–14 PARKING BRAKE (BOSCH 12") ANCHOR SCREW, LEVER AND CAM REPLACEMENT REMOVING COMPONENTS NOTICE The anchor screw, lever, and cam should all be replaced at the same time. Do not replace just one or two of the three parts at any time. Inspection of these parts is recommended at 250,000 miles or 5 years for typical use, or more often under severe operating conditions.
Page 443 PARKING BRAKE (BOSCH 12") BR07–15 Remove the flat washers (if installed on your application for Release 1 level brake), anti-rattle spring, lever, cam, and adjuster cable. See Fig- ure 11. SHTS06Z080700013 INSTALLING COMPONENTS NOTICE If for any reason the cam, lever, and anchor screw is removed, a com- plete new set is recommended for service.
Page 444 BR07–16 PARKING BRAKE (BOSCH 12") Reinstall the adjuster cable, new cam plate, new lever, anti-rattle spring (small coil end toward screw head for Release 2), flat washers (if previously installed on your application), and new anchor screw as shown in Figure 12. Make sure the adjuster cable end fitting is installed to allow the cam plate to sit flat on the fitting and anchor post.
Page 445 PARKING BRAKE (BOSCH 12") BR07–17 SHTS06Z080700014 The shoe cage should now be adjusted per the SHOE CAGE ADJUSTMENT PRIMARY procedure or after the drum has been rein- stalled, per the SHOE CAGE ADJUSTMENT ALTERNATE procedure in this service manual. Make a final inspection of the shoe linings and the inside of the drum to ensure that no grease or other contamination is present.
Page 446 BR07–18 PARKING BRAKE (BOSCH 12") INSPECTION INSPECT PARTS. NOTICE It is not necessary to raise vehicle for “inspection” in most cases. However, if required, follow steps (1) through (3) in SHOE REPLACE- MENT section. Anytime service is required, it is recommended that a complete visual inspection be performed on all components in the park brake assembly.
Page 447 PARKING BRAKE (BOSCH 12") BR07–19 Clean-out all dust or grease present on the inside of drum. Use a 12 inch caliper or an inside diameter micrometer to measure the manu- facturer’s recommended inside diameter of the drum. Replace drum if it exceeds maximum inside diameter (which typically is stamped on the inside of the drum near the mounting holes), is worn unevenly, has deep grooves, heavy corrosion or excessive runout.
Page 448: Inspection And Repair
BR07–20 PARKING BRAKE (BOSCH 12") INSPECTION AND REPAIR EN06Z0807H300001 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Brake lining: 7.00 0.76 Replace. Measure Lining thickness {0.277} {0.03} Brake drum: 304.8 305.7 Replace. Measure Inside diameter {12} {12.035}...
Page 449: Adjustment
PARKING BRAKE (BOSCH 12") BR07–21 ADJUSTMENT EN06Z0807H300002 INSTALL THE CABLE Connect the cable inner wire to the brake assy and set the cable to cab side. Pull and release the parking brake cable 2 to 3 times with specified force. Pull up force: 220-270 N (22-28 kgf, 49-62 lbf) at 207 mm (8.1 in.) from pivot of the lever.
Page 450 BR07–22 PARKING BRAKE (BOSCH 12") Confirmation of parking brake application. After completing all-brake adjustment, stop the vehicle on a safe slope or using a brake tester, confirm whether the parking brake is securely applied.
Page 451 Hino Motors Sales U.S.A., Inc. 41180 Bridge Street, Novi, MI 48375 Telephone: (248) 699-9300 PRINTED IN JAPAN Pub.No. S1-UNAE11A 1/2 '13.11...

Save PDF