SIBS Fuso Canter Workshop Manual
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SIBS Fuso Canter Workshop Manual

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SIBS® 4 WORKSHOP MANUAL
FUSO CANTER

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Summary of Contents for SIBS Fuso Canter

  • Page 1 SIBS® 4 WORKSHOP MANUAL FUSO CANTER...

  • Page 2: Revision History

    MAN-059 8 FEB 2017 Revision History Revision Issue Date Author Comments 1 Mar 2016 M. O’Driscoll Initial Release 8 Feb 2017 M. O’Driscoll Sections 14, 15, 16 and 17 updated with new service regime. 6 Apr 2017 M. O’Driscoll Wiring and hydraulic sections updated with 24V details. ©...

  • Page 3: Table Of Contents

    MAN-059 8 FEB 2017 Table of Contents Revision History ..................................2 Table of Contents..................................3 Important Information ................................4 Terminology ..................................... 5 Brake Description ..................................6 Exploded Views & Parts Lists - Differential Brake Assembly ....................7 Wiring Diagram 12V ................................10 Wiring Diagram 24V ................................

  • Page 4: Important Information

    Important Information This manual applies to the fourth generation Sealed Integrated Braking System (SIBS® 4) for Fuso Canter 4x4 Trucks. The manual details how to install the SIBS® 4 system correctly to ensure optimum safety and performance. All information contained in this manual is based on the latest SIBS®...

  • Page 5: Terminology

    EMMA™ Electronically Modulated Mechanically Applied Original equipment manufacturer Park Brake Brakes applied independently of the service brake Pad wear indicator ® SIBS Sealed Integrated Braking System ® ® SIBS Cooling Fluid Specially formulated cooling fluid for use in SIBS brakes...

  • Page 6: Brake Description

    ) is a Spring Applied Hydraulic Release system operating in isolation from any other ® braking system fitted to the vehicle. SIBS has been configured for mounting to the driveline of light to medium goods vehicles. The brake is bolted to the input side of the rear differential carrier. The torque generated by the brake is transmitted to the rear wheels via the differential and axle shafts.

  • Page 7: Exploded Views & Parts Lists - Differential Brake Assembly

    MAN-059 8 FEB 2017 Exploded Views & Parts Lists - Differential Brake Assembly...
  • Page 8 MAN-059 8 FEB 2017 TORQUE ITEM PART NO. DESCRIPTION QTY/ BRAKE (Nm) 21-9008 BOLT DRIVE SHAFT 21-9010 NUT PINION Ref. Canter manual 21-9009 WASHER DRIVE SHAFT 31-5015 NIPPLE GREASE 21-2010 YOKE DRIVE SHAFT 31-4013 SEAL V-LIP 25-2049 SEAL CASSETTE HOUSING 31-9000 CAP BLEED NIPPLE 31-5001...
  • Page 9 MAN-059 8 FEB 2017 21-2009 CAGE BEARING MODIFIED (FROM VEHICLE) 21-9006 SEAL PINION 31-2001 BACK-UP WASHER SMALL EMMA PISTON 31-2000 O-RING SMALL EMMA PISTON 31-2002 O-RING LARGE EMMA PISTON 31-2003 BACK-UP WASHER LARGE EMMA PISTON 25-2006 PISTON EMMA 31-0002 DISC SPRING 25-2061 SPRING COVER GASKET 25-2008...

  • Page 10: Wiring Diagram 12V

    MAN-059 8 FEB 2017 Wiring Diagram 12V TO SPEED SIGNAL TO IGNITION TO OIL PRESSURE TO SEAT BELT...
  • Page 11 MAN-059 8 FEB 2017 12V POWER 10A FUSE 30A FUSE...

  • Page 12: Wiring Diagram 24V

    MAN-059 8 FEB 2017 Wiring Diagram 24V TO SPEED SIGNAL TO IGNITION TO OIL PRESSURE TO SEAT BELT...
  • Page 13 MAN-059 8 FEB 2017...

  • Page 14: Pump Hardware Parts List 12V

    MAN-059 8 FEB 2017 Pump Hardware Parts List 12V...
  • Page 15 MAN-059 8 FEB 2017 ITEM PART NO. DESCRIPTION QTY/KIT 18-9015 ENCLOSURE BASE/RESERVOIR 18-9026 POWER UNIT 12V (PUMP + ADAPTER + MOTOR) 18-9014 MANIFOLD ASSEMBLY 12V 18-9027 LEVEL SENSOR 18-9028 ENCLOSURE GASKET 18-9028 ENCLOSURE LID 18-9024 FILL CAP 18-9029 POWER UNIT GASKET 18-9030 LEVEL WINDOW 18-9031...

  • Page 16: Pump Hardware Parts List 24V

    MAN-059 8 FEB 2017 10. Pump Hardware Parts List 24V...
  • Page 17 MAN-059 8 FEB 2017 ITEM PART NO. DESCRIPTION QTY/KIT 18-9015 ENCLOSURE BASE/RESERVOIR 18-9044 POWER UNIT 24V (PUMP + ADAPTER + MOTOR) 18-9025 MANIFOLD ASSEMBLY 24V 18-9027 LEVEL SENSOR 18-9028 ENCLOSURE GASKET 18-9028 ENCLOSURE LID 18-9024 FILL CAP 18-9029 POWER UNIT GASKET 18-9030 LEVEL WINDOW 18-9031...

  • Page 18: Installation - Driveline Brake (Light - Medium Trucks)

    Attach the pinion seal to the bearing cage. Apply Loctite 515 between the bearing cage and the SIBS® inner brake housing. Note: in some cases a mounting adapter is required between the bearing cage and the inner housing. If required apply Loctite 515 to both sides.
  • Page 19 Fit the 12x M10 bolts and torque to 50Nm in sequence. Ensure each bolt is torqued twice. Attach the 2x grease nipples to the yoke. Attach the pinion shaft nut. Set preload and torque as per Fuso Canter Manual. Ensure the diff rotates freely when the SIBS® brake is released.
  • Page 20 Route the hose away from the exhaust and any moving components. Allow extra length for axle articulation. Protect areas of the hose that may abrade using spiral guard. Ensure SIBS® fluid can easily drain back into the brake units. Secure the hose using supplied P-clips.

  • Page 21: Installation - Hydraulic System

    Figure 6: SIBS® 4 Hydraulic Schematic. Mount the SIBS® 4 pump enclosure in a suitable location on the vehicle chassis as close to the battery as possible. Drill the pump mounting bracket as required and mount the SIBS® pump using provided mounting hardware.
  • Page 22 MAN-059 8 FEB 2017 Attach bulkhead fitting to the vehicle chassis rail behind the pump enclosure. Attach the other end of the short hydraulic hose to this bulkhead fitting on the outside of the vehicle chassis. Attach one end of the long hydraulic hose to the bulkhead fitting on the inside of the chassis rail. Route the other end of the hydraulic hose down along the chassis rail to the brake on the rear diff centre and connect.

  • Page 23: Installation - Electrical System

    Mount the control unit to the dash: Mount the SIBS® control unit on the dash above the centre console using the provided bracket. Position so that bracket is close to the driver and aligned with the vehicle axis. 4x holes will need to be drilled.
  • Page 24 MAN-059 8 FEB 2017 De-pin both the 2 pin connector plug with the red and yellow cables attached and the large 2 pin connector socket next to it. Remove the glove box and the panel from in front of the passenger seat. Route the harness down behind the glove box until it drops out underneath on the floor.
  • Page 25 Open the top of the dash above the centre console. Connect the Deutsch end of the vehicle interface harness to the 6 pin connector on the SIBS® cabin harness. Connect the interface harness wires to the desired vehicle interlock wires behind the instrument cluster. Cut the wires to the desired length.
  • Page 26 Connect the battery power extension harness to the 2x 2 pin connectors on the cabin harness located on the chassis rail. Route the battery power extension harness towards the vehicle battery. Connect the battery power extension harness to the battery power harness. SIBS fuses Earth connection SIBS relay Figure 15: Battery power harness.

  • Page 27: Pre-Service Inspection

    14. Pre-Service Inspection Top up all reservoirs with the specified fluids. Use SIBS® cooling fluid for the brake. 800ml approx. required. Use ATF Dexron III for the SIBS® pump reservoir (park/emergency system). Filler cap Fill level Figure 17: SIBS® 4 pump enclosure with lid removed.
  • Page 28 Bleed screws Figure 18: Park/emergency brake bleed screws. Affix the SIBS® caution label to the inside top corner of the windshield on the driver’s side. Complete a vehicle pre-start check. If the vehicle is to be used on public roads it will require approval for road use.

  • Page 29: Control System Setup

    15. Control System Setup Ensure the battery is fully charged and in good working condition before connecting the SIBS® controller. With the vehicle engine running, twist and release the red E-stop button to release the brakes - the system will automatically detect the correct brake release pressure during its first release.

  • Page 30: Service Schedule

    16. Service Schedule The following table shows the recommended service intervals for SIBS® 4 brake systems fitted to vehicles being operated in a harsh mining environment. ABT recommends each site undertake a review of the service intervals and adjust to suit their specific conditions.

  • Page 31: Pre-Start Check

    8 FEB 2017 17. Pre-Start Check Check SIBS® pump reservoir level. If low, top up with ATF Dexron III and check system for leaks. With the doors closed, engine running and driver’s seat belt connected, press the E-Stop button: The brake status light on the SIBS® control unit should be solid red.

  • Page 32: Minor Service (100 Hrs)

    Drain and discard the SIBS® cooling fluid from the driveline brake. At least 800 ml of SIBS® cooling fluid should be found in the brake. Check for leaks if this amount is not found. The SIBS® oil should drain freely from the brake. If it comes out in a “glug, glug” fashion ensure there is no...
  • Page 33 Dispose of used SIBS® cooling fluid responsibly in accordance with regulatory and environmental legislation. Refit the drain plug with a new sealing washer. Refill the brake up to the level plug (fill to spill). Approximately 1 litre of SIBS® cooling fluid is required. Conduct a “vehicle pre-start check”.

  • Page 34: Major Service

    Drain and discard the SIBS® cooling fluid from the driveline brake. At least 800 ml of SIBS® cooling fluid should be found in the brake. Check for leaks if this amount is not found. The SIBS® oil should drain freely from the brake. If it comes out in a “glug, glug” fashion ensure there is no blockage in the SIBS®...
  • Page 35 MAN-059 8 FEB 2017 Inspect the rotor and yoke splines for wear. Check for movement between the rotor and yoke. If there is movement between the splines of the mating components the rotor should be replaced. Inspect the rotor friction surface. If there are signs of scouring covering more than 50% of the surface the rotor should be replaced.
  • Page 36 MAN-059 8 FEB 2017 Attach the piston seals to the pistons. Ensure o-rings and back-up washers are installed in the correct position. EMMA™ piston Back-up ring large O-ring large O-ring small Back-up ring small Figure 22: Park/emergency brake piston with seals installed. Clean the exposed areas of the park/emergency pistons in cases where the pistons have not been removed.
  • Page 37 Install the outer housing assembly onto the yoke. Install the rotor onto the yoke spline ensuring correct orientation. Using a suitable lifting apparatus fit the SIBS® brake unit over the pinion shaft. Hold the brake rotor to prevent it from detaching from the yoke during assembly.
  • Page 38 Remove the SIBS® cooling fluid fill plug. Fill the SIBS® brake unit with new SIBS® cooling fluid and refit the fill plug with a new copper washer. Approximately 1 litre of SIBS® cooling fluid is required.

  • Page 39: Troubleshooting

    Check vehicle diff lock is functioning correctly. Check wiring connections to diff lock switch. iii. Check SIBS diff lock relay. Cycle ignition to clear the fault from the control unit. 8x flashes then rest – pressure sensor fault Ensure wiring is not causing a short or open circuit to pressure sensor.
  • Page 40 Check seatbelt switches. Check oil-pressure switches. SIBS® park/emergency brake is poor. Brake not holding on inclines. Brake pads and/or rotor worn. Check pad wear indicators. If pads below wear limit conduct a major service. SIBS® park/emergency brake slow to apply Brake pads worn.
  • Page 41 Adjust to desired application speed by loosening locknut and turning adjusting screw out. Adjust ½ turn at a time & test. SIBS® pump runs intermittently during service (brake status light flashes red and beeps occasionally). Minor leak in park/emergency brake system Check all hydraulic hoses and connections for signs of leaking ATF.

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