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PREVOST X3-45 Multiplex Maintenance Manual
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PREVOST X3-45 Multiplex Maintenance Manual

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COACH MANUFACTURER
MAINTENANCE MANUAL
X3 COACHES
PA1562
th
(4
edition)

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Questions and answers

ted leclert
May 1, 2025

problem there is no can line j pro has ddl pin H and J no communication on the male side of connecter C72 pin 32 has a ground both with key off and key on, can anyone tell the location of connecter C380A, to see if there is power out of pin C380A 13

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Related Manuals for PREVOST X3-45 Multiplex

Summary of Contents for PREVOST X3-45 Multiplex

  • Page 1 COACH MANUFACTURER MAINTENANCE MANUAL X3 COACHES PA1562 edition)
  • Page 2 PA1562 4 edition Date: April 2009 Starting from vehicle: 9-9640 Featuring: New Bosch alternators on DDEC, new Sound System & new evaporator compartment motor...

  • Page 3: Table Of Contents

    SECTION 00: GENERAL INFORMATION CONTENTS FOREWORD............................2 SCHEMATICS ............................2 PRECAUTIONS TO BE OBSERVED BEFORE WELDING ..............2 SAFETY NOTICE ........................... 4 ....................4 LATES ERTIFICATIONS 4.1.1 Engine ............................4 4.1.2 Transmission ..........................5 4.1.3 Drive Axle ..........................5 4.1.4 Front Axle ..........................

  • Page 4: Precautions To Be Observed Before Welding

    Operator's Manual. Audio/Video system operator instructions are also included in a NOTE separate manual. For X3-45 Multiplex vehicles, also execute More specific information on engine and procedure PR060034 "MULTIPLEX transmission operating, maintenance, MODULES DISCONNECTION PROCEDURE...
  • Page 5 Section 00: GENERAL INFORMATION STEEL – STEEL WELDING CAUTION Before welding, perform multiplex modules disconnection procedure. NOTE Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that would render welding impossible. DANGER Only a qualified and experienced person must do welding. FCAW (Flux Cored Arc Welding) process ;...

  • Page 6: Safety Notice

    Section 00: GENERAL INFORMATION STAINLESS STEEL - STAINLESS STEEL WELDING SS Thickness Voltage Current Wire Feed Rate Shielding Gas 90% He – 7.5% Ar, Any type 20 ± 1.5 volts 130 ± 15 Amps 290 ipm approx. 2.5% CO2 If necessary and with great care to prevent perforating the material, it is possible to use a conventional electric arc welding machine according to the following specifications: SMAW (Shield Metal-Arc Welding) process;...

  • Page 7: Figure 1: Detroit Diesel Series 60

    Section 00: GENERAL INFORMATION FIGURE 4: ZF-ASTRONIC TRANSMISSION 00040 4.1.3 Drive Axle FIGURE 1 : DETROIT DIESEL SERIES 60 00043 FIGURE 5: TYPICAL SERIAL & MODEL NUMBERS 00007 4.1.4 Front Axle FIGURE 2: VOLVO D13 ENGINE DATA PLATE 00052 4.1.2 Transmission The transmission identification plate is located on the oil level dipstick side of the transmission (WT) or on transmission, on the vehicle R.H.

  • Page 8: Power Steering Pump

    4.1.8 DOT Certification Label FIGURE 8 : POWER STEERING PUMP NAMEPLATE 00035 This certifies that coaches manufactured by Prevost Car Inc., comply with all Federal Motor • Volvo D13 Engine Vehicle Safety Standards at the time of Power steering pump is mounted on the engine manufacture.

  • Page 9: Vehicle Identification Number (Vin)

    Section 00: GENERAL INFORMATION 4.1.11 Vehicle Identification Number (VIN) seventeen digit vehicle identification number (VIN) is located on a plate (Fig. 11 & 12) located on the windshield frame pillar (driver's side). The VIN is visible from the outside of the coach.

  • Page 10: Figure 12: Vehicle Identification Number

    Section 00: GENERAL INFORMATION FIGURE 12 : VEHICLE IDENTIFICATION NUMBER 00050 YEAR CODE YEAR CODE 2000 2006 2001 2007 2002 2008 2003 2009 2004 2010 2005 2011 PA1562...

  • Page 11: Fastener Strength Identification

    Section 00: GENERAL INFORMATION 5. FASTENER STRENGTH IDENTIFICATION metric fasteners, be careful to use fasteners of the same or greater strength than the original Most commonly used metric fastener strength fasteners (the same number marking or higher). property classes are 9.8 and 10.9 with the class It is also important to select replacement identification embossed on the head of each fasteners...

  • Page 12: Self-Locking Fasteners

    Section 00: GENERAL INFORMATION 5.1 SELF-LOCKING FASTENERS 5.2 RECOMMENDATIONS FOR REUSE A self-locking fastener is designed with an Clean, unrusted self-locking fasteners may be interference fit between the nut and bolt threads. reused as follows: This is most often accomplished by distortion of a) Clean dirt and other foreign matter from the top thread of an all-metal nut or bolt or by the fastener;...

  • Page 13: Figure 16: Metric - Us Standard Conversion Table

    Section 00: GENERAL INFORMATION FIGURE 16: METRIC - US STANDARD CONVERSION TABLE 00005 PA1562...

  • Page 14: Figure 17: Conversion Chart

    Section 00: General Information FIGURE 17: CONVERSION CHART 00006 PA1562...
  • Page 15 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING PROCEDURE NO: PR060034 REVISION 4 2007-05-31 Material : Equipment(s) : Phillips-head screwdriver Ratchet handle 3/8" socket Electric tape Long nose pliers Reference schematics: Safety rules : - Wear safety goggles - Set the battery master switch to the OFF position first Recommendations: This procedure should be performed by qualified personnel only.
  • Page 16 PROCEDURE NO: PR060034 REVISION 4 SECTION 1 H3 Coaches & VIP 1.00 Location: Main power compartment and dashboard Set the battery master switch to the OFF position. Place the ignition switch to the OFF position. 1.05 Location: Main power compartment Trip circuit breakers CB2, CB4, CB6 Push the red button to open the circuit Page 2 of 15...
  • Page 17 PROCEDURE NO: PR060034 REVISION 4 1.10 Location: Main power compartment Remove the protective cover WARNING LIVE WIRE This 12-volt terminal remains energized Disconnect the electronic ground terminals from the stud Using electric tape, insulate the 2 largest gage wires. Make sure the ring terminals do not touch each others and the vehicle body.
  • Page 18 PROCEDURE NO: PR060034 REVISION 4 1.15 Location: Main power compartment Disconnect the electronic modules : Disconnect the I/O A and I/O B modules Disconnect C397 Disconnect connector C717 Unplug 3 connectors per I/O B modules Unplug 3 connectors on the I/O A module 1.20 Location: Front electrical compartment VIP + COACH: Disconnect the I/O A, I/O B, ABS, master ID, CECM and CPC modules.
  • Page 19 PROCEDURE NO: PR060034 REVISION 4 Unplug 1 connector from the master ID Disconnect CPC connectors Unplug 3 connectors from the CECM Unplug connector C92 Page 5 of 15...
  • Page 20 PROCEDURE NO: PR060034 REVISION 4 1.25 Location: pneumatic accessory panel inside right console Remove the access panel on the right console (R.H. side of dashboard) Disconnect both I/O B modules 1.30 Location: Evaporator compartment Remove protective cover disconnect the I/O B module Page 6 of 15...
  • Page 21 PROCEDURE NO: PR060034 REVISION 4 1.40 Kidde Automatic Fire Detection and Suppression System (optional) Disconnect C466 Kidde AFSS module is located on the lateral control panel. 1.45 When all the previous steps are done, you ENSURE THAT THE WELDING GROUND RETURN can do welding on the vehicle CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC...
  • Page 22 PROCEDURE NO: PR060034 REVISION 4 SECTION 2 X3 Coaches 2.00 Location: Rear electrical compartment and dashboard Set the battery master switch to the OFF position. Place the ignition switch to the OFF position. 2.05 Location: Rear electrical compartment Trip circuit breakers CB2-CB4-CB6 located on rear junction panel Push the red button in to open the circuit Page 8 of 15...
  • Page 23 PROCEDURE NO: PR060034 REVISION 4 2.10 Location: Rear electrical compartment Disconnect the electronic ground terminals from this stud Warning: The remaining terminals may still be energized Use electric tape; make sure that cables do not touch each others and the vehicle body. NOTE With disconnection of the electronic ground terminals,...
  • Page 24 PROCEDURE NO: PR060034 REVISION 4 2.20 Location: front electrical compartment Disconnect I/O A, I/O B, ABS, master ID, CECM and CPC modules and also disconnect connector C92 Disconnect the 3 connectors from the I/O B and I/O A modules Disconnect the 2 connectors from the ABS module Disconnect CPC connectors Disconnect connector from master ID...
  • Page 25 PROCEDURE NO: PR060034 REVISION 4 Disconnect the 3 connectors from CECM Disconnect connector C92 2.25 Location: Entrance door & wiper control panel Remove windshield wiper motor access panel and disconnect both I/O B modules 2.30 When all the previous steps are done, you can do ENSURE THAT THE WELDING GROUND welding on the vehicle RETURN CLAMP IS WELL SECURED AND...
  • Page 26 PROCEDURE NO: PR060034 REVISION 4 SECTION 3 XLII MTH 2.00 Location: Dashboard Place the ignition switch to the OFF position. 2.05 Location: Engine compartment R. H. side area Trip circuit breakers CB1-CB2 located on circuit breaker panel. Push the blue button in to open the circuit 2.10 Location: Rear Junction Box Disconnect the electronic ground terminals from this stud.
  • Page 27 PROCEDURE NO: PR060034 REVISION 4 Location: Rear Junction Box 2.15 Disconnect the electronic modules: Disconnect all I/O A and I/O B modules Disconnect C397 Disconnect transmission module (A1) Disconnect 3 connectors from each I/O B Disconnect 3 connectors from each I/O A 2.20 Location: Front Electrical Compartment Disconnect I/O A, I/O B, ABS, master ID, CECM,...
  • Page 28 PROCEDURE NO: PR060034 REVISION 4 Disconnect connectors from CPC Disconnect connector from master ID Disconnect 3 connectors from CECM Disconnect connector C92 Page 14 of 15...
  • Page 29 PROCEDURE NO: PR060034 REVISION 4 Location: Wiper Control Panel Remove windshield wiper motor access panel And disconnect I/O B modules When all the previous steps are done, you can do 2.30 ENSURE THAT THE WELDING GROUND welding on the vehicle RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE...
  • Page 31 SECTION 01: ENGINE CONTENTS VOLVO D13 ENGINE ..........................3 ........................... 3 YSTEM VERVIEW ........................... 7 NGINE VERVIEW ............................8 NGINE 1.3.1 General............................ 8 1.3.2 Oil Quality ..........................8 1.3.3 Oil Change Intervals........................ 9 1.3.4 Oil Filters ..........................9 1.3.5 Synthetic Lubrication ....................... 9 1.3.6 Oil Viscosity ...........................

  • Page 32: Illustrations

    Section 01: ENGINE ILLUSTRATIONS ......................6 IGURE ENGINE SENSORS LOCATION ) ....................7 IGURE F ENGINE TURBO SIDE TYPICAL )..................8 IGURE F ENGINE ALTERNATOR SIDE TYPICAL ..........................9 IGURE F OIL FILTERS ........................11 IGURE OIL FILTER WRENCH ........................ 11 IGURE OIL FITER REPLACEMENT ........................

  • Page 33: Volvo D13 Engine

    SECTION 01: ENGINE • 1. VOLVO D13 ENGINE Ambient Air Temperature Sensor • Ambient Pressure sensor 1.1 SYSTEM OVERVIEW • Boost Air Pressure (BAP) Sensor NOTE • The “Premium Tech Tool” (PTT) is the Camshaft Position (Engine Position) Sensor preferred tool for performing diagnostic work. •...
  • Page 34 Section 01: ENGINE The Ambient (Atmospheric) Pressure Sensor is the exhaust temperature of the EGR system to built into the Engine Management System confirm EGR operation. The sensor uses a (EMS) Module. thermistor that is sensitive to the change in temperature.
  • Page 35 SECTION 01: ENGINE Exhaust Temperature Sensor (DPF Sensors) Intake Manifold Pressure Sensor The exhaust gas temperature sensor detects The Intake Manifold Pressure Sensor contains a exhaust gas temperature for DPF protection as pressure sensitive diaphragm and an electrical well as DPF regeneration control. The sensor amplifier.
  • Page 36 Section 01: ENGINE FIGURE 1: ENGINE SENSORS LOCATION Fuel Pressure Air Temperature Crankcase Pressure Humidity/Ambient Air Temperature Oil Level/Temperature Camshaft Speed EGR Differential Pressure Crankshaft Speed EGR Temperature Oil Pressure Coolant Temperature AFI Fuel Pressure Boost Pressure PA1562...

  • Page 37: Engine Overview

    SECTION 01: ENGINE 1.2 ENGINE OVERVIEW NOTE For maintenance on or repair of engine components or engine-related components, please refer to Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service, purchase engine literature, D13F engine. FIGURE 2: D13F ENGINE, TURBO SIDE (TYPICAL) 1.

  • Page 38: Engine Oil

    Section 01: ENGINE FIGURE 3: D13F ENGINE, ALTERNATOR SIDE (TYPICAL) 1. Venturi Pipe 8. Fuel Pump 2. EGR Mixing Chamber 9. Hand Primer 3. Intake Manifold 10. Fuel/Water Separator 4. Engine Electronic Control Unit (EECU) 11. Fuel Filter 5. Breather Tube 12.

  • Page 39: Oil Filters

    SECTION 01: ENGINE EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use in all 2007 emission compliant Volvo engines. Chassis equipped with a 2007 emission compliant engine, which can be identified by the presence of a Diesel Particulate Filter (DPF), also require the use of Ultra Low Sulfur Diesel (ULSD) fuel. EO-O Premium Plus oils exceed the new API service category CJ-4.

  • Page 40: Oil Viscosity

    Section 01: ENGINE levels specified on the previous pages, that is: 1.3.8 Oil Consumption both VDS-4 and EO-O Premium Plus. Once the engine is stopped, check the oil level The use of synthetic oils does not permit the daily. If the engine has just been stopped and it is warm, wait approximately five minutes to allow extension of the recommended oil change the oil to drain back to the oil pan before...

  • Page 41: Oil Filters Change

    SECTION 01: ENGINE • It is important to drain as much oil as possible. Prefill the new oil filters with approved Try to change oil immediately after driving, when engine oil. Also, lubricate the filter gaskets the oil is warm. Always replace the oil filters with engine oil (1).

  • Page 42: Checking The Oil Level

    Section 01: ENGINE • Check the oil level. Add approved engine CAUTION recommended level, necessary. Do not overfill. Tag hoses and cables for identification before disconnecting in order to facilitate reinstallation. 1.3.11 Checking the Oil Level Plug all openings to prevent dirt from entering Ensure that the vehicle is parked on level the system.
  • Page 43 SECTION 01: ENGINE Inside engine compartment, disconnect pressure regulator is mounted in the upper section of engine compartment backwall starter, alternators and heater cables. and is accessible through the engine Also disconnect AFSS cable compartment R.H. side door. applicable. 5. Untighten bolts A and C. Remove bolts B Disconnect from engine,...
  • Page 44 Section 01: ENGINE Disconnect and remove the air intake CAUTION duct mounted between the turbocharger outlet and the air cooler inlet. To avoid damage to turbocharger, cover the Disconnect and remove surge tank hose turbocharger inlet opening to prevent foreign connected to pump inlet pipe and hose material from entering.

  • Page 45: Power Plant Assy. Installation

    SECTION 01: ENGINE FIGURE 11: ENGINE COMPARTMENT X3 COACHES (TYPICAL) 01184_A 1.5 POWER PLANT ASSY. INSTALLATION To install a power plant assembly, follow the same procedure as in "Power Plant Assembly Removal" except in reverse order, then proceed with the following: 1.

  • Page 46: Engine Mounts

    Section 01: ENGINE 1.6 ENGINE MOUNTS It is recommended that new rubber mounts be installed at each major overhaul. The power plant assembly is mounted to the NOTE cradle by means of rubber mounts and supports. Refer to the table on the following page for Two engine support brackets are used at the engine cradle tightening torques.

  • Page 47: Ddc Series 60 Engine

    SECTION 01: ENGINE DRY TORQUES REFERENCE DESCRIPTION Lbf-Ft SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G8.8 SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G10.9 SCREW, CAP HEXAGONAL HEAD M10 – 1.5 G10.9 SCREW, CAP HEXAGONAL HEAD M12 – 1.75 G8.8 SCREW, CAP HEXAGONAL HEAD M14 –...

  • Page 48: Harnesses

    Section 01: ENGINE completely (depending on option selection) in the event of damaging engine conditions, such as low oil pressure or high engine temperature. 2.2 HARNESSES There are two major harnesses: the Engine Harness (EH) and the Vehicle Interface Harness (VIH).

  • Page 49: Engine Overview

    SECTION 01: ENGINE 2.3 ENGINE OVERVIEW 1- Starter motor 2- Oil pan drain plug 3- Primary fuel-filter/water- separator 4- MCM (DDEC VI Electronics) 5- Secondary fuel filter shutoff valve 6- Secondary fuel filter 7- Fuel pump 8- Air compressor 9- Engine oil filling tube 10- Bosch alternators (2) 11- Engine oil dipstick 12- EGR delta pressure sensor...

  • Page 50: Ddec Vi Sensors

    Section 01: ENGINE 24- Water pump 25- EGR cooler 26- Oil filter (2) 27- Crankcase breather tube 28- EGR tube FIGURE 15: DETROIT DIESEL 2007 SERIES 60 ENGINE (TYPICAL) 01150 2.4 DDEC VI SENSORS • Camshaft Position Sensor (CMP Sensor): •...

  • Page 51: Other Sensors

    SECTION 01: ENGINE 2.5 OTHER SENSORS 2.7 COMMON POWERTRAIN CONTROLLER (CPC) • Engine Coolant Level Sensor (ECL The CPC is the interface between the MCM and Sensor): Senses coolant level for engine the vehicle/equipment for engine control and protection (mounted on coolant surge tank). manages other vehicle/equipment functions.

  • Page 52: Check Engine Telltale Light (Awl)

    Section 01: ENGINE 2.8.3 Stop Engine Warning Light (RSL) problem solving in the form of a code. The MCM and CPC continuously perform self diagnostic This light, also mounted on the telltale light checks monitor other system panel, illuminates to indicate that a major engine components.
  • Page 53 SECTION 01: ENGINE Active Codes: Codes that are currently keeping the Check Engine or Stop Engine telltale light illuminated. Active codes are flashed via the Stop Engine Light when checked with the stop-engine-override switch. Inactive Codes: These are all the codes logged in the CPC, which have previously occurred, (whether or not they are currently turning on the Stop or Check Engine Light).
  • Page 54 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2113 Vehicle Speed Failure 2113 Vehicle Speed Sensor Circuit Failed High 2113 Vehicle Speed Sensor Circuit Failed Low 2113 VSS Anti Tamper Detection via Virtual Gear Ratio 2113 VSS Anti Tamper Detection via Fixed Frequency Device 2113 VSS Anti-Tamper Detection via ABS Vehicle Speed...
  • Page 55 SECTION 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2122 Air Filter Signal Circuit Failed Low 2122 Air Filter Signal Circuit Failed High 2123 Coolant Temperature High 2123 Coolant Temperature Very High 2124 Coolant Level Low 2124 Coolant Level Circuit Failed High 2124 Coolant Level Circuit Failed Low 2124...
  • Page 56 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2134 Idle Validation Switch 2 Circuit Failed High 2134 Idle Validation Switch 1 Circuit Failed Low 2134 Idle Validation Switch 1 Circuit Failed High 2135 J1939 Cruise Control Enable Switch Signal from Source #1 is erratic 2135 J1939 Cruise Control Enable Switch Signal from...
  • Page 57 SECTION 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2144 J1939 Cruise Control Accelerate Switch Signal from Source #2 is erratic 2144 J1939 Cruise Control Accelerate Switch Signal from Source #2 is missing 2144 J1939 Cruise Control Accelerate Switch Signal from Source #3 is erratic 2144 J1939 Cruise Control Accelerate Switch Signal...
  • Page 58 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2615 MCM Fault Code Table Inconsistant - Upgrade MCM Software 2615 Insufficient Static Fault Code Storrage Memory - Upgrade CPC Software 2615 MCM Fault Code Table Inconsistant - Upgrade MCM Software 2153 J1939 Data Link Failure 2211...
  • Page 59 SECTION 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2243 Throttle inhibit switch signal not plausible due to excess vehicle speed 2615 J1939 EBC1 Message is missing 2244 J1939 Engine Retarder Selection Signal Missing 2244 J1939 Engine Retarder Selection Signal Erratic 2245 Remote Accelerator Pedal Supply Voltage Out of Range...

  • Page 60: Ddec Vi Mcm Diagnostic Codes List

    Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 3695 2334 DPF Regen Inhibit MUX Switch Message Contains Data Error Indicator 3695 2334 DPF Regen Inhibit MUX Switch Message Contains SNV Indicator 3695 2334 DPF Regen Inhibit MUX Switch Message Stopped Arriving 3695 2334...
  • Page 61 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1115 Turbo Charger Speed Above Threshold (Low Box) 1115 Turbo Charger Speed Sensor Circuit Failed Low 1115 Turbo Charger Speed Sensor Circuit Failed High 1211 Barometric Pressure Circuit Failed Low 1211 Barometric Pressure Circuit Failed High 1211 Ambient Pressure Plausibility Fault (Low Box)
  • Page 62 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low 1615 MU_ISP_T_TBD4_SRL Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High 1615 MU_ISP_T_TBD4_SRH Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low 1615 MU_ISP_T_TBD1_SRL Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High...
  • Page 63 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1615 RCP Test Function 1 Circuit Failed Low 1615 RCP Test Function 1 Circuit Failed High 1615 RCP Test Function 1 Circuit Failed Open 1615 RCP Test Function 2 Circuit Failed Low 1615 RCP Test Function 2 Circuit Failed High 1615...
  • Page 64 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1542 Turbo Control Circuit Failed High 1542 Turbo Control Circuit Open 1241 Smart Remote Actuator 5 (VGT), No Failsafe Mode, Motor Off 1241 Smart Remote Actuator 5 (VGT), Failsafe Mode, Motor Off 1241 Smart Remote Actuator 5 (VGT), Failsafe Mode, Motor On 1241...
  • Page 65 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1251 Injector Cylinder #5 Needle Control Valve, Valve Shorted Circuit 1251 Engine Smoothness Control / Cylinder #5 Value Out of Range 1252 Injector Cylinder #6 Needle Control Valve Abnormal Operation 1252 Injector Cylinder #6 Needle Control Valve Abnormal Rate of Change Injector Cylinder 6, Nozzle Control Valve or Spill Control Valve, Jammed 1252...
  • Page 66 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1073 1315 Jake Brake Stage 2 Circuit Failed Open 1074 1345 Exhaust Brake Circuit Failed Low 1074 1345 Exhaust Brake Circuit Failed High 1074 1345 Exhaust Brake Circuit Failed Open 1241 1077 Rail Pressure Governor Error, Open Loop Error 1077...
  • Page 67 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1636 1511 Intake Manifold Temperature Circuit Failed High 1636 1511 Intake Manifold Temperature Plausibility Error Difference Intake Manifold Temperature and EGR Temp. Less Than 1636 1511 Threshold (Low Box) Difference Intake Manifold and I Cooler Temperature Out Less Than 1636 1511 Threshold (Low Box)
  • Page 68 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 2797 1524 Injector Needle Control Valve Cylinder 4,5,6, Shorted to Battery 2797 1615 Injector Needle Control Valve Bank 3, Shorted to Battery 2798 1615 Injector Spill Control Valve Cylinder 1, 2, 3 Shorted to Ground 2798 1615 Injector Spill Control Valve Cylinder 4, 5, 6 Shorted to Ground...
  • Page 69 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3470 1311 Actuator Turbo Compound Bypass Circuit Failed High 3470 1311 Actuator Turbo Compound Bypass Circuit Failed Open 3471 1323 HC Doser Circuit Failed Low 3471 1323 HC Doser Circuit Failed High 3471 1323 HC Doser Circuit Failed Open...
  • Page 70 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3610 1555 DPF Pressure Sensors - Plausibility Error 3610 1555 DPF Outlet Pressure Sensor Drifted High In Range Fault (Low Box) 3610 1555 DPF Outlet Pressure Sensor Drifted High In Range Fault (High Box) 3610 1555 DPF Outlet Pressure Sensor Drifted Low In Range Fault (Low Box)
  • Page 71 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 4076 1615 Engine Coolant Sensor (IN), General Temp. Plausibility Error 4077 1543 Doser Fuel Line Pressure Sensor Circuit Failed Low 4077 1543 Doser Fuel Line Pressure Sensor Circuit Failed High 4077 1543 Doser Fuel Line Pressure Failed Self Test 4226...

  • Page 72: Engine Oil Level

    Section 01: ENGINE The vehicle may be provided with an oil reserve 2.12 ENGINE OIL LEVEL tank in the engine compartment. To adjust oil level, open the oil reserve tank drain valve and allow oil to discharge into the engine until the MAINTENANCE "Full"...
  • Page 73 SECTION 01: ENGINE However, changes that are more frequent may 5. Clean the filter adapter with a clean rag. be required when the engine is subject to high 6. Lightly coat the filter gasket (seal) with clean levels of contamination and/or overheating. engine oil.

  • Page 74: Recommended Engine Oil Type

    Section 01: ENGINE 2.14 RECOMMENDED ENGINE OIL TYPE NOTE No parts within the MCM are serviceable. If To provide maximum engine life, lubricants shall found defective, replace the MCM as a unit. meet the following specifications: SAE Viscosity Grade: 15W-40 API Classification: CJ-4. 1.
  • Page 75 SECTION 01: ENGINE 6. Disconnect and remove the engine-air 18. Disconnect the steel-braided airline from the intake duct mounted between air cleaner A/C compressor air bellows. housing and turbocharger inlet. 19. Remove the power steering pump, leaving the supply and discharge hoses connected CAUTION to it.
  • Page 76 Section 01: ENGINE close to yoke. On right side: close to the 36. Using a suitable equipment, with a minimum solenoid valve of the output retarder. capacity of 4,000 lbs (1 800 kg), slightly raise the power plant cradle. 33. From under the vehicle, disconnect the propeller shaft as detailed in Section 09, 37.

  • Page 77: Power Plant Assy. Installation

    SECTION 01: ENGINE 2.16 POWER PLANT ASSY. INSTALLATION 2.17 JAKE BRAKE To install a power plant assembly, follow the Refer to both "The Jake Brake Troubleshooting same procedure as in "Power Plant Assembly and Maintenance Manual" and "Installation Removal" except in reverse order, then proceed Manual for Model 790 Engine Brakes"...

  • Page 78: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    Section 01: ENGINE 3. ELECTRONIC FOOT PEDAL ASSEMBLY (EFPA) & THROTTLE POSITION SENSOR The Electronic Foot Pedal Assembly (EFPA) connects the accelerator pedal to a Throttle Position Sensor (TPS). The (TPS) is a device, which sends an electrical signal to the Motor Control Module (MCM). The TPS varies in voltage depending on how far the pedal is depressed.

  • Page 79: Engine Troubleshooting Guide

    SECTION 01: ENGINE 4. ENGINE TROUBLESHOOTING GUIDE START does the is the go to engine engine step 2 rotate ? starting ? note 1 plug the Diagnostics Data Reader DDR into the receptacle does the red or momentarily depress the go to "Stop Engine"...

  • Page 80: Specifications

    Section 01: ENGINE step 3 with diagnostic code in hand, contact your note 1 Detroit Diesel service REFERENCES center -Operator's Manual chap. 3,4 & 8 -Detroit Diesel pamphlet "DDEC III/IV diagnostic codes and MPSI reader functions" -8V92 series engine, switch is located in service compartment voir note 1...
  • Page 81 Detroit Diesel Series 60 engine ratings Series 60 engine ratings used in Prevost Car Models are listed in the following tables. The standard engine ratings are written in bold, customer may easily switch from one rating to another within the same table by having the DDEC V system reprogrammed.
  • Page 82 Section 01: ENGINE Lubricating oil filter elements Make....................AC Rochester Div. GMC # 25014505 Make..........................A/C Filter # PF-2100 Type ..............................Full Flow Prévost number..........................510458 Torque specification Engine oil filter................Tighten 2/3 of a turn after gasket contact Filters Engine Air Cleaner Filter Make ..........................
  • Page 83 SECTION 03: FUEL SYSTEM CONTENTS FUEL SYSTEM WITH DETROIT DIESEL SERIES 60 ENGINE ............3 ............................ 3 ESCRIPTION ............................ 3 ALVES ........................... 4 ILTERS ..................4 ACOR ATER EPARATOR ERVICING & S ) ............. 5 ILTER ERVICING RIMARY ECONDARY ......................... 6 NSTALLATION FUEL SYSTEM WITH VOLVO D13 ENGINE ..................
  • Page 84 Section 03: FUEL SYSTEM ILLUTRATIONS )................3 IGURE FUEL SYSTEM SCHEMATIC DDC SERIES ENGINE ) ..............3 IGURE MANUAL SHUT OFF VALVES LOCATION DDC S ENGINE 382 ( ) ........... 4 IGURE MANUAL SHUT OFF VALVE WITH DAVCO FUEL PRO DDC S ENGINE ..........................

  • Page 85: Fuel System With Detroit Diesel Series 60 Engine

    Section 03: FUEL SYSTEM FUEL SYSTEM WITH DETROIT DIESEL SERIES 60 ENGINE 1.1 DESCRIPTION Figure 1 shows a schematic of the fuel system. Fuel is drawn from the fuel tank through a manual shut-off valve, a primary fuel filter (fuel-filter/water-separator) before it enters the MCM and the fuel pump. If the vehicle is equipped with the optional “Davco Fuel Pro 382”, this one replaces the primary fuel filter.

  • Page 86: Fuel Filters

    Section 03: FUEL SYSTEM NOTE For information on the Davco Fuel Pro 382 fuel filter, refer to paragraph 3. 1.4 RACOR FUEL/WATER SEPARATOR SERVICING MAINTENANCE The Racor fuel/water separator should be drained periodically, when water separator telltale light on the dashboard illuminates.

  • Page 87: Spin-On Type Fuel Filter Servicing (Primary & Secondary)

    Section 03: FUEL SYSTEM 5. Screw bowl onto new filter cartridge snugly not exceed 12 inches of mercury (41 kPa) with a by hand. dirty system. At normal operating speeds and with the CAUTION standard fuel pressure regulator, the fuel pressure at the cylinder head inlet is 58-72 psi Do not use tool to tighten.

  • Page 88: Fuel Pump Installation

    Section 03: FUEL SYSTEM 7. Start the engine and check for leaks. NOTE When correctly positioned, the outlet fitting on NOTE the pump should be in approximately an 8 There is a fuel system shut-off valve on the o'clock position when viewed from the rear, discharge side of the secondary fuel filter.

  • Page 89: Fuel System With Volvo D13 Engine

    Section 03: FUEL SYSTEM 2. FUEL SYSTEM WITH VOLVO D13 ENGINE 2.1 DESCRIPTION NOTE For additional information concerning Volvo D13 engine components or engine-related components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service. On Volvo web site, you will find detailed service procedures for parts replacement, repair and maintenance.

  • Page 90: Engine

    Section 03: FUEL SYSTEM removed. It is not necessary to bleed the fuel FUEL LINE FITTINGS – VOLVO D13 ENGINE system after replacing the filter, since this is 13 ± 2 ft-lb (18 ± 3 Nm) performed automatically when the engine is 20.5 ±...

  • Page 91: Primary Fuel Filter Replacement

    Section 03: FUEL SYSTEM 4. Unscrew and remove the primary fuel filter from the fuel filter housing. Drain filter. MAINTENANCE 5. Unscrew and remove the separation bowl The primary and secondary fuel filters are of a from the filter cartridge. spin-on type and must be replaced at every 6.

  • Page 92: Secondary Fuel Filter Replacement

    Section 03: FUEL SYSTEM 14. Start the engine and carry out a fuel- CAUTION tightness check. Let the engine run for about 5 minutes to remove air pockets from the fuel system. When priming the system, movement of the primer pump should be as up and down as 2.3.2 Secondary Fuel Filter Replacement possible.

  • Page 93: Fuel Pump Removal And Installation

    Section 03: FUEL SYSTEM • 2.5 FUEL PUMP REMOVAL Install the fuel pump. Torque-tighten bolts to INSTALLATION specification. The pump is located underneath the air NOTE compressor and is accessible through the engine compartment R.H. access door. Use a new sealing ring. Check that the fuel pump drive axle sits correctly in the power To remove the pump, proceed as follows: steering pump.
  • Page 94 Section 03: FUEL SYSTEM 11. Open the shut-off valve; 12. Start engine, raise rpm for 2-3 minutes, hand tighten collar again; 13. After the air is purged and with the engine still running, slowly loosen the vent cap on the filter cover. The fuel level in the cover will start falling.

  • Page 95: Fuel Lines And Flexible Hoses

    Section 03: FUEL SYSTEM FUEL LINES AND FLEXIBLE HOSES FUEL TANK Make a visual check for fuel leaks at all engine- X3-45 coaches are equipped with a high-density mounted fuel lines and connections and at the cross-link polyethylene fuel tank with a capacity fuel tank suction and return lines.

  • Page 96: Tank Installation

    Section 03: FUEL SYSTEM 5. Unscrew engine supply and return lines 7. From under the vehicle, on R.H. side, from fuel tank connection-panel, identify unscrew the 4 bolts (2 in front, 2 in back) them for reinstallation. retaining the tank support to the frame. 8.

  • Page 97: Fuel Tank Verification

    3. Drill perforation with a 23/64" bit. Make sure . Similarly for Volvo engine. ILTERS drill hole is perfectly round. 4. Insert a screw (Prevost #500196) and a CAUTION washer (Prevost #5001244) into anchor nut (Prevost #500331). ULSD fuel is necessary to avoid fouling the engine’s...

  • Page 98: Blending

    Volvo, encouraged to monitor their diesel-powered Detroit Diesel or Prevost product warranty. Also, vehicles closely for potential fuel system leaks any engine performance problem related to the...

  • Page 99: General Recommendations

    Section 03: FUEL SYSTEM Install cleaner element as follows: 8.4 AIR CLEANER RESTRICTION INDICATOR 1. Inspect the gasket-sealing surface inside the A resettable restriction indicator may be installed air cleaner. It must be smooth, flat and clean; on the engine air-intake duct, clearly visible from the rear engine compartment.

  • Page 100: Fuel Pedal

    Section 03: FUEL SYSTEM CAUTION Note the routing and clamping locations of the cable before disassembly. Proper cable routing and fastening is critical to the operation of this system. Marking the foot pedal assembly to record cable routing is recommended. 2.
  • Page 101 Section 03: FUEL SYSTEM SPECIFICATIONS Davco Fuel Pro 382 Fuel Filter / Water Separator Element Prevost number ............................510795 Racor Primary Fuel Filter / Water Separator (optional) (May be used instead of regular primary filter (never use with a primary filter).
  • Page 102 Standard (X3-45)......................208 US gallons (787 liters) Air Cleaner Make ................................Nelson Prevost Number ............................530206 Service Part No ............................7182 8N Prevost number (element cartridge) ......................530197 Air Cleaner Restriction Indicator Make ..............................Donaldson Model ..............................RBX00-2220 Indicates .........................at 20" (508 mm) of water Prevost number ............................530161...
  • Page 103 SECTION 04: EXHAUST SYSTEM CONTENTS EXHAUST AND AFTERTREATMENT SYSTEM OVERVIEW ............. 2 ..........................2 AINTENANCE ....................3 LEXIBLE OUPLING NSTALLATION AFTERTREATMENT DEVICE (ATD) ....................3 ............4 IESEL ARTICULATE ILTER EMOVAL NGINES DIFFUSER ASSEMBLY........................6 ........................6 IFFUSER DJUSTMENT ..........................7 AINTENANCE ....................

  • Page 104: Exhaust And Aftertreatment System Overview

    Section 04: EXHAUST SYSTEM EXHAUST AND AFTERTREATMENT 1.1 MAINTENANCE SYSTEM OVERVIEW Inspect the exhaust system periodically for restrictions and leaks. Figure 1 presents the technology behind clean emissions major components of the exhaust system. technology exhaust Aftertreatment Exhaust leaks are commonly the result of loose Device (ATD) which replaces today’s muffler.

  • Page 105: Flexible Coupling Installation

    Section 04: EXHAUST SYSTEM 1.2 FLEXIBLE COUPLING INSTALLATION The flexible coupling contains a rigid interior pipe (Fig. 2). To allow appropriate flexibility once installed, be sure interior pipe is concentric to flexible part and that the flexible coupling is straight when installed. This piece of equipment handles vibration and thermal expansion.

  • Page 106: Diesel Particulate Filter (Dpf) Removal - Both Engines

    Section 04: EXHAUST SYSTEM 4. From under the ATD, loosen the water drain WARNING pipe clamp to set free the pipe as it will move up with the ATD later in this procedure. TOXICITY Do not initiate a stationary regeneration in a 5.
  • Page 107 Section 04: EXHAUST SYSTEM 12. Set the pressure pick-up tubes aside and pull the DPF cartridge out of the compartment. Use appropriate handling equipment. CAUTION HEAVY DEVICE A suitable lifting or holding device is required. Properly support and attach lifting equipment to prevent the DPF from falling when servicing.

  • Page 108: Diffuser Assembly

    Section 04: EXHAUST SYSTEM 4. Be sure to return the support rod to its clip 2. For proper angular position, make sure that before closing the door, this prevents rattles. the two edges shown on figure 10 are parallel with each other. DIFFUSER ASSEMBLY During stationary regeneration, exhaust gases temperature may reach up to 1200°F (650°C) at...

  • Page 109: Maintenance

    • Check that the warning plate ”THIS DIFFUSER SURFACE MUST BE FLUSH WITH THE ROOF is still in place. SURFACE” 3.3 EXHAUST GAS COLLECTION ADAPTER diffuser adapter (Prevost #040710) available through Prevost Parts to permit connection with current exhaust gas collecting system. PA1562...
  • Page 111 SECTION 05: COOLING SYSTEM CONTENTS DESCRIPTION ............................3 MAINTENANCE ............................ 4 ......................4 ENERAL ECOMMENDATIONS 60 E ................4 EHICLES QUIPPED ERIES NGINE 2.2.1 Vehicles without coolant filters ....................5 2.2.2 Vehicles with coolant filters ..................... 5 D13 E ................. 5 EHICLES QUIPPED OLVO...
  • Page 112 Section 05: COOLING SYSTEM 13.1 L ..............18 OCKING ADIATOR MERGENCY PERATION 13.1.1 Electrical Locking ........................18 13.1.2 Mechanical Locking....................... 18 13.2 M ..........................18 AINTENANCE 13.3 I ............................ 19 NSPECTION 13.4 F ......................19 EMOVAL NSTALLATION FAN RIGHT ANGLE GEARBOX..................... 19 14.1 M ..........................

  • Page 113: Section 05: Cooling System

    Section 05: COOLING SYSTEM 1. DESCRIPTION A radiator and thermo-modulated fan are used to effectively dissipate the heat generated by the engine. A centrifugal-type water pump is used to circulate the engine coolant (Fig. 1). Two full blocking-type thermostats are used in the water outlet passage to control the flow of coolant, providing fast engine warm-up and regulating coolant temperature.

  • Page 114: Maintenance

    Section 05: COOLING SYSTEM • Inspect the water pump operation. A leaky pump sucks in air, increasing corrosion. • Repair all leaks promptly. Unrepaired leaks can lead to trouble. Inspect and tighten radiator mounts periodically. Test and replace thermostats regularly. NOTE In order to ensure the integrity of the system, it is recommended that a periodic cooling system...

  • Page 115: Vehicles Without Coolant Filters

    Section 05: COOLING SYSTEM MAINTENANCE MAINTENANCE Drain, flush, thoroughly clean and refill the Drain, flush, thoroughly clean and refill the system every two years or every 200,000 miles system with Extended Life Coolant (ELC) every (320 000 km), whichever comes first. For four years or every 600,000 miles (1 000 000 vehicle equipped with coolant filters, change km), whichever comes first.

  • Page 116: Installation

    Section 05: COOLING SYSTEM 100 lbf-in. (10 to 11 Nm). The Belleville spring washer stacks should be nearly collapsed flat and the screw tip should extend ¼" (6 mm) beyond the housing (Fig. 8). FIGURE 8: CONSTANT-TORQUE CLAMP 05037 CAUTION The hose clamps will break if over-torqued.

  • Page 117: Maintenance

    Section 05: COOLING SYSTEM 4. THERMOSTAT OPERATION 4.1 DETROIT DIESEL SERIES 60 ENGINE Coolant temperature is controlled by two blocking-type thermostats located in a housing attached to the cylinder head, on the turbo side of the engine (Fig. 11). At coolant temperature below approximately 182°F-188°F (83°C-86°C), the thermostat valves remain closed and block the flow of coolant from the engine to the radiator.

  • Page 118: Thermostat Checking

    Section 05: COOLING SYSTEM 5. COOLANT 5.1 COOLANT LEVEL VERIFICATION Coolant level is correct when cold coolant is visible through the surge tank sight glass (Fig. 13). If coolant level is low, fill cooling system. FIGURE 12: THERMOSTAT HOUSING (VOLVO D13 ENGINE) 3.

  • Page 119: Coolant Recommendations For Detroit Diesel Series 60 Engine

    5. Maintain the prescribed inhibitor strength levels as required. 6. Do not mix different base inhibitor packages. 05104 7. Always maintain proper coolant level. Recommended phosphate free coolants for Detroit Diesel Series 60 engine: • Prevost #685125; PA1562...

  • Page 120: Coolant Not Recommended

    Section 05: COOLING SYSTEM be spongy, and holes can develop completely CAUTION through them. Always test the solution before adding water 5.5.3 Inhibitor Test Procedures or antifreeze. Test Kits are commercially available to check 8. If cooling system is not at the proper engine coolant for nitrite concentration.

  • Page 121: Coolant Recommendations For Volvo D13 Engine

    Section 05: COOLING SYSTEM 5.6 COOLANT RECOMMENDATIONS FOR Recommended coolants for Volvo D13 VOLVO D13 ENGINE engine: Coolant mixture consisting of 50/50 antifreeze • Prevost #685241 (pre-diluted 50/50 and deionized water solution should be used mixture); year-round to provide freeze and boil-over •...

  • Page 122: Draining Cooling System

    Section 05: COOLING SYSTEM 6. DRAINING COOLING SYSTEM Use the following procedures to drain the cooling system partially or completely. To drain engine and related components: 1. Stop engine and allow engine to cool. Close both heater line shutoff valves. On X3- 45 coaches, the valves are located in the engine compartment.

  • Page 123: Flushing

    Section 05: COOLING SYSTEM 2. Refill with clean water. NOTE On Volvo D13 engine, the regular drain plugs CAUTION are replaced by quick connect fittings to ease draining and filling of coolant system. Coolant If the engine is hot, fill slowly to prevent rapid system may be refilled by the use of the quick cooling and distortion of the engine castings.

  • Page 124: Reverse Flushing

    Section 05: COOLING SYSTEM 4. Turn on the water until the jackets are filled, After using the solvent and neutralizer, fully drain the system, and then reverse flush the and then turn on the air in short blasts. Allow engine and radiator (see "Reverse Flushing" in jackets to fill with water between air blasts.

  • Page 125: Radiator

    Do not use fuel oil, PRECHARGE ELEMENT FILTER kerosene, gasoline, or any caustic material. It may be necessary to clean the radiator more Prevost number: 550629 frequently if the vehicle is operated in MAINTENANCE ELEMENT FILTER extremely dusty or dirty areas. Refer to...

  • Page 126: Charge Air Cooler Leakage

    Section 05: COOLING SYSTEM 11. CHARGE AIR COOLER LEAKAGE 2. Dismount the drive pulley. Gain access to the 6 mounting bolts from behind the pulley, Spec for CAC acceptable leakage: through the opening in the cast aluminum support (Fig. 15). “The CAC is considered acceptable if it can hold 30 psi (206 kpa) gauge pressure with less than 3.

  • Page 127: Variable Speed Cooling Fan

    Section 05: COOLING SYSTEM FIGURE 23: IDLER MOUNTED ON THE CAST ALUMINUM SUPPORT 4. Bolt the new idler on the cast aluminum support. Tighten to 32 lbf-ft (44 Nm). 5. Place a new protective cap. 13. VARIABLE SPEED COOLING FAN The cooling fan clutch has two thermostatically controlled speeds,...
  • Page 128 Section 05: COOLING SYSTEM 13.1.2 Mechanical Locking pressure dropping 130 psi: fan HIGH SPEED disengages Once mechanically locked, the fan is rigidly psi: SPEED connected to the drive mechanism and will disengages rotate continuously, with no considerations for the cooling needs. This is an emergency situation and the vehicle shall not be operated in WARNING that situation for an extended period.
  • Page 129 7. When questions arise, obtain answers before proceeding. Assistance is available through the Prevost After-Sales Service Support serving your area. 13.3 INSPECTION FIGURE 25: RADIATOR FAN MOUNTING BOLTS 05125 DANGER 14. FAN RIGHT ANGLE GEARBOX...
  • Page 130 Section 05: COOLING SYSTEM 6. Loosen the gearbox support bracket top 2. Set the ignition to the OFF position and remove the key from the contact switch to bolts. prevent accidental starting of the engine or 7. Unscrew and remove 4 gearbox mounting set the rear start panel selector switch to the bolts.
  • Page 131 4. Release the tensioner slowly and let it return to its natural position. COOLING FAN DRIVE BELT With Detroit Diesel Series 60 engine Type: 14PK2605 Prevost number: 550926 With Volvo D13 engine Type: 14PK2526 Prevost number: 5060097 16. SPECIFICATIONS Cooling System Capacity (Approximation) Includes heating system......................
  • Page 132 Fully closed............................185°F (85°C) Cooling Fan Drive Belt - Detroit Diesel Series 60 Engine Type ............................Poly-Rib 14PK2605 Qty ..................................1 Prevost number ............................550926 Cooling Fan Drive Belt – Volvo D13 Engine Type ............................Poly-Rib 14PK2526 Qty ..................................1 Prevost number ............................5060097 Coolant - Detroit Diesel Series 60 Engine Prevost Number ............................685125...
  • Page 133 Postfach / P.O.Box 1430 D - 88672 Markdorf Tel.: + 49 7544 / 964 0 Fax: + 49 7544 / 6218 Internet: http://www.linnig.com Mail: webinfo@linnig.com Reparaturanleitung LINNIG Drehschwingungsdämpfer LDD (außer LDD12) Austausch Gummidämpfer 127.032 mit EB0112 Repair instructions LINNIG Torsional vibration damper LDD (except LDD12) Replacement of the rubber damper 127.032 with EB0112 Instrucciones de servicio LINNIG Polea antivibratoria LDD (excepto LDD12)
  • Page 134 Lieferumfang / Delivery / Volumen de suministro Ersatzteilbaugruppe / Assembly group / Juego de refacciones EB0112 6 × 127.032 Gummidämpfer Rubber damper Amortiguadores de goma 6 × 50.099 3 × 65.003 Zyl.-Schraube IN-STAR LIKO-Schraube Socket head cap screw IN-STAR LIKO-screw Tornillo cabeza allen Tornillo IN-STAR LIKO 4 ×...
  • Page 135 4 Zyl.-Schrauben M5 Remove 4 socket head Retire los 4 tornillos M5 bzw. 3 IN-STAR LIKO- cap screws M5 resp. 3 o 3 tornillos M6 IN- Schrauben M6 am IN-STAR LIKO-screws STAR LIKO de la tapa Deckel entfernen. M6 on the cover. de la polea.
  • Page 136 4 bzw. 6 neue Zyl.- Protect 4 resp. 6 new Aplicar Loctite 270 Schrauben 50.099 mit socket head cap screws o equivalente a los Loctite 270 versehen und 50.099 with Loctite 270 4 o 6 tornillos M8 4 bzw. 6 neue and attach the 4 resp.
  • Page 137 SECTION 06: ELECTRICAL CONTENTS GENERAL DESCRIPTION........................4 ..........................4 IRING IAGRAMS 1.1.1 Using Wiring Diagrams......................4 1.1.2 Testing Circuits........................5 ........................5 IZES AND OLORS ........................... 5 PARE IRES ........................6 LEANING ONNECTORS ........................... 6 IRCUIT REAKERS ..........................7 ULTIPLEX USES ............................
  • Page 138 Section 06: ELECTRICAL 4.8.1 Available Functions ....................... 31 ..............31 LOWER PRIORITY MODULES FOR BREAKDOWN SERVICE 4.10 M ........................32 ULTIPLEX ODULES 4.10.1 CECM ............................ 32 4.10.2 MASTER ID ........................... 32 4.10.3 IO-A ............................32 4.10.4 IO-B ............................32 4.11 M ....................
  • Page 139 Section 06: ELECTRICAL 10.5.2 Removal and Replacement of In-Station Fluorescent Tubes ..........45 10.5.3 Removal and Replacement of Reading Lamp Bulb .............. 45 10.6 E ....................46 NGINE OMPARTMENT IGHTING 10.7 L ..........................46 AVATORY IGHT LIGHT BULB DATA ........................46 SPECIFICATIONS ...........................

  • Page 140: General Description

    100 amps on the 12 volt system. Both the 12 and 24 volt 12, you will find the location, the b) At item CB systems are controlled through individual main Prevost number, the breaker function, the battery relays. volt self-rectified...

  • Page 141: Testing Circuits

    Section 06: ELECTRICAL b) In first column DEVICE ID, look for device Yellow Multiplex modules communication SW61, SW62. CAN-H (twisted with green) Green Multiplex modules communication c) At device SW61,SW62, find the fault CAN-L (twisted with yellow) message, the minimum condition to activate, Orange Connected to multiplex outputs other inputs involved in logic, the multiplex...

  • Page 142: Cleaning Connectors

    Section 06: ELECTRICAL Rear distribution 12 VI 40 amps NOTE WCL or other option 24VD 50 amps Spare wires identified wire CB10 Front distribution 12 VI 70 amps identification number and by the letters “SP”, to CB11 Sound system 24 VD 50 amps designate “spare”.

  • Page 143: Multiplex Fuses

    Section 06: ELECTRICAL MULTIPLEX FUSES the OFF position and/or a component could be pressurized even if air tanks are emptied. The multiplex outputs are protected in current by Always refer to the appropriate wiring and internal “soft-fuse”. Each output pneumatic diagrams prior to working on programmed specific maximum...
  • Page 144 06630 Remove the terminal by disengaging the flexible lock tab on the terminal. Gently remove the terminal from the connector by pulling on the wire. EXTRACTOR/TOOL: Prevost #682256 (Packard INSERT 12094429) EXTRACTOR HERE Remove the terminal by disengaging the flexible lock tab on the terminal.

  • Page 145: X3 Coaches Electrical Compartments

    Section 06: ELECTRICAL X3 COACHES ELECTRICAL COMPARTMENTS FIGURE 4: ELECTRICAL COMPARTMENTS (X3-45 COACH) 06672 the last baggage compartment (Super bay) on MAINTENANCE the driver side of the vehicle. The compartment A Cortec VCI-238 corrosion inhibitor has been accessible from last baggage sprayed in all electrical compartments to protect compartment by removing a plastic access...

  • Page 146: Front Electrical And Service Compartment

    Section 06: ELECTRICAL Luggage 4-Cmpt Parcel Rack Rear Electrical Compartment Luggage 2-Cmpt Rear Lights Multiplex Modules Luggage 1-Cmpt Rear Lights I/O-A I/O-B Condenser fans Rear Lights I/O-B I/O-B Condenser fans Rear Lights I/O-B I/O-B Unloader LH Not used Spare I/O-B Relays Master relay Aisle &...

  • Page 147: Engine Rear Start Panel

    Section 06: ELECTRICAL Spare fuse Defroster unit Digital Clock Spare Spare fuse Upper Defroster Spare fuse Pro Driver Spare fuse Witness red LED Lower wipers Power Mux A44 Sound system ZF Steering Control Customer Diodes Accessories Service brake Driver Liq Sol Vlve Ignition Engine Brake Not used...

  • Page 148: Condenser Compartment

    Section 06: ELECTRICAL CONDENSER COMPARTMENT ENTRANCE DOOR & WIPER CONTROL PANEL The batteries are located inside the condenser To access the entrance door & wiper control compartment on the X3-45 coach. panel of the right console, remove the panel under the larger utility compartment at the base of the windshield.
  • Page 149 Section 06: ELECTRICAL greatly reduces the possibility of overcharge The battery has four (4) major functions: damage. 1. Providing a source of current for starting the The vents require keeping the battery in an engine; upright position to prevent electrolyte leakage. 2.

  • Page 150: Battery Discharge Protection

    Section 06: ELECTRICAL FIGURE 11: BATTERY CONNECTIONS 06636 • Battery equalizer check module; BATTERY DISCHARGE PROTECTION • MCM; To prevent discharge of the batteries when the engine in not running, some functions are • TCM (World transmission); automatically switched off if the batteries voltage •...

  • Page 151: Battery Rating

    Section 06: ELECTRICAL NOTE DANGER A protective silicone free, coating should be applied on all terminals that have been prevent possible electric shocks disconnected. We recommend the use of sparking, the battery master switches should Cortec VCI-238 (Prévost #682460) on all be in the "Off"...

  • Page 152: Visual Inspection

    Section 06: ELECTRICAL evidence of corrosion. Correct conditions as required before proceeding with tests. 3.5.2 Removing Surface Charge Disconnect cables from the battery and attach alligator clamps to the contact lead pad on the battery as shown in figure 16. Connect a 300 ampere load across the terminal for 15 seconds to remove surface charge from the battery.

  • Page 153: Testing Battery Cables

    Section 06: ELECTRICAL temperatures below 70ºF (21ºC), refer to the NOTE following "Voltage and Temperature Chart". If it is necessary to extend the voltmeter lead Voltage and Temperature Chart for this test, use a #16 (AWG) or larger wire. Ambient Temperature Minimum Voltage 3.
  • Page 154 Section 06: ELECTRICAL 2. Do not break live circuits at battery terminals because a spark usually occurs at the point where a live circuit is broken. Care must always taken when connecting or disconnecting booster leads or cable clamps on chargers. Poor connections are a common cause of electric arcs, which cause explosions.

  • Page 155: Battery Charging Guide

    Section 06: ELECTRICAL 3.6.1 Battery Charging Guide Booster Block On X3-45 coaches, booster block is located Fast Charging Rate near the preheater in the engine compartment 20 amps @ 3-¾ hours on the R.H. side and is accessible through 30 amps @ 2-½ hours engine R.H.

  • Page 156: Cleaning And Inspection

    Section 06: ELECTRICAL Apply parking brake and place the transmission CLEANING AND INSPECTION shift lever or push-button pads in Neutral (N) The external condition of the battery and the position in both vehicles. Turn off lights, heater battery cables should be checked periodically. and other electrical loads.

  • Page 157: Troubleshooting

    Section 06: ELECTRICAL 8. A constant drain caused by a shorted circuit 3.10.1 "Bat" Telltale Light Definitions such as an exposed wire or water infiltration Voltmeter drops below 24.4 volts dc in junction boxes causing ground fault. Check alternator output. 9.

  • Page 158: Probing Voltage On The Multiplex Circuits

    Section 06: ELECTRICAL Once the problem corrected, the MCD still CAN NETWORK shows the fault as being active. You have to The CAN network wiring is separated in sections leave the FAULT DIAGNOSTIC menu, wait and uses connectors that are not shared with approximately 20 to 30 seconds and then return other circuits.

  • Page 159: Spare Can

    Section 06: ELECTRICAL 4.3.2 Spare Can Engine ignition rear switch Entrance door inside closing switch A spare CAN network is installed between the Entrance door outside opening /closing switch front and the rear of the vehicle. It has Entrance door electric window down switch connectors installed at each end to facilitate Entrance door electric window up switch swapping from the regular CAN network to the...

  • Page 160: Test Mode For Electric Motors

    Section 06: ELECTRICAL In test mode, with the parking brake applied and Using the test mode: the passenger set point set to a value higher o During the entire test, the telltale panel than 64°F (18°C), the circulator pump is not set audible alarm gives a signal each second to to OFF as it would normally do when the outside remind that the motor test mode is underway.

  • Page 161: Can Network Layout And Troubleshooting

    Section 06: ELECTRICAL o Auxiliary A/C clutch (parcel rack cooling 5 beeps from the back-up alarm indicate to system) activates 3 times at 1 second go to inside the vehicle (10 SECONDS interval. DELAY). 5 beeps from the back-up alarm indicate to Inside the vehicle: go to the evaporator compartment (10 o Upper section defroster fan motor runs for 5...

  • Page 162: Troubleshooting

    Section 06: ELECTRICAL TROUBLESHOOTING Problem/Symptom Probable Causes Actions Vehicle does not Start Rear Start selector switch is 1. Check that the rear start selector not in the NORMAL position switch is flipped up to NORMAL start position and master cut-out switch is Master cut-out switch in the flipped up to ON and retry cranking rear electrical compartment...
  • Page 163 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions 4. Try disconnecting CECM completely, leave it disconnected and see if the limp-home functions (start of the vehicle from the engine compartment, wipers speed flashers, etc ) are functioning Many secondary functions The CECM module does not 1.
  • Page 164 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions HVAC condenser fans not Circuit breaker CB7 was Check / reset circuit breaker CB7 functioning in speed 1 manually tripped and not reset HVAC condenser fans not Circuit breaker CB7 was Check / reset circuit breaker CB7 functioning in speed 2 manually tripped and not reset...
  • Page 165 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Rear flashers not Module A51 is not powered 1. Check the SYSTEM DIAGNOSTIC functioning or is faulty menu of the message center display (MCD). Select FAULT DIAGNOSTIC Stoplights and center and ELECTRICAL SYSTEM. The stoplights not functioning message “No Response ModA51, Active”...
  • Page 166 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Active” indicates a power problem on the module. (A CAN network problem would show the same message but doesn't produce this symptom). 2. Check / reset circuit breaker CB5 3. Check / replace fuse F67 , F68 4.

  • Page 167: Essential Functions To Operate The Vehicle

    Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Press the push-button one time to engage the clutch in 1 speed, press a second time to engage in 2 speed, press a third time to stop the fan, press once again to return to 1 speed.

  • Page 168: Multiplex Modules

    Section 06: ELECTRICAL 4.10 MULTIPLEX MODULES To disconnect the black connector, slide downwards the red latch. Remove the lower 4.10.1 CECM screw that holds the cable attachment rod onto the floor portion of the panel and flip the The CECM plays the role of interface between rod up, this will relieve the IO-B module, (see the engine ECM, the transmission ECU, the Fig.

  • Page 169: Bosch Alternators

    Section 06: ELECTRICAL DIAGNOSTIC menu of the message center 4. Mount the lower alternator using bolt and display (MCD). Select FAULT DIAGNOSTIC nut (3a, figure 19), and also bolt and nut (3b, and ELECTRICAL SYSTEM. Check the error figure 19). Fix the lower portion of the messages.
  • Page 170 Section 06: ELECTRICAL FIGURE 18: ALTERNATOR DRIVE BELT 01180 FIGURE 19: TWIN BOSCH ALTERNATORS INSTALLATION (DDEC SERIES 60) 01077 PA1562...

  • Page 171: Volvo D13 Twin Bosch Alternators Installation

    Section 06: ELECTRICAL FIGURE 20: ALTERNATORS AND ACCESSORIES MOUNTING TORQUES (DDEC SERIES 60) 01182 VOLVO D13 TWIN BOSCH ALTERNATORS INSTALLATION Two 28 volt 140A, self regulated, belt driven, air-cooled T1 BOSCH alternators are used in the 24 volt electrical system. MAINTENANCE Change the brushes and voltage regulator as per “Repair and Testing Instructions for T1 Alternator 0120 69 552”...
  • Page 172 Section 06: ELECTRICAL FIGURE 21: BOSCH ALTERNATORS MOUNTING TORQUES (VOLVO D13) FIGURE 22: TWIN BOSCH ALTERNATORS INSTALLATION (VOLVO D13) PA1562...

  • Page 173: Alternator Drive Belt

    Section 06: ELECTRICAL 5.2.1 Alternator Drive Belt CAUTION Removal DDEC SERIES 60 ENGINE ONLY 1. Remove the radiator fan driving mechanism belt, the A/C compressor belt, and then the Prior to the installation of the Mitsubishi coolant pump belt. starter, the Flywheel Ring Gear must be examined for excess wear or damage.

  • Page 174: Exterior Lighting

    Section 06: ELECTRICAL 9.1.1 Headlight Beam Toggle Switch The multifunction lever located on the steering column is used to select proper lighting. High beams or low beams can be selected by pulling the lever rearward. A high beam indicator on the central dashboard panel is illuminated when the high beam circuit is energized.

  • Page 175: Headlight Adjustment

    Section 06: ELECTRICAL ground to the light source center of the CAUTION headlight, according to table1. Use a soft cloth to clean the parking and front 5. High beam headlights are aimed so that the turn signal lamp. center of the high-intensity zone is located horizontal straight ahead...

  • Page 176: Sealed-Beam Unit

    Section 06: ELECTRICAL 9.1.4 Sealed-Beam Unit Bulb Removal and Replacement 1. Pull the release handle located inside the front service compartment to tilt down the entire bumper assembly. 2. Remove the headlight screw fixing the headlight assembly, then tilt headlight assembly down (Fig.

  • Page 177: Front Turn Signal

    Section 06: ELECTRICAL NOTE The headlight aim must be checked and adjusted even if it was properly adjusted before the sealed beam unit was replaced. 9.1.5 Front Turn Signal The front turn signal is part of the front headlight assembly. The turn signal is a sealed unit (LED) located on each front corner and should be replaced as an assembly.

  • Page 178: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights

    Section 06: ELECTRICAL very high probability that the ballast is OK if the CAUTION ballast can ignite the bulb. One simple test to check the ballast would be to Never connect a voltmeter or V.O.M. to measure the Nominal current of 1.58 A after one measure bulb voltage as instrument will be minute for the 24V ballast.

  • Page 179: Clearance, Identification And Marker Lights

    Section 06: ELECTRICAL 1. Pry out the rubber seal with a small 3. Unscrew the outer ring. Disconnect the light screwdriver. Pull on the LED unit and unit connection and remove the bulb. disconnect it. 4. Install the new bulb, reconnect the light unit 2.

  • Page 180: Telltale Light Replacement

    Section 06: ELECTRICAL FIGURE 33: VARIOUS LIGHTS LOCATION 06640 10.1.2 Telltale Light Replacement 1. Unscrew the two Phillips-head screws retaining the lens to the wall, and remove it. Telltale module is non-serviceable and must be replaced as a unit. 2. With the light lens removed, pull bulb from the lamp while applying lateral pressure.

  • Page 181: Passenger Section Lighting

    Section 06: ELECTRICAL 3. Install the new bulb by pushing it in position. 10.5.2 Removal and Replacement of In-Station Fluorescent Tubes 4. Replace the lamp by snapping it back in place. 1. Start by pulling out the corner of the lens then delicately peeling it out of its seat.
  • Page 182 Section 06: ELECTRICAL FIGURE 34: PARCEL RACK LIGHTING 06419 10.6 ENGINE COMPARTMENT LIGHTING 10.7 LAVATORY LIGHT A switch located on R.H. side of rear junction The halogen lavatory light is installed on ceiling. box can be used to actuate the two oval engine A microswitch, mounted in the door exterior compartment lights.
  • Page 183 Section 06: ELECTRICAL LIGHT BULB DATA APPLICATION PREVOST TRADE OR WATTS OR VOLTS PART NO. SAE NUMBER CANDLE POWER EXTERIOR LIGHTING Hi/Lo-beam 930291 9004 65/45 W Lo-Beam Xenon (optional) 930388 35 W Docking & cornering 930319 9415 37.5W 930361 55 W...
  • Page 184 Section 06: ELECTRICAL LIGHT BULB DATA APPLICATION PREVOST TRADE OR WATTS OR VOLTS PART NO. CANDLE NUMBER POWER Parcel rack 560144 1820 1.6 W Driver’s area 830176 Q20MR16 20 W “EMERGENCY EXIT” 560601 decal 563108 “LAVATORY OCCUPIED” 561166 1820 1.6 cp “WATCH YOUR STEP”...
  • Page 185 Model Number..........................0120689552 Series ................................T1 Hot output -Amperes........................140 at 25°C (AMBIENT) -Volts ................................28 -Approximate rpm............................ 6000 Ground .............................. negative Prevost Number ..........................562752 Battery equalizer Make..............................Vanner Model..............................66-100 Amperes ............................100 amps Prévost Number ..........................563334 Starter Make....................Mitsubishi Electric Corporation (MELCO)
  • Page 186 Section 06: ELECTRICAL Starter solenoid Make....................Mitsubishi Electric Corporation (MELCO) Model Number........................... 1115557 Pull In Voltage ..........................16 volts max. PA1562...
  • Page 187 Mitsubishi Electric Corporation (MELCO) Service Bulletin ME003-P STARTER MOTORS (105P70) Figure 1 - 105P70 STARTER A starter is one of the parts installed to the flywheel housing. MELCO’s 105P70 starter Figure 2 shows the circuit diagram for the uses the planetary gear reduction system, 105P70 Ground-float type...
  • Page 188 Figure 3 - CROSS-SECTIONAL VIEW (GROUND-FLOAT TYPE) When the engine starts, the clutch prevents not be closed for more than 3 seconds. If excessive overrun of the armature. Because this time is exceeded, the starter solenoid the clutch is for a short-time rating, the start may be damaged.
  • Page 189 Figure 6 - TESTING HOLD-IN WINDINGS (GROUND- FLOAT TYPE) Figure 4 - TESTING PINION MOVEMENT AND PULL- Below are the resistance values for the P- IN WINDINGS (GROUND-FLOAT TYPE) and H-coils for reference. For the starter switch coils, refer to the switch circuit diagrams for the ground-wire Coil Resistance (reference)
  • Page 190 * If the output shaft does not move, stop brush pig tails, or poor contact between voltage application. If voltage continues to commutator and brushes be applied, excessive heat will occur in 6. High revolution speed and high current the starter solenoid and give thermal draw indicate: damage to the coil, thereby making it unserviceable.
  • Page 191 Repair and Testing Instructions for T1 Page 1 Alternator 0120 689 552 Edition 001 Repair and Testing Instructions for T1 Alternator 0120 689 552 All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC...
  • Page 192 Repair and Testing Instructions for T1 Page 2 Alternator 0120 689 552 Edition 001 Modifications Edition Date Name Modifications 8/28/98 I. Serra Original 12/4/98 I. Serra Update 8.98 Instructions All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC...
  • Page 193 Repair and Testing Instructions for T1 Page 3 Alternator 0120 689 552 Edition 001 Table of contents GENERAL ................................5 SAFETY PRECAUTIONS............................6 ............................6 PECIAL SAGE ................................6 ............................... 6 ROTECTION ..............................6 OMPRESSED ..............................6 XPLOSION SPECIFICATIONS ..............................7 ........................
  • Page 194 Repair and Testing Instructions for T1 Page 4 Alternator 0120 689 552 Edition 001 10.3 ......................29 OLLECTOR HIELD SSEMBLY 10.4 ............................30 ECTIFIER SSEMBLY 10.5 ............................32 TATOR SSEMBLY 10.6 ....................32 OTOR AND RIVE HIELD NSTALLATION 10.7 ...................... 33 EGULATOR AND APACITOR NSTALLATION...

  • Page 195: General

    Repair and Testing Instructions for T1 Page 5 Alternator 0120 689 552 Edition 001 1 General This manual contains repair and testing instructions with corresponding test specifications for the 0 120 689 5... series alternators. T1 (RL) 28V 70/140A Note: Alternator 0 120 689 543 was utilized in preparing these instructions. All rights rest with Robert Bosch Corp, including patent rights.

  • Page 196: Safety Precautions

    Repair and Testing Instructions for T1 Page 6 Alternator 0120 689 552 Edition 001 2 Safety Precautions 2.1 Special Tool Usage The use of incorrect or unsuitable tools and test equipment can lead to personal injury and may damage the alternator or its component parts. Only use tools that are specified in this instruction or meet the specification of the recommended tools.

  • Page 197: Specifications

    Repair and Testing Instructions for T1 Page 7 Alternator 0120 689 552 Edition 001 3 Specifications 3.1 Electrical Test Specifications 1.8 … 2.6 lF (microfarad) Interference suppression capacitor Load current less than/equal to 10A 27.6 … 28.4 V (volts, regulated) Damping Resistance 3.1 …...

  • Page 198: Mechanical Test Specifications

    Repair and Testing Instructions for T1 Page 8 Alternator 0120 689 552 Edition 001 3.2 Mechanical Test Specifications Rotor to Stator Air Gap (Between any side of stator and rotor) Greater than 0.3 mm (0.012 in) Eccentricity (Rotor mounted at Outer Diameter Of Rotor 0.05 mm (0.002 in) maximum bearing points)

  • Page 199: Alternator Schematic

    Repair and Testing Instructions for T1 Page 9 Alternator 0120 689 552 Edition 001 4 Alternator Schematic Figure 3 Alternator/Voltage Regulator Schematic Alternator Battery Positive Battery Negative Dynamo + (Warning Lamp Output) Tachometer Output Voltage Regulator Dynamo + (Alternator Output) Dynamo Field Dynamo - All rights rest with Robert Bosch Corp, including patent rights.

  • Page 200: Alternator Coding

    Repair and Testing Instructions for T1 Page 10 Alternator 0120 689 552 Edition 001 5 Alternator Coding T 1 R 28V 70/ 140A Rated current in amps measured at 6000 rpm Rated current in amps measured at 1500 rpm Alternator Voltage Direction of Rotation (→) Or R Clockwise...

  • Page 201: Parts Cleaning

    Repair and Testing Instructions for T1 Page 11 Alternator 0120 689 552 Edition 001 6 Parts Cleaning Caution: Fire Risk To provide radio interference suppression, the alternator is equipped with capacitors with a long storage time. Cleaning of alternator components may cause and electrical discharge when they are immersed in cleaning fluid.

  • Page 202: Tools, Test Equipment Lubricants And Adhesives

    Repair and Testing Instructions for T1 Page 12 Alternator 0120 689 552 Edition 001 7 Tools, Test Equipment Lubricants and Adhesives 7.1 Test Equipment Description Bosch Number Alternator Test Bench Commercially Available Internal Short-Circuit Tester (Flash Tester) KDAW 9978 0 986 619 110 Universal Multi-Meter MMD 302 0 684 500 302...

  • Page 203: Lubricants And Adhesives

    Repair and Testing Instructions for T1 Page 13 Alternator 0120 689 552 Edition 001 7.3 Lubricants and Adhesives Description Manufacturer Bosch Number Number Roller Bearing Grease UNIREX N3 5 975 560 125 Ft1 v 34 5 700 009 000 VS 15164-Ft 5 975 560 000 Molycote Paste Ft 70 v 1...

  • Page 204: Exploded View

    Repair and Testing Instructions for T1 Page 14 Alternator 0120 689 552 Edition 001 8 Exploded View Figure 4 Alternator Exploded View Item Designation Item Designation Drive End Shield Plain Washer Ball Bearing Oval-Head Screw Cover Plate Washer & Screw Assembly Rotor Suppression Capacitor Collector Ring...

  • Page 205: Alternator Disassembly And Testing

    Repair and Testing Instructions for T1 Page 15 Alternator 0120 689 552 Edition 001 9 Alternator Disassembly and Testing 9.1 Rear Cover Removal Clamp alternator in clamping fixture KDAW 9999 (Bosch Number 0 986 619 362). Remove four nuts holding on the air intake cover. (Figure 5) Figure 5 Air Intake Cover Removal (1) Note: The voltage regulator must be removed before any further disassembly of the alternator takes place.

  • Page 206: Brush Replacement

    Repair and Testing Instructions for T1 Page 16 Alternator 0120 689 552 Edition 001 Figure 6 Voltage Regulator (1) and Suppression Capacitor (2) 9.2.1 Brush Replacement 1. The exposed length of the carbon brushes must be measured to determine if they require replacement. Measure the length of each brush.

  • Page 207: Pulley And Fan Removal

    Repair and Testing Instructions for T1 Page 17 Alternator 0120 689 552 Edition 001 2. Connect Multimeter MMD 302 (Bosch Number 0 684 500 302) or equivalent to the lead of the suppression capacitor and the B- terminal of the alternator. (Figure 8) Figure 8 Testing of Suppression Capacitor 3.

  • Page 208: Rectifier Assembly Testing

    Repair and Testing Instructions for T1 Page 18 Alternator 0120 689 552 Edition 001 2. Slide the drive end shield and rotor out of the collector end shield. Figure 10 Drive End Shield Removal 9.6 Rectifier Assembly Testing Note: The following testing of the rectifier is to be performed with the rectifier assembly installed and wired in to the stator.

  • Page 209: Removal And Testing Of Stator Assembly

    Repair and Testing Instructions for T1 Page 19 Alternator 0120 689 552 Edition 001 b. Using a Diode Tester Connect the negative (black) lead of the tester to the collector end shield and the positive (red) lead to each of the stator connection solder joints. No current should pass through the rectifier assembly. ii) Connect the positive (red) lead of the tester to the collector end shield and the negative (black) lead to each of the stator connection solder joints.

  • Page 210: Rectifier Assembly Removal

    Repair and Testing Instructions for T1 Page 20 Alternator 0120 689 552 Edition 001 4. Using insulation tester KDAW 9983 (Bosch Number 0 986 619 110) or equivalent, apply 80 VAC to each of the stator phase leads with one probe while the other probe is in contact with the exterior of the stator. (Figure 13) No continuity should be present.

  • Page 211: Dampening Resistor Testing And Removal

    Repair and Testing Instructions for T1 Page 21 Alternator 0120 689 552 Edition 001 9.9 Dampening Resistor Testing and Removal 1. The W Terminal incorporates a dampening resistor. Using a Multimeter MMD 302, connect one lead to the exterior portion of the W terminal and connect the other lead to the other side of the W Terminal. The Multimeter should read between 3.1 and 3.5 k (kilohm).

  • Page 212: Removal Of Sliding Bushing In Collector End Shield

    Repair and Testing Instructions for T1 Page 22 Alternator 0120 689 552 Edition 001 5. If the roller bearing is stuck in end shield, proceed as follows: Remove extractor KDLJ 6009 from the bearing. Destroy the bearing cage with a screwdriver or similar tool. Remove rollers from bearing.
  • Page 213 Repair and Testing Instructions for T1 Page 23 Alternator 0120 689 552 Edition 001 3. Press out rotor. Figure 18 Pressing out Rotor 4. Remove spacer ring from rotor shaft. Notes: Protect the threads of the rotor from damage prior to pressing. Always replace the drive end bearing if the rotor has been pressed out.

  • Page 214: Removal Of Bearing And Seal From Drive End Shield

    Repair and Testing Instructions for T1 Page 24 Alternator 0120 689 552 Edition 001 9.13 Removal of Bearing and Seal from Drive End Shield 1. Loosen and remove the four (4) screws holding the bearing cover plate. (Figure 19) 2. Remove the spacer ring (Refer to arrow in Figure 19). 3.

  • Page 215: Rotor Inspection

    Repair and Testing Instructions for T1 Page 25 Alternator 0120 689 552 Edition 001 9.15 Rotor Inspection 1. Using electric tester ETE 014.00 or Multimeter MMD 302, measure the resistance between the two collector rings of the rotor. The resistance measured should be between 7.5 and 8.3 . (Figure 21) Figure 21 Rotor Resistance Testing 2.

  • Page 216: Collector Ring Replacement

    Repair and Testing Instructions for T1 Page 26 Alternator 0120 689 552 Edition 001 4. Position dial indicator (Magnetic Base T-M 1 (Bosch Number 4 851 601 124) and Dial Indicator EFAW 7 (Bosch Number 1 687 233 011)) to measure the concentricity of the rotor at:: (Figure 23) a.

  • Page 217: Alternator Assembly

    Repair and Testing Instructions for T1 Page 27 Alternator 0120 689 552 Edition 001 10 Alternator Assembly 10.1 Rotor Assembly 1. Position rotor in arbor press with the drive end pointing down. 2. Press the lead for the rotor winding into the slot of the rotor. 3.

  • Page 218: Drive End Shield Assembly

    Repair and Testing Instructions for T1 Page 28 Alternator 0120 689 552 Edition 001 Note: Do not allow the spacer ring to twist while pressing onto the rotor. 8. Place the inner bearing race of the collector end shield bearing onto the rotor shaft. 9.

  • Page 219: Collector Ring End Shield Assembly

    Repair and Testing Instructions for T1 Page 29 Alternator 0120 689 552 Edition 001 7. Place rotor into the drive end bearing. 8. Place tool KDLJ 6018 onto the end of the rotor and press the rotor into the drive end bearing until the bearing seats against the support ring.

  • Page 220: Rectifier Assembly

    Repair and Testing Instructions for T1 Page 30 Alternator 0120 689 552 Edition 001 10. With tool KDLJ 6015, press sliding bushing into end shield until the bushing is flush with the inner surface of the mounting/pivot boss. (Figure 30) Figure 30 Sliding Bushing Installation 11.
  • Page 221 Repair and Testing Instructions for T1 Page 31 Alternator 0120 689 552 Edition 001 2. Coat the keyhole shaped surface of the rectifier with adhesive. (Figure 32) 3. Place the rectifier seal ring onto the keyhole shaped surface of the rectifier. Make sure the seal conforms to the shape of the keyhole.

  • Page 222: Stator Assembly

    Repair and Testing Instructions for T1 Page 32 Alternator 0120 689 552 Edition 001 10.5 Stator Assembly 1. Position the stator on the collector end shield. The side of the stator with the winding leads should be closest to the collector end shield. 2.

  • Page 223: Regulator And Capacitor Installation

    Repair and Testing Instructions for T1 Page 33 Alternator 0120 689 552 Edition 001 8. Remove the four feeler gauges from between the stator and rotor. 9. Turn the rotor by hand. The rotor should rotate freely by hand. If the rotor does not turn freely, loosen the drive end shield to collector end shield screws and repeat steps 6, 7, 8 and 9.
  • Page 224 Repair and Testing Instructions for T1 Page 34 Alternator 0120 689 552 Edition 001 4. Align the mounting holes of the regulator to holes of the alternator housing. Note: When aligning the mounting holes, pay attention to the force used as damage can occur to the brushes. 5.

  • Page 225: Functional Testing

    Repair and Testing Instructions for T1 Page 35 Alternator 0120 689 552 Edition 001 11 Functional Testing 11.1 General Information The functional testing of the alternator is broken into two categories, Power Output and Voltage Trace Evaluation. All of the tests describe here are performed with the voltage regulator installed on the alternator. 11.1.1 Power Output Tests The power output tests verify the capability of the alternator to produce rated current and voltage at different speeds.

  • Page 226: Power Output Test

    Repair and Testing Instructions for T1 Page 36 Alternator 0120 689 552 Edition 001 3. Connect the test leads of the test bench to the alternator as follows: a. Connect the +24 v lead of the test bench to the B+ terminal of the alternator. b.

  • Page 227: Voltage Trace Evaluation

    Repair and Testing Instructions for T1 Page 37 Alternator 0120 689 552 Edition 001 3. Hold test bench at this speed and load for 30 minutes. Monitor alternator output and speed during the test period. 4. Remove load and operate the alternator at 7000 rpm for one minute to allow the alternator to cool. 5.

  • Page 228: Normal Pattern

    Repair and Testing Instructions for T1 Page 38 Alternator 0120 689 552 Edition 001 11.3.2 Normal Pattern This image represents a properly functioning alternator. The D.C. voltage produced has a small harmonic wave. Small spikes may be superimposed on the oscilloscope screen if the voltage regulator is regulating. Applying a load to the alternator output terminals can turn off the regulator.
  • Page 229 Repair and Testing Instructions for T1 Page 39 Alternator 0120 689 552 Edition 001 11.3.3 Open Exciter Diode This pattern displays a characteristic dip in the normally smooth wave characteristic of a defective exciter diode. This would require disassembly of the alternator and replacement of the rectifier assembly. Figure 41 Open Exciter Diode All rights rest with Robert Bosch Corp, including patent rights.

  • Page 230: Open Positive Rectifier Diode

    Repair and Testing Instructions for T1 Page 40 Alternator 0120 689 552 Edition 001 11.3.4 Open Positive Rectifier Diode This pattern identifies an open positive rectifier diode. In the case of multiple diodes in parallel, all of the diodes on the circuit must be open. An example is: There are two diodes in the rectifier for each phase of the stator.
  • Page 231 Repair and Testing Instructions for T1 Page 41 Alternator 0120 689 552 Edition 001 11.3.5 Open Negative Rectifier Diode This pattern identifies an open negative rectifier diode. In the case of multiple diodes in parallel, all of the diodes on the circuit must be open. An example is: There are two diodes in the rectifier for each phase of the stator.
  • Page 232 Repair and Testing Instructions for T1 Page 42 Alternator 0120 689 552 Edition 001 11.3.6 Shorted Exciter Diode This pattern identifies a shorted exciter diode. This would require disassembly of the alternator and replacement of the rectifier assembly. Figure 44 Shorted Exciter Diode All rights rest with Robert Bosch Corp, including patent rights.
  • Page 233 Repair and Testing Instructions for T1 Page 43 Alternator 0120 689 552 Edition 001 11.3.7 Shorted Positive Rectifier Diode This pattern identifies a positive rectifier diode that is shorted. This defect requires replacement of the rectifier assembly. Figure 45 Shorted Positive Rectifier Diode All rights rest with Robert Bosch Corp, including patent rights.
  • Page 234 Repair and Testing Instructions for T1 Page 44 Alternator 0120 689 552 Edition 001 11.3.8 Shorted Negative Rectifier Diode This pattern identifies a negative rectifier diode that is shorted. This defect requires replacement of the rectifier assembly. Figure 46 Shorted Negative Rectifier Diode All rights rest with Robert Bosch Corp, including patent rights.
  • Page 235 Repair and Testing Instructions for T1 Page 45 Alternator 0120 689 552 Edition 001 11.3.9 Open Phase of Stator This pattern illustrates a stator with an open phase winding. This type of defect would require replacement of the stator. Figure 47 Open Stator Phase All rights rest with Robert Bosch Corp, including patent rights.
  • Page 237 ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § Owner’s Manual Incorporated VoltMaster Battery Equalizer 24 V G N D 12 V Family 1 Family 2 Family 3 Family 4 Family 5 60-10B 60-100C...
  • Page 238 © ¢  ¤  ¥  ¥  ¨  © ¢  ¤  ¥  ¥  ¨  Owner’s Manual Incorporated Introduction Thank you for purchasing a Vanner VoltMaster Battery Equalizer. We are confident that you will be very pleased with its performance because our Battery Equalizers are designed and manufactured by skilled professionals using the highest standards in workmanship.
  • Page 239  ¢  ¤  ¥  ¥  ¨   ¢  ¤  ¥  ¥  ¨  Specifications Incorporated Specifications Family 1 Family 2* Family 3* / Family 4 Family 5 60-60* 60-80* 60-100* Model Number 60-10B 60-20A 60-50A* 60-100E*...
  • Page 240  ¢ ¤ ! ¥ ! ¥ " ¨ #  ¢ ¤ ! ¥ ! ¥ " ¨ # Specifications Incorporated Family 3 Equalizer Dimensions Family 4 and Family 5 Dimensions 9.00" .50" (228.7) (12.7) 8.00" 2.50" 10.50 (203.3) (255.6) (63.5) 9.13...
  • Page 241 $ ¢ % ¤ & ¥ & ¥ ' ¨ ( $ ¢ % ¤ & ¥ & ¥ ' ¨ ( Typical Applications Incorporated of the Battery Equalizer, Battery A will supply the extra current to the load. The Battery Equalizer will then replenish the energy to Battery A after the surge has passed.
  • Page 242 ) ¢ 0 ¤ 1 ¥ 1 ¥ 2 ¨ 3 ) ¢ 0 ¤ 1 ¥ 1 ¥ 2 ¨ 3 Typical Applications Incorporated PRIVATE COACH Battery Isolator or Paralleling Switch HOUSE BATTERY SYSTEM COACH BATTERY SYSTEM +24V +24V +24V +24V VANNER...
  • Page 243 4 ¢ 5 ¤ 6 ¥ 6 ¥ 7 ¨ 8 4 ¢ 5 ¤ 6 ¥ 6 ¥ 7 ¨ 8 Installation Incorporated Installation Instructions When connecting wires or cables to the available post (+24, GND, +12) when installing Vanner Equalizer Models 60-60, 60-80, 60-100, do not exceed the specified torque of 120 in-lbs.
  • Page 244 9 ¢ @ ¤ A ¥ A ¥ B ¨ C 9 ¢ @ ¤ A ¥ A ¥ B ¨ C Installation Incorporated Caution adding 12volt batteries +24V +24V BATTERY A AND BATTERY B BATTERY A AND BATTERY B ARE NOT THE SAME SIZE.
  • Page 245 D ¢ E ¤ F ¥ F ¥ G ¨ H D ¢ E ¤ F ¥ F ¥ G ¨ H Testing and Trouble Shooting Incorporated B), and less than 0.05 VDC between the Equalizer' s GND terminal and the battery ground terminal (Battery A negative terminal that is connected to chassis ground).
  • Page 246 I ¢ P ¤ Q ¥ Q ¥ R ¨ S I ¢ P ¤ Q ¥ Q ¥ R ¨ S Testing and Trouble Shooting Incorporated Test Procedure for Family 1 Battery Equalizers Models 60-10B, 60-20A, 60-50A CAUTION To avoid Reverse Polarity Damage to Family 1 and Family 2 Equalizers when servicing the electrical system or when performing any work which involves making battery connections always: 1.
  • Page 247 T ¢ U ¤ V ¥ V ¥ W ¨ X T ¢ U ¤ V ¥ V ¥ W ¨ X Testing and Trouble Shooting Incorporated No, the Battery Equalizer electronically limits the output current to a value less than the amount required to trip the circuit breaker.
  • Page 248 Y ¢ ` ¤ a ¥ a ¥ b ¨ c Y ¢ ` ¤ a ¥ a ¥ b ¨ c Testing and Trouble Shooting Incorporated Test Procedure for Family 2 Battery Equalizers 2 4 V 1 2 V G N D Models 60-100C, 60-100D and 60-100E General: Family 2 Equalizers were designed to be more energy conservative during low power...
  • Page 249 d ¢ e ¤ f ¥ f ¥ g ¨ h d ¢ e ¤ f ¥ f ¥ g ¨ h Testing and Trouble Shooting Incorporated 12. If the voltage drops below the calculated value from Step 9 and the clamp-on ammeter has not jumper from approximately 0 to more than 3 amps of current wait for an additional 30 seconds.
  • Page 250 i ¢ p ¤ q ¥ q ¥ r ¨ s i ¢ p ¤ q ¥ q ¥ r ¨ s Testing and Trouble Shooting Incorporated Subtract Battery A voltage from Battery B voltage and compare readings. Indicator Voltage Comparison Equalizer Status Light Stand-by Mode.
  • Page 251 t ¢ u ¤ v ¥ v ¥ w ¨ x t ¢ u ¤ v ¥ v ¥ w ¨ x Warranty Incorporated NORTH AMERICAN LIMITED WARRANTY Vanner Inc., doing business as The Vanner Power Group, referred to herein as Vanner, warrants that this product is free from defects in materials and workmanship for a period of two (2) years from date of installation or two and one half (2 1/2) years from date of manufacture, whichever is less if and only if the following requirements are complied with:...
  • Page 252 y ¢ € ¤  ¥  ¥ ‚ ¨ ƒ y ¢ € ¤  ¥  ¥ ‚ ¨ ƒ BATTERY EQUALIZER OWNER’S MANUAL Incorporated Vanner Incorporated 4282 Reynolds Drive Hilliard, Ohio 43026 1-800-AC POWER (1-800-227-6937) Tel: 614-771-2718 Fax: 614-771-4904 www.vanner.com e-mail: pwrsales@vanner.com...
  • Page 253 FAULT CODE MANUAL Created on 00-04-25 15:30 FAULT CODE MANUAL B7L, B7TL, B12 - 1 -...
  • Page 254 FAULT CODE MANUAL Created on 00-04-25 15:30 Preface The content of this manual has been based upon information from design department at Volvo Bus, Volvo Trucks and external suppliers. Due to problems with retrieving updated documents, new signal specifications etc. we cannot guarantee that the information is 100% correct.
  • Page 255 FAULT CODE MANUAL Created on 00-04-25 15:30 Table of contents Bus Instrument Cluster (BIC)...................... 4 The instrument display........................ 4 The windscreen wiper handle ...................... 4 Display menus..........................5 Setting the display language......................5 Read fault codes from ECU......................6 Comparing chassis number with the VIC..................

  • Page 256: Bus Instrument Cluster (Bic)

    FAULT CODE MANUAL Created on 00-04-25 15:30 1. Bus Instrument Cluster (BIC) The bus instrument cluster contains a number of indicators and lamps that shows the status of different parts of the bus. It can also be used to display faultcodes from the different control units by using the windscreen wiper handle.

  • Page 257: Display Menus

    FAULT CODE MANUAL Created on 00-04-25 15:30 4. Display menus The image below displays the main menus in the display window. The window can only display three items at once, therefore the up/down button on the windscreen wiper handle must be used to browse through the menus. Simply press the “Return” button on the windscreen wiper handle to enter a desired menu.

  • Page 258: Read Fault Codes From Ecu

    FAULT CODE MANUAL Created on 00-04-25 15:30 6. Read fault codes from ECU From the main menu, use the up/down button on the windscreen wiper handle to move down to the “System diagnostic” menu and press the “Return” key. The line “Fault diagnostic” should now be highlighted, if it’s not you can simply use the up/down button on the windscreen wiper handle to move to that line.
  • Page 259 FAULT CODE MANUAL Created on 00-04-25 15:30 As in the example above, you can see that the fault code is set in MID 130, the SID number is 191 and the FMI number is 2. By looking at the fault code table for MID 130 (which represents the TECU) you can see that SID number 191 means “Output speed level error”...

  • Page 260: Comparing Chassis Number With The Vic

    FAULT CODE MANUAL Created on 00-04-25 15:30 7. Comparing chassis number with the VIC The VIC (Vehicle Identification Card) is a card that comes with every new bus that identifies the chassis number for the bus and the HW/SW id for each control unit. To check chassis number, select “Data log mode”...
  • Page 261 FAULT CODE MANUAL Created on 00-04-25 15:30 The image below shows the HW/SW id for the CECM, the display cannot display both SW id and HW id at the same time, therefore you have to use the up/down buttons on the windscreen wiper handle to show SW id instead of HW id.

  • Page 262: Fault Codes, Abs (Mid 136)

    FAULT CODE MANUAL Created on 00-04-25 15:30 9. Fault codes, ABS (MID 136) (P)PID/SID Seriousness Component/Function Display text SID 1 Air gap Sensor wheel sp LF SID 1 Incorrect tyre Sensor wheel sp LF SID 1 Shorted to UBATT Sensor wheel sp LF SID 1 Shorted to ground Sensor wheel sp LF...
  • Page 263 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID Seriousness Component/Function Display text SID 5 Air gap SID 5 Incorrect tyre SID 5 Shorted to UBATT SID 5 Shorted to ground SID 5 Open circuit SID 5 Short circuit SID 5 Incorrect pole wheel SID 5 Slip...
  • Page 264 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID Seriousness Component/Function Display text SID 14 Diag. 1 Voltage, low voltage/open Valve relay circuit SID 14 Ground diagonal, open circuit Valve relay SID 14 ECU-Ground or WL-Ground Valve relay SID 14 Ground diagonal 1, shorted to low Valve relay SID 14 Voltage feeding solenoid valve Valve relay...

  • Page 265: Fault Codes, Bic (Mid 140 & 234)

    FAULT CODE MANUAL Created on 00-04-25 15:30 10. Fault codes, BIC (MID 140 & 234) (P)PID/SID Seriousness Component/function Display text PID 84 Speed Road speed PID 190 Number of revolutions Engine speed 140&234 SID 240 Program memory Program memory 140&234 SID 253 EEPROM Calibration memory 140&234 SID 253...

  • Page 266: Fault Codes, Cecm (Mid 164)

    FAULT CODE MANUAL Created on 00-04-25 15:30 11. Fault codes, CECM (MID 164) (P)PID/SID Seriousness Component/Function Display text PID 43 Starting sw. status PID 43 Starting sw. status PID 70 Park brake switch PID 117 Brake pressure #1 PID 117 Brake pressure #1 PID 118 Brake pressure #2...

  • Page 267: Fault Codes, Cim (Mid 164)

    FAULT CODE MANUAL Created on 00-04-25 15:30 12. Fault codes, CIM (MID 164) (P)PID/SID FMI Seriousness Component/function Display text PSID 31 Short-circuit to battery PSID 31 Short-circuit to ground PSID 3 Alternator not charging PSID 4 Alternator not charging PSID 45 Alternator not charging PSID 46 Alternator not charging...

  • Page 268: Fault Codes, Eecu (Mid 128)

    FAULT CODE MANUAL Created on 00-04-25 15:30 13. Fault codes, EECU (MID 128) (P)PID/SID FMI Seriousness Component/function Display text PID 45 Yellow lamp Starting heater status relay Inlet air heat stat PID 45 Yellow lamp Starting heater status relay Inlet air heat stat PID 45 Yellow lamp Starting heater status relay...
  • Page 269 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID FMI Seriousness Component/function Display text PPID 100 Yellow lamp Outer actuator Ext. timing act. PPID 100 Yellow lamp Outer actuator Ext. timing act. PPID 100 Yellow lamp Outer actuator Ext. timing act. PPID 109 Yellow lamp Exhaust pressure governor EPG3...
  • Page 270 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID FMI Seriousness Component/Function Display text SID 24 Red lamp Control rod position Rack positoin sens. SID 24 Red lamp Control rod position Rack positoin sens. SID 64 Yellow lamp Engine speed pump Tim.

  • Page 271: Fault Codes, Tecu Voith 863,3 Retarders And Transmission (Mid 130)

    FAULT CODE MANUAL Created on 00-04-25 15:30 14. Fault codes, TECU Voith 863,3 retarders and transmission (MID 130) (P)PID/SID FMI Seriousness Component/function Display text PID 40 Hand brake sensor Retarder switches PID 65 Foot brake sensor Brake pedal switch PID 92 Software Engine load, % PID 93...
  • Page 272 FAULT CODE MANUAL Created on 00-04-25 15:30 15. Fault codes, ZF HP 502 retarder (MID 222) and transmission (MID 130) (P)PID/SID FMI Seriousness Component/function Display text PID 1 Transmission slip Invalid data PID 155 Not used dig. Out shorted high Aux.
  • Page 273 FAULT CODE MANUAL Created on 00-04-25 15:30 SID 10 Ret_On Valve shorted ground (P)PID/SID FMI Seriousness Component/function Display text SID 10 Ret_On Valve current circuit break SID 11 Retarder current resistor SID 11 Retarder current shorted high SID 11 Retarder current shorted ground SID 11 Retarder current circuit break SID 12...

  • Page 274: Fault Codes, Voith 115V Retarder (Mid 222)

    FAULT CODE MANUAL Created on 00-04-25 15:30 16. Fault codes, Voith 115v retarder (MID 222) (P)PID/SID FMI Seriousness Component/function Display text PID 110 Eng. coolant temp. Eng. coolant temp. PID 110 Eng. coolant temp. Eng. coolant temp. PID 110 Eng. coolant temp. Eng.
  • Page 275 FAULT CODE MANUAL Created on 00-04-25 15:30 17. Fault codes, retarder 133 To the right of the bus instrument cluster there is a green checklamp (5022) for the retarder function and fault indications. At every voltage inflow the lamp will normally be lit for five seconds, if the lamp doesn’t go out after five seconds have passed, a fault code is set in the retarder.
  • Page 276 FAULT CODE MANUAL Created on 00-04-25 15:30 Code Description Internal fault concerning: ROM (CRC check). EEPROM (data record) 2/2-way valve fault Non-plausibility of brake pedal operation Pressure sensor fault Time-out > 500ms press signal (VECU) Time-out > 500ms ABS-signal (J1939) J 1939 link "bus off".
  • Page 277 FAULT CODE MANUAL Created on 00-04-25 15:30 18. Fault codes, VECU (MID 144) (P)PID/SID FMI Seriousness Component/Function Display text PID 29 Yellow lamp Extra throttle, percentage mode Second throttle PID 29 Yellow lamp Extra throttle, percentage mode Second throttle PID 46 Wet tank air pressure Wet tank air press PID 46...
  • Page 279 Service Bulletin A1-M1N-1729EN Flywheel Ring Gear Wear / Damage (Sample of Maximum Ring Gear Wear /Damaged) Please refer to the above photos and please replace the ring gear which has similar level of damage as these. See the next page for the method to measure the depth of the damage. (Depth of wear / damage on ring gear)
  • Page 280 Less than 0.5mm (Measurement method) Dimension between the mounting surface and the end surface of ring gear Dimension between the mounting surface and the damage depth portion of ring gear...

  • Page 281: Figure 3: Allison Transmission

    SECTION 07: TRANSMISSION CONTENTS DESCRIPTION ............................3 ....................3 LLISON UTOMATIC RANSMISSION 1.1.1 Retarder (if applicable) ......................3 ......................3 STRONIC RANSMISSION WELDING PROCEDURES ........................4 MAINTENANCE ............................ 4 ........................4 LLISON RANSMISSION 3.1.1 Manual Fluid Level Check ....................... 4 3.1.2 Cold Check ..........................
  • Page 282 Section 07: TRANSMISSION SPECIFICATIONS ........................... 32 ILLUSTRATIONS ........................3 IGURE ALLISON TRANSMISSION ....................3 IGURE ALLISON TRANSMISSION CONTROL PAD ......................4 IGURE ASTRONIC TRANSMISSION .) ....................4 IGURE OIL LEVEL DIPSTICK AUTO RANS ........................... 5 IGURE COLD CHECK ............................. 5 IGURE HOT CHECK .......................

  • Page 283: Description

    Section 07: TRANSMISSION DESCRIPTION this information, it computes shift points and clutch pressures to meet immediate needs. X3 Series coaches may be provided with either Using closed loop adaptive logic; the electronic an Allison automatic transmission or a ZF- control looks at a number of parameters during AsTronic transmission.

  • Page 284: Welding Procedures

    Section 07: TRANSMISSION constant-mesh gearbox and an automated dry 3.1.1 Manual Fluid Level Check clutch. DANGER If the AS TRONIC transmission system is to be used, the vehicle must have an electronic engine control unit well When checking the oil level, be sure that the communication.

  • Page 285: Cold Check

    Section 07: TRANSMISSION 3.1.2 Cold Check CAUTION The purpose of the Cold Check is to determine if the transmission has enough fluid to be operated DO NOT operate the transmission for extended periods of time until a Hot Check has verified safely until a Hot Check can be made.

  • Page 286: Fluid Level Check Using The Pushbutton Shift Selector

    Section 07: TRANSMISSION 6. Be sure fluid level checks are consistent. CODE CAUSE OF CODE Check level more than once and if readings O L…H I… 2 Oil Level is HIgh 2 quarts are not consistent, check to be sure the Oil Level is HIgh 3 or more transmission breather is clean and not O L…H I…...
  • Page 287 Drain Intervals. TranSynd™ is fully qualified to temperature is increased. the Allison TES295 specifications and is available through Prevost Parts. 3.1.8 Oil Contamination NOTE At each oil change, examine the drained oil for The prognostics package requires the use of evidence of dirt or water.

  • Page 288: Coolant Leakage

    Section 07: TRANSMISSION external circuits, coolers, and all other areas defined operating period will result in illumination where the particles could lodge. of the CHECK TRANS light on the dashboard telltale panel, indicating the increased probability that the service condition will develop into a CAUTION more serious condition.
  • Page 289 Section 07: TRANSMISSION also be reset by selecting N-R-N-R-N-D-N on CAUTION the shift selector, pausing briefly (less than 3 seconds) between each selector movement, Required calendar-based oil & filter change with the ignition on and the engine not running. intervals (based on month) still apply because Oil Life Monitor function cannot measure time Transmission Health Monitor while ignition power is OFF.
  • Page 290 Section 07: TRANSMISSION The following table illustrates how to access Oil Level Check, Prognostics & Diagnostic Troubleshooting Codes functions on the Allison pushbutton shift selector. Description SELECT MONITOR (up) & (down) arrow buttons pressed simultaneously " - " " - " press Allison transmission oil level check Other codes will be displayed...

  • Page 291: Oil And Filter Change Interval

    Section 07: TRANSMISSION TABLE 2 Recommended Fluid and Filter Change Intervals Using 100% TranSynd /TES 295 Approved Fluid Severe General Coaches equipped with retarder Coaches without retarder Filters Filters Fluid Fluid Main Internal Lube/ Main Internal Lube/ Auxiliary Auxiliary 150,000 Miles 75,000 Miles Overhaul 75,000 Miles...
  • Page 292 Section 07: TRANSMISSION IMPORTANT NOTE General or Severe Vocation Allison Transmission recommends that FLUIDS Change fluid when indicated customers use fluid analysis as the primary TRANSMISSION SERVICE indicator method for determining fluid change intervals. Prognostics or 60 month (five years) whichever Many customers have a systematical annual enabled occurs first.

  • Page 293: Zf As-Tronic Transmission

    Section 07: TRANSMISSION 6. Inspect the drain plug and O-ring. Replace if ZF AS-TRONIC TRANSMISSION necessary. Reinstall the drain plug and tighten information needed removal to 18-24 lbf-ft (25-32 Nm). /installation maintenance 7. Reinstall transmission protective panel transmission is included in the documents annexed at the end of this section.
  • Page 294 Section 07: TRANSMISSION excess grease from the exterior of the clutch sure that the bell housing contacts the disc hub. It is very important that no flywheel housing. excess grease is left on the exterior of Warning! the clutch hub or clutch disk! •...

  • Page 295: Installation Of Zf Or Allison Transmission Brackets On Vehicles Equipped With Detroit Diesel Engine Only

    Section 07: TRANSMISSION INSTALLATION OF ZF OR ALLISON TRANSMISSION BRACKETS ON VEHICLES EQUIPPED WITH DETROIT DIESEL ENGINE ONLY FIGURE 9: ZF OR ALLISON TRANSMISSION BRACKETS 07131 ALLISON TRANSMISSION REMOVAL NOTE For more clearance between the tag axle and The following procedure deals with the removal of transmission, the tag axle may be unloaded the Allison transmission without removing the and jacked up or retracted (if applicable).

  • Page 296: Transmission Oil Cooler Removal

    Section 07: TRANSMISSION 6. Remove transmission dipstick and filler tube. Volvo D13 Engine Only 7. Disconnect propeller shaft from transmission Remove starter motor located on engine L.H. and remove its safety guard. Refer to Section side. Removing the starter motor will allow access 09, "PROPELLER SHAFT".

  • Page 297: Volvo D13 Engine

    Section 07: TRANSMISSION system as per Section 05 ‘’Cooling’’, paragraph WARNING 7: Flushing. 1. Disconnect and remove the engine air intake A significant amount of oil may drain from oil duct mounted between the air cleaner lines when they are disconnected. housing and the turbocharger inlet.

  • Page 298: Cleaning And Inspection Of Allison Automatic Transmission

    Section 07: TRANSMISSION conditions will determine the frequency of such inspections. Inspect the transmission for: 1. Loose bolts (transmission and mounting components); 2. Oil leaks (correct immediately); 3. Loose, dirty, or improperly adjusted throttle sensor linkage; FIGURE 13: COOLER WITH RETARDER 07073 4.
  • Page 299 Section 07: TRANSMISSION 1. Place the transmission on a transmission Volvo D13 Engine Only jack. Remove the plug located below starter motor and 2. Install a headless guide bolt into one of the 12 install cranking tool (88800014). Crank the engine threaded holes for flexible plate attaching to gain access to the threaded holes by turning screws in the flywheel.

  • Page 300: Allison Automatic Transmission Troubleshooting

    Section 07: TRANSMISSION Open the coach rear baggage compartment then remove the rear electrical compartment door in order to get access to the TCM; Remove the electrical cable connectors; Unscrew the TCM unit; Replace by reversing the procedure. CAUTION Place the battery master switch to the ‘’OFF’’ position.

  • Page 301: Diagnostic Codes - Allison 4 Generation Controls

    Section 07: TRANSMISSION DOC™ diagnostic tool, refer to the User DIAGNOSTIC CODES – ALLISON 4 GENERATION CONTROLS Guide. When the diagnostic mode is entered, the first o Using the pushbutton shift selector. code (position d1) is displayed as follows: Example: Code P0722 To begin the diagnostic process: Displayed as: d1…P…07…22 1.
  • Page 302 Section 07: TRANSMISSION DNS - Do Not Shift Response 2. Begin operating as normal. Have the transmission checked earliest Release lock up clutch and inhibit lock up opportunity by an Allison Transmission operation. distributor or dealer. Inhibit all shifts. NOTE Turn ON the CHECK TRANS light.

  • Page 303: Diagnostic Troubleshooting Codes (Dtc) List - Allison

    Section 07: TRANSMISSION DIAGNOSTIC TROUBLESHOOTING CODES (DTC) LIST - ALLISON 4 GENERATION CONTROLS CHECK Inhibited Operation Description TRANS Description Light May inhibit retarder operation if not C1312 Retarder Request Sensor Failed Low using J1939 datalink May inhibit retarder operation if not C1313 Retarder Request Sensor Failed High using J1939 datalink...
  • Page 304 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P071A RELS Input Failed On Inhibit RELS operation P071D General Purpose Input Fault None P0720 Output Speed Sensor Circuit P0721 Output Speed Sensor Circuit Performance DNS, Lock in current range P0722 Output Speed Sensor Circuit No Signal DNS, Lock in current range...
  • Page 305 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P0971 Pressure Control Solenoid 3 (PCS3) Control Circuit High DNS, SOL OFF (hydraulic default) P0973 Shift Solenoid 1 (SS1) Control Circuit Low DNS, SOL OFF (hydraulic default) P0974 Shift Solenoid 1 (SS1) Control Circuit High DNS, SOL OFF (hydraulic default) P0975 Shift Solenoid 2 (SS2) Control Circuit Open...

  • Page 306: Zf-Astronic Transmission System Faults And Error Messages

    Section 07: TRANSMISSION 10. ZF-ASTRONIC TRANSMISSION SYSTEM Calling up error numbers FAULTS AND ERROR MESSAGES - Switch on ignition 10.1 SYSTEM FAULTS (ERROR MESSAGES) - Depress “N” key - Hold down “ ” key If the “SM” symbol appears in * One or more error numbers the display, a system error has appear on the display.
  • Page 307 Section 07: TRANSMISSION DESCRIPTION 8, 7 Easy Start, Brake doesn't open completely 8, 14 Easy Start, Not Available 20,6 Short circuit to ground at output ACC (wakeup control signal for ZMTEC, keep alive signal for voltage doubler, and power signal for speed sensor #2) 20,5 Interruption at output ACC (wakeup control signal for ZMTEC, keep alive signal for voltage doubler, and power signal for speed sensor #2)
  • Page 308 Section 07: TRANSMISSION DESCRIPTION 34,3 Short circuit to positive at output stage to small disengagement clutch valve 34,3 Short circuit to positive at output stage to small engagement clutch valve 34,3 Short circuit to positive at output stage to large disengagement clutch valve 34,3 Short circuit to positive at output stage to large engagement clutch valve 35,5...
  • Page 309 Section 07: TRANSMISSION DESCRIPTION 51,3 Short circuit to positive at output stage to Y7 (Valve Shift) 54,6 Short circuit to ground at output stage to Y1 (inertia brake valve) 54,5 Interruption at output stage to Y1 (inertia brake valve) 54,3 Short circuit to positive at output stage to Y1 (inertia brake valve) 55,7 Clutch engaged unintentionally at standstill, gear engaged...
  • Page 310 Section 07: TRANSMISSION DESCRIPTION 151,14 Plausibility error between transmission input speed and output speed 152,6 Short circuit to ground at output stage to Y10 (Main valve) 152,5 Interruption at output stage to Y10 (Main valve) 152,3 Short circuit to positive at output stage to Y10 (Main valve) 153,14 Error on ISO 14320 communications line 154,14...
  • Page 311 Section 07: TRANSMISSION DESCRIPTION 231,14 CAN ”Engine retarder configuration” timeout 231,14 CAN EBC1 timeout 231,14 Error on ”ABS active” signal (EBC1) 231,14 Error on ”ASR engine control active” signal (EBC1) 231,14 Error on ”ASR brake control active” signal (EBC1) 231,14 Error on ”Cruise control active”...
  • Page 312 Capacity (excluding external circuits) ..............Initial fill 47 US qts (45 liters) Oil change..........................24 US qts (23 liters) Oil change (with retarder)....................27.6 US qts (26 liters) Oil Filters: Make ............................. Allison Transmission Type ............................Disposable cartridge Prevost Part Number (2-filter replacement kit) ..................571709 PA1562...
  • Page 313 SECTION 09: PROPELLER SHAFT CONTENTS PROPELLER SHAFT ..........................2 ............................ 2 ESCRIPTION REMOVAL, DISASSEMBLY, REASSEMBLY AND INSTALLATION ..........2 CLEANING, INSPECTION AND LUBRICATION ................. 3 ....................... 3 LEANING NSPECTION ............................ 3 UBRICATION EXPLANATION OF COMMON DAMAGES..................3 TROUBLESHOOTING .......................... 3 SPECIFICATIONS..........................
  • Page 314 Section 09: PROPELLER SHAFT The rise and fall of the drive axle bring about PROPELLER SHAFT these variations as the vehicle passes over uneven surfaces. The slip joint also eases DESCRIPTION removal of the transmission or the drive axle. The propeller shaft transmits power from the transmission to the differential (Fig.
  • Page 315 Section 09: PROPELLER SHAFT CLEANING, INSPECTION AND EXPLANATION OF COMMON DAMAGES LUBRICATION 1. Cracks: Stress lines due to metal fatigue. CLEANING AND INSPECTION Severe and numerous cracks will weaken the metal until it breaks. Thoroughly clean grease from bearings, journal, lubricating grease fittings and other parts.
  • Page 316 U-joint kit (slip yoke), Prevost number .......................580062 Cap and bolt kit, bolt torque 115-135 lbf•ft (156-183 N•m), Supplier number ........6.5-70-18X Cap and bolt kit, bolt torque 115-135 lbf•ft (156-183 N•m), Prevost number ...........580063 Bolts kit, bolt torque 38-48 lbf•ft (52-65 N•m), Supplier number ............6-73-209 Bolts kit, bolt torque 38-48 lbf•ft (52-65 N•m), Prevost number ..............580071...
  • Page 330 Table of Contents Safety ..... . 1 Lubrication ....11 General Safety .
  • Page 331 Safety Safety Note: Spicer 10 Series™ Driveshafts are found on vehicles throughout the world. Therefore, this manual includes CAUTION worldwide terminology. Spicer 10 Series™ Driveshaft assemblies can weigh in excess of 100 pounds (46 kilograms). Be sure to use proper General Safety lifting techniques when handling Spicer 10 Series™...
  • Page 332 Safety Component Safety Driveline Failure to torque bolts to specification can cause driveline fail- ure, which can result in separation of the driveline from the WARNING vehicle. A separated driveline can result in property damage, serious personal injury, or death. Failure to replace damaged driveline components can cause CAUTION driveline failure, which can result in separation of the driveline...
  • Page 333 Safety Tubing Center Bearing WARNING WARNING Bent or dented tubing can cause imbalance or vibration in the Loose center bearing bracket bolts can result in driveline fail- driveshaft assembly. Imbalance or vibration can cause com- ure, which can result in separation of the driveline from the ponent wear, which can result in separation of the driveline vehicle.
  • Page 334 Safety Lubrication (When Applicable) Incompatible greases that are applied to universal joints and/ or slip members can result in driveline failure and can result in WARNING separation of the driveline from the vehicle. A separated drive- line can result in property damage, serious personal injury, or death.
  • Page 335 Inspection Inspection Spicer 10 Series™ Driveshafts should be carefully inspected Grasp the end fitting with both hands and rotate left at recommended original-equipment manufacturer’s service to right, feeling for play and backlash. There should intervals and/or at Spicer recommended lubrication intervals not be any movement in the end fittings relative to as shown in the Lubrication section on page 11.
  • Page 336 Inspection Bearing Plate (Full Round) Yoke Inspection Check the yoke lug cross holes with a No-Go Wear Please refer to the End Fitting information in the Component Gauge, and then use a Spicer Alignment Bar to Safety section on page 2. inspect for damage by sliding through both cross holes simultaneously.
  • Page 337 Inspection Quick Disconnect™ (Half Round) End Yoke Inspection Assemble bearing straps and bolts, tightening bolts Please refer to the End Fitting information in the Component a minimum of 30 lbs. ft. (41 N•m). Insert the align- Safety section on page 2. ment bar into one bushing.
  • Page 338 Inspection Universal Joint Inspection Please refer to the Universal Joint information in the Compo- Re-lubable Style Universal Joints nent Safety section on page 2. With re-lubable style universal joints, check for the Check for excessive looseness between the ends of presence of all grease zerk (nipple) fittings.
  • Page 339 Inspection Slip Member Assembly Tubing This information refers to slip yokes and tube shaft assem- Please refer to the Tubing information in the Component blies. Please refer to the Slip Member information in the Com- Safety section on page 2. ponent Safety section on page 2.
  • Page 340 Inspection Center Bearings Please refer to the Center Bearing information in the Compo- Midship End Fitting nent Safety section on page 2. Please refer to the safety information in the General Safety section and the Midship Nut information in the Component Inspect the center bearing bracket bolts for loose- Safety section on page 2.
  • Page 341 Lubrication Lubrication Members Lubrication Intervals Lack of proper lubrication is among the most common causes of universal joint and slip member problems. Properly sized Carefully review the lubrication specifications found Spicer universal joints that are adequately lubricated at rec- in this manual. ommended intervals will normally meet or exceed vehicle operation requirements.
  • Page 342 Lubrication Lubrication for Universal Joints Spicer recommends the following requirements be met for Lubrication Procedure for Universal Joints any grease used to service most vehicular and industrial Please refer to the Lubrication information in the Component applications and all auxiliary driveshaft applications: Safety section.
  • Page 343 Lubrication Quick Disconnect™ (Half Round) Universal Joints Series Strap Kit Recommended N•m Assemblies Bolt Torque 1310 2-70-18X 13-18 lbs. ft. 17.6 - 24.4 1330 2-70-18X 13-18 lbs. ft. 17.6 - 24.4 1350 3-70-18X 30-35 lbs. ft. 40.7 - 46.5 1410 3-70-18X 30-35 lbs.
  • Page 344 Lubrication Bearing Plate (Full Round) Universal Joints Series Bolt Recommended N•m Part Number Bolt Torque 1610 5-73-709 26-35 lbs. ft. 35.3 - 47.5 1710 6-73-209 38-48 lbs. ft. 51.5 - 65.1 1760 6-73-209 38-48 lbs. ft. 51.5 - 65.1 1810 6-73-209 38-48 lbs.
  • Page 345 Lubrication Lubrication for Slip Members Lubrication of Center Bearing Assemblies Please refer to the Lubrication information in the Component Safety section on page 2. Spicer center bearings are lubricated for life. No attempt The grease used for universal joints is satisfactory for slip should be made to add to or change grease within the bearing members.
  • Page 346 Disassembly and Reassembly Disassembly and Reassembly For procedures used in the removal and installation of Spicer Set the yoke in the arbor press with a piece of tube Driveshafts from the vehicle, please consult the vehicle manu- stock beneath it. Position the yoke with the universal facturer’s service manual.
  • Page 347 Disassembly and Reassembly Reassembly - Snap Ring Design Move one end of the journal cross to cause a trun- Please refer to the Universal Joint information in the Compo- nion to project through the cross hole beyond the nent Safety section on page 2. outer machined face of the yoke ear.
  • Page 348 Disassembly and Reassembly Flip the yoke 180°. Check the bearings for skewed or Disassembly - Bearing Plate Style dropped needle rollers. Place another bearing cup Please refer to the Universal Joint information in the Compo- assembly over trunnion diameter, and align it to the nent Safety section on page 2.
  • Page 349 Disassembly and Reassembly Place a bearing assembly over the trunnion diameter When the bearing assembly is completely seated, and align it to the cross hole. put the lock plate tab (if used) in place and use the "Grade 8" cap screws furnished with the universal joint and insert them through the cap screw holes in both the lock strap and/or the bearing plate assem- bly.
  • Page 350 Disassembly and Reassembly Center Bearing Assembly Mark the counterbore of the coupling shaft end yoke to midship “nose” with a marking stick, paint marker or other legible marking device. This assures proper reassembly of the coupling shaft end yoke in its orig- inal phased position.
  • Page 351 Disassembly and Reassembly On some Spicer center bearing assemblies, a metal 10. Using a puller, follow the tool manufacturer’s retainer spans the outside center bearing bracket. If instructions to remove the bearing assembly from the metal retainer is present, remove it and discard. the midship.
  • Page 352 Disassembly and Reassembly Midship Nut Specifications Table Series Washer Head Size Nut Torque Part Number Catalog Color Part Number N•m lbs. ft. 1310 231781 cadium plate 230123-12 15/16" 136-163 100-120 & wax 230123-14 1310 10-74-101 cadium plate 230123-12 15/16" 136-163 100-120 (Toyota Only) &...
  • Page 353 Disassembly and Reassembly Using a puller, follow the tool manufacturer’s Reassembly - Inboard Slip Style instructions to remove the bearing assembly from Please refer to the Center Bearing information in the Compo- the midship. Discard the center bearing. nent Safety section on page 2. This information pertains to SAE, DIN, and T-Type Companion Flange/Flange Yoke, Quick Disconnect, and Bearing Plate styles.
  • Page 354 Disassembly and Reassembly Carefully align the new center bearing assembly with Visually inspect the midship washer (if applicable) the ground surface of the midship tube shaft. Install for flatness, corrosion, or cracks. If the washer is the center bearing onto the midship tube shaft. Mini- bent, corroded, or cracked, the washer must be mal force should be necessary to push the center replaced.
  • Page 355 Disassembly and Reassembly Reassembly - Outboard Slip Style Wipe the bearing surface of the midship tube shaft with a fine emery cloth. Install a new slinger (included in the center bearing replacement parts kit) on the midship tube shaft, using a section of tubing to avoid damaging the slinger.
  • Page 356 Disassembly and Reassembly Grease Zerk (Nipple) Fittings or Plugs For procedures used in the removal and installation of Spicer Driveshafts from the vehicle, please consult the vehicle manu- facturer’s service manual. Once the driveshaft has been removed or the defective grease zerk (nipple) fitting or plug is accessible, follow the steps listed in the Disassembly - Universal Joint section on page 16 for replacement.
  • Page 357 Glossary Glossary Alignment Bar A device (gauge) used to check yoke cross hole alignment. Ball Yoke See Tube Yoke. Bearing Cross Hole See Cross Hole. Bearing Cup Assembly Consists of a bearing cup with needle rollers, generally held in place by a seal guard and bear- ing seal.
  • Page 358 Glossary Half Round Cross Hole A semicircular hole located on the end of each lug ear of some end yoke and flange yoke designs used to locate a bearing cup assembly. Inboard Bearing Assembly Contained in inboard yoke. Inboard Yokes Yokes that make up the ends of a driveshaft or coupling shaft assembly, i.e.
  • Page 359 Glossary Stub Shaft See Tube Shaft. Tang A nib of metal found on half round end yoke and/or flange yoke style cross holes, used to locate a bearing cup assembly. T-Flange A companion flange and flange yoke design, which has a serrated flange face. Found most often in European applications.
  • Page 361 SECTION 10: FRONT AXLE CONTENTS FRONT AXLE ............................2 ............................ 2 ESCRIPTION LUBRICATION ............................2 MAINTENANCE ............................ 2 ...................... 3 DJUSTMENT REMOVAL AND REPLACEMENT......................3 ............................3 EMOVAL ..........................4 EPLACEMENT SERVICE INSTRUCTIONS FOR STEER AXLE................... 4 ........................ 4 EARING NSPECTION ........................

  • Page 362: Front Axle

    Section 10: FRONT AXLE FRONT AXLE LUBRICATION Pressure lubricate axle every 6 months or DESCRIPTION 30,000 miles (48 000 km) whichever comes first (Fig. 2). Tie rod ends and knuckle pins are This front axle is of the ‘’Reverse Elliot’’ type provided with grease fittings for pressure manufactured by Dana Spicer Europe.

  • Page 363: Tie Rod End Play Adjustment

    Section 10: FRONT AXLE overhaul work is necessary, the axle assembly CAUTION should be removed. Use only the recommended jacking points as CAUTION outlined in section 18 “Body”. Should removal of a locking device be required 2. Exhaust compressed air from the air supply when undergoing repairs, disassembly or system by opening the drain valve of each adjustments, always replace with a new one.

  • Page 364: Replacement

    Section 10: FRONT AXLE REPLACEMENT KING PIN INSPECTION An inspection should be made at intervals of Reverse front axle “Removal” procedure. Ensure 30,000 miles (48 000 km). cleanliness of air bellows support mounting plates. Aspects to be considered are: Lateral slackness and Vertical slackness.

  • Page 365: Front Wheel Alignment

    Section 10: FRONT AXLE FRONT WHEEL ALIGNMENT Check adjust turning angle adjustment. Correct front wheel alignment must be maintained Check the camber angle. for steering comfort and satisfactory tire life. Road shocks and vibrations, as well as normal stress Check and adjust the caster angle. and strains on the front-end system can, under Check and adjust the toe-in.

  • Page 366: Turn Adjustment

    Section 10: FRONT AXLE adjusted any time any component of the steering 2. Verify the nearest point of contact of the ball system is repaired, disassembled or adjusted. socket body with the air bellows support assembly. Measure the distance between Check if front tires rub against the frame or if the those two points.

  • Page 367: Camber Check

    Section 10: FRONT AXLE a trailing effect. This results in stabilized steering and a tendency for the wheels to return to the straight-ahead position after taking a turn. FIGURE 5: CASTER 10007 Excessive caster results in hard steering around corners. A shimmy may also develop when FIGURE 4: CAMBER 10006 returning to the straight ahead position (pulling...

  • Page 368: Inspection And Adjustment

    Section 10: FRONT AXLE be measured from the center of tire tread or from For toe-in specifications, refer to paragraph 8 the inside of the tires. Take measurements at ‘’Specifications’’ in this section. both front and rear of axle (see ’’A and ‘’B’’ in fig. By rolling the vehicle forward, all tolerances in the front suspension are taken up and the When setting toe-in adjustment, the front...

  • Page 369: Troubleshooting

    Section 10: FRONT AXLE TROUBLESHOOTING CONDITION CAUSE CORRECTION Tires wear out 1. Tires have incorrect air pressure. 1. Put specified air pressure in tires. quickly or have 2. Tires out-of-balance. 2. Balance or replace tires. uneven tire tread 3. Incorrect tag axle alignment. 3.

  • Page 370: Specifications

    Section 10: FRONT AXLE SPECIFICATIONS Front Axle Make ..........................DANA SPICER EUROPE Model ................................NDS Front Track ........................84.4 inches (2 145 mm) Rated load capacity......................16,500 lbs (7 500 kg) Torque specifications FIGURE 7: AIR BELLOWS MOUNTING SUPPORT AND AXLE 10030 For more torque specifications, see ‘Dana Spicer Maintenance Manual NDS Axles and Maintenance Manual Model NDS’’...

  • Page 371: 4: Camber

    Section 10: FRONT AXLE FRONT WHEEL ALIGNMENT SPECIFICATIONS Front Wheel Alignment Minimal Nominal Maximal Camber, (degrees) -0.250 0.125 0.375 R.H. and L.H. * Caster, (degrees) 2.75 R.H. and L.H. Toe-in (A minus B), 0.06 0.08 0.10 (degrees) NOTE Camber angle changes with loading. The given numbers are for an empty vehicle. PA1562...
  • Page 373 SERVICE MANUAL GENERAL INFORMATION NDS Axle range place product photo here SPICER SPECIALITY AXLE DIVISION...
  • Page 374 Spicer SpecialityAxle Division - Technical Publications INFORMATION ABOUT THIS MANUAL. THIS MANUAL IS DIVIDED INTO THE FOLLOWING GENERAL SECTIONS:- GENERAL INFORMATION (this section) LUBRICATION AND MAINTENANCE REMOVAL AND REFITTING OF THE SWIVEL (KNUCKLE) ASSEMBLY REMOVAL AND REFITTING OF THE BRAKE ASSEMBLY PARTS IDENTIFICATION The description, testing procedures, and specifications contained in this parts / service publication were current at time of printing.
  • Page 375 Spicer SpecialityAxle Division - Technical Publications IMPORTANT NOTICE THIS SYMBOL IS USED THROUGHOUT THIS MANUAL, TO CALL ATTENTION TO PROCEDURES WHERE CARELESSNESS OR FAILURE TO FOLLOW SPECIFIC INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR COMPONENT DAMAGE. DEPARTURE FROM THE INSTRUCTIONS, CHOICE OF TOOLS, MATERIALS AND RECOMMENDED PARTS MENTIONED IN THIS PUBLICATION MAY JEPORDISE THE PERSONAL SAFETY OF THE SERVICE TECHNICIAN OR VEHICLE OPERATOR.
  • Page 376 Spicer SpecialityAxle Division - Technical Publications WARNINGS! NON ASBESTOS FIBRES! ALTHOUGH NON OF THE BRAKE LININGS USED ON THE NDS RANGE OF AXLES CONTAIN ASBESTOS. IT SHOULD BE NOTED THAT NON ASBESTOS BRAKE LININGS CAN STILL CONTAIN INGREDIENTS WHICH CAN PRESENT HEALTH RISKS IF INHALED. ACCORDINGLY CARE SHOULD BE TAKEN TO AVOID THE CREATION AND INHALATION OF DUST WHEN BRAKES ARE SERVICED.
  • Page 377 Spicer SpecialityAxle Division - Technical Publications GLOSSARY OF TERMS Due to the international nature of Spicer Speciality Axle Division products certain terms and wordsrequire clarification; hence the following list:- ENGLISH U.S.A SWIVEL KNUCKLE COTTER PIN DRAW KEY AXLE BED I BEAM STEERING LEVER TIE ROD ARM HUB NUT...
  • Page 378 Spicer SpecialityAxle Division - Technical Publications GENUINE SPICER SERVICE PARTS Should an axle assembly require replacement component parts, it is recommended that Spicer Speciality Axle Division service parts be used. Spicer Speciality Axle Division service parts are manufactured under the same rigid specification as are the original equipment axle components.
  • Page 380 APPLICATION POLICY Capability ratings, features and specifications vary depending upon the model type of service. Applications approvals must be obtained from Spicer Speciality axle division. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice. SPICER SPECIALITY AXLE DIVISION ABBEY ROAD LEEDS LS5 3NF...
  • Page 381 BACK / RETOUR Maintenance Manual NDS axles Lubrication and Maintenance NDS Axle range Issue D place product photo here SPICER SPECIALITY AXLE DIVISION...
  • Page 382 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications MANUAL ISSUE SHEET Page No. Issue Description / Alteration Reason Date New Manual Nov. 99 Mileage interval altered Updated spec. Mar.2000 Mileage interval altered Updated spec. Mar.2000 Tie rod torques added New tie rod Mar.2000 Tie rod torques added...
  • Page 383 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications LUBRICATION AND ROUTINE MAINTENANCE FOR NDS AXLE RANGE SECTION 1 LUBRICATION GREASING PERIODS 1.1.1 ON HIGHWAY APPLICATIONS Pressure lubricate every 6 months or 30000 miles (48000 km) A more frequent lubrication cycle is required for axles used in on/off highway, refuse, or other severe service applications.
  • Page 384 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 2 ROUTINE MAINTENANCE Hub bearing check should be carried out every 30000 miles (48000 km) Before commencing checks, apply parking brake, raise wheels off ground and support axle on stands. and remove brake drum (if fitted) .
  • Page 385 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 2 ROUTINE MAINTENANCE Cont. Check permissible slackness in swivel (king) pins every 30000 miles (48000 km) as follows :- Aspects to be considered are :- Lateral slackness. Vertical slackness. Before commencing checks, apply parking brake, raise wheels off ground and support axle on stands. Checking lateral slackness Whilst this is being carried out the brake must be applied.
  • Page 386 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 2 ROUTINE MAINTENANCE Cont. Every 6 months inspect ball joints for corrosion as follows :- NOTE:- INSPECTION OF BALL JOINTS IS IMPORTANT, ESPECIALLY THOSE IN OLDER VEHICLES. DAMAGED SEALING BOOTS, SALT ON ROADS IN WINTER AND CLIMATIC CONDITIONS CAN CAUSE LOSS OF THE CORROSION PROTECTION COATING APPLIED DURING MANUFACTURE.
  • Page 387 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 3 CARE OF WHEELS AND FIXING FACES (ALL AXLES WITH SPIGOT FIXING) At approximately 100 miles after fitting wheels, wheel nut torque should be checked with wheel ends in " cold " condition ( ie not after prolonged braking.). If any relaxation of original torque (see specification) has occured, re-tighten.
  • Page 388 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications WHEELNUT TIGHTENING TORQUE SEQUENCE 6 - STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 8 - STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 10 - STUD FIXING © Spicer Speciality Axle Division Page No.8 NDS2 issue A...
  • Page 389 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 4 Guidance standards for acceptable brake drum crazing (if fitted). Every 30000 miles (48000 km) or whenever brake drums are removed for axle maintenance purposes they should be checked for crazing. Brake drums with crazing in excess of that shown in fig.6 below, and which are of Spicer Speciality axle division manufacture should not be re introduced into service.
  • Page 390 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications EVALUATION OF BRAKE DISC SURFACE TP1627 Upon removal of brake disc Fig. 9. It's surface should be checked for defects. Inspection should cover both sides of the braking surface as well as the outer diameter of the disc.
  • Page 391 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications TP1631 EVALUATION OF BRAKE DISC SURFACE CONTINUED Grooving - Scoring can be light or heavy, If light grooving is found as shown in Fig. 13 then the disc can continue to be used. Fig.
  • Page 392 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications © Spicer Speciality Axle Division Page No.12 NDS2 issue A...
  • Page 393 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / AXLE BED TIGHTENING TORQUES Fig.No.17 PART N DESCRIPTION ----------------------------------- TIGHTENING TORQUE ---- 1 ------- Brake backplate nut 1/2" UNF ---------------- 85 - 103 lbs.ft -------- 115 - 140 NM ------- (All axles) 2 ------- Brake backplate stud 1/2"...
  • Page 394 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / AXLE BED TIGHTENING TORQUES Fig.No.18 PART N DESCRIPTION ----------------------------------- TIGHTENING TORQUE ---- 6 ------- Swivel top cap ------------------------------------- 25 - 75 lbs.ft ---------- 34 - 102 NM -------- (All axles) 7 ------- Swivel top cap lubricator ----------------------- 10 - 15 lbs.ft ---------- 14 - 20 NM ---------- (All axles) 9 ------- Top lever bolts M20 x 2.5 grade 10.9 ------- 433 - 479 lbs.ft ------- 587 - 649 NM ------- (NDS 35/41/56) -------- Top lever bolts M20 x 2.5 grade 12.9 ------- 520 - 575 lbs.ft ------- 705 - 780NM ------- (NDS 56)
  • Page 395 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / HUB END TIGHTENING TORQUES Fig.No.19 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM...
  • Page 396 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / HUB END TIGHTENING TORQUES Fig.No.20 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM...
  • Page 397 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications 9< Fig.No.21 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM Hub flange retaining bolt M14 x 1.5 ---------------------------- 174 - 192 lbs.ft...
  • Page 398 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications Fig.No.22 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM Brake air cylinder retaining nuts M16 X 1.5 ------------------ 133 - 155 lbs.ft...
  • Page 399 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications Fig.No.23 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM Hub flange retaining bolt M14 x 1.5 ---------------------------- 174 - 192 lbs.ft...
  • Page 400 BACK / RETOUR APPLICATION POLICY Capability ratings, features and specifications vary depending upon the model type of service. Applications approvals must be obtained from Spicer Speciality Axle Division. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice.
  • Page 401 Maintenance manual Model NDS Hub and brake assembly With Knorr Bremse Disc brake Fitted to offset barrel swivel SPICER SPECIALITY AXLE DIVISION...
  • Page 402 Spicer Speciality Axle Division - Technical Publications MANUAL ISSUE SHEET Page No. Issue Description / Alteration Reason Date New Manual Mar.2000 Page added all subsequent pages re numbered Brake disc checking added Oct.2000 Optimol Paste Added To prevent fretting ECN 8695 Aug.2002 ©...
  • Page 403 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES PREPARATION Prepare for axle overhaul as follows: Set parking brake and block drive wheels to prevent vehicle movement. Raise vehicle until tyres are off the ground. support raised vehicle with safety stands. WARNING! NEVER WORK UNDER A VEHICLE SUPPORTED ONLY BY A JACK.
  • Page 404 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END DISASSEMBLY Loosen but do not remove hub flange bolts. Remove 2 diametrically opposed hub flange bolts. Replace 2 diametrically opposed hub flange bolts with 2 studs (loosely fitted). NOTE! REPLACEMENT STUDS SHOULD PROTRUDE BEYOND FRONT FACE OF HUB FLANGE TO AID REMOVAL...
  • Page 405 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END DISASSEMBLY Once hub flange has been removed, insert two bolts into brake disc extraction holes Tighten to free brake disc from hub bearing. Support weight of brake disc and carefully slide along dummy studs to remove.
  • Page 406 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END DISASSEMBLY Using a small ended chisel, pry off the "staking" on the hub nut. Remove hub nut and discard. Remove bearing thrust washer. Fit bearing guide sleeve onto swivel thread. (See chart at front of swivel assembly ) Carefully pull unitised hub bearing assembly towards end of swivel stub and remove.
  • Page 407 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY Follow instructions contained in swivel / axle bed reassembly section, before attempting to reassemble hub end. Fit Unitised hub bearing guide sleeve onto swivel stub . (see chart at front of swivel section) Lightly smear the axle stub bearing journal with a thin layer of anti-fretting assembly paste, white...
  • Page 408 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Place unitised hub bearing thrust washer onto axle stub. Fit hub nut. Tighten to specified torque. NOTE:- ROTATE UNITISED HUB BEARING WHILST TIGHTENING. © Spicer Speciality Axle Division Page No.8 Manual No.
  • Page 409 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Stake the hub nut by deforming with a round nosed chisel. Using a modified hub flange bolt as a guide. carefully position brake disc onto unitised hub bearing. Tap securely home (using a hide faced hammer to avoid damaging the brake disc itself.)
  • Page 410 Spicer Speciality Axle Division - Technical Publications HUB FLANGE BOLT TIGHTENING TORQUE SEQUENCE FOR 8 BOLT FIXING HUB FLANGE BOLT TIGHTENING TORQUE SEQUENCE FOR 10 BOLT FIXING HUB FLANGE BOLT TIGHTENING TORQUE SEQUENCE FOR 14 BOLT FIXING © Spicer Speciality Axle Division Page No.10 Manual No.
  • Page 411 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Once the hub flange has been correctly fitted; it is necessary to check the axial run out of the brake disc. Position a metric dial test indicator onto axle in a suitable position as shown.
  • Page 412 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Refit ABS sensor bush and sensor into swivel NOTE:- A NEW SENSOR BUSH SHOULD BE FITTED WHENEVER A NEW SENSOR IS FITTED. IF FITTING A NEW SENSOR AND BUSH INTO AN ABS READY AXLE.
  • Page 413 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Check A.B.S. sensor performance as follows :- Before commencement of this check It is important that the number of teeth be checked and found to be the correct, on both LH and RH hubs. Insert the probes from a volt-meter into the two plugs in the sensor connector.
  • Page 414 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Using suitable lifting equipment, support the brake caliper. WARNING! BRAKE CALIPER IS HEAVY. Offer brake caliper up to brake bracket. (Ensure correct hand of brake caliper is selected) Insert brake caliper retaining bolts and tighten hand tight.
  • Page 415 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Refit lockstop screws and adjusting nuts Reset lockstop screws to achieve correct lock angles as shown on installation drawing or vehicle manufacturers specifications. NOTE:- DO NOT ALLOW LOCKSTOP THREADS TO PROTRUDE THROUGH FRONT FACE OF SWIVEL.
  • Page 416 Spicer Speciality Axle Division - Technical Publications OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED Re-connect brake to vehicle hydraulic system as recommended in brake manufacturer’s manual. Clean interfaces of wheelnuts, wheel rim & hub then re-fit road wheels securing with wheel nuts and tighten in correct sequence (as shown on following page) to specified torque.
  • Page 417 Spicer Speciality Axle Division - Technical Publications WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 6 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 8 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 10 STUD FIXING © Spicer Speciality Axle Division Page No.17 Manual No. NDS8...
  • Page 418 Spicer Speciality Axle Division - Technical Publications TP1193 © Spicer Speciality Axle Division Page No.18 Manual No. NDS8...
  • Page 419 Spicer Speciality Axle Division - Technical Publications ILLUSTRATION OF NDS HUB END WITH SEPARATE BRAKE BRACKET PART NUMBER DESCRIPTION 1 ..........Wheel nut (Not Supplied By Spicer Speciality Axles) 2 ..........Hub flange 3 ..........Wheel stud 4 ..........Brake Caliper 5 ..........
  • Page 420 APPLICATION POLICY Capability ratings, features and specifications vary depending upon the model type of service. Applications approvals must be obtained from Spicer Speciality axle division. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice. SPICER SPECIALITY AXLE DIVISION ABBEY ROAD LEEDS LS5 3NF...
  • Page 421 SECTION 11: REAR AXLES CONTENTS DRIVE AXLE ............................2 ............................ 2 ESCRIPTION DCDL (D ) ..............2 RIVER ONTROLLED MAIN IFFERENTIAL LOCK ......................... 2 RIVE UBRICATION ..........................3 AINTENANCE 1.4.1 Checking and Adjusting the Oil Level ..................3 1.4.2 Draining and Replacing the Oil ....................3 1.4.3 Speed Sensors (Anti-Lock Brake system, ABS) ..............

  • Page 422: Drive Axle

    Section 11: REAR AXLES DRIVE AXLE DESCRIPTION The Meritor drive axle is equipped with a single reduction standard carrier mounted in front of the axle housing. The carrier consists of a hypoid drive pinion, a ring gear set and gears in the differential assembly.

  • Page 423: Maintenance

    Section 11: REAR AXLES 2. Make sure the axle is "cold" or at room temperature. 3. Clean the area around the fill plug. Remove the fill plug from the differential axle housing bowl (Fig. 4). 4. The oil level must be even with the bottom of the hole of the fill plug.

  • Page 424: Speed Sensors (Anti-Lock Brake System, Abs)

    Section 11: REAR AXLES 1.4.3 Speed Sensors (Anti-Lock Brake NOTE system, ABS) Position the hoses so they will not be damaged when removing the axle. For removing and installing the drive axle speed sensors (for anti-lock brake systems, ABS), refer 8.

  • Page 425: Gear Set Identification

    Section 11: REAR AXLES GEAR SET IDENTIFICATION If the axle has been removed for repairs or servicing and if all the parts are reinstalled Gear identification covered under exactly in the same place, the axle alignment is applicable heading in Meritor's "MAINTENANCE not necessary.
  • Page 426 Section 11: REAR AXLES NOTE For an accurate alignment, the tag axle must be aligned with the drive axle. NOTE Reinstall wheel mount sensors as shown in figure 8. • Adjust tag axle according to specifications' chart below in reference with drive axle. TAG AXLE ALL VEHICLES Alignment / value...

  • Page 427: Method

    Section 11: REAR AXLES 1.12 AXLE SHAFT SEALING METHOD c. Install the lock washers and nuts on the studs. Tighten nuts to the correct torque The following method is to be used to ensure value. that axle shaft installation is fluid-tight: NOTE Torque values are for fasteners that have a light application of oil on the threads (refer to...

  • Page 428: Retracting Tag Axle For Repair Purposes

    Section 11: REAR AXLES 2. Transferring extra weight and additional Front and tag axle hub bearings need to be traction to the drive wheels on slippery checked every 30,000 miles (48 000 km). surfaces. NOTE The tag axle service brakes operate only when For more information on front and tag axle the axle is in normal driving (loaded) position.

  • Page 429: Tag Axle Alignment

    Section 11: REAR AXLES required, refer to Section 13, "Wheels, Hubs CAUTION And Tires"). 2. Exhaust compressed air from the air supply On vehicles equipped with an automatic system by opening the drain cock on each air transmission (with or without the output reservoir and deplete air bags by moving retarder), move tag assembly very carefully.
  • Page 430 Section 11: REAR AXLES SPECIFICATIONS Drive Axle Make ................................Meritor Drive track........................76.7 inches (1 949 mm) Gear type ..............................Hypoid Axle type .............................. Full floating Lube capacity .........................41 pints (19,3 liters) Drive axle ratio World Transmission ZF Transmission 4.30:1 Standard 3.73:1 Standard 4.10:1 Optional 3.42:1 Optional 4.56:1 Optional...
  • Page 431 TP-9539 Revised 06-07 Approved Rear Drive Axle Lubricants Technical Bulletin CAUTION You must fill Meritor axles with Meritor-specified lubricants only. Do not fill an axle with non-approved lubricants, which will void Meritor’s warranty. Damage to axle components also can result. To avoid axle component damage, fill Meritor axles with approved lubricants only.
  • Page 432 Table B: Axle Oil Specifications A.P .I. Viscosity ArvinMeritor Outside Gear Oil Type Specification Grade Specification Specification Temperature 85W/140 O76-A Above +10°F (–12°C) 80W/140 O76-B Above –15°F (–26°C) 80W/90 O76-D Above –15°F (–26°C) 75W/90 O76-E Above –40°F (–40°C) Petroleum with SAE J2360 Tested GL-5 From –40°F (–40°C)
  • Page 433 Table C: Extended-Drain-Approved Synthetic Axle Oil Suppliers — United States Distributors Name of Lubricant Viscosity Manufacturer Gibraltar Syn-Gear 75W/90, 80W/140 David Weber Oil Company Gulf Syngear 75W/90, 80W/140 Gulf Oil Hi-Tek Synthetic 75W/90, 80W/140 Industrial Oils Limited Imperial SGO 75W/90, 80W/140 IPAC Lubemaster Syn EP 75W/90, 80W/140...
  • Page 434 Table D: Additional Extended-Drain-Approved Axle Oil Suppliers CANADA: Name of Lubricant Viscosity Manufacturer HDH Synthetic 75W/90, 80W/140 Irving Oil Limited NEMCO Syngear 75W/90, 80W/140 NemCo Resources Limited Sonic MP Gear Oil 75W/90, 80W/140 Federated Cooperatives Limited Titan Syndrive 75W/90, 80W/140 Fuchs Lubricants Canada Limited MEXICO: Name of Lubricant...

  • Page 435: Specifications

    For Meritor R-170 Axles Equipped Lubrication Analysis ® With Traction Equalizer Recommendations Meritor’s R-170 axles with Traction Equalizer Meritor recommends using a lubricant analysis normally operate with either standard petroleum, program. Perform lubricant analysis at semi-synthetic or full-synthetic oils. regularly-scheduled preventive maintenance intervals.
  • Page 436 Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is 2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the Troy, MI 48084 USA information presented or to discontinue the production of parts described at any time.
  • Page 437 TP-96105 Revised 07-03 ® Applying Loctite Ultra Grey Flange Sealant 5699/Meritor Maintenance Part Number 2297-Z-7098 Manual Update TP-96105 Revised 1 Maintenance Manual Update 07-03 Hazard Alert Messages Clean the surfaces where you will apply the silicone gasket material. Remove all oil, grease, dirt and moisture. Figure 1. Read and observe all Warning and Caution hazard alert messages in Dry both surfaces.
  • Page 438 Maintenance Manuals The information in this Technical Bulletin updates the following Maintenance Manuals. Title Date Tandem Axle Forward Rear Drive 09-88 Units Single-Reduction Hypoid Drive 08-79 Unit Tandem Axle Forward Rear Drive 03-91 Units Double-Reduction Differential 08-84 Carriers Hypoid Planetary Two-Speed 08-90 Differential Carriers Heavy-Duty Front Drive Steer...
  • Page 439 TP-99125 Issued 12-99 Forward and Rear Axle Carrier Diagnostic Flowcharts TECHNICAL BULLETIN...
  • Page 440 Introduction How to Use This Publication Performing the Diagnostic Introduction Procedures in This Bulletin Refer to the following diagnostic flowcharts to help you determine the source of axle differential Refer to the following publications when you carrier complaints. perform the diagnostic procedures in this bulletin. Before you use the flowcharts, investigate the axle r Lubrication carrier complaint and confirm that the problem...
  • Page 441 Forward Tandem Carrier Vehicle Will Not Move Forward Tandem Carrier Vehicle Will Not Move Visually inspect the carrier Check for further carrier in the axle damage. If none is found, housing. Damaged or repair or replace the oil contaminated? pump, clean or replace the Remove the oil screen and install the carrier from the...
  • Page 442 Forward Tandem Carrier Vehicle Will Not Move This flowchart continues from the previous page. When the carrier is When the carrier is If damaged, repair the reassembled later, reassembled later, Backlash input shaft, inter-axle set the backlash set the backlash within spec? differential, side gears or to the recorded...
  • Page 443 Forward Tandem Carrier Differential Making Noise Forward Tandem Carrier Differential Making Noise Visually inspect the carrier in the axle housing. Check for further carrier damage. If none is found, Remove the Damaged or repair or replace the carrier from the contaminated? oil pump, clean or replace axle housing.
  • Page 444 Forward Tandem Carrier Differential Making Noise This flowchart continues from the previous page. When the main When the main differential is differential is Reassemble and install reassembled later, Backlash reassembled later, set the main differential. within spec? set the backlash to the backlash to spec.
  • Page 445 Forward Tandem Carrier Oil Leak Forward Tandem Carrier Oil Leak Visually inspect the carrier in the axle housing. Drain and inspect the lubricant. Remove the carrier Refer to MM 1. from the axle housing. Repair the carrier or Damaged? install a remanufactured carrier.
  • Page 446 Rear Tandem or Single Carrier Vehicle Will Not Move Rear Tandem or Single Carrier Vehicle Will Not Move Visually inspect the carrier in the axle housing. When the carrier is When the carrier is Backlash reassembled later, reassembled later, set Remove the within spec? set the backlash to...
  • Page 447 Rear Tandem or Single Carrier Differential Making Noise Rear Tandem or Single Carrier Differential Making Noise Visually inspect the carrier in the axle housing. When the carrier is When the carrier is Backlash reassembled later, reassembled later, within spec? Remove the carrier set the backlash to set the backlash to from the axle housing.
  • Page 448 Rear Tandem or Single Carrier Oil Leak Rear Tandem or Single Carrier Oil Leak Visually inspect the carrier in the axle housing. Clean and prepare the housing and carrier Remove the carrier flanges. Apply the correct from the axle housing. gasket or silicone.
  • Page 449 All Rear Axles Contaminated Lubricant Found During Preventive Maintenance All Rear Axles Contaminated Lubricant Found During Preventive Maintenance Visually inspect the lubricant. Clean and prepare the housing and carrier Indicates Milky, Indicates flanges. Apply the correct that water Brownish Silvery metallic Lubricant gasket or silicone.
  • Page 450 Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is 2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the Troy, MI 48084 USA information presented or discontinue the production of parts described at any time.
  • Page 451 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS AIR SYSTEM ............................. 5 BRAKES ............................5 AIR RESERVOIRS..........................5 ..........................5 AINTENANCE 3.1.1 Wet (Main) Air Tank ........................ 6 3.1.2 Primary Air Tank........................6 3.1.3 Accessory Air Tank ......................... 6 3.1.4 ZF transmission Air Tank ......................6 3.1.5 Secondary Air Tank.........................
  • Page 452 Section 12: BRAKE AND AIR SYSTEM STOPLIGHT SWITCHES......................... 13 PARKING BRAKE ALARM SWITCH ..................... 13 BRAKE RELAY VALVE (R-12 & R-14) ..................13 QUICK RELEASE VALVES (QR-1) ....................14 SPRING BRAKE VALVE (SR-7) ..................... 14 PRESSURE PROTECTION VALVE (PR-4) ..................14 LOW PRESSURE INDICATOR (LP-3)....................

  • Page 453: Illustrations

    Section 12: BRAKE AND AIR SYSTEM 31.3 ........................27 OMPONENTS 31.3.1 Electronic Control Unit (ECU) ....................27 31.3.2 ABS Modulator Valve ......................28 31.3.3 Sensors ..........................28 31.3.4 Spring clip..........................29 FITTING TIGHTENING TORQUES ....................29 SPECIFICATIONS ........................... 31 ILLUSTRATIONS ......................
  • Page 454 Section 12: BRAKE AND AIR SYSTEM ....................... 28 IGURE ABS MODULATOR VALVE ........................ 28 IGURE ABS SENSOR LOCATION ..........................29 IGURE SPRING CLIP ..........................29 IGURE HOSE FITTINGS ..........................29 IGURE HOSE FITTING ..........................29 IGURE HOSE FITTING ..........................30 IGURE HOSE FITTING PA1562...

  • Page 455: Brakes

    Section 12: BRAKE AND AIR SYSTEM AIR SYSTEM Furthermore, the brake application or release, which is speed up by a pneumatic relay valve (R- The basic air system consists of an air 12), will start with the rear axles and will be compressor, reservoirs, valves, filters and...

  • Page 456: Primary Air Tank

    Section 12: BRAKE AND AIR SYSTEM FIGURE 2: I-BEAM FRONT SUSPENSION AIR RESERVOIRS LOCATION 12213 3.1.1 Wet (Main) Air Tank This reservoir, located above the L.H. wheel of drive axle in the rear wheelhousing, is provided with a bottom drain valve. A recommended purge using the bottom drain valve should be done every 12,500 miles (20 000 km), or once a year, whichever comes first.

  • Page 457: Ping Tank

    15 psi (105 kPa) between will pass through the standard air filtering filter inlet and outlet ports. Check condition of all system provided by Prevost. Do not fill system by any point on the system. three O’rings for damage. Replace when necessary (Fig.

  • Page 458: Air Filter Dryer Purge Tank

    Section 12: BRAKE AND AIR SYSTEM Pay particular attention to the internal passages. Its purpose is to remove moisture that could Inspect all parts for damage and replace if damage the air system before the air enters the necessary. system reservoir. The air filter/dryer also filters the air to remove dirt, compressor oil, and other contaminants that can damage the system.

  • Page 459: Flexible Hoses

    Section 12: BRAKE AND AIR SYSTEM the parts must be free of burrs, copper cuttings, sometimes be corrected by tightening the and dirt. Blow out piping with compressed air. connection. If this fails to correct the leakage, Any such particles will destroy sealing seats in new fittings, nylon tubing, copper tubing, air control units.

  • Page 460: Pressure Setting Procedure

    Section 12: BRAKE AND AIR SYSTEM cleaning solvent (Fig. 7). Examine 2. Turn the adjustment screw clockwise to diaphragm; if cracked, worn or damaged, increase the pressure slowly until the re- replace with a new one. If the valve is quired pressure setting is reached.

  • Page 461: Compressor Removal And Installation

    Section 12: BRAKE AND AIR SYSTEM 10.1.1 Compressor Removal and Installation Flange Nut (3) Torque to 15lb-ft (20 Nm) 1. Exhaust compressed air from air system by Nipple (2) opening the drain valve of each air tank. Hose Assembly 2. Drain the engine cooling system. See Section 5: "Cooling System".

  • Page 462: Emergency/Parking Brake Control Valve (Pp-1)

    Section 12: BRAKE AND AIR SYSTEM in the applicable booklet annexed to this section 11. EMERGENCY/PARKING BRAKE under reference number SD-03-3611. CONTROL VALVE (PP-1) A push-pull control valve mounted on the L.H. lateral console is provided for parking brake application or release. The spring brakes are self-actuated whenever the control valve supply pressure drops below 40 psi (275 kPa).

  • Page 463: Dual Brake Application Valve (E-10P)

    Section 12: BRAKE AND AIR SYSTEM 1. Replace the linkage, loosen threaded rod lock nuts and screw or unscrew the threaded adjustment rod in order to obtain a brake pedal inclination (Fig. 14). 2. Tighten threaded rod lock nuts. 14.1.1 Maintenance Maintenance and repair information on the E-10P dual brake application valve is supplied in the applicable booklet annexed to this section under...
  • Page 464 Section 12: BRAKE AND AIR SYSTEM FIGURE 18: R-14 12207 FIGURE 20: SR-7 18. QUICK RELEASE VALVES (QR-1) 12206 The quick release valve is located on the front 20. PRESSURE PROTECTION VALVE (PR-4) axle service brakes air line and permit rapid exhaust of air pressure from brakes, thus Maintenance and repair information on the pressure protection valve is supplied in the...
  • Page 465 Section 12: BRAKE AND AIR SYSTEM 21. LOW PRESSURE INDICATOR (LP-3) 23. EMERGENCY DOOR OPENING VALVES Maintenance and repair information on the low Two emergency door opening three-way valves pressure indicators is supplied in the applicable are installed on coaches. One is in the front booklet annexed to this section under reference service compartment, readily accessible.
  • Page 466 Section 12: BRAKE AND AIR SYSTEM • 27. AIR BRAKES Clogged engine air cleaner. • Worn compressor or excessive wear on 27.1 DISC BRAKES piston and/or ring. Knorr-Bremse SN7000 disc brakes are used on • Engine speed too low. all axles. The front and drive axle discs are actuated by 24 square inch effective area air Air pressure rises above a normal setting: brake chambers, while on tag axle, the brake...
  • Page 467 Section 12: BRAKE AND AIR SYSTEM perform this procedure before replacing the rotor to ensure the cause of the problem is properly solved. 1. Check for presence of residual pressure: To check if there is any residual air pressure in the brake chamber, make four or five brake applications, then try to turn the wheel manually, if the wheel does not turn, use a wrench to crack...
  • Page 468 Section 12: BRAKE AND AIR SYSTEM The pad thickness can be seen but would require removal of the tire and rim. An indicator of the pad wear condition is available by inspecting the floating pin location in relation to the rubber bushing as shown in figure 31. When pads are in new thickness condition, the pin will be exposed (C) 19 mm (¾”).
  • Page 469 Section 12: BRAKE AND AIR SYSTEM a) Using hand pressure only, the caliper (1) New friction material has a thickness of 21 mm (B, Fig. 33) must slide freely with its guide pin arrange- ments (4-7) across a distance of 1 3/16 inch (30 mm) when the pads are removed.
  • Page 470 Section 12: BRAKE AND AIR SYSTEM b) If boots are damaged but show no corrosion, the boots and tappets should be replaced (Prévost #611177). 27.1.9 Pad Installation Turn adjuster pinion (23, Fig. 37) counterclock- wise until tappets are fully retracted and clean pad seat area.
  • Page 471 Section 12: BRAKE AND AIR SYSTEM 27.1.13 Torque specifications For proper caliper maintenance, refer to the following figures. FIGURE 38: RUNNING CLEARANCE 12116 27.1.11 Brake Tools Four brake tools are available from Prévost to FIGURE 40: TORQUE SPECIFICATION 12145 facilitate disc brake maintenance: a) #641321, Tappet with boot (item 13).
  • Page 472 Section 12: BRAKE AND AIR SYSTEM 29. AIR BRAKE TROUBLESHOOTING The following tests and check lists have been WARNING designed to identify the cause(s) of a sluggish performance and/or leaks in the system. These tests require very little time to perform, and give Whenever possible, work on brakes in a you a general idea of the system condition.
  • Page 473 Section 12: BRAKE AND AIR SYSTEM • Pressure Build-Up / Low Pressure Warning / If discharge valves leak, pull head and Cutoff Point Filter/Dryer Built-in correct or replace cylinder head. Governor Cutout • If drive is slipping, replace gear. CONDITION: Vehicle leveled, parking brake •...
  • Page 474 Section 12: BRAKE AND AIR SYSTEM Excessive leakage on brake service side: • With the primary air system at normal operating pressure (95 - 125 psi (655 - 860 kPa)) and foot brake applied, coat all air line connections and brake pneumatic components with a water and soap solution.

  • Page 475: Drive Axle

    Section 12: BRAKE AND AIR SYSTEM 2. Install new diaphragm or any other part if 30.3 BRAKE CHAMBER REMOVAL worn or deteriorated. WARNING NOTE To prevent personal injuries, brakes should be When the diaphragm, spring, or both are inoperative prior to working on any of their replaced, they should be replaced in the components.
  • Page 476 Section 12: BRAKE AND AIR SYSTEM To avoid such injury, the following recommen- 31. ANTI-LOCK BRAKING SYSTEM (ABS) dations must be applied: This device has been designed to ensure o Prévost recommends the installation of a stability and permit steering control of vehicle new spring brake chamber if it is found to during hard braking, and to minimize its stopping be defective.
  • Page 477 Section 12: BRAKE AND AIR SYSTEM DANGER CAUTION Disconnect the ECU or pull the ABS fuse ESP can make the vehicle decelerate before towing vehicle. automatically. ESP can slow the vehicle with or without the operator applying the brake, and even when the throttle is being 31.1 TROUBLESHOOTING AND TESTING applied.
  • Page 478 Section 12: BRAKE AND AIR SYSTEM ately. Consequently, the electronic control unit CAUTION will command the solenoid control valve to decrease the pressure at the corresponding In order to protect the ABS electronic control brake chamber. unit from voltage surges, always disconnect before performing any welding procedure on Maintenance vehicle.
  • Page 479 Section 12: BRAKE AND AIR SYSTEM CAUTION Use only this type of grease on the sensors. 2. Insert spring clip in the holder on hub. Make sure the spring clip tabs are on the inboard side of the vehicle. Push in until the clip stops.
  • Page 480 Section 12: BRAKE AND AIR SYSTEM AB-Type Copper Piping: Hand tighten nut (Fig. 51). From that point, tighten with a wrench the number of turns indicated in the following chart. Piping diameter Number of additional turns (inches) required following hand tightening 1/4, 3/8, 1/2 5/8, 3/4...
  • Page 481 Section 12: BRAKE AND AIR SYSTEM 33. SPECIFICATIONS Air Compressor (with Detroit Diesel Series 60 Engine) Make..........................Bendix Westinghouse Model..............................BA-921 Capacity (at 1250 rpm) ....................15.7 cfm (0,445 m /min.) Prévost number........................... 641990 BA-921 Service Kits ST-4 Safety Valve Prévost number........................... 641989 Series 60 Seal Kit Prévost number...........................
  • Page 482 Section 12: BRAKE AND AIR SYSTEM Brake Relay Valves Make..........................Bendix Westinghouse Model............................... R-12 Supplier number.............................. Prévost number............................... Brake Relay Valve Make............................Meritor Wabco Model............................... R-14 Prévost number............................... Quick Release Valve Make..........................Bendix Westinghouse Model..............................QR-1 Prévost number........................... 641429 Spring Brake Valve Make..........................
  • Page 483 Section 12: BRAKE AND AIR SYSTEM Prévost number........................... 641432 Piggy Back (On Drive Brakes) Make............................Knorr-Bremse Type ............................ 24 as emergency Prévost number........................... 641433 Tag Axle Brake Chambers Make............................Knorr-Bremse Type ................................14 Prévost number........................... 642087 Tag Axle Brake Chambers Make............................Knorr-Bremse Type ................................16 Prévost number...........................
  • Page 485 Effective Date: 12/02/05 Bendix Air Disc Brake Pad Replacement on Prevost Car Vehicles Subject: Prevost Car and Bendix Spicer Foundation Brake • Shear testing of the friction material adhesion LLC are issuing this product notification about resulted in the friction material completely...
  • Page 486 work clothes home. Work clothes should be • Brake workers must take steps to minimize their exposure to airborne brake lining particles. vacuumed using a high efficiency particulate Procedures to reduce exposure include: filter (HEPA) vacuum and laundered separately working in a well-ventilated area, segregating without shaking.
  • Page 487 L31166 DRYest Air Dryer 9/02 Installation and Maintenance .5 space for cartridge change Governor Valve Safety Valve Port 1, 21 Inlet, Outlet 1/2-14 NPTF Heater 12V & 24V Turbo Protection Valve Port 22 Regeneration Port 4 Control Reservoir 1/4-18 NPTF 1/4 -18 NPTF Chassis Mount Silencer...

  • Page 488: Adjustment

    Application Schematics FIG. 2.A. Standard System Regeneration with Integrated Governor Unloader Check Valve Port #4 Integrated Governor Primary Check Valve Supply Tank Dryer Output Compressor Port #21 Secondary Integrated Regeneration Dryer Turbo-Protection Port #22 Inlet Valve Valve Pressure Controlled (plugged) Port #1 Check Valve FIG.
  • Page 489 Installing the DRYest IMPORTANT CAUTION General 1. Park the vehicle on a level surface, apply the The vehicle installation guidelines presented in the parking brakes and always block the wheels. Application Schematic apply to all DRYest Air Dryer 2. Stop the engine when working around the installations.
  • Page 490 Installing the DRYest Testing the DRYest (con’d) Compressor Discharge Line Before placing the vehicle in service, perform General the following tests. While minimum diameters are specified, larger 1. Close all reservoir drain cocks. line diameters generally improve performance 2. Build up system air pressure to governor and life and reduce temperatures, particularly cut-out and note that the air dryer purges in severe applications.
  • Page 491 Troubleshooting Problem Cause Repair 1. Contaminants in desiccant. 1. Change desiccant cartridge. Check Water in air compressor for excessive oil passage. system 2. Leaks in air system. 2. Tighten air connections, soap connection and recheck for leaks per Testing the DRY est section. 1.
  • Page 492 Service Parts General Instructions The following parts are available for maintenance and repair. Each service kit comes with specific repair instructions. Desiccant Cartridge: 47178964 Safety Valve: 47178275 Check Valve: 47177433 Regeneration Valve: 47177434 Valve Pack with Integrated Governor: 47177343 Valve Pack w/o Integrated Governor: 47177442 Pressure Controlled Check Valve: 47110007...
  • Page 493 System Saver 636 Twin Cylinder Air Compressor for Mack E-Tech Engines Maintenance Manual MM-0204 Issued 08-02...
  • Page 495 Service Notes Before You Begin Access Product and Service Information Service Notes Service Notes Service Notes on Our Website This manual provides service and repair procedures for the Meritor WABCO System Saver Enter meritorwabco.com in your browser’s address 636 twin cylinder air compressor for Mack E-Tech box for quick access to our website.
  • Page 496 Table of Contents Section 1: Introduction Application ................1 Description Operation .
  • Page 497 Section 1 Introduction Application Description Section 1 Introduction Used on Mack engines. Figure 1.1 . The Meritor WABCO System Saver 636 twin cylinder air compressor provides and maintains Swept volume displacement: 37.4 cubic feet per air under pressure to operate devices in the air minute.
  • Page 498 Section 1 Introduction Operation 4. After unloading, the unloader pistons return the sliding leaf valves to the loaded position. The compressor is driven by the engine. The This seals the unloader ports and compression compressor’s crankshaft turns continuously while resumes. Figure 1.4 . the engine is running.
  • Page 499 Section 1 Introduction Visual Inspection A visual check of the compressor can detect minor problems (see legend for examples of these problems). This check should be part of the vehicle preventive maintenance program. Figure 1.5 . Figure 1.5 4000267c Check water ports for leakage. Check air inlet and discharge ports for leakage.
  • Page 500 Notes Copyright 2002 Maintenance Manual MM-0204 Page 4 ArvinMeritor, Inc. Issued 08-02...
  • Page 501 Section 2 Troubleshooting Use the following chart to troubleshoot the Meritor WABCO System Saver 636 twin cylinder air Section 2 Troubleshooting compressor. NOTE: If you have any questions or need additional information, please contact the Meritor WABCO Customer Service Center at 866-668-7221. Table A: Compressor Troubleshooting Guide Condition Possible Cause...
  • Page 502 Section 2 Troubleshooting Table A: Compressor Troubleshooting Guide (Continued) Condition Possible Cause Solution No air delivery Discharge line blockage Check for freeze up in the discharge line. Low air delivery Check low spots and eliminate any traps in the discharge line. Low air pressure Inspect and repair compressor discharge port and clear any line restrictions.
  • Page 503 Section 2 Troubleshooting Table A: Compressor Troubleshooting Guide (Continued) Condition Possible Cause Solution Compressor leaks Loose fitting Check fittings at compressor and engine for leaks and verify engine coolant fittings are properly torqued. Cracked coolant port Replace cylinder head. Porosity in cylinder head Replace cylinder head.
  • Page 504 Notes Copyright 2002 Maintenance Manual MM-0204 Page 8 ArvinMeritor, Inc. Issued 08-02...

  • Page 505: Figure 3.1

    Section 3 Compressor Replacement The cylinder head portion of the compressor is Compressor Removal Section 3 Compressor Replacement replaceable. The crankcase is not replaceable. 1. Set the spring (parking) brakes and block the If the crankcase is damaged or malfunctioning, wheels of the vehicle.

  • Page 506: Figure 3.2

    Section 3 Compressor Replacement 9. Start the engine and allow air system to build Figure 3.2 to governor cutout. Stop the engine. Use a soap and water solution at connection points to check for air leaks. Make any necessary repairs. 10.
  • Page 507 Section 3 Compressor Replacement Installation Figure 3.5 ® NOTE: A Torx tool is required for this procedure. Cylinder head valve components MUST be aligned in the proper position in order for the compressor to function. 1. Install the sliding leafs. The two holes in each sliding leaf must be installed over the two pins on the base of the cylinder head.
  • Page 508 Section 3 Compressor Replacement 5. Install the six hex head mounting bolts that Table B: Bolt Tightening Sequence hold the cylinder head in place. Tighten the Torque mounting bolts in sequence per Table B, Rotation following Steps 1-12. Figure 3.7 . Step Bolt (N•m)
  • Page 509 Section 3 Compressor Replacement Performance Testing Test the vehicle air system as follows: 1. Bleed the vehicle air system reservoir gauges down (apply brakes several times) to approximately 85 psig. 2. With the engine running at full governed speed (no load, no air accessories being used), the compressor should reach governor cutout pressure, then unload.
  • Page 510 Meritor WABCO Information contained in this publication was in effect at the time the publication was approved for Vehicle Control Systems printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise 3331 West Big Beaver Road, Suite 300 the information presented or discontinue the production of parts described at any time.
  • Page 511 main local global operation trouble- menu search search shooting BA-921BENDIX AIR POWER COMPRESSOR GOVERNOR UNLOADER WATER CONNECTION BALANCE COVER PORT PISTON UNLOADER AIR INLET DISCHARGE PISTON PORT PORT(2) CYLINDER HEAD CYLINDER WATER SPRING VALVE PLATE ASSY. HEAD PORT PISTON RINGS WATER VALVE PLATE PISTON...
  • Page 512 DISCHARGE AIR INLET VALVE PORT UNLOADER CLOSED DISCHARGE PORT PORT VALVE PLATE UNLOADER INLET PISTON VALVE DOWN & OPEN SEATED FIGURE 2 - BA-921 CRANKCASE COVER OPERATION The compressor is driven by the vehicle engine and func- tions continuously while the engine is in operation. Actual PISTON MOVING DOWN compression of air is controlled by the compressor unload- FIGURE 4 - OPERATIONAL-LOADED (INTAKE)
  • Page 513 AIR INLET AIR FROM DISCHARGE PORT GOVERNOR VALVE Discharge Air Inlet UNLOADER CLOSED DISCHARGE PORT Cavity Cavity PORT Unloader Piston Coolant Bore Transfer Slots VALVE PLATE Valve Plate Assembly Side of Cylinder Head UNLOADER INLET PISTON UP VALVE Air Inlet Slots &...
  • Page 514 restrictions to flow. Minimum coolant line size is 3/8" I.D. UNLOADER COOLANT IN OR OUT COVER HEAD Check coolant lines for internal clogging from rust scale. If (ONE OR OTHER NOT USED) BOLT (4) coolant lines appear suspicious, check the coolant flow and compare to the tabulated technical data present in the back of this manual.
  • Page 515 minimum required reservoir volume for the vehicle. This test record the time required to raise system pressure from is performed with the engine operating at maximum recom- 100 psi to 130 psi Run this test three times and use the mended governed speed.
  • Page 516 3. If the vehicle is equipped with air brakes, make 2. Drain the engine cooling system and the cylinder head certain to drain the air pressure from all reservoirs of the compressor. Identify and disconnect all air, water before beginning any work on the vehicle. and oil lines leading to the compressor.
  • Page 517 ¶ CYLINDER HEAD Valve Plate Assembly CRANKCASE & CYLINDER BLOCK END COVER SCREW CRANKCASE COVER END COVER CRANKCASE SCREW Item Qty. Description Item Qty. Description Item Description Unloader Cover Cap Screw O-Ring Head Gasket Unloader Cover O-Ring Intentionally Left Blank Unloader Cap Gasket Unloader Piston Inlet Reed Valve/Gasket...
  • Page 518 4. Remove the balance piston (4) and its spring (5) from 5. Make certain the unloader vent passage under the un- the cylinder head. loader cover (2) in the head is open and free of debris. 5. Remove the four hex head bolts and washers from the INSPECTION OF PARTS cylinder head.
  • Page 519 To convert foot pounds to inch pounds of torque, multiply 9. Position the unloader cover (2) on top of the balance foot pounds by 12. piston (4) making certain the stamped logo is visible. 1 Foot Pound x 12 = 12 Inch Pounds Example: 10.

  • Page 520: Torque Specification

    RPM., the time required to raise the reservoir(s) pressure TORQUE SPECIFICATIONS from 85 psi to 100 psi should not exceed 5 seconds. Dur- Assembly Torques in inch pounds (in. Ibs.) ing this test, the compressor should be checked for gasket M8x1.25-6g Cylinder Head .........
  • Page 521 COMPRESSOR TROUBLESHOOTING CHART REMEDY SYMPTOMS CAUSE 1. Compressor passes A. Restricted air intake. A. Check engine air cleaner and replace if excessive oil as evidenced necessary. Check compressor air inlet for kinks, by presence of oil at excessive bends and be certain inlet lines have the exhaust ports of minimum specified inside diameter.
  • Page 522 COMPRESSOR TROUBLESHOOTING CHART (Continued) SYMPTOMS CAUSE REMEDY 1. (Continued.) F. Compressor runs loaded F. Vehicle system leakage should not exceed indus- an excessive amount of try standards of 1 psi pressure drop per minute time. without brakes applied and 3 psi pressure drop per minute with brakes applied.
  • Page 523 COMPRESSOR TROUBLESHOOTING CHART (Continued) REMEDY SYMPTOMS CAUSE 2. (Continued.) D. Worn or burned out D. Check for proper oil pressure in the compressor. bearings. Minimum required oil pressure; 15 psi engine idling, 15 psi maximum governed engine rpm. Check for excessive oil temperature—should not exceed 240 degrees Fahrenheit.
  • Page 524 COMPRESSOR TROUBLESHOOTING CHART (Continued) REMEDY SYMPTOMS CAUSE 4. Compressor fails to A. Faulty governor or A. Test the governor for proper operation and unload. installation. inspect air lines to and from it for kinks or restrictions. Replace or repair the governor or connecting air lines B.
  • Page 525 COMPRESSOR TROUBLESHOOTING CHART (Continued) REMEDY SYMPTOMS CAUSE 7. Compressor leaks A. Improperly installed plugs A. Check torque of fittings and plugs and tighten as coolant. and coolant line fittings. necessary. Over torqued fittings and plugs can crack the head or block casting. B.
  • Page 526 16 BW2158 © Honeywell Commercial Vehicle Systems Company 4/2001. Printed in USA.
  • Page 535 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g TW-1, TW-3, TW-4, TW-5 & TW-6 CONTROL VALVES *Formerly SD-03-64 REVERSED LEVER...
  • Page 536 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g PUSH BUTTON SCREW FIGURE 3 - TW-4 FIGURE 4 - TW-6 Disconnect all air lines and remove the valve.
  • Page 537 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g with moving, rotating, leaking, heated, or electrically TW-1 TW-3 & TW-6 charged components.
  • Page 543 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g PRESSURE PROTECTION VALVES *Formerly SD-03-55 to delay filling of auxiliary reservoirs to insure a quick DESCRIPTION build-up of brake system pressure.
  • Page 544 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g 4. (PR-3 only) Build pressure up again and shut off engine. OPERATION Slowly exhaust air from the supply side of the PR-3.
  • Page 545 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g IMPORTANT! PLEASE READ component or plug unless you are certain all system pressure has been depleted.
  • Page 555 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g *Formerly SD-03-69 QR AND QR-1 QUICK RELEASE VALVES QR-1 VALVE QR VALVE Brake Valve...
  • Page 556 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g c. Install O-Ring in cover groove; install cover and tighten 1.
  • Page 557 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g E-8P & E-10P DUAL BRAKE VALVES TREADLE TREADLE MOUNTING MOUNTING PLATE...
  • Page 558 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g TP-5 TRACTOR MV-3 TRAILER CONTROL SLACK SPRING BRAKE SLACK (E-8P OR E-10P) QUICK...
  • Page 559 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g - Refer to Figure 3 OPERATION BALANCED: NO. 2 OR SECONDARY CIRCUIT When the air pressure on the delivery side of the relay pis- APPLYING: NORMAL OPERATION - NO.
  • Page 560 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g Using light oil, lubricate the treadle roller, roller pin, and hinge Refer to figures 4, 5 and 6 for item numbers referenced in pin.
  • Page 561 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g UPPER BODY UPPER BODY LOWER LOWER BODY BODY BODY BODY ATTACHING...
  • Page 562 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g FIGURE 6 - E-10P BRAKE VALVE - EXPLODED VIEW FIGURE 5 - E-8P BRAKE VALVE - EXPLODED VIEW FIGURE 6 - E-10P BRAKE VALVE - EXPLODED VIEW FIGURE 5 - E-8P BRAKE VALVE - EXPLODED VIEW...
  • Page 563 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g 11. Remove the relay piston (20), relay piston spring (21), 6.
  • Page 564 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g 2. Reconnect all air lines to the valve using the identifica- tion made during VALVE REMOVAL step 1.
  • Page 565 m a i n local global operation trouble- m e n u s e a r c h s e a r c h s h o o t i n g BW2066 © AlliedSignal Truck Brake Systems Co. 7/1999. Printed in USA.
  • Page 567 ® SR-7 SPRING BRAKE MODULATING VALVE MOUNTING STUDS (2) BALANCE PORT PARK CONTROL (FROM DASH VALVE) CONTROL PORT DELIVERY SUPPLY DELIVERY PORT EXHAUST EXHAUST PIPE PLUG (INCLUDED IN QUICK RELEASE VALVE APPLICATIONS) FIGURE 1 - EXTERIOR VIEW 2. Modulates the spring brake actuator application using DESCRIPTION the dual brake valve should a primary failure occur in The SR-7 Spring Brake Modulating Valve is used in...
  • Page 568 MAIN PISTON CONTROL PISTON DOUBLE CHECK VALVE O-RING SPRING GUIDE CHECK VALVE UPPER BODY COVER RETAINING RING O-RING PARK CONTROL PORT O-RING SPACER IN-LINE SINGLE MAIN PISTON SPRING CHECK VALVE SPRING STATIC PISTON O-RING O-RING O-RING SUPPLY PORT STATIC PISTON SPRING O-RING CHECK VALVE...
  • Page 569 FIGURE 3 - SYSTEM SCHEMATIC WITH PP-DC PARK CONTROL DC-4 FIGURE 4 - SYSTEM SCHEMATIC WITH PP-1 PARK CONTROL AND DC-4 DOUBLE CHECK VALVE...
  • Page 570 à CONTROL LINE PRESSURE à BALANCE PORT SECONDARY RESERVOIR CONSTANT PRESSURE CONTROL PORT DELIVERY TO SPRING BRAKES à à INLET / EXHAUST VALVE OPEN FIGURE 5 - CHARGING LESS THAN 107 PSI CHARGING SPRING BRAKE ACTUATORS CHARGING SPRING BRAKE ACTUATORS ABOVE BELOW 107 PSI (FIGURE 5) 107 PSI (FIGURE 6) With the air brake system charged and the parking brakes...
  • Page 571 à CONTROL LINE PRESSURE à BALANCE PORT - PRIMARY CIRCUIT PRESSURE SECONDARY RESERVOIR CONTROL PORT - SECONDARY CONSTANT PRESSURE CIRCUIT PRESSURE DELIVERY TO SPRING BRAKES à INLET / EXHAUST VALVE SEATED FIGURE 7 - NORMAL SERVICE APPLICATION NORMAL SERVICE APPLICATION (FIGURE 7) PARKING (FIGURE 8) During a service brake application, the valve remains in the Actuating the park brakes (by pulling the dash valve button...
  • Page 572 MAIN PISTON MOVES UP à CONTROL LINE PRESSURE à BALANCE PORT - LOSS OF PRIMARY CIRCUIT PRESSURE SECONDARY RESERVOIR CONTROL PORT - SECONDARY CONSTANT PRESSURE CIRCUIT PRESSURE AIR EXHAUSTS FROM SPRING BRAKES INLET VALVE SEATED FIGURE 9 - SERVICE APPLICATION LOSS OF PRIMARY CIRCUIT SERVICE APPLICATION WITH LOSS OF AIR IN SERVICE APPLICATION WITH LOSS OF AIR IN PRIMARY CIRCUIT (FIGURE 9)
  • Page 573 à NO CONTROL LINE à PRESSURE BALANCE PORT - PRIMARY CIRCUIT PRESSURE à SECONDARY RESERVOIR CONTROL PORT - CONSTANT PRESSURE SECONDARY CIRCUIT PRESSURE à DELIVERY TO SPRING BRAKES à INLET / EXHAUST VALVE OPEN FIGURE 11 - ANTI-COMPOUNDING 2. With parking control valve in “release” position, note ANTI COMPOUNDING (FIGURE 11) gauge pressure reading.
  • Page 574 SERVICING THE SR-7 10. Components with stripped threads or damaged parts should be replaced rather than repaired. IMPORTANT! PLEASE READ AND FOLLOW THESE Repairs requiring machining or welding should not INSTRUCTIONS TO AVOID PERSONAL INJURY OR be attempted unless specifically approved and DEATH.
  • Page 575 ® Bendix EC-60 ABS / ATC Controllers (Advanced Models) ® ™ See SD-13-4863 for Standard and Premium Controllers TABLE OF CONTENTS PAGE General System Information Introduction ....... . 1 Components .
  • Page 576 The ESP system only functions within the limits of Sensor physics. Clamping 90° Speed Sleeve ESP functionality mitigates potential vehicle stability Sensors incidents, but cannot prevent them in all cases. Other factors such as driving too fast for road, traffic or weather Straight Speed conditions, oversteering, an excessively high vehicle Center Sensors...
  • Page 577 Input Sensors PMVs ESP/ Blink Retarder Serial Communication Voltage Codes J1587 J1939 Off-Road Mud/Snow Relay 12 VDC 4/5/6 CHART 1 - EC-60 ADVANCED CONTROLLER FEATURES ™ ECU MOUNTING The Bendix EC-60 advanced cab-mounted controller is ® ™ not protected against moisture, and must be mounted in an environmentally protected area.
  • Page 578 Diagnostic Blink Code Switch A momentary switch that grounds the ABS Indicator Lamp output is used to place the ECU into the diagnostic blink code mode and is typically located on the vehicle’s dash panel. Optional ABS Off-Road Switch and Indicator Lamp Operation Advanced EC-60 controllers use an optional dash-...
  • Page 579 Bendix YAS-60 Yaw Rate/Lateral Acceleration 2. When full ABS operation is not available due to ® ™ presence of a DTC on the ECU. Sensor 3. If the ECU is unplugged or has no power. The Yaw Rate/Lateral Acceleration Sensor is used to provide the controller an indication of vehicle lateral 4.
  • Page 580 (If you need to know if this EC-60 controller uses a serial ™ communications message to operate the lamp, e-mail ABS System Power Application ABS@bendix.com, specifying the ECU part number, or call Status Indicators 1-800-AIR-BRAKE and speak to the Bendix TechTeam.) 2.0 2.5 3.0 (sec.) SAE J1708/J1587 Serial Communications Powered Vehicle ABS...
  • Page 581 The EC-60 controller will perform a PMV chuff test on all With the EC-60 advanced controller, at the completion of ™ installed modulators in the following order: the second round of PMV & TCV chuff tests, the controller (if configured to do so) will perform a test to cross-check the •...
  • Page 582 WARNING: The ABS off-road mode should not be The ATC/ESP dash lamp illuminates: used on normal, paved road surfaces because vehicle 1. During power up (e.g. when the vehicle is started) for stability and steerability may be reduced. The ABS approximately 2.5 seconds and turns off after the self Indicator Lamp will flash slowly to indicate to the driver test is completed, providing no diagnostic trouble codes...
  • Page 583 Bendix Smart ATC Traction Control ® ™ 5. When certain diagnostic trouble code conditions are detected. The EC-60 controller has an additional feature known as ™ Smart ATC traction control. Smart ATC traction control ™ ™ Optional ATC Mud/Snow (Off-Road) Mode monitors the accelerator pedal position (using J1939) to In some road conditions, the vehicle operator may desire help provide optimum traction and vehicle stability.
  • Page 584 IMPORTANT SAFETY INFORMATION ABOUT THE BENDIX STABILITY SYSTEM ® ® ESP May Reduce The Vehicle Speed Automatically ESP can make the vehicle decelerate automatically. ESP can slow the vehicle with or without the operator applying the brake, and even when the throttle is being applied.
  • Page 585 To Maximize The Effectiveness Of ESP: The Dynamometer Test Mode may be activated by pressing and releasing the diagnostic blink code switch five times or • Loads must be properly secured at all times. by using a hand-held or PC-based diagnostic tool. •...
  • Page 586 SYSTEM IMPACT DURING ACTIVE Brake Demand Pressure Sensor Diagnostic Trouble Code TROUBLE CODES ESP is disabled. ABS and ATC remain active. ABS PARTIAL SHUTDOWN Load Sensor Diagnostic Trouble Code Depending on which component the trouble code is ESP is disabled. ABS and ATC remain active. detected, the ABS, ATC, and ESP functions may be fully or partially disabled.
  • Page 587 Troubleshooting: General SAFE MAINTENANCE PRACTICES certain all components and systems are restored to their proper operating condition. WARNING! PLEASE READ AND FOLLOW 11. For vehicles with Antilock Traction Control (ATC), THESE INSTRUCTIONS TO AVOID PERSONAL the ATC function must be disabled (ATC indicator INJURY OR DEATH: lamp should be ON) prior to performing any vehicle When working on or around a vehicle, the following...
  • Page 588 For further information, contact either the vehicle Installation: manufacturer, Bendix or your local authorized Bendix 1. Obtain a new sensor. The sensor is not repairable in dealer. the field. 1. Position and secure the EC-60 controller in the original ™ 2.
  • Page 589 BRAKE DEMAND SENSOR CALIBRATION Diagnostics: The yaw rate sensor is only operational in conjunction with Calibration must be performed under the following conditions: an Advanced ABS ECU. No independent diagnostics can • After servicing any pressure sensor related DTCs be performed on the sensor. •...
  • Page 590 Troubleshooting: Blink Codes and Diagnostic Modes ECU DIAGNOSTICS BLINK CODES The EC-60 controller contains self-testing diagnostic Blink codes allow a technician to troubleshoot ABS ™ circuitry that continuously checks for the normal operation problems without using a hand-held or PC-based diagnostic of internal components and circuitry, as well as external tool.
  • Page 591 DIAGNOSTIC MODES Blink Code Timing The ECU responds with a sequence of blink codes. The In order to communicate with the ECU, the controller has overall blink code response from the ECU is called a several modes that the technician can select, allowing “message.”...
  • Page 592 Using blink codes, the technician may review all inactive 1st Number System Power trouble codes stored on the ECU. The ABS indicator 12 Volts lamp will display inactive diagnostic blink codes when the 2nd Number Wheel Speed Sensors diagnostic blink code switch is depressed and released two 4 Sensors times.
  • Page 593 Troubleshooting: Using Hand-Held or PC-Based Diagnostic Tools USING HAND-HELD OR PC-BASED vehicle. (See Figure 15.) If there are multiple diagnostic trouble codes on the ABS system, the RDU tool will display ™ DIAGNOSTICS one diagnostic trouble code first, then once that Diagnostic Troubleshooting and diagnostic trouble code clearing (as Trouble Code has been repaired and cleared, the next code well as reconfiguration) may also be carried out using...
  • Page 594 LED Diagnostic Trouble Codes LFT - Left ECU - ABS Controller RHT - Right SEN - Wheel Speed DRV - Drive Axle Sensor ADD - Additional MOD - Pressure Modulator STR - Steer Axle Valve VLT - Power TRC - Traction Control Example: If the Diagnostic LEDs...
  • Page 595 Active or Inactive Diagnostic Trouble Codes: INDEX How to interpret the first digit of messages received when Active or Inactive Diagnostic Trouble Code Mode Blink Go Here for Troubleshooting Tests Code Number 1 ....... . No faults (1,1) 2 .
  • Page 596 Troubleshooting Diagnostic Trouble Codes: Wheel Speed Sensors 1st. Blink Location Code Left Steer Axle Sensor Right Steer Axle Sensor Left Drive Axle Sensor Right Drive Axle Sensor Left Additional Axle Sensor Right Additional Axle Sensor 2nd. Diagnostic Blink Trouble Code Code Description Repair Information Excessive...
  • Page 597 Speed Sensor Repair Tests: 1. Take all measurements at ECU harness connector pins in order to check wire harness and sensor. Probe the connector carefully so that the terminals are not damaged. 2. Wheel speed sensor measurements should read: Location Measurement Sensor 1500 - 2500 Ohms...
  • Page 598 Troubleshooting Diagnostic Trouble Codes: Pressure Modulator Valves 1st. Blink Location Code Left Steer Axle Right Steer Axle Left Drive Axle Right Drive Axle Left Additional Axle Right Additional Axle Trailer PMV 2nd. Diagnostic Blink Trouble Code Code Description Repair Information Release Verify no continuity between PMV leads and ground.
  • Page 599 Pressure Modulator Valve Repair Tests: 1. Take all measurements at ECU harness connector pins in order to check wire harness and PMV. Probe the connector carefully so that the terminals are not damaged. 2. Pressure modulator resistance should read: Location Measurement Release to Common 4.9 to 5.5 Ohms...
  • Page 600 Troubleshooting Diagnostic Trouble Codes: Traction Control Valves 1st. Blink Location Code Drive Axle Traction Control Valve Steer Axle Traction Control Valve 2nd. Diagnostic Blink Trouble Code Code Description Repair Information TCV Solenoid Verify 7 to 19 ohms between TCV and TCV common. Verify no continuity between Shorted to TCV leads and ground.
  • Page 601 Troubleshooting Diagnostic Trouble Codes: Power Supply 1st. Blink Location Code Power Supply 2nd. Diagnostic Blink Trouble Code Code Description Repair Information Battery Voltage Measure battery voltage under load. Check vehicle battery and associated components. Too Low Check for damaged wiring. Check for damaged or corroded connectors and connections. Battery Voltage Measure battery voltage under load.
  • Page 602 Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications 1st. Blink Location Code J1939 2nd. Diagnostic Blink Trouble Code Code Description Repair Information J1939 Serial Link Loss of communications between the EC-60 controller and other devices connected ™ to the J1939 link. Check for damaged or reversed J1939 wiring. Check for corroded or damaged connectors.
  • Page 603 Troubleshooting Diagnostic Trouble Codes: 1st. Blink Location Code 2nd. Diagnostic Blink Trouble Code Code Description Repair Information ECU (02) ECU (10) ECU (11) ECU (12) ECU (13) 2-24: Check for damaged or corroded connectors. Check for damaged wiring. ECU (14) Clear trouble codes.
  • Page 604 Troubleshooting Diagnostic Trouble Codes: Miscellaneous 1st. Blink Location Code Miscellaneous 2nd. Diagnostic Blink Trouble Code Repair Information Code Description Stop Lamp Switch ECU has not detected the presence of the stop lamp switch since ignition power was applied (note that stop lamp Not Detected switch input may be applied to the EC-60 controller using either hardwire input or J1939).
  • Page 605 Miscellaneous Troubleshooting (continued) For all tests below, take all measurements at ECU Retarder Relay harness connector pins in order to check wire harness 1. Measure resistance between retarder disable output of and sensor. Probe the connector carefully so that the EC-60 controller and voltage / ground.
  • Page 606 Troubleshooting Diagnostic Trouble Codes: Steering Angle Sensor (SAS-60 sensor) ™ 1st. Blink Location Code Steering Angle Sensor 2nd. Diagnostic Blink Trouble Code Repair Information Code Description SAS has not been calibrated. Perform SAS calibration procedure. SAS Not Calibrated SAS calibration procedure is underway. SAS Calibration in Progress SAS signal incorrect.
  • Page 607 Troubleshooting Diagnostic Trouble Codes: Steering Angle Sensor (SAS-60 sensor) ™ (continued) Looking into wire harness connector Steering Angle Sensor Tests 5. Follow the prompts to perform a calibration of the Steering Angle Sensor. 1. Measure resistance between input voltage and ground at the sensor wiring harness connector.
  • Page 608 Troubleshooting Diagnostic Trouble Codes: Yaw Rate Sensor (YRS) 1st. Blink Location Code Yaw Rate Sensor 2nd. Diagnostic Blink Trouble Code Repair Information Code Description YRS Signal YRS signal incorrect. Verify proper installation of the YRS. Verify proper wiring between the ECU and the YRS. Out of Range Check YRS output.
  • Page 609 Troubleshooting Diagnostic Trouble Codes: Yaw Rate Sensor (YRS) (continued) Looking into wire harness connector Yaw Rate Sensor Tests 5. Follow the prompts to perform a calibration of the Yaw Rate Sensor. 1. Measure resistance between input voltage and ground at the sensor wiring harness connector. 6.
  • Page 610 Troubleshooting Diagnostic Trouble Codes: Lateral Acceleration Sensor (LAS) 1st. Blink Location Code Lateral Acceleration Sensor 2nd. Diagnostic Blink Trouble Code Repair Information Code Description LAS signal incorrect. Verify proper installation of the YRS/LAS. Verify proper wiring LAS Signal between the ECU and the YRS/LAS. Check YRS/LAS output. Perform LAS calibration Out of Range procedure.
  • Page 611 Troubleshooting Diagnostic Trouble Codes Brake Demand/Load Sensors 1st. Blink Location Code Brake Demand/Load Sensors 2nd. Diagnostic Blink Trouble Code Repair Information Code Description PS1 Open or Check wiring between Brake Demand Sensor (primary brake circuit) and ECU. Verify Shorted operation of pressure sensor. PS2 Open or Check wiring between Brake Demand Sensor (secondary brake circuit) and ECU.
  • Page 612 EC-60 Controller Wire Harness Connector Part ™ Numbers and Pin Assignments: ADVANCED CAB CONNECTOR CONNECTOR CONNECTOR CONNECTOR Advanced Cab Model EC-60 Controller ™ Advanced cab models utilize four AMP connectors for wire harness connections. X1 Connector Pin Assignments Pin Designation Pin Designation Pin Designation Ground...
  • Page 613 Troubleshooting: Wiring ABS/ATC WIRING WARNING: All wires must be carefully routed to avoid contact with rotating elements. Wiring must be properly ECU Wiring Harness Connectors secured approximately every 6 to 12 inches using UV The Advanced EC-60 controller is designed to interface ™...
  • Page 614 ABS Component Connector Wire Wire Seal/ Terminal Terminal Terminal Plug Lock Crimp Tool Controller Harness 927768-9 17-Way AMP 1 - 2.5 mm MCP 2.8 (X1) X1-12 & 18 967634 1718091-1 Controller Harness 18-Way AMP 968874 MCP 2.8 (X2) 8-968974-1 2.5 - 4 mm Controller Harness 15-Way AMP...
  • Page 615 Troubleshooting: Wiring (Continued) Max. Gap (Sensor to Exciter) Mounting Block .015 Inches Speed Sensor Mounting Block WS-24 speed sensor ™ 100 Tooth (typical) Speed Sensor Exciter Ring 100 Tooth Exciter Brake Drum Ring WS-24 Speed Sensor ™ 90° Speed Sensors Hub Assembly Sensor Straight Speed...
  • Page 616 Troubleshooting: Wiring Schematic FIGURE 20 - STANDARD CAB WIRING SCHEMATIC REVISED 5/31/05...
  • Page 617 Glossary ABS — Antilock Brake System. J1587 — The SAE heavy duty standard diagnostic data link. ABS Event — Impending wheel lock situation that causes the J1708 — An SAE standard which defines the hardware and ABS controller to activate the modulator valve(s). software protocol for implementing 9600 baud heavy vehicle data links.
  • Page 618 Appendix A: J1587 SID and FMI Codes and Their Bendix Blink Code Equivalents General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) - ..-..No DTCs ......1 ..1 ..No DTCs 1.
  • Page 619 General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) 53 ..4 ..Pressure Modulator Valve DTCs ..17 ..1 ..AA Right PMV REL Solenoid Shorted to Ground 66 .
  • Page 620 General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) 22 ..7 ..Miscellaneous DTCs ....12 ..11 ..Wheel Speed Sensors Reversed on an Axle 102.
  • Page 621 General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) 103..2 ..Yaw Rate Sensor DTCs ... . . 22 ..12 ..YRS Plausibility Check (Ref Yaw Rate) 103.
  • Page 622 BW2429 ©2005 Bendix Commercial Vehicle Systems LLC • All Rights Reserved • 5/05 • Printed in U.S.A. REVISED 5/31/05...
  • Page 623 ® Bendix ® M-32 ™ and M-32QR ™ AntiLock Modulators Delivery Port ™ M-32 (Casting has Modulator Supply Port ™ M-32QR 2, DEL) Modulator* (Casting has 1, SUP) Supply Port (Casting has 1, SUP) Electrical Connector Electrical * All M-32QR modulators ™...
  • Page 624 Front Axle Systems Rear Axle System Wheel Control Wheel Control Axle Control Wheel Control Service Brake Chamber To Antilock To Antilock To Antilock Controller To Antilock Controller Controller Controller M-32QR ™ ™ ™ M-32 or M-32QR ™ ™ M-32 or M-32QR Modulator Modulator Modulator...
  • Page 625 Brake Supply Delivery Brake Supply Delivery Valve Bias Port Port Valve Port Port Valve Brake Brake Chamber Chamber Supply or Hold Supply or Hold Diaphragm Diaphragm Spring Spring Exhaust Exhaust Valve Valve ™ ™ M-32 M-32QR Modulator Modulator Exhaust Exhaust Exhaust Exhaust Port...
  • Page 626 Brake Supply Delivery Brake Supply Delivery Bias Valve Port Port Valve Port Port Valve Brake Brake Chamber Chamber Supply or Hold Supply or Hold Diaphragm Diaphragm Open Open Spring Spring Exhaust Exhaust Valve Valve Open Open ™ M-32 ™ M-32QR Modulator Modulator Exhaust...
  • Page 627 Brake Supply Delivery Brake Supply Delivery Bias Valve Port Port Valve Port Port Valve Brake Brake Chamber Chamber Supply or Hold Supply or Hold Diaphragm Diaphragm Closed Spring Spring Exhaust Exhaust Valve Valve Open ™ ™ M-32 M-32QR Solenoid Solenoid Solenoid Solenoid Energized:...
  • Page 628 PREVENTIVE MAINTENANCE OPERATION TEST To properly test the function of the modulator will require two GENERAL (2) service technicians. Perform the tests and inspections presented at the 1. Park the vehicle on a level surface and block or chock prescribed intervals. If the modulator fails to function as the wheels.
  • Page 629 Source Hold Exhaust 43 Threaded (Metric) Connector Twist-Lock Connector (Bayonet Connector) ™ ™ FIGURE 10: M-32 AND M-32QR MODULATORS CONNECTOR VIEWS 2. Stop the engine and remove ignition key when size, type and strength as original equipment and working under or around the vehicle. When be designed specifically for such applications and working in the engine compartment, the engine systems.
  • Page 630 Port Designation Supply Delivery 2 Exhaust 3 Electrical Control Source Hold Exhaust 43 ™ ™ FIGURE 11: M-32 AND M-32QR MODULATORS DIN SYMBOL MODULATOR INSTALLATION TECHNICAL INFORMATION 1. Install all air line fittings and plugs, making certain thread Supply Port (from brake, relay or quick Porting sealing material does not enter the valve.
  • Page 631 Maintenance Manual MM-0112 Anti-Lock Braking System (ABS) for Trucks, Tractors and Buses Revised 07-05 For E Version ECUs 12-Volt Systems...
  • Page 632 Service Notes About This Manual ArvinMeritor’s Customer Service Center Call ArvinMeritor’s Customer Service Center at 800-535-5560. This manual contains maintenance procedures for Meritor WABCO’s Anti-Lock Braking System (ABS) for trucks, tractors and buses. Technical Electronic Library on CD Before You Begin The DriveTrain Plus™...
  • Page 633 Contents Asbestos and Non-Asbestos Fibers Appendix I — System Configuration Layouts ABS Configurations Section 1: Introduction Appendix II — Wiring Diagrams Contents ECU Connector Pin Assignments Description How ABS Works Appendix III — Additional ABS Information ABS Configuration Troubleshooting ABS Indicator Lamp Meritor WABCO ABS Valve Package Trailer ABS Indicator Lamp Reconfiguration Procedure...
  • Page 634 Asbestos and Non-Asbestos Fibers ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos fiber dust, a cancer and lung disease hazard.
  • Page 635 1 Introduction Contents In the event of a malfunction in the system, the ABS in the affected 1 Introduction wheel(s) is disabled; that wheel still has normal brakes. The other This manual contains service information for E version Meritor wheels keep the ABS function. WABCO Anti-Lock Braking System (ABS) and ABS with Automatic Two ABS indicator lamps, one for tractor and one for trailer, let Traction Control (ATC) for trucks, tractors and buses.
  • Page 636 1 Introduction ABS Configuration The ABS configuration is defined by the number of wheel-end sensors and modulator valves. There are three common ABS With the E Basic ECU, 4S/4M is the only configuration used. configurations used with E version ECUs. Figure 1.3.
  • Page 637 1 Introduction ABS Indicator Lamp The ABS indicator lamp works as follows: Ignition ON Normal Operation ABS lamp comes on at ignition System is OK. momentarily for a bulb check, then goes out. After servicing ABS ABS lamp does not go out at When vehicle is driven at speeds ignition.
  • Page 638 1 Introduction Removing a trailer with a fault will cause the ABS lamp to turn off. Remember to have the trailer with the fault repaired as soon as possible before returning it to service. Table B: Dash-mounted Trailer ABS Indicator Lamp Operation (Information for Service Technicians) Status of Trailer ABS Signal from Trailer to Tractor ECU Lamp on Vehicle Dash...
  • Page 639 1 Introduction Table B: Dash-mounted Trailer ABS Indicator Lamp Operation (Information for Service Technicians) Status of Trailer ABS Signal from Trailer to Tractor ECU Lamp on Vehicle Dash Explanation Action Single Trailer to Multiples ABS lamp is on and There was a fault in Use lamp on side of stays on when a new existence before the...
  • Page 640 1 Introduction Easy Listening Tip! Apply the brakes. To ensure the ABS valves are working — just listen! Figure 1.5. Turn on the ignition. Wait for the ABS indicator lamp to come on. Figure 1.5 NOTE: In previous versions of ABS, the valves are cycled diagonally.
  • Page 641 1 Introduction Figure 1.6 WHEEL SPEED SENSORS REAR ABS VALVE PACKAGE LAMPS WHEEL SPEED SENSORS 001 20/98 472 500 30. 0 MADE IN GERMANY FRONT ABS VALVE PACKAGE AIR LINES ELECTRICAL LINES 4S/4M CONFIGURATION — ABS ONLY 1002007e Figure 1.6 ABS Sensors The type of axle determines sensor mounting location.
  • Page 642 1 Introduction Off-Road ABS A tooth wheel is mounted at, or cast in, the hub of each sensed wheel, with a sensor installed so that its end is against the tooth On some vehicles, an off-road ABS function may be selected. wheel.
  • Page 643 1 Introduction The rear ABS valve package combines two modulator valves and TOOLBOX™ Software is a PC-based diagnostics program that can one service relay valve. Figure 1.10. display wheel speed data, test individual components, verify ® installation wiring and more. Runs in Windows , Me, 2000 or Figure 1.10 .
  • Page 644 Automatic Traction Control (ATC), Deep Snow and Mud Switch and Roll Stability Control (RSC) 2 Automatic Traction Control (ATC), Deep Snow and Mud Switch and Roll Stability Control (RSC) Figure 2.1 EXCESSIVE WHEEL SPIN ATC Automatic traction control is available as an option on all E version OPERATIONAL ABS ECUs and is standard on most.
  • Page 645 Automatic Traction Control (ATC), Deep Snow and Mud Switch and Roll Stability Control (RSC) ATC Components Figure 2.4 ATC may be used with individual ABS modulator valves, or installed with the ABS valve package. When installed with individual ABS modulator valves, an ATC solenoid valve is mounted on the frame or cross member, near the rear of the vehicle.
  • Page 646 Automatic Traction Control (ATC), Deep Snow and Mud Switch and Roll Stability Control (RSC) Roll stability control is an option designed to assist drivers in managing the conditions that result in commercial vehicle rollovers. When RSC senses conditions that may result in a rollover, it reduces engine torque, engages the engine retarder, applies enough pressure to the drive axle brakes and may modulate the trailer brakes to slow the vehicle down.
  • Page 647 Automatic Traction Control (ATC), Deep Snow and Mud Switch and Roll Stability Control (RSC) Because ATC and RSC functions share the same dash indicator RSC Components lamp, understanding how the ABS and ATC/RSC lamps work is very An additional solenoid valve is needed for RSC. The RSC valve important.
  • Page 648 3 Diagnostics, Troubleshooting and Testing General To display E version ABS faults: 3 Diagnostics, Troubleshooting and Testing Connect the computer to the vehicle: Maintenance Information Attach the cable from your computer to the J1708 to There is no regularly scheduled maintenance required for the RS232 converter box.
  • Page 649 3 Diagnostics, Troubleshooting and Testing From the pull-down menu, select Faults to bring up the Fault Blink Code: A series of blinks or flashes that describe a particular ABS system fault or condition. Information screen. Figure 3.3. Blink Code Cycle: Two sets of flashes with each set separated by a Figure 3.3 one-and-one-half second pause.
  • Page 650 3 Diagnostics, Troubleshooting and Testing Diagnostic Mode If the system displays eight quick flashes followed by a system configuration code, the clear was successful. Stored ABS faults To enter the diagnostic mode, press and hold the blink code switch have been cleared from memory. for one second, then release.
  • Page 651 3 Diagnostics, Troubleshooting and Testing Blink Code Illustrations Figure 3.5 1 Second Active Fault Hold 1-8 Flashes 1-6 Flashes Continues until Pause Pause Pause Pause ignition is turned off 1.5 s 1.5 s 1.5 s Light ON Repeat of Blink Code 1st Digit 2nd Digit ( 3 )
  • Page 652 3 Diagnostics, Troubleshooting and Testing Figure 3.6 Note: After faults are cleared and vehicle is started, ABS lamp will stay on until vehicle is driven over 4 mph (6 km/h). 3 Second Faults Cleared Hold Continues until ignition Pause Pause Pause Pause Pause...
  • Page 653 3 Diagnostics, Troubleshooting and Testing Blink Code Identification Use the following information to identify the blink code: Second Digit — First Digit (Type of Fault) Specific Location of Fault 1 No faults 1 No faults 2 ABS modulator valve 1 Right front steer axle (curb side) 3 Too much sensor gap 2 Left front steer axle (driver’s side) 4 Sensor short or open...
  • Page 654 3 Diagnostics, Troubleshooting and Testing Blink Code Troubleshooting and Repair Blink Code Action Required Reference 2-1, 2-4 Check ABS modulator valve, valve cable and connectors. Refer to Valve Tests in this section. 2-2, 2-5 Verify 4.0-9.0 ohms resistance (ABS modulator valve). 2-3, 2-6 3-1, 3-4 Adjust wheel sensor to touch tooth wheel.
  • Page 655 3 Diagnostics, Troubleshooting and Testing ® Pro-Link Plus Diagnostics Fault Information Screens Existing Faults: Use these screens to identify existing faults. The NOTE: You must use the Multiple Protocol Cartridge (MPC) and ® Pro-Link Plus screen displays a written description of the fault, Meritor WABCO applications card, version 2.0 or higher, with including the location on the vehicle where each exists.
  • Page 656 3 Diagnostics, Troubleshooting and Testing ® J1939 Datalink Verification — Pro-Link Plus ® ® The Pro-Link Plus diagnostic tool may be used to verify J1939 datalink connection. If you do not have a Pro-Link Plus, you can use the blink code switch to verify this connection.
  • Page 657 3 Diagnostics, Troubleshooting and Testing System Information Figure 3.8 TOOLBOX™ Software Display NOTE: Refer to the procedure in this section for TOOLBOX™ Software instructions, or refer to the Software Owner’s Manual, TP-99102, for complete operating instructions. The quickest method of verifying system information is the TOOLBOX™...
  • Page 658 3 Diagnostics, Troubleshooting and Testing Figure 3.12 Figure 3.10 4005306a Figure 3.12 4004007a NOTE: Trailer Brake Valve = RSC Valve Figure 3.10 RSC Data Figure 3.11 Select RSC Data from the pull down menu for RSC status information. Figure 3.13. For RSC Control Status: NA —...
  • Page 659 3 Diagnostics, Troubleshooting and Testing Component Tests RSC Trailer Valve Select Component Tests from the Tractor ABS Main Screen. A pull Select RSC Trailer Valve from the pull down menu to cycle the RSC down menu will appear. Figure 3.14. trailer valve.
  • Page 660 3 Diagnostics, Troubleshooting and Testing Lamps Figure 3.20 Select Lamps from the pull down menu to turn the tractor ABS, trailer ABS or ATC (wheel spin) indicator lamps on or off. Figure 3.18. Figure 3.18 4005314a Figure 3.20 Select Disable ATC from the pull down menu to send a command to the ECU to disable automatic traction control.
  • Page 661 3 Diagnostics, Troubleshooting and Testing Reset Memorized Component Test Screens Select Reset Memorized from the pull down menu to tell the ECU These screens help you test ABS components. Select this function to reset the memorized or “learned” components. from the Tractor ABS/ATC menu. The ECU has the ability to learn the following components: ATC ABS VALVES valve, engine datalink and retarder relay.
  • Page 662 3 Diagnostics, Troubleshooting and Testing The following definitions explain the function of each test. Table E: Definitions Component Test Function Vehicle Voltages Monitors the voltage signals powering the ECU. ABS Valves Cycles the valves, one at a time. With brake pedal applied, you should hear four short air exhausts, then one long air pressure hold.
  • Page 663 3 Diagnostics, Troubleshooting and Testing Tire Size Range Testing Components CAUTION When troubleshooting and testing the ABS system, do not For correct ABS/ATC operation with the standard ECU, front and rear damage the connector terminals. tire sizes must be within ± 14% of each other. When this tire size range is exceeded without electronically modifying the ECU, the system Voltage Check performance can be affected and the indicator lamp can illuminate.
  • Page 664 3 Diagnostics, Troubleshooting and Testing Location of Sensors Sensor Resistance On steering axles, the sensor is accessible on the in-board side of The sensor circuit resistance must be between 900 and the steering knuckle. 2000 ohms. Resistance can be measured at the sensor connector, or at the pins on the ECU connector.
  • Page 665 3 Diagnostics, Troubleshooting and Testing RSC Valve Figure 3.26 OPEN-STYLE CONNECTOR Measure resistance across the two electrical terminals on the RSC valve to ensure 7.0 to 14.0 ohms. Figure 3.28. If the resistance is greater than 14.0 ohms, clean the electrical contacts on the solenoid.
  • Page 666 3 Diagnostics, Troubleshooting and Testing Dynamometer Testing Vehicles with ATC TOOLBOX™ Software At the ABS Main Menu, select the Disable ATC icon or use the WARNING pull down menu to send the command to the ECU to disable The automatic traction control (ATC) function must be disabled the ATC.
  • Page 667 4 Component Replacement Hazard Alert Messages 4 Component Replacement Figure 4.1 SENSOR Read and observe all Warning and Caution hazard alert messages in SPRING CLIP this publication. They provide information that can help prevent serious personal injury, damage to components, or both. WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.
  • Page 668 4 Component Replacement Remove the sensor from the sensor holder. Use a twisting Wheel Speed Sensor Removal — Rear Axle motion if necessary. Do not pull on the cable. Figure 4.2. NOTE: When replacing the wheel speed sensor, the sensor spring clip must also be replaced.
  • Page 669 4 Component Replacement NOTE: After installation, there should be no gap between the ABS Modulator Valve sensor and the tooth wheel. During normal operation, a gap of Removal up to 0.04-inch (1.016 mm) is allowable. Turn the ignition switch to the OFF position. Apply the parking Push the sensor completely into the sensor spring clip until it brake.
  • Page 670 4 Component Replacement Installation If necessary, raise the vehicle off the ground. Place safety stands under the axle. CAUTION Relieve line pressure by bleeding the air from the Moisture can affect the performance of all ABS/ATC systems, appropriate supply tank. as well as the standard braking system.
  • Page 671 4 Component Replacement Checking the Installation Remove the two mounting capscrews and nuts. Remove the RSC valve. To test the ATC valve: Installation Start the vehicle. Install the RSC valve with two mounting capscrews and nuts. Fully charge the reservoirs with air. Shut off the vehicle. Apply the brakes.
  • Page 672 4 Component Replacement Front or Rear ABS Valve Package Replace the ABS valve package: Tighten the bolts to the vehicle manufacturer’s recommendation. Remove the blocks Removal and Installation — Complete Package and safety stands as necessary. Place blocks under tires to stop the vehicle from moving. Test the installation.
  • Page 673 4 Component Replacement ATC Valve on the Rear ABS Valve Package Figure 4.10 MOUNTING BOLTS Removal VALVE NOTE: If there is enough room to work, it is not necessary to TREADLE AIR LINE remove the valve package from the vehicle before replacing the ATC valve.
  • Page 674 4 Component Replacement Lubricate the replacement seal and install it in Port 2 of the Checking the Installation ATC valve. Start the vehicle. Lubricate the large replacement O-ring and install it in the Fully charge the reservoirs with air. Shut off the vehicle. groove of the relay valve supply port.
  • Page 675 5 Appendix I — System Configuration Layouts ABS Configurations 5 Appendix I — System Configuration Layouts Refer to Figure 5.1, Figure 5.2, Figure 5.3, Figure 5.4, Figure 5.5, Figure 5.6 and Figure 5.7 for system configuration layouts. Figure 5.1 Figure 5.3 STANDARD OR BASIC 4S/4M ABS 6S/6M ABS VALVE PACKAGE...
  • Page 676 5 Appendix I — System Configuration Layouts Figure 5.5 Figure 5.7 6S/4M ABS/ATC 6S/6M ABS/ATC VALVE PACKAGE VALVE PACKAGE INSTALLATION (REAR) INSTALLATION (REAR) LAMPS ATC VALVE ATC VALVE VALVE PACKAGE VALVE PACKAGE INSTALLATION (FRONT) INSTALLATION (FRONT) AIR LINES AIR LINES ELEC.
  • Page 677 6 Appendix II — Wiring Diagrams — ECU Connector Pin Assignments 6 Appendix II Wiring Diagrams Refer to Figure 6.1, Figure 6.2, Figure 6.3, Figure 6.4, Figure 6.5, Figure 6.6 and Figure 6.7 for ECU wiring diagrams. Figure 6.1 BASIC 4004024a BASIC ECU (CAB-MOUNTED) Figure 6.1...
  • Page 678 6 Appendix II — Wiring Diagrams Basic ECU (Cab-mounted) Figure 6.4 INLET RIGHT FRONT VALVE INLET INLET 16 AWG INLET ABS VALVE VALVE VALVE VALVE OUTLET VALVE INLET LEFT FRONT VALVE 16 AWG ABS VALVE OUTLET OUTLET OUTLET OUTLET VALVE VALVE VALVE VALVE...
  • Page 679 6 Appendix II — Wiring Diagrams 6S/6M Universal ECU (Cab-mounted) Figure 6.5 J1587 B J1587 B J1587 A J1587 A J1939 L J1939 L J1939 TR-WL J1939 J1939 H J1939 H BATTERY 14 AWG 15A AMP ECU+ 10 AMP 14 AWG ECU- RETARDER RETARDER...
  • Page 680 6 Appendix II — Wiring Diagrams 4S/4M Universal ECU (Cab-mounted) with RSC Figure 6.6 INLET RIGHT FRONT VALVE INLET INLET 16 AWG INLET ABS VALVE VALVE VALVE VALVE OUTLET VALVE INLET LEFT FRONT VALVE 16 AWG ABS VALVE OUTLET OUTLET OUTLET OUTLET VALVE...
  • Page 681 6 Appendix II — Wiring Diagrams Frame-mounted ECU Figure 6.7 *4 VALVES – 5 AMP +12V IGN *6 VALVES – 10 AMP 15AMP OR BATTERY 14 AWG +12V SENSOR (6S/4M AND 6S/6M ONLY) 14 AWG +12V R3RD 5 OR 10 AMP* 14 AWG OUTLET 14 AWG...
  • Page 682 7 Appendix III — Additional ABS Information — Troubleshooting 7 Appendix III Additional ABS Information Meritor WABCO ABS Valve Package This troubleshooting information is a reference tool to help identify possible malfunctions of the ABS modulator or relay valves. It does not take the place of diagnostic tests or other service instructions.
  • Page 683 7 Appendix III — Additional ABS Information Reconfiguration Procedure Figure 7.1 How to Reconfigure an ECU (E Version) Before reconfiguring the ECU, contact ArvinMeritor’s Customer Service Center at 800-535-5560 for additional information. 4004034a Figure 7.1 E version ECUs memorize the following components if they are connected at power-up: Figure 7.2 ATC valve...
  • Page 684 7 Appendix III — Additional ABS Information Manual Reconfiguration Refer to Table H and Figure 7.3 for information on manual reconfiguration. Table H Action Result Reason Turn the ignition ON. The ABS lamp displays the ABS system Stored faults cleared, no active faults configuration code: present.
  • Page 685 7 Appendix III — Additional ABS Information Figure 7.3 A system reconfiguration is illustrated below: IGNITION ON SWITCH 3 Second Hold Continues ATC Reset until Confirmation power is Pause Pause Pause Pause Pause Pause Pause turned off 1.5 s System ID System ID System ID System ID...
  • Page 686 Meritor WABCO Vehicle Control Systems 2135 West Maple Road Printed in USA Troy, MI 48084-7121 USA 800-535-5560 Copyright 2005 Revised 07-05 meritorwabco.com ArvinMeritor, Inc. Maintenance Manual MM-0112 (16579/24240)
  • Page 687 TP-0139 Revised 01-02 Engine Torque Reduction Diagnostics (J1922 Datalink Verification) for D-Version Meritor WABCO Pneumatic Technical Bulletin ECUs with Date Codes of 25/00 or Higher B. The ABS lamp will come on and blink eight WARNING times. If the lamp does not blink eight times, there are faults that must be cleared To prevent serious eye injury, always wear safe before you continue with this test.
  • Page 688 5. Send the Blink Code J1922 engine torque 2. Select the Pro-Link Engine Datalink choice, reduction command, as follows: as follows: A. Press the arrow key(s) to find the A. Step on the accelerator. Bring the engine Component Test choice. to 1000 RPM.
  • Page 689 SECTION 13: WHEELS, HUBS & TIRES CONTENTS WHEELS..............................3 WHEEL MAINTENANCE ........................3 ............................3 NSPECTION ........................3 SINGLE WHEEL EMOVAL ......................4 INGLE WHEEL NSTALLATION DUAL WHEELS............................. 4 ........................4 UTER HEEL REMOVAL ........................... 4 NNER HEEL ......................4 NNER HEEL NSTALLATION...
  • Page 690 Section 13: WHEELS, HUBS & TIRES ILLUSTRATIONS ....................3 IGURE ALUM STEEL WHEEL ARRANGEMENT ........................3 IGURE TIGHTENING SEQUENCE ....................... 6 IGURE DIAL GAUGE INSTALLATION ........................6 IGURE STUD MOUNTED WHEELS ........................7 IGURE MOUNTED WHEELS ..................... 9 IGURE WARNING REFLECTORS LOCATION ......................
  • Page 691 Section 13: WHEELS, HUBS & TIRES 1. WHEELS tightened every 100 miles (160-km) for the first 500 miles (800-km) to allow setting in of The vehicle is equipped with hub-mounted clamping surfaces. wheels as standard equipment, all studs and Wheel studs and nuts must be kept free from nuts have right-hand threads When the vehicle grease and oil.
  • Page 692 Section 13: WHEELS, HUBS & TIRES 2. Unscrew inner cap nuts NOTE 3. Remove inner wheel. stud-mounted wheels, turn nuts counterclockwise for R.H. side and clockwise 3.3 INNER WHEEL INSTALLATION for the L.H. side of vehicle. For hub-mounted wheels, turn nuts counterclockwise on both 1.
  • Page 693 Section 13: WHEELS, HUBS & TIRES 5. Buff, turning cloth frequently, until surface is CAUTION clean and shiny. Let air dry. Use power buffer to improve ease of use and gloss The actual length of thread engagement uniformity. present in an assembled wheel can not 6.

  • Page 694: Drive Axle

    Section 13: WHEELS, HUBS & TIRES When installing wheel studs to hubs, check nuts retaining the wheel stud to wheel hub and replace if they are deformed, damaged or severely corroded. Install nut (and washer where applicable) to new stud. Torque to 450 - 500 Ft- lbs (610 - 680 Nm).
  • Page 695 Section 13: WHEELS, HUBS & TIRES 7. HUB MOUNTED WHEELS 7.1 CARE OF WHEELS Wheel surfaces in contact with hubs, nuts or Check for cracks in wheels, especially around other wheels should be kept free of all rust, the fixing holes, studs, nuts and washers. If in doubt, renew.
  • Page 696 Section 13: WHEELS, HUBS & TIRES 4. Tighten lock check bearing NOTE adjustment. Replace the axle shaft using a If original bearing unit is re-fitted, and end-float new gasket. is measured at 1 mm, with hub not fully tightened to correct torque [575-626 lbs-ft 9.2 DISASSEMBLY AND REPAIR (778-849 Nm)], then the retaining clip within 1.
  • Page 697 Section 13: WHEELS, HUBS & TIRES 8. Assemble axle flange to axle using a new on the spring loaded locking pin located at the gasket. Apply sealant in stud area. After both top of the retaining bracket and remove the wheels have been assembled according to bracket.
  • Page 698 Section 13: WHEELS, HUBS & TIRES corrosion. In addition, check if spare wheel NOTE covering is in good condition and check that Check the inflation pressure of the spare tire spare tire is securely fastened in compartment. periodically to keep it ready for use. Inflate spare tire to the pressure of the tire, which has 11.
  • Page 699 Section 13: WHEELS, HUBS & TIRES consist of checking pressure while the tires have not fully cooled down which leads into under- inflated tires. Relying on the TPMS eliminate this mistake. Running tires at optimal pressure reduce tire wear, improve safety and fuel economy. NOTE It is more accurate to use the TPMS display to set the tire pressures than a pressure gauge.
  • Page 700 Section 13: WHEELS, HUBS & TIRES NOTE WARNING It is recommended that all tires on coach be of the same type. Incorrect tire pressures cause increased tire wear and adversely affect road holding of the vehicle, which may lead to loss of vehicle 11.3 WHEEL BALANCING control.
  • Page 701 Section 13: WHEELS, HUBS & TIRES 12. SPECIFICATIONS STEEL WHEELS (except inner drive axle) Wheel size............................ 9.0" X 22.5" Wheel nut torque.................... 450 - 500 lbf-ft (610 - 680 Nm) Tire size............................ 315/80 R 22.5 STEEL WHEELS (inner drive axle) Wheel size..........................
  • Page 703 WHEEL SERVICE HEAVY DUtY tRUCk | tRAILER | BUS | MANUAL MOtOR HOME IMPORtANt SAFEtY PRECAUtIONS FOR tRUCk RIMS AND WHEELS JANUARY 2009 (SUPERSEDES JANUARY 2007) IMPORtANt: Federal OSHA Regulations require all employers to make sure their employees who service rims/wheels understand the safety information contained in this manual. Do not let your employees service rims/wheels unless they are thoroughly trained and completely understand this safety information.
  • Page 704 LIMItED WARRANtY WARNING Wheels that are not properly FOR HEAVY DUtY tRUCkS, tRUCk tRAILERS, installed or maintained may not be safe. BUSES, RV and MOtORHOME WHEELS Failure to follow proper wheel installation or (Wheels with bead seat diameters measured in .5 inch maintenance practices may result in injury or increments and Alcoa tube type wheels) WARNING...
  • Page 705 table of Contents How to use ▼ Section Number Page Number ▼ this manual 1 Safety .................................2 2 Wheel Specifications ..........................3 This manual is written in a style 3 Inspection and Maintenance ........................6 called structured text. Inspect thoroughly and frequently ...........................6 Throughout the manual you Wheel alteration................................6 will find numbers which look...

  • Page 706: Safety

    Safety Safe service practices WARNING An inflated wheel and tire assembly contains enough air pressure to cause an are a matter of life explosive separation. and death. Unsafe handling or failure to follow approved mounting and demounting procedures can lead to serious injury or death. WARNING Study, understand and follow the procedures contained in this manual.

  • Page 707: Wheel Specifications

    Wheel Specifications Alcoa aluminum disc wheel mounting dimensions are consistent with SAE Recommended Practice J694 June 2007. Part numbers listed for all sizes are brushed finish (the last digit of the six-digit numerical part number is “0”). Polished finishes are indicated by changing the last digit of the part number listed to one of the following: For polished outside only, part number should end in “1.
  • Page 708 tUBELESS WHEELS (round hand holes) ENGLISH UNItS — continued Maxi- Valve Rear Rear in- Maximum Approx. Inset Item Wheel Outset stem*** Part Available Stabi- Front outer cap inner ner cap Rear outer cap wheel load 1 Wheel wt. inch- inflation inches 3 number 2 finishes 4...
  • Page 709 tUBELESS WHEELS (round hand holes) ENGLISH UNItS (MEtRIC UNItS) Approx. Maxi- Maximum Valve Rear Rear in- Wheel Outset Inset wheel load 1 Item Wheel descrip- stem*** Part Available Stabi- Front outer cap inner ner cap Rear outer cap inches 3 wt.

  • Page 710: Inspection And Maintenance

    Inspection and Maintenance Inspect thoroughly Safe operation requires thorough examination of wheels and attaching hardware, at frequent intervals, both on and off the vehicle. and frequently Wheels that have been in service need to be inspected at regular intervals to assure proper and safe perfor- mance.
  • Page 711 Heat damage WARNING Excessive heat from fire, brake malfunction, wheel bearing failure, tire failure or other sources may weaken the metal and cause the wheel/tire assembly to separate explosively. Exploding wheel/tire assembly can cause serious injury or death. WARNING Immediately and permanently remove from service any wheel that has been exposed to excessive heat.

  • Page 712: Dimension Checks

    Dimension Open side circumference check checks WARNING Wheels that have been subjected to high pressure tire and rim separation or excessive heat damage may no longer have sufficient dimension and contour to retain the tire bead while under pressure. Exploding wheel/tire assembly can cause serious injury or death. WARNING Immediately and permanently remove from service any wheel that has been exposed to high pressure tire and rim seperation or excessive heat.
  • Page 713 Dimension checks tire wear or ride problems (continued) If you experience tire wear or ride problems it may be helpful to check radial run out. Remove the wheel from the vehicle, deflate and remove the tire (see Section 4-5, for recommendations and instructions for demounting tubeless tires).
  • Page 714 Mounting area Stud hole cracks are usually caused by improper torquing (see Sections 5-8, and 6-2), excessive load- ing or insufficient mounting flange support by the hub or brake drum. Remove wheel from service. Shown below are stud hole cracks emanating from bolt hole to bolt hole. Causes are: undersized diameter of wheel support surface (see specifications on next page), support surface not flat, incorrect attachment parts (see Section 5-2) and insufficient torque (see Sections 5-8, 5-11, 6-2).
  • Page 715 Mounting area Support surface diameters (continued) Support surface should be flat to the diameter recommended per SAE J694: Number of Bolts Bolt Circle Mounting type Backup Diameter thread Size Number of Boltns Bolt Circle Mounting type Backup Diameter thread Size 11.25 inch U.S.
  • Page 716 Bolt holes If wheels are run loose, both stud located wheels and hub piloted wheels can be damaged. Look for wallowed out or elongated ball seats on stud located wheels. On hub piloted wheels look for elongated stud holes. Over torquing can lead to damaged ball seats on stud located wheels and can damage the disc surface of hub piloted wheels.
  • Page 717 Rim area Check the entire rim area for nicks, gouges and cracks. Loss of air may be caused by cracks in areas around the valve stem hole. Remove the wheel from service. 3-10  Valve hole crack Drop center crack Bead Seat area Loss of air may be caused by cracks in the bead seat areas around the rim.
  • Page 718 Rim Flange wear is not a warrantable issue. Only Dura-Flange ® Rim flange wheels have a warranty on rim flange wear against sharp edges for wear the 24 month warranty period. 3-12 Irregular wear on the surface of the rim flange is caused by abrasion from the tire chafer and sidewall.
  • Page 719 Rim flange STEP 2. After the wheel is separated from the tire, verify the circumference of the bead seat on the open side is acceptable (see Section 3-4). Check the wheel flange with the Alcoa Rim wear (continued) Flange Wear Gauge to determine if the wheels must be removed from service for excessive rim flange wear (photo 1 on previous page).
  • Page 720 Rim flange Edge Removal Procedures wear (continued) There are many tools available to remove the sharp edge on the wheel caused by rim flange wear. Here are some examples of commonly used tools: File. A file can be used very effectively to remove the edge (photo 4). Photo 4.
  • Page 721 Rim flange Die Grinder. Used with a sanding wheel, cutting stone or grinding tool, this is a version of an electric grinder. This tool is very quick and effective as well, and care must be taken wear (continued) to remove metal as uniformly as possible and not to gouge the wheel (photo 7 on previous page).
  • Page 722 Rim flange STEP 5. After the edge is removed, run the sharpness indicator gauge along the area of edge removal to check for any remaining sharpness. If the rubber is still cut, perform the steps wear (continued) again to remove the sharp edge. Always remove the minimum amount of material necessary to eliminate the sharp edge.
  • Page 723 Dura-Flange ® 1. Dura-Flange® has a 24 month warranty against wear which creates a sharp edge that would require maintenance per section 3-12. maintenance 2. Minor wear or minor pitting is not a warrantable condition. 3. Edge re-conditioning cannot be performed on Dura-Flange® wheels including those described in Section 3-12.

  • Page 724: Mounting Alcoa Wheels With Tubeless Tires

    Mounting Alcoa wheels with tubeless tires Recommendations for WARNING Damaged tires or wheels can lead to an explosive separation mounting of tires and wheels. tubeless tires Explosive separation can cause serious injury or death. WARNING Inspect tires and wheels for damage before removing from vehicle. If damage is found, the tire must be completely deflated before loosening cap nuts.

  • Page 725: Recommendations For Mounting Tubeless Tires

    Recommendations for mounting tubeless WARNING Never use a volatile or flammable material, such as ether or gasoline, as an aid to seating the tire beads on the wheel can lead to an uncontrolled pressure build- tires up in the tire and may result in an explosion. (continued) WARNING Explosive separation of the tire and wheel can occur while seating beads...
  • Page 726 Mounting tubeless CAUTION The use of liquid tire balancers or sealants in Alcoa wheels may cause extremely rapid tires (continued) corrosion of the wheel rim surface. Severely corroded wheels are unsuitable for service. Alcoa wheels corroded by the use of liquid tire CAUtION balancers or sealants will not be replaced under the Alcoa limited warranty.

  • Page 727: Rim Width To Tire Matching

    Rim width to tire Rim to tire matching chart for medium and heavy trucks. matching tire Size tire Size Approved Approved (for both radial (for both radial Rim Widths Rim Widths and bias tires) and bias tires) 8R17.5 5.25, 6.00 8R22.5 5.25, 6.00, 6.75 9R17.5...

  • Page 728: Recommendations For Demounting Tubeless Tires

    Recommendations for 1. When hand demounting tires from wheels, placing aluminum wheels on a clean wooden floor or rubber mat is recommended. Remove valve core/air from tire wheel assembly prior to removal from demounting tubeless vehicle. Additional care should be used when demounting Alcoa Dura-Bright ® surface treated wheels tires (continued) since minor nicks and scratches can not be polished out (see Section 3-15, for specific cautions, care and maintenance procedures).

  • Page 729: Wheel Installation

    Wheel Installation Recommendations for 1. Make sure all wheel cap nuts are properly torqued — check them often (see Section 5-8). If the wheel is loose, the holes will pound out (deform). If some cap nuts are tight and others are loose, the wheel may develop cracks or proper studs may break.
  • Page 730 Wheel cap nuts WARNING Use of chrome-plated cap nuts which have chrome plating on the surfaces which contact the wheel can cause reduced and inconsistent wheel clamping. this condition can cause wheels to loosen and disengage from the vehicle, causing serious injury or death.
  • Page 731 How to measure Stud standout is measured from the axle end mounting surface (the hub, for inboard mounted drums, and the drum, for outboard mounted drums) to the first complete thread at the outside end of the stud standout stud. Exposed Drum shoulder...
  • Page 732 Single and wide Disc Mate (when used) Alcoa Aluminum Wide Base Wheel base wheel, stud Drum located, ball seat Outer Cap Nut P/N 5996R or L 1-1/8" Stud mounting (See 5-2, page 26) (continued) NOtICE: Do not exceed maximum wheel load. Cus tomer must compare OEM vehicle load rating to maximum wheel load rating.
  • Page 733 Dualed wheels, stud Most vehicles have standard length studs (1.31" [1-5/16"] to 1.44" [1-7/16"] stud standout). Some vehicles use studs longer than standard (up to 1.88" [1-7/8"] standout). located, ball seat When changing types of brake drums be sure to check for excessive stud standout (greater than 1.88" mounting (contin- [1-7/8"]).
  • Page 734 Dualed wheels, steel Disc Mate wheel spacers are recommended for use with Alcoa Dura-Bright ® surface treated wheels to protect the wheel contact surfaces from marring. Disc Mate wheel spacers are placed between the inner / aluminum contact surfaces of the Dura-Bright ® wheel and the brake drum and between the steel and aluminum outer stud located wheels as shown below.
  • Page 735 tightening stud Cap nuts must be kept tight, and studs and nuts should be checked frequently. Nuts should be retorqued if necessary. At tire changes, nuts and studs should be inspected for cracks and stripped located, ball seat or damaged threads. After each wheel mounting, cap nut torque should be checked with a torque cap nuts wrench.
  • Page 736 tightening stud Stud located, ball seat mounting system. located, ball seat cap nuts (continued) It is recommended to torque to between 450 and 500 foot-pounds. If lubricated with SAE 30W oil torque should be between 350 and 400 foot-pounds. Note: when dualing steel wheels with Alcoa aluminum wheels, follow the steel wheel manufacturer’s recommendations regarding the proper torque and use of thread lubricants to mount the wheel.
  • Page 737 tightening stud After 5-50 miles of operation, torque should be rechecked, unless your documented fleet practices determine otherwise. Loosen outer cap nuts on every other stud to check the torque on inner cap nuts, then retorque located, ball seat outer cap nuts. Repeat steps on remaining studs. Check torque frequently from then on. If nuts require cap nuts frequent tightening, studs break frequently, or wheel nut seats are pounding out, hardware and mounting prac- tices should be reviewed.
  • Page 738 Single, dualed Hubs designed for steel hub piloted wheels may not have enough pilot length to locate dualed aluminum wheels. Pay close attention to pilot length, particularly when converting from steel to and wide base aluminum duals. Measure the hub pilot to make sure the hub has a minimum pilot length of 1.38-inch wheels, hub piloted or (35mm) for dualed wheels.
  • Page 739 Lubricate the hub pads or the wheel hub bore generously with a non-water-based tightening hub- lubricant. piloted mounting, two-piece flange nuts Lube here (continued) Lube Lube here here Lube here Do NOt lubricate the face of the hub, wheel face or brake drum Before installing two-piece flange nuts, lightly lubricate the stud threads and the contact surfaces between the cap nut and the washer as illustrated below with an SAE 30W oil.
  • Page 740 Incorrect assemblies WARNING Use of two-piece flange nuts on ball seat wheels, ball seat cap nuts on hub piloted wheels or single-piece flange nuts in place of 2-piece flange nuts is dangerous. Using the wrong wheel nuts can cause loss of torque, broken studs and cracked wheels, conditions which can lead to serious injury or death.

  • Page 741: Proper Torque, Wheel Identification And Valves

    Proper torque, Wheel Identification and Valves Abuse can shorten the life of a wheel. Lack of care in changing a tire, heavy pounding of the Avoid abuse wheel rim, overloading, exposure to excessive heat or hitting curbs at high speed or a sharp angle can damage wheels.
  • Page 742 Balance weights Balance weights for Alcoa wheels are available from your Alcoa Wheel Distributor. With radial tires it may be necessary to temporarily reduce the tire pressure when installing clip-on weights to allow (clip-on) clearance of the weight clamp over the rim flange. Use of coated balance weights is recommended to avoid staining and corrosion of the aluminum wheel surface.
  • Page 743 Identification Alcoa wheel identification Since 1977, all Alcoa aluminum disc wheels have been identified with a stamp that shows the wheel load rating, maximum inflation pressure, date of manufacture, part number, wheel description and DOT marking designation. Prior to June 1996, all Alcoa heavy duty truck wheels had the Alcoa identification symbol on the outside of the disc near the hand hole in line with the valve location.

  • Page 744: Osha Regulations

    OSHA Regulations OSHA Regulations Sec. 1910.177 Servicing multi-piece and single piece rim wheels. (a) Scope (1) this section applies to the servicing of multi-piece and single piece rim wheels used on large vehicles such as trucks, tractors, trailers, buses and off-road machines. It does not apply to the servicing of rim wheels used on automobiles, or on pickup trucks and vans utilizing automo- bile tires or truck tires designated “Lt”.
  • Page 745 OSHA Regulations Single piece rim wheel means the assemblage of single piece rim wheel with the tire and other components. (continued) Single piece wheel means a vehicle wheel consisting of one part, designed to hold the tire on the wheel when the tire is inflated. trajectory means any potential path or route that a rim wheel component may travel during an explosive separation, or the sudden release of the pressurized air, or an area at which an airblast from a single piece rim wheel may be released.
  • Page 746 OSHA Regulations Each restraining device or barrier shall have the capacity to withstand the maximum force that would be transferred to it during a rim wheel separation occurring at 150 (continued) percent of the maximum tire specification pressure for the type of rim wheel being serviced.
  • Page 747 OSHA Regulations (continued) (ii) When there is obvious or suspected damage to the tire or wheel components. (3) Rubber lubricant shall be applied to bead and rim mating surfaces during assembly of the wheel and inflation of the tire, unless the tire or wheel manufacturer recommends against it. (4) If a tire on a vehicle is underinflated but has more than 80% of the recommended pressure, the tire may be inflated while the rim wheel is on the vehicle provided remote control inflation equipment is used, and no employees remain in the trajectory during inflation.
  • Page 748 OSHA Regulations (continued) Appendix A - trajectory Appendix B - Ordering Information for NHtSA Charts OSHA has printed two charts entitled “Demounting and Mounting Procedures for truck/Bus tires” and “Multi-piece Rim Matching Chart, ” as part of a continuing campaign to reduce accidents among employees who service large vehicle rim wheels.

  • Page 749: Glossary Of Common Terms

    Glossary of Common terms Glossary of 1/2 DUAL SPACING - One half the distance between the two center lines of dualed wheels. The dimension is the same as the OUTSET dimension. Common terms 1-PIECE FLANGE NUT - A one-piece washer and nut combination not recommended for use on any Alcoa wheel application.
  • Page 750 Glossary of LOCK RING - The third piece of a three piece rim assembly which positions and supports the side Common terms ring to the rim base. (continued) MAXIMUM INFLATION - The highest amount of air pressure allowed, measured at normal ambient temperatures. mm - Abbreviation for millimeters.

  • Page 751: Wheel Measurement

    Wheel How to measure minimum dual spacing measurement Minimum dual spacing measurement is determined by the tire manufacturer and may be obtained from the tire manufacturer's handbook. To determine if the Alcoa aluminum dual wheel assembly has adequate minimum dual spacing for the selected tires, double the wheel outset measurement of the Alcoa wheel used.

  • Page 752: Conversion Tables

    Conversion tables Inch Fraction, Decimal and Millimeter Equivalents Chart (Up to 1 inch)
  • Page 753 Conversion Inches to Millimeters Factors Inches 25.4 Millimeters Millimeters to Inches Millimeters x 0.03937 Inches PSI to kPa 6.8948 kPa to PSI 0.145 Pounds to kilograms Pounds 0.4536 kilograms to Pounds 2.2046 Pounds Foot-pounds to Newton Meters Ft-lbs 1.35582 Newton Meters to Foot-pounds .737561 Ft-lbs...
  • Page 754 Alcoa Wheel Products 1600 Harvard Avenue Cleveland, Ohio 44105 (800) 242-9898 www.alcoawheels.com Copyright © 2009 Alcoa Wheel Products All Rights Reserved Form E37-13584 Printed in USA 05/06/30M...
  • Page 755 Alcoa Dura-Bright ® Wheel Finish Care and Maintenance New Dura-Bright® wheels shed dirt, brake dust and grease. Wash them off - no scrubbing, no special chemical solutions - and watch them shine.
  • Page 756 Alcoa Dura-Bright Wheel ® Care and Maintenance 1. Clean frequently with high-pressure water from a hose. The use of a mild Maintenance detergent will speed the cleaning process. Do not clean with abrasives, abrasive against corrosion brushes, steel wool, scouring pads or strong chemicals, such as acids or lye- based products.
  • Page 757 Rim flange wear Irregular wear on the sruface of the rim flange is caused by the chafer and side wall area of the tire working on the surface of the rim flange. Remove the wheel from service when rim flange wear is excessive. Excessive wear can be determined using an Alcoa approved wear gauge and procedures.
  • Page 758 Wheel cap nuts must be kept tight (see section 4 of the Alcoa Wheel Service Keep wheel nuts Manual, July 2002). When checking the cap nuts on dual disc wheels using the tight stud located ball seat mounting system, loosen every other outer cap nut and then check the torque of the inner cap nuts.
  • Page 759 Limited Warranty Alcoa Inc. warrants to the original purchaser from Alcoa or its authorized distributor that a new Alcoa Dura-Bright® aluminum disc heavy duty truck, truck trailer or FOR HEAVY DUTY bus wheel is free from defects in material and workmanship. Alcoa agrees, without TRUCKS, TRUCK charge, to repair or replace a Dura-Bright®...
  • Page 761 SECTION 14: STEERING CONTENTS STEERING SYSTEM..........................3 .................. 3 TEERING YSTEM ESCRIPTION ........... 4 NDEPENDENT RONT USPENSION TEERING YTEM ESCRIPTION POWER STEERING GEAR ........................5 ............................ 5 ESCRIPTION ....................6 OWER TEERING EMOVAL ..................... 6 OWER TEERING NSTALLATION BLEEDING POWER STEERING HYDRAULIC SYSTEM..............6 HYDRAULIC PRESSURE TEST......................
  • Page 762 Section 14: STEERING TORQUE SPECIFICATIONS......................15 SPECIFICATIONS ........................... 16 ILLUSTRATIONS ..................... 3 IGURE BEAM AXLE STEERING SYSTEM SETUP ......................4 IGURE IFS STEERING SYSTEM SETUP ........................5 IGURE POWER STEERING GEAR ......................5 IGURE FRONT SERVICE COMPARTMENT ........................7 IGURE FUEL PUMP REMOVAL ........................
  • Page 763 Section 14: STEERING STEERING SYSTEM These elements are: 1. Steering stabilizer (damper); 2. A vane type hydraulic pump; and I-BEAM AXLE STEERING SYSTEM 3. Hydraulic reservoir and hoses. DESCRIPTION The steering stabilizer reduces road shocks and The steering system consists of the steering vibrations in the system.
  • Page 764 Section 14: STEERING INDEPENDENT FRONT SUSPENSION STEERING SYTEM DESCRIPTION The steering system consists of the steering wheel and column assembly, a vane-type hydraulic pump, reservoir, filter, interconnecting system lines and hoses, integral power steering gear and linkage (Fig. 2). The steering linkage consists of tie rods connected to the bell crank and the steering arm at the left side of the coach, and to the idler arm and steering arm at the right side of the coach.
  • Page 765 Section 14: STEERING POWER STEERING GEAR FIGURE 4: FRONT SERVICE COMPARTMENT 18611 A torsion bar, which is pinned with the valve slide and the worm, keeps the control valve in the neutral position as long as no opposing force is FIGURE 3: POWER STEERING GEAR 14035 applied to the steering wheel.
  • Page 766 Section 14: STEERING POWER STEERING GEAR REMOVAL NOTE vehicles equipped with WARNING SERVOCOMTRONIC unit, refer supplement repair manual The steering gearbox weighs approximately 100 SERVOCOM. lbs (45 kg) dry. Exercise caution when handling. POWER STEERING HYDRAULIC PUMP 1. Put a container into place, then disconnect both the inlet and outlet hoses from the power steering gear.
  • Page 767 Section 14: STEERING • 6.1.3 Maintenance Check that the adapter and fuel pump drive axle are not damaged. Refer to the "ZF-SERVOCOM Repair Manual" and the "TRW - Power Steering Pump Service Manual" annexed to this section. WITH VOLVO D13 ENGINE 6.2.1 Description The power steering pump is a gear driven...
  • Page 768 Section 14: STEERING • To disassemble the steering column from system, Connect the hydraulic lines to the power refer to figure 8 & 9. The steering column has no steering pump. lubrication points. The lower steering column • Install the fuel pump. Torque-tighten bolts to U-joint is easily accessible through the front specification.
  • Page 769 Section 14: STEERING 1. Set the battery master switch located in the rear electrical compartment to the "OFF" position. 2. Pull the horn pad straight up gently to detach it from the steering wheel (Fig. 10). 3. Disconnect the horn wire (white) connected to the horn pad and the steering wheel harness 4-pin connector.
  • Page 770 Section 14: STEERING steering wheel column and fix harness along CAUTION the steering wheel column. To prevent the steering damper from interfering with the adjustment of turning angles, make sure its fixing bracket is at correct location on the axle (refer to "12.2 Steering Stabilizer Cylinder (Damper)).
  • Page 771 Section 14: STEERING 11.2 INSTALLATION 11. PITMAN ARM 1. Position pitman arm on sector gear shaft with 11.1 REMOVAL reference marks aligned. 1. Remove cotter pin, nut and washers from 2. Install fixing nut (Prévost #661050). Tighten drag link ball stud at pitman arm. nut to 470-570 lbf-ft (637-773 Nm).
  • Page 772 Section 14: STEERING previous heading "Pitman arm removal". CAUTION Adjust to the proper angle. 4. When adjustment is achieved, replace fixing Do not operate the pump without fluid in the nut and torque to 400-450 lbf-ft (545-610 power steering fluid reservoir. Nm).
  • Page 773 Section 14: STEERING 3. Insert dipstick in reservoir. Remove it again to check fluid level (Fig. 19). 4. Adjust level to "FULL" mark using proper dipstick side depending on fluid temperature, use "Dexron-IIE or Dexron-III" automatic transmission oil. 5. Reinsert and tighten the dipstick. FIGURE 19: POWER STEERING FLUID RESERVOIR 14018A 12.2 STEERING...
  • Page 774 Section 14: STEERING FIGURE 20: STEERING STABILIZER (DAMPER) 14042 12.4 POWER STEERING HYDRAULIC PUMP • With DDC Series 60 Engine For maintenance of the power steering hydraulic pump, refer to the "TRW - Power Steering Pump Service Manual" annexed to this section. 13.
  • Page 775 Section 14: STEERING 14. TORQUE SPECIFICATIONS FIGURE 21: DRAG LINK COMPONENTS 14038 FIGURE 22: TIE ROD END 14036 FIGURE 23: FRONT AXLE COMPONENTS 14045 PA1562...
  • Page 776 15. SPECIFICATIONS Power Steering Gear Make ..........................ZF-SERVOCOMTRONIC Model ................................8098 Supplier number ..........................8098-988-571 Prevost number ............................661044 F.E.W........................... 16,600 lbs (7 545 kg) Pressure rating ........................2,175 psi (150 Bar) Gear ratio (center) ............................22.2 : 1 Gear ratio (extremities)..........................26.2 : 1 Minimum pump flow for 1.5 hwt/sec ..................4.22 gpm (16 lpm) Power Steering Gear Make ............................ZF-SERVOCOM...
  • Page 777 Oil capacity ..........................4 US qts (3.7 liters) Supplier number ............................91410A Prevost number ............................660982 Make ............................... Nelson Muffler Element filter - Supplier number ......................83804 E Element filter - Prevost number .........................660987 Steering Stabilizer Cylinder (Damper) Make ................................Arvin Extended length..........................32.73±0.12" Collapsed length..........................20.26±0.12"...
  • Page 879 Design Operation Maintenance Inspection R R R R ZF Servocom Types 8090, 8095, 8097 and 8098 ZF Lenksysteme GmbH D-73522 Schwäbisch Gmünd Telephone (07171) 31-0 Fax (07171) 31-4396 8090 I 04/06 e...
  • Page 881 Table of Contents / Safety Note Table of contents Page Safety note ..............Design and operation .

  • Page 882: Design And Operation

    Design and Operation II. Design and operation Design The housing of the ZF Servocom steering gear houses the steering valve, the steering cylinder and a complete manual steering gear. The oil flow and the pressure required by the steering gear is supplied by an engine-driven pump. To achieve this, the oil is taken in from the oil tank and fed back to the tank via the pump and the steering gear.
  • Page 883 Design and Operation The steering valve consists of the valve rotor (C) which is carried in a needle bearing in the worm and is provided with six control grooves on the circumference, and of the valve sleeve (D) on the worm.
  • Page 884 Design and Operation 2.1 Forward steering motion to the right (piston with right-handed thread) Fig. 2 Valve rotor in operating position Steering wheel turned clockwise J Inlet slot K Inlet slot L Return slot M Return slot N Axial groove O Axial groove P Return groove Operating pressure...
  • Page 885 Design and Operation Forward steering motion to the left (piston with right-handed thread) Fig. 3 Valve rotor in operating position Steering wheel turned counter-clockwise Inlet slot Inlet slot Return slot M Return slot Axial groove Axial groove Return groove Operating pressure Return line pressure When the steering wheel is turned to the left, the piston will shift to the left (Fig.
  • Page 886 Design and Operation Operation of the hydraulic steering limitation The hydraulic steering limitation prevents a steering to the lock stops at full hydraulic pressure. It, thus, protects the pump and the steering linkage and prevents high oil temperatures. A double-acting steering limiting valve with spring-loaded valve pins (T and U) is arranged in the longitudinal direction in the piston (B).

  • Page 887: Servicing Work

    Servicing Work III. Servicing work Hints In a number of countries a safety inspection (Sicherheitsprüfung = SP) is prescribed by law for vehicles with more than 8 passenger seats or a gross vehicle weight rating in excess of 7.5 t. Attention: On vehicles not subject to the safety inspection (SP), the work detailed in Chapter III.

  • Page 888: Maintenance

    Servicing Work Maintenance Maintenance intervals: We recommend to carry out the following work within the scope of the general maintenance work.¡ 2.1 Test driving During the test drive, in particular look out for the following chacteristics: return to neutral sticking increased friction play 2.2 Checking and inspecting for external leakproofness/damages...
  • Page 889 Servicing Work For vehicles with ZF Servocom RAS (Rear Axle Steering System) Check the oil level in the straight ahead driving position. If the oil level is above the top mark, there may be a leakage in the master cylinder of the ZF Servocom RAS steering.

  • Page 890: Inspection

    Servicing Work 3 Inspection Attention: The inspection intervals depend on how the vehicle is used. Therefore, the table below distinguishes between different kinds of use which may, though, be overlapping. For the sake of increased traffic safety, we recommend to inspect the steering system in accor- dance with the inspection intervals listed below.
  • Page 891 Servicing Work - starting from date of manufacture/repair 1/94 Kind of use Ist inspection Further inspections Inspection on the vehicle Inspection on the vehicle Long-distance vehicles 600 000 km after a further Coaches with high mileages 300 000 km, ea. Buses 300 000 km every 300 000 km...
  • Page 892 Servicing Work Attention: Below is a list of all work that has to be carried out on the steering gear within the scope of the safety inspection (SP). This list represents the currently valid status and is not subject to the Updating Service. 3.5 Steering gear play (part of SP) Start the engine Rotate the steering gear to the straight ahead driving position.

  • Page 893: Oil Change And Bleeding

    Servicing Work Oil change and bleeding 4.1 Oil change 4.1.1 Draining the oil Note: An oil change is only required if steering gear units were repaired or replaced. Do not use any drained oil to refill the system. Avoid any blending of oils. 4.1.2 Draining the steering system Jack the steered axle up.
  • Page 894 Servicing Work To achieve a quick draining, open the one among the components referred to above which is lowest in the installed position. Rotate the steering gear manually from lock to lock until no more oil is draining. Unscrewed components must be screwed in again at the following tightening torques: Screw plug (55): 40 Nm (M16x1.5) 50 Nm (M18x1.5)
  • Page 895 Servicing Work 4.3 Bleeding For steering gear versions with automatic bleeding: Steering gear versions with automatic bleeding do not have any bleed scews. These steering gears automatically bleed any air remaining within the steering system. Note: Automatic bleed valves operate in the idle pressure range only; therefore, any unnecessary pres- sure build-up should be avoided.
  • Page 896 Servicing Work Versions with bleeder (57): With the engine running, open the bleeder (57) until nothing but oil is coming out (Fig. 7). Afterwards, close the bleeder again until it is oil-tight. On versions without automatic bleeding (installed position horizontal, steering output shaft in the bottom position) the topmost screw/set screw (20 and 128, respectively) can be used for bleeding.

  • Page 897: Setting The Hydraulic Steering Limitation

    Servicing Work Setting the hydraulic steering limitation A setting of the steering limitation is necessary if or when a new or repaired steering gear is fitted or new screws (20 and 128) were fitted to the automatically adjusting steering limitation or alterations to or adjustments of the front axle were carried out.
  • Page 898 Servicing Work ° ° Test temperature: 50 C ±10 S Rigid axle: Relieve the axle by jacking it up or place it on swivel plates. ¡ S Single-wheel suspension: Place the steered wheels on swivel plates. S With the engine running at idling speed, rotate the steering gear to the lock stop. Upon reaching the lock stop, overcome the return force of the steering valve by rotating the steer- ing wheel further for a short time (5 sec.
  • Page 899 Servicing Work Proceed as described above for the setting of the second lock stop. Note: At variance with the setting described above, the vehicle manufacturer may specify a different way of adjustment, e.g. by inserting a spacer to ensure that, when the steering limitation responds, a distance dimension “C”...
  • Page 900 Servicing Work Fig. 13 Initial position Sliding bushes not yet adjusted 5.2.1 Operating mode of the automatically adjusting steering limitation In the end positions, the valve piston tappets run up against the sliding bushes (20 and 128, respectively) and open the steering limiter valves (U and T, respectively). The opening of the steering limiter valve is determined by the position of the sliding bushes on the screws (20 and 128).
  • Page 901 Servicing Work For vehicles with single-wheel suspension: Place the wheels on swivel plates. Rotate the steering wheel, with and without hydraulic assistance, to the maximum lock stop. This will cause the piston to push the sliding bush on the screw (20 and 128) up to the required cut-off position (Fig.

  • Page 902: Repair Of External Leakages

    Repair of External Leakages Repair of External Leakages IV. Repair of external leakages depending on the case depending on the case Fig. 16 Valve insert (22) - Pressure relief valve Unscrew the valve insert (22) from the housing (Fig. 16) and remove O ring rests. If the pressure does not conform to the specified value or if there is any leakage, replace the complete valve insert (22).

  • Page 903: Replacing And Setting The Switch (222) And The Potentiometer

    Replacing and Setting the Switch (222) and the potentiometer (232) V. Replacing and setting the switch (222) and the potentiometer (232) Replacing the switch (222) Unscrew the switch (222) and replace it by a new one (tightening torque: 50 Nm). Starting from mid-position, rotate the steering gear to the left and to the right.
  • Page 904 Replacing and Setting the Switch (222) and the potentiometer (232) Fitting the potentiometer (232) again Check whether the steering gear is in mid-position. Fit an O ring (232.1) to the potentiometer (232). Place the deep groove of the potentiometer (232) drive on the carrier (230). Note: The slider of the potentiometer (232) being spring-loaded, it will return to its initial position when disassembled.
  • Page 905 Replacing and Setting the Switch (222) and the potentiometer (232) Setting the potentiometer (232) to steering gear mid-position Connect tools [6] and [7] and the Multimeter measuring instrument as shown in Fig. 20. Fig. 20 Tool [7] Cable colour green black Tool [6] blue...

  • Page 906: Removal And Re-Installation Of The Steering Gear

    Removal and Re-Installation of the Steering Gear VI. Removal and re-installation of the steering gear Removing the steering gear Thoroughly clean the steering gear and its immediate surroundings, in particular the pipe connections. Drain the oil as described in Chapter III.. Take a note of the pressure and return lines‘...
  • Page 907 Removing and Re-Installing the Steering Gear Re-installing the steering gear Attention: To guarantee a safe operation of the steering system, maximum cleanliness is an absolute must when re-installating all units that are part of the system. Note: To avoid malfunctions caused by foreign bodies or impurities in the oil circuit of the steering gear, the plugs in the ports of the steering gear, the oil pump, the steering cylinder, the valves etc.
  • Page 908 Removal and Re-Installation of the Steering Gear Fig. 23 mark housing mark protecting cap protecting cap steering input shaft mark mark steering drop arm sector shaft Place the steering gear into the mounting bracket and fasten it with screws. Note: Make sure that the position of the fitting bolt is correct.
  • Page 909 Removal and Re-Installation of the Steering Gear Additionally, for vehicles with adjustable driver’s workplace: Put the universal joint on without damaging the steering gear seal. Tighten the clamping screw (M10x1,25) applying a torque of 48+5 Nm. Relieve the tool, e.g. the ratchet belt (see Fig. 22), cautiously and remove it. Move the steered wheels of the vehicle to the straight ahead driving position.
  • Page 910 Removal and Re-Installation of the Steering Gear Peen the locking nut (50) as shown in Fig. 24. ¡ Fig. 24 at least 1.5 Put the drag link or the tie rod into place and tighten it. ¡ Rotate the steering gear to the left until reaching the stop. Take off the drag link or the tie rod.
  • Page 911 Removal and Re-Installation of the Steering Gear 2.14 Connect the pressure and return lines between the pump, the steering gear and the steering cylinder according to the notes taken on the removal. Fill the steering system with oil and bleed it. See Chapter III.

  • Page 912: Special Tools

    Special Tools VII. Special tools Note: The tools described below are universal tools. For special applications, special tools recom- mended by the vehicle manufacturer may therefore be necessary. Ordering ref. No. Tool [1] ZF Servotest 600 tester 7418 798 600 Tool [2] Dial with pointer 7418 798 452...
  • Page 913 Special Tools Ordering ref. No. Tool [6] Adapter cable 7418 798 567 Tool [7] Servotronictest tester 7418 798 545 Instructions on Design, Operation, Maintenance and Inspection...

  • Page 914: Troubleshooting

    Troubleshooting VIII. Troubleshooting Troubleshooting on the steering system, incl. checking the hydraulic functions Checking the play of the input shaft bearing in the steering column By moving (shaking) the steering wheel sideward to and fro, check whether there is any play. If so, replace or repair the steering column/the bearing.
  • Page 915 Troubleshooting Checking the straight ahead driving position of the steering gear and the vehicle Attention: Steering gears equipped with an automatically adjusting hydraulic steering limitation must not be rotated to the end positions if the steering linkage had been removed previously. Vehicles with single-wheel suspension: Place the wheels of the steered axle on swivel plates.
  • Page 916 Troubleshooting Checking the belt tension of the pump drive Check the tension of the drive belt. ¡ Even at maximum pump pressure, the drive belt must transmit the power without any slip. Checking the hydraulic functioning of pump and steering gear 1.6.1 Installing tool [1] (ZF Servotest tester) For the implementation of the pressure and leakage oil tests described below, it is necessary to distinguish 2 kinds (variants Œ...
  • Page 917 Troubleshooting Fit tool [1] (ZF Servotest) to variants Œ Œ Œ Œ or     in such a way that the readings can be seen from the driver’s seat. Check the oil level and bleed the steering system - see Chapter III. °...
  • Page 918 Troubleshooting 1.6.3 Checking the flow rate of the ZF pump Note: Specified values for flow rate, test pressure and test speed: see table below. Designations and operation of tool [1] (ZF Servotest power steering tester 6..): see separate operating instructions for ZF Servotest 6..
  • Page 919 Troubleshooting Minimum values Pump speed r.p.m. Minimum values Pump speed r.p.m. Instructions on Design, Operation, Maintenance and Inspection...
  • Page 920 Troubleshooting 1.6.4 Checking the hydraulic steering limitation 1.6.4.1 Manually adjustable hydraulic steering limitation Vehicles with a rigid axle: Jack the steered axle up. ¡ Vehicles with single-wheel suspension: Place the wheels of the steered axle on swivel plates. Rotate the steering wheel clockwise. When the axle stop and the lock stop, respectively, are reached, continue to rotate the steering wheel until a positive stop is reached.
  • Page 921 Troubleshooting 1.6.5 Checking the maximum pressure and the leakage oil of the steering gear For steering systems with pressure relief ahead of tool [1]: Variant Œ Œ Œ Œ Between the lock stops, insert tool [3] or approx. 15 mm thick thrust pads (Fig. 28) en- suring that the steering motion is stopped 1/2 to 3/4 steering wheel turn before reaching the axle stop/lock stop.
  • Page 922 Troubleshooting 1.6.7 Checking the steering gear play Prerequisite for the test described below: Tool [4] The transmission parts between the steering wheel and the road wheel must be free from play. Versions with leaf spring: Lock the LH front wheel (the RH front wheel if the vehicle is RH steered) in the straight ahead driving position by fitting tool [4] be- tween the wheel rim (rear and front) and the...
  • Page 923 Troubleshooting Troubleshooting Troubleshooting aid Fault Cause Remedial action Noise Air in the oil Bleed steering system ¢ Oil level too low Top up with oil Pump defective Repair © Replace © Replace © Stiff operation to either side Oil level too low Repair leakage Top up with oil ¢...
  • Page 924 Troubleshooting Fault Cause Remedial action Self-centring hampered Stiff operation of axle/ Repair ¡ axle guide components Steering gear/steering column Eliminate fitted twisting ¡ in twisted position Stiff operation of steering column Eliminate stiff operation ¡ Steering gear defective Repair © Replace ©...
  • Page 925 Troubleshooting Fault Cause Remedial action Internal malfunction Check potentiometer (see be- low) No tripping of potentiometer Replace steering gear © (232) Wrong operation of poten- Wrong setting Set potentiometer £ tiometer (232) Wrong cabling Check cabling £ Cap screws (223 and 235) loose Check and tighten £ Potentiometer (232) mounted in- Check £...

  • Page 926: Key To Numbers In Figures And Exploded Drawing

    Key to Numbers in Figures and Exploded Drawing IX. Key to numbers in figures and exploded drawing Set screw/screw 20.1 O ring 20.9 Screw Collar nut Valve insert O ring Screw O ring Valve insert Sealing ring Screw plug Bleeder Set screw/screw 128.1 O ring 128.9 Screw...
  • Page 927 Maintenance Report for ZF Servocom Steering Gears Original for duplicating Customer: ........Steering gear version: .
  • Page 928 Inspection Report for ZF Servocom Steering Gears Original for duplicating Customer: ........Steering gear version: .
  • Page 929 TRW Automotive Commercial Steering Systems Power Steering Pump Service Manual PS SERIES Die Cut...
  • Page 930 Design Features Cover rotatable in 90 degree increments • Made in the USA • Three inlet port locations Heavy duty bearing package • Two outlet port locations Lightweight aluminum housing (overall weight approx. • Three displacements available in a single housing 7.2 lbs.) size •...
  • Page 931 Hazard Warning Definitions A warning describes hazards or unsafe practices which could result in WARNING severe personal injury or death. A caution describes hazards or unsafe practices which could result in CAUTION personal injury or product or property damage. A note gives key information to make following a procedure NOTE easier or quicker.
  • Page 932 Contents Section 1 General Information Introduction ................... 6 General Design & Operation ............7 Oil Flow Illustration ............... 8 Approved Hydraulic Fluids ............8 Torque Chart ................. 9 Pump Specification Numbers ............9 Service Parts List ................ 10 Exploded View ................11 Part Number Breakdown ............
  • Page 933 Section 1 General Information Introduction ..............6 General Design & Operation ........... 7 Oil Flow Illustration ............8 Approved Hydraulic Fluids ..........8 Torque Chart ..............9 Pump Specification Numbers .......... 9 Service Parts List ............10 Exploded View ............... 11 Part Number Breakdown ..........

  • Page 934: Introduction

    Introduction The three-column format used in the Service Manual will help make it easy for you to service a power steering pump. Column 1 illustrates the procedure with photographs, column 2 gives a brief key as well as tools to be used for each procedure, and column 3 explains in detail the procedure you should follow.
  • Page 935 General Design 3 The cam ring that contains the internal contour Description of the TRW Commercial Steering that defines the amount of fluid that is output Division Power Steering Pump with each revolution of the rotor. The PS power steering pump is a balanced, positive displacement, sliding vane type, two line pump with an Two Line internal pilot operated flow control and relief valve.

  • Page 936: Oil Flow Illustration

    Oil Flow Illustration Inlet Pressure Boost Pressure Outlet Pressure Seal Drain Pilot Pressure Approved Hydraulic Fluids Fluids approved and recommended for use in TRW steering systems include: Automatic Transmission Fluid Dexron II Mack EO-K2 Engine Oil • Automatic Transmission Fluid Dextron II, III, Mercon Automatic Transmission Fluid Type "E"...

  • Page 937: Torque Chart

    Torque Chart Part Name Item # Torque Range Dry Torque Range Lubricated Bolts (4) 20-30 lbf•ft (27-41 N•M) Relief valve seat assembly 7-15 lbf•ft (9-20 N•M) Plug 15-25 lbf•ft (20-34 N•M) Pressure port (outlet) 37 lbf•ft maximum (50 N•M) Suction port (inlet) 74 lbf•ft maximum (100 N•M) Item numbers referenced are shown on the exploded view, pages 7A &...

  • Page 938: Service Parts List

    Service Parts List Item Description Part Number Input shaft (11 tooth) 086128 Input shaft (woodruf key) 086129 Seal Kit (includes following parts) SK000131 O-ring 032845 O-ring 032844 Backup ring 032846 O-ring 032843 O-ring 032842 Shaft seal 032847 Shaft seal grease...
  • Page 939 PS Series Exploded View -- Typical 12 11 Housing Spring Locating pins Boost tube O-ring O-ring Orifice Plug O-ring Bolts Spring Cover Washers O-ring Needle bearing Valve spool assembly Backup ring Shaft seal Spool Top plate Spacer Spring Cam ring Retaining ring (2) Poppet Vanes...
  • Page 940 Part Number PS 18 12 15 R 1 01 00 Family designation Displacement per revolution 18 = 18 cc (1.10 cir) 22 = 22 cc (1.34 cir) 25 = 25 cc (1.53 cir) 28 = 28 cc (1.71 cir) 32 = 32 cc (1.95 cir) 36 = 36 cc (2.20 cir) Flow control 12 = 12 lpm (3.17 gpm)

  • Page 941: Initial Installation

    Section 2 Initial Installation Installation ..............14 Maintenance Tips ............15...
  • Page 942 Initial PS Installation Install fittings to input and output ports, if fittings for this application can be preinstalled. Install a gear on the input shaft, if required for this application. Install the retaining nut, if required for this applica- tion, and torque to the manufacturer's specification. Position either a gasket or o-ring, dependent on the application, which will seal the pump face to the mounting surface.

  • Page 943: Maintenance Tips

    Maintenance Tips Never high-pressure wash or steam clean a power steering Always clean off around the reservoir filler cap before you pump while off the vehicle. Doing so could force contaminants remove it. Prevent dirt or other foreign matter from inside the pump and cause it to malfunction.

  • Page 944: Reseal & Repair

    Section 3 Reseal & Repair Disassembly ..............17 Inspection ..............23 Assembly ............... 25 Internal Damage Repair (by reference) Input Shaft Replacement ........31 Needle Bearing Removal ........32...
  • Page 945 Disassembly Preparation Stop the vehicle with wheels pointed straight ahead. Clean off all outside dirt from around fittings and hose connections before you remove the pump. Remove the pump from the vehicle and take it to a clean work surface. Clean and dry the pump before you start to disassemble it.
  • Page 946 Disassembly Tools Required Materials Required Hammer Vise Marker, solvent-proof Press Small Rod (1/8" dia. or less) Ratchet Retaining Ring Pliers Screwdriver Sockets: 1 1/4", 9/16", 7/16" Position pump in Place the pump in a vise, clamping firmly on the vise cover.
  • Page 947 Mark cover Make a mark across the housing (1) and cover (21) orientation to make reassembly easier. Marker, solvent proof Remove bolts Prepare for fluid drainage and remove 4 bolts (4), and washers (5). 9/16" Socket Remove housing Separate the housing (1) from the cover (21) using a twisting motion.
  • Page 948 Remove top plate, 10. Hold the cam ring (14) in place, and remove the top 0-ring and backup plate (13). ring Remove the o-ring (11) and Teflon backup ring (12) from the top plate. Discard the o-ring and Teflon backup ring. Remove cam ring, 11.
  • Page 949 Remove o-rings 15. Remove o-rings (19 & 20) from the cover, and discard the o-rings. Remove retaining 16. Turn the cover over and remove the large retaining ring ring (27). Don't deform the cover with excessive clamping force. Retaining ring pliers Press out shaft &...
  • Page 950 Remove shaft seal 20. Remove the shaft seal (23) being careful not to damage the bore. Discard the shaft seal. Hammer Damage to the bore could cause CAUTION Screwdriver leakage. Inspect needle 21. Make sure all needles roll freely in the needle bearing bearing (22).

  • Page 951: Inspection

    Inspection Make sure all sealing surfaces and seal cavities are free from nicks and corrosion. Any nicked or corroded surface requires part replacement to ensure proper sealing. Wash all parts in clean, OSHA approved solvent. Air blow them dry only. Because they are flammable, be extremely careful when using any solvents.
  • Page 952 Inspect rotor and Inspect the rotor (16) and vanes (15) for abnormal vanes wear or damage. There will be normal polish marks on both the top and bottom. The vanes need to be free to slide both up and down and in and out. If vanes are removed for inspection, make sure to reinstall them with the rounded edge out.

  • Page 953: Assembly

    Assembly Preparation Wash all parts in clean, OSHA approved solvent. Air blow-dry them only. Because they are flammable, be extremely careful when using any solvents. Even a small WARNING explosion or fire could cause injury or death. WARNING Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements.
  • Page 954 Insert input shaft Insert the input shaft (28), small splined end first, into cover into the cover. Don't allow the splines to contact the shaft seal (23). Engage the shaft into the seal by hand until the ball bearing contacts the cover. Press 7/8""...
  • Page 955 Install bottom Notice there is a bar in one of the four cutouts in the Pockets plate cover. This bar should be covered by the bottom plate when it is installed. Install the bottom plate (17) with the pockets facing up. The bottom plate is installed correctly if the: •...
  • Page 956 Install backup ring 14. Install the backup ring (12) on the top plate. Seat it at the bottom of the groove. Install o-ring 15. Install a new o-ring (11) on the top plate without allowing it to roll. Seat it at the top of the groove. Grease o-ring and 16.
  • Page 957 Install housing 19. Place the housing (1) over the cover assembly. Make sure the orientation is correct by matching the original markings made on the housing and cover during disassembly. Install bolts and 20. Install the bolts (4) and washers (5). Thread all four washers bolts into the cover evenly, and torque alternately to 25 lbf•ft.
  • Page 958 Install spring 24. Install the spring (7). Install o-ring 25. Install a new o-ring (8) onto the plug (9). Install plug & 26. Lightly grease the o-ring (8) and plug (9) threads. o-ring Install into housing, and torque to 20 lbf•ft. (27 N•M) 1 1/4"...

  • Page 959: Input Shaft Replacement

    Input Shaft Replacement Tools Required Press Retaining ring pliers 7/8" Deep well socket Remove retaining Remove the retaining ring (25), nearest the engine ring drive end, from the shaft. Remove woodruf key, if equipped. Retaining ring pliers Press shaft from Press the input shaft (28) from the ball bearing (26) bearing applying pressure to the engine drive end of the...

  • Page 960: Needle Bearing Removal

    Needle Bearing Removal Tools Required Press 11/16" and 7/8" Deep well sockets Press out needle Place the cover in a press with the flange side bearing down. Press the needle bearing (22) out of the cover. Press 11/16" Socket or other suitable tool Inspect needle Make sure all needles roll freely in the needle...
  • Page 961 Section 4 Reinstallation Reinstallation ..............34 Filling and Air Bleeding the System ....... 35 Maintenance Tips ............36...

  • Page 962: Reinstallation

    Reinstallation Reinstall any fittings removed prior to disassembly. Reinstall the gear on the input shaft if one was removed prior to disassembly. Reinstall the retaining nut, if one was removed prior to disassembly, and torque to manufacturer's specification. Position the new gasket or o-ring (whichever was removed) which will seal the pump face to the mounting surface.
  • Page 963 Filling & Air Bleeding the TRW System (TAS Gear) Tools Required Materials Required ⁄ Socket Hydraulic fluid " Lbf•in. Torque wrench Make sure poppets are set cor CAUTION rectly before beginning this procedure. Run engine for 10 Fill the reservoir nearly full. Do not steer. Start and seconds, turn off run the engine for 10 seconds, then shut it off.

  • Page 964: Maintenance Tips

    Maintenance Tips Never high-pressure wash or steam clean a power steering Always clean off around the reservoir filler cap before you pump while off the vehicle. Doing so could force contaminants remove it. Prevent dirt or other foreign matter from inside the pump and cause it to malfunction.

  • Page 965: Glossary

    Section 5 Glossary Glossary ................. 39...

  • Page 966: Glossary

    Glossary Abnormal Wear Erosion Output Port Any wear other than normal "polish Gradual wearing away or deteriorat- Opening in the pump through which marks" made by the spinning motion ing. fluid is forced to the steering gear. of the rotor and vanes. Abnormal (Pressure port).
  • Page 968 TRW Automotive Commercial Steering Systems 800 Heath Street Lafayette, IN 47904 Tel 765.423.5377 Fax 765.429.1868 www.trucksteering.com © TRW Inc. 2006 TRW1312 Rev. 3/06...
  • Page 969 SECTION 16: SUSPENSION CONTENTS DESCRIPTION ............................5 I-BEAM AXLE FRONT SUSPENSION ....................5 ............................ 5 PRINGS 2.1.1 Inspection ..........................5 2.1.2 Removal ..........................6 2.1.3 Installation ..........................6 .......................... 6 HOCK BSORBERS 2.2.1 Inspection ..........................7 2.2.2 Removal ..........................7 2.2.3 Installation ..........................
  • Page 970 Section 16: SUSPENSION 3.15.1 Visual Inspection ........................21 3.15.2 Play Measurement ........................ 21 3.16 F ........................21 RONT LIGNMENT 3.16.1 Alignment Terminology......................22 3.16.2 Front End Inspection ......................22 3.16.3 Front Wheel Camber ......................23 3.16.4 Front Wheel Toe-In ....................... 23 3.16.5 Front Axle Caster ........................

  • Page 971: Figure

    Section 16: SUSPENSION ................... 39 ELLOWS ONTROL OLENOID ALVES 9.3.1 Removal and installation .......................39 HIGH-BUOY SYSTEM........................39 10.1 P ......................39 RINCIPLES PERATION 10.2 M ..........................40 AINTENANCE 10.3 H – P .................. 40 RESSURE EGULATING ALVE 10.3.1 Adjustment..........................40 10.3.2 Disassembly ..........................
  • Page 972 Section 16: SUSPENSION ....................... 22 IGURE STEERING LINKAGE MEASURE ....................24 IGURE FRONT END ALIGNMENT DIAGRAM ..........................25 IGURE AIR SPRINGS ....................26 IGURE AIR SPRING AND SHOCK ABSORBER ........................27 IGURE SHOCK ABSORBER ) ....................28 IGURE SWAY BAR FRONT SUSPENSION ) ....................
  • Page 973 Section 16: SUSPENSION DESCRIPTION The vehicle is provided with an air suspension system. The system consists of air springs, height control valves, radius rods, sway bars, tripod and shock absorbers (Fig. 1, 2, 11, 36, 37 and 38). The system operation is fully automatic and maintains a constant vehicle height regardless of load, or load distribution.
  • Page 974 Section 16: SUSPENSION permissible. Repair or replace defective 5. Remove the air spring upper nut, and then parts. the two lower nuts. Remove air spring. NOTE 2.1.3 Installation If air spring is removed from vehicle, bellows 1. Compress air spring as necessary, then can be lightly inflated and submerged in water to detect any leakage.
  • Page 975 Section 16: SUSPENSION designed to permit a very slight seepage to are eye-type mountings. The front axle is provided with two shock absorbers (Fig. 1, 2, lubricate the rod. Units that leak should be replaced. and 4). 4. Visually check shock for dents that could Shock absorbers are non-adjustable and non- cause the shock to bind.
  • Page 976 Section 16: SUSPENSION 2.2.3 Installation 1. Ensure that the shock absorber mounting pins are tight and that the threads are not stripped. 2. Install new rubber mounting bushings on shock absorbers (upper and lower). 3. Place the inner washers (with washer convex side facing the shock absorber rubber bushing) on each shock absorber pin (Fig.
  • Page 977 Section 16: SUSPENSION FIGURE 8: RADIUS ROD BUSHING INSTALLATION 16012 FIGURE 7: RADIUS ROD BUSHING REMOVAL 16011 2.3.5 Installation 2. Place a flat steel disc, slightly smaller than the outside diameter of the bushing (Fig. 7). 1. Lightly spray the radius rod support with water.
  • Page 978 Section 16: SUSPENSION CAUTION It is extremely important upon reconnection of the rods that the proper clearance height between the axle and body be maintained. Otherwise, the rubber bushings in radius rod ends will become preloaded, thus reducing their life span. SWAY BAR A sway bar is provided on the front axle to increase vehicle stability.
  • Page 979 Section 16: SUSPENSION FIGURE 11: SUSPENSION AND STEERING LINKAGE 16125 Turning Angle CAUTION The maximum turning angle is set mechanically through the two steering stop screws installed If clamps are not correctly installed, they can on the swivel assembly. The turning angle (58° interfere with other parts.
  • Page 980 Section 16 : SUSPENSION FIGURE 12: LOCATION OF CLAMPS 16168 FIGURE 13: CLAMP POSITIONING 16169 FIGURE 14: CLAMP POSITIONING 16170 PA1562...
  • Page 981 Section 16: SUSPENSION FIGURE 15: CLAMP POSITIONING 16171 FIGURE 17: PITMAN ARM ALIGNMENT 14057 4. Install drag link to pitman arm and adjust opposite end of drag link to fit mounting stud hole in bell crank. 5. Install tie rods, and then adjust toe-in as per "Front End Alignment"...
  • Page 982 Section 16 : SUSPENSION 4. Check the radial position of the pitman arm may draw studs too far into holes and dust cover in relation to the sector shaft prior to parts may become damaged which can result in removal of pitman arm. component failure.
  • Page 983 Section 16: SUSPENSION Bell crank: Disconnect drag link, tie rod and relay rod from bell crank by removing cotter pins, stud nuts and washers from ball studs. Separate socket assemblies from the bell crank. Idler arm: Remove cotter pins, nuts and washers from ball studs connecting relay rod and tie rod to idler arm.
  • Page 984 Section 16 : SUSPENSION FIGURE 21: BELL CRANK AND IDLER ARM BALL JOINT 16109 RELAY ROD 3. Remove stud nuts and washers then remove studs. Relay rod ends are equipped with lubrication fittings and should be lubricated as directed in 4.
  • Page 985 Section 16: SUSPENSION Tie rod end sockets require no maintenance 3.10 STEERING ARMS other than periodic lubrication and inspection to The left and right wheel steering arms are see that ball studs are tight. Replace socket secured to a swivel at one end and to a tie rod at ends when there is excessive up and down the other end.
  • Page 986 Section 16 : SUSPENSION 1. Drag Link Ends: Lubricate at two fittings, 4. Swivel Assembly: Refer to DANA SPICER one at each end of link, every 6,250 miles MAINTENANCE MANUAL NDS AXLES (10 000 km) with good quality lithium-base Lubrication and Maintenance" annexed at grease NLGI No.
  • Page 987 Section 16: SUSPENSION 3.12 BALL JOINTS FIGURE 23: BALL JOINTS LOCATION 16137 When the following characteristics are noted, 3.13 LOWER AND UPPER A-ARM BALL the joint is to be changed: JOINT Free play; The assembly work may be done only by a Radial cracking of the external sheet-metal recognized specialized workshop.
  • Page 988 Section 16: SUSPENSION 3.13.3 Assembly Execute assembly of the new joint parts in the following sequence: 1. Complete moistening of the contact surface between housing bore and ball pin through application of the grease. NOTE Apply grease, only in the case of repair kit (Prévost # 611114)).
  • Page 989 Section 16: SUSPENSION 3. Faultlessly apply grease by mechanical means to bracket-outer core and ball-inner cone. Insert bracket outer cone in fixture with distance ring and then use press tool to apply pressure to press mount with ball- inner cone. FIGURE 28: UPPER A-ARM CENTRAL BALL JOINT 16116 3.16 FRONT END ALIGNMENT...

  • Page 990: Front Axle

    Section 16: SUSPENSION FIGURE 29: STEERING LINKAGE MEASURE 16130 3.16.1 Alignment Terminology 3.16.2 Front End Inspection Wheel Camber Before checking front end alignment, make the following inspection: The amount the wheels are inclined from the 1. Check that the vehicle is at normal ride vertical plane (A, Fig.
  • Page 991 Section 16: SUSPENSION 3.16.3 Front Wheel Camber 2. Hoist the front of the vehicle and spin the wheels marking the centerline of the tire Positive camber is the outward inclination of the treads. wheels at the top, negative or reverse camber is the inward inclination of the wheels at the top.
  • Page 992 Section 16: SUSPENSION FIGURE 30: FRONT END ALIGNMENT DIAGRAM 16134 ALIGNMENT SPECS (See Figure 30) Minimal Nominal Maximal WHEEL CAMBER 0.150 0.35 KING PIN INCLINATION 8° (not adjustable) CASTER 2.35 2.85 TOTAL TOE 0.06 0.08 0.10 PA1562...
  • Page 993 Section 16: SUSPENSION 3.16.6 Major Damage WARNING If the suspension has sustained major damage, it may be necessary to shim the bell crank and To prevent personal injury, do not apply more the idler arm to avoid the bump steer or roll than 10 psi (69 kPa) air pressure to the steer.
  • Page 994 Section 16: SUSPENSION FIGURE 32: AIR SPRING AND SHOCK ABSORBER 16145 1. Compress air spring as necessary, then 6. Check operation of bellows and with the aligning studs with their holes, position air primary air system at normal operating spring between both the lower and upper pressure (95 - 125 psi (655 - 860 kPa), coat supports.
  • Page 995 Section 16: SUSPENSION 3.18.2 Shock Absorber Installation CAUTION 1. Check that the shock absorber mounting pin torque is proper (350-400 lbf-ft (475-545 When a shock absorber is found defective, Nm)). Ensure that the stud is clean and not always replace with a new set on affected stripped (upper side).
  • Page 996 Section 16: SUSPENSION FIGURE 34: SWAY BAR (FRONT SUSPENSION) 16138B FIGURE 35: SWAY BAR (REAR SUSPENSION) 16144 PA1562...
  • Page 997 Section 16: SUSPENSION REAR SUSPENSION For a description of all these systems, refer to the appropriate heading in this section. FIGURE 36: REAR SUSPENSION COMPONENTS 16167 FIGURE 37: DETAILS OF REAR SUSPENSION 16106 FIGURE 38: TAG AXLE SUSPENSION 16107 PA1562...
  • Page 998 Section 16: SUSPENSION AIR SPRINGS 4.1.2 Removal NOTE The air springs are made from a special compound rubber molded to the proper contour Suspension air springs (drive and tag axles) and dimensions. The entire vertical load of the can be removed without removing the entire vehicle is supported by these springs.
  • Page 999 Section 16: SUSPENSION shock absorber becomes inoperative, complete NOTE unit must be replaced. To facilitate air spring installation, compress it manually then put a piece of tape over the air CAUTION line threaded fitting. This prevents air from getting back into the bag and keeps it When a shock absorber is found defective, compressed, thus enabling to place the bag in always replace with a new set on affected...
  • Page 1000 Section 16: SUSPENSION 6. Visually inspect the shock mountings and 4. Install the shock absorber eyes over the vehicle mounting for: mounting pins, then the outer washers (with washer convex side facing the shock a) Broken mounts; absorber rubber bushing) on each shock b) Extreme bushing wear;...
  • Page 1001 Section 16: SUSPENSION 4.3.1 Inspection 3. Using an arbor press or a suitable driving tool, press or drive the old bushing out of the The following instructions apply to all radius rods rod and discard the bushing. used on this vehicle: CAUTION 1.
  • Page 1002 Section 16: SUSPENSION 4.3.5 Installation connected to the front air tank support. These connections allow the valves to apportion air 1. Lightly spray the radius rod support with pressure in the springs to the vehicle load, water. Place the radius rod end over the maintaining normal ride height.
  • Page 1003 Section 16: SUSPENSION NOTE The measurement should be taken from underneath the upper air spring support on subframe to top of the lower air spring support on axle (refer to figure 46 for more details). 2. Loosen the clamp on the height control valve rubber coupling and bring it up or down (Fig.
  • Page 1004 Section 16: SUSPENSION Neutral Position suspension. An air system schematic diagram is annexed at the end of this section for better When vehicle body reaches the normal ride understanding of the system. height, the height control valve overtravel lever reaches the "neutral" position and keeps both The air coming from the air dryer is first directed to the wet air tank, then to the primary (for the the supply and exhaust ports closed to ensure...
  • Page 1005 Section 16: SUSPENSION FIGURE 49: IFS AIR TANKS LOCATION 24034 FIGURE 50: I-BEAM FRONT SUSPENSION AIR TANKS LOCATION 24035 PA1562...
  • Page 1006 Section 16: SUSPENSION 7.1.5 Expansion Air Tank Two expansion tanks will be installed in front wheelhousing if the IFS was chosen as an option. These air tanks are located behind secondary and accessory air tank. Also, six expansion tanks are located near rear air springs (Fig.
  • Page 1007 Section 16: SUSPENSION FRONT KNEELING SYSTEM module to cut off the bellows control solenoid valve, about 1" (25 mm) below normal ride The kneeling system is used to lower front of height. The final height adjustment is achieved vehicle. This allows passengers to board the by the height control valve.
  • Page 1008 Section 16: SUSPENSION 2. Disassemble regulator in accordance with the item numbers on the exploded view. The air coming from the control valve flows through double shuttle valves, to supply air 10.3.3 Cleaning springs. The double shuttle valves prevent height control valves from releasing air from air 1.
  • Page 1009 Section 16: SUSPENSION 2. Assemble the regulator as shown on the Down: exploded view. The control valve, on the L.H. control panel, cuts off air supply, so air is released from air springs. Torque Table A relay valve prevents height control valves from Item Torque in lbf-inch (Nm) supplying air springs.
  • Page 1010 Section 16: SUSPENSION 13. PARTS SPECIFICATIONS Drive and tag axle shock absorbers Make ............Sachs Front suspension and tag axle air springs Color ............Black Make......Goodyear Tire and Rubber Type ..........N45X225HA Model............1200 Ext. Diam..........75 mm Type ........... Mae West Collapsed length ......
  • Page 1011 Section 16: SUSPENSION Valve (3 way, 2 positions) Sway bar bushing (Front Suspension) Type ............. N/C Make ............Prévost Supplier number....... 411-C-456235W Prévost number ........630020 Prévost number........641357 Sway bar link Type ............. N/O Make ........Tennaco Automotive Supplier number......411-D-456236X Supplier number ........934400 Prévost number........641356 Prévost number ........630230 Radius rod bushing...
  • Page 1013 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers Index: 1) Inspection 2) Misting 3) Leakage 4) Noise – Rubber Bushings 5) Noise – Scratching Metal Dust Cover 6) Damping Performance 1) Inspection It is recommended to inspect Sachs shocks visually during regular maintenance schedules, however at least: linehaul applications: every 100,000 miles vocational applications: every 50,000 miles...
  • Page 1014 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 2) “Misting“ Appearance might be deceptive. A certain degree of vapor is normal and actually necessary for lubrication of the rod seal. The inspection must not be conducted after drive in wet weather or a vehicle wash. Shock needs to be free from water.
  • Page 1015 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 3) „Leaker“ OBSERVATION A shock is considered a „leaker“, if • the reservoir tube (smaller diameter) is largely covered with oil • finger gets wet, when touching shock (see „Misting“) • after above finger test, shock exhibits a glossy film of oil and/or dirt, or an oil droplet forms on reservoir tube...
  • Page 1016 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 4) Noise - Rubber Bushings Noise emitted during operation is not necessarily caused by defective shocks. Therefore in case of noise issues: Check all relevant suspension and axle components, e.g. rubber mounts, springs, jounce stops, bushings, steering.
  • Page 1017 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 5) Noise - Scratching Metal Dust Cover Noise emitted during operation is not necessarily caused by defective shocks. Therefore in case of noise issues: Check all relevant suspension and axle components, e.g. rubber mounts, springs, jounce stops, bushings, steering.
  • Page 1018 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 6) Degradation of Damping Performance It is impossible to verify the correct damping characteristic of a shock absorber without a dynamometer. In the field, the following, more practical test can help to identify a shock, which is suspected to have failed: 1) Conduct test few minutes after operating the vehicle 2) Touch a metal element of the chassis to determine a reference temperature...
  • Page 1019 SECTION 18: BODY CONTENTS VEHICLE EXTERIOR VIEW ..................5 VEHICLE STRUCTURE.................... 6 VEHICLE EXTERIOR MAINTENANCE ..............6 ......................... 6 ORROSION REVENTION ....................7 REVENTIVE AINTENANCE CHEDULE ......................7 NHIBITOR PPLICATION COMMON FIBERGLASS REPAIR PROCEDURE ..........12 ....................12 EPAIR SING IBERGLASS LOTH ....................
  • Page 1020 Section 18: BODY 8.1.1 Fixed Window Removal......................35 8.1.2 Preparation of Structure and Installation of Window............. 36 ......................36 MERGENCY INDOWS 8.2.1 Emergency Exit Release Bar ....................37 8.2.2 Emergency Exit Window Adjustment ..................37 8.2.3 Emergency Exit Window Replacement ................. 37 ........................
  • Page 1021 Section 18: BODY VEHICLE JACKING POINTS ................68 17.1 ......................... 69 YDRAULIC TOWING THE VEHICLE ..................70 18.1 ........................70 IFTING OWING 18.2 ......................71 OWING ITHOUT IFTING SPECIFICATIONS ....................72 ILLUSTRATIONS ......................5 IGURE COACHES EXTERIOR VIEW ........................13 IGURE FIBERGLASS REPAIR ........................
  • Page 1022 Section 18: BODY ......................59 IGURE SEAT PEDESTAL ASSEMBLY ..............61 IGURE TARABUS FLOOR COVERING ADHESIVE APPLICATION ....................61 IGURE APPLICATION OF SIKA GRAY ......................69 IGURE JACKING POINTS ON FRAME ......................69 IGURE FRONT END JACKING POINTS ......................69 IGURE REAR END JACKING POINTS ..................
  • Page 1023 Section 18: BODY VEHICLE EXTERIOR VIEW FIGURE 1: X3 COACHES EXTERIOR VIEW 18606 Engine air intake 17. Diesel Particulate Filter (DPF) compartment 2. Engine compartment curb-side door access door 3. Hinged rear fender 4. Baggage compartment 5. Fuel filler door 6.
  • Page 1024 Section 18: BODY underside of the vehicle is sprayed with a heavy VEHICLE STRUCTURE application of asphalt base undercoating. The body of the X3 vehicles is an integral The operating environment the vehicle is structure made of 14, 16 and 18 gauge welded subjected to will largely influence the amount of and braced high tensile steel and stainless steel dirt and corrosion that will accumulate over a...
  • Page 1025 Section 18: BODY PREVENTIVE MAINTENANCE SCHEDULE NOTE TECTYL 185 GW rust inhibitor may have been applied on your vehicle underbody as an option, if this is the case, follow this procedure thoroughly. For future application of product, refer to paragraph 3.3 in this section.
  • Page 1026 Section 18: BODY 1.0 Wash both wheelhousing mechanical parts before A water-hose nozzle is recommended. Water may be hot masking. to reduce washing time especially during winter. If parts are soiled with oil, clean using R1KG21. Avoid rubber parts. 2.0 Dry all water sprayed parts. Surface temperature Air pressure system may be used, refer to annex 1 for and dew point must be respected before applying surface temperature and dew point.
  • Page 1027 Section 18: BODY 3.3 Front wheelhousing (Entire braking system) 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) 4.1 Rear wheelhousing (Entire braking system) PA1562...
  • Page 1028 Section 18: BODY 4.2 Rear wheelhousing (Entire braking system) 4.3 Rear wheelhousing 5.0 Close off wheelhousing using masking paper. Prevent rust inhibitor from coming in contact with paint. To close off wheelhousing, a polythene sheet may be used. 6.0 Apply TECTYL 185 GW black rust inhibitor onto A spray gun and pumping system are required to apply wheelhousing mechanical parts.
  • Page 1029 Section 18: BODY DEW POINT Relative Humidity (%) 20 30 40 50 60 70 80 90 100 Temp (c) -16 -11 -8 -5 -3 -1 0 -15 -10 -7 -5 -3 -1 1 -14 -10 -6 -4 -1 0 -13 -9 -5 -3 -1 1 -13 -8 -5 -2 0 -11 -7 -4 -1 1 -11 -8 -3 0...
  • Page 1030 Section 18: BODY COMMON FIBERGLASS REPAIR NOTE PROCEDURE Roughening the surface improves adhesion of All repairs to fiberglass parts consist of filling the resin. damaged area with fiberglass cloth and resin or If part is warped from original shape, use clam- strand fiberglass and resin.
  • Page 1031 Section 18: BODY Preheat the area to be repaired using heat lamps. Mix desired quantities of resin and hardener according manufacturer's instructions. Add powdered fiberglass strand into mixture to thicken it into a putty state. NOTE If repair is made on a vertical surface, adding powdered filler material to mixture will reduce tendency of hot resin to flow or run.
  • Page 1032 Section 18: BODY During the first 30 days: • Do not use a commercial bus wash. Stiff brushes or sponges could mar the finish and damage the surface. Wash the vehicle by hand only and with cool water and a very mild bus wash solution.
  • Page 1033 Section 18: BODY If you sand through to metal surface, first prime 5.3.1 Safety with Standox “Etch Primer (ST-11858)” then with Care should be exercised in storing, handling, Standox “Non Stop Fill Primer (ST-11000)”. mixing, and applying paint and chemicals listed in this manual.
  • Page 1034 Section 18: BODY GENERAL DESCRIPTION The following procedures explain the steps to be followed for proper repair, installation and replacement for various doors, panels and windows. The paragraph divides the vehicle into zones to facilitate the search; each zone is then sub-divided into components. Refer to the appropriate zone then component for complete procedure.
  • Page 1035 Section 18: BODY and install the front bumper. Safely support the CAUTION bumper and remove the two bolts on each bumper side to separate the bumper from the Do not exceed the crest dedicated surface. spare wheel compartment door. To install bumper, reverse the removal procedure.
  • Page 1036 Section 18: BODY REAR VIEW MIRRORS (RAMCO) NOTE Your vehicle is equipped with two exterior Position the ball cup halves so the joint mirrors. between them lies on the centerline of the arm. Ensure that the setscrews are not on the The mirrors may be equipped with an optional joint between the cup halves.
  • Page 1037 Section 18: BODY button’s (4) sides to adjust the selected mirror A metal rod or screwdriver to clean the seal viewing angle. groove, A filler insertion tool, Disassembly Goggles and protective gloves. At end of mirror arm, loosen the setscrews to •...
  • Page 1038 Section 18: BODY • filler contraction over time then insert filler Using the same type of plastic spatula, into groove. repeat the same operation from inside of vehicle, gradually inserting the windshield into the groove. FIGURE 14: APPLICATION 0F SIKA 221 BLACK •...
  • Page 1039 Section 18: BODY To open the door, initial movement of the rocker switch de-energizes the air lock solenoid valve, venting the door locking cylinders. The return locking spring pulls the door lock away from the latch, unlocking the door. Door movement starts only when pressure in the central air door lock is below 10 psi.
  • Page 1040 Section 18: BODY 7.7.2 Emergency Exit Valves 7.7.3 Door Cycle Speed Adjustment To do any adjustment, remove the two panels From inside the vehicle, an emergency exit located next to the door hinge, as well as the valve located near the door on the dash panel, door’s upper hinge control.
  • Page 1041 Section 18: BODY 4. Loosen the horizontal bolts retaining the door to the hinges. Adjust the door horizon- tally and vertically with the jack. Tighten the bolts to 30-36 Lbf-ft (40-50 Nm). Remove the jack and the wooden block. CAUTION Make sure the front side door does not interfere with the exterior panel.
  • Page 1042 Section 18: BODY 3. If required loosen the bolts retaining the 4. Clean the surface with alcohol. door to the hinges. Adjust the bolts to obtain the proper seal compression. WARNING Door Seal Replacement Wear rubber gloves and do not smoke when 1.
  • Page 1043 Section 18: BODY SYMPTOM PROBABLE CAUSE REMEDY Adjust upper lock. Lubricate upper latch The upper lock blocks the door. bolt. Adjust upper latch height. Power supply is cut at solenoid. Place switch in open position. DOOR LOCKS STAY Check voltage at solenoid lock when door ENGAGED WHEN DOOR IS is OPEN.
  • Page 1044 Section 18: BODY • • Apply Sika 255 at junction of frame and Clean door frame again using anti-silicone. window. • Apply some Sika 206 G+P onto door frame. • Install and center window onto door frame. Using your hands, compress window. •...
  • Page 1045 Section 18: BODY • Line-up body panel with window. There must be a gap of 4±2mm between window and body panel. • Apply some masking tape 1mm from window edge and body panel. • Apply Sika 255 onto door frame structure. •...
  • Page 1046 Section 18: BODY • Use a tack cloth to remove any dust or 7.7.8 Front Electrical & Service Compartment Door Body Panel and Window residue from the body panel surface. • Clean body panel using anti-silicone. Door Body Panel • Apply some Sika 206 G+P onto body panel. For the removal of front electrical &...
  • Page 1047 Section 18: BODY • Check body panel flatness using a 2-foot ruler (must be within 2mm). • From inside the door, apply some Sika 252 at the corners of window wiper. • Check proper power window sliding inside window frame. •...
  • Page 1048 Section 18: BODY • Insert window into frame. • Secure window pane to raising mechanism. • Apply anti-silicone inside right angle. • Apply Sika 205 inside right angle. • Adjust window travel (6±3mm above window wiper). • Apply 1/16 x1/4 double face self-adhesive tape onto gutter.
  • Page 1049 Section 18: BODY • From inside of vehicle, cut Sika bead around window perimeter using a “Zip gun” while another person hold the window from the outside. NOTE Wear ear plugs during this operation. • Then, move outside of vehicle and cut Sika •...
  • Page 1050 Section 18: BODY • L.H. side: Front of window must line up Apply masking tape onto front face before with front of driver’s window. Use shims applying Sika glue to protect paint and to adjust window height if necessary. adjacent surfaces. R.H.
  • Page 1051 Section 18: BODY • Apply Sika 205. • Clean gutter using anti-silicone. • From vehicle’s interior, apply some Sika 255 and make 2 finishing joints. Smooth down the joints and remove masking tape. • To seal screw holes, remove screw, apply Sika 205 inside the hole then apply Sika 252.
  • Page 1052 Section 18: BODY • Position and fix vertical molding. Lean vertical molding against lateral molding. Make sure vertical molding lines up with structural tubing. • Apply masking tape on each side of vertical molding. Apply Sika 252 to fill the gap between molding and windows.
  • Page 1053 Section 18: BODY ZONE 2 FIGURE 24: ZONE 2 18625 * Hammer or; LATERAL FIXED WINDOW * Drill equipped with a sharp pointed rod into Nine passenger side windows are provided on which a small hole was drilled; each side on X3-45. They are made of fixed, * Braided windshield wire and a pair of single or double-glazed, heat absorbing AS-3 handles;...
  • Page 1054 Section 18: BODY Method B Installation of Window • Using a drill equipped with the special sharp • Use window cleaner around window interior pointed rod, drill through the window seal perimeter and edges to remove any oily film into one of the bottom corners, from a 30º while inspecting for damages.
  • Page 1055 Section 18: BODY 8.2.2 Emergency Exit Window Adjustment Emergency exit windows should be checked periodically for easy opening and closing. Pulling the lower part of the release bar with both hands placed near the safety latches should disengage both locks on the window simultaneously.
  • Page 1056 Section 18: BODY CAUTION CAUTION Use of lubricants, paints, or other coatings Hinge assembly is critical and hinge should such as graffiti deterring sprays is not never be removed from cover assembly. recommended. Fasteners used in this assembly are special and have critical torque requirements and Suggested maintenance...
  • Page 1057 Section 18: BODY CAUTION 8.3.4 Escape Hatch Frame When necessary, the escape hatch frame can When installing, roof escape hatch’s hinge be removed and replaced in the following way: must be toward the front of vehicle, to prevent the hatch from being ripped out if accidentally 1.
  • Page 1058 Section 18: BODY 3. Adjust the doors position depending on the REAR BUMPER gap needed between exterior finishing Remove three bolts on each side holding panels. bumper to vehicle and remove bumper. 4. Tighten the bolts. To install bumper, reverse the procedure. 5.
  • Page 1059 Section 18: BODY 5. Check that the door swings freely and 10.1 REAR FENDER closes properly. It may be necessary to adjust the door latch to get proper fit and On the "X3" series vehicle, rear fenders are operation. hinged maintenance brakes To adjust the latch mechanism (3, Fig.
  • Page 1060 Section 18: BODY 4. Tighten the bolts. 1. Open the door to access the striker pin. 5. Check that the door swings freely and 2. Slightly loosen the striker pin. closes properly. It may be necessary to 3. Using a hammer, adjust the striker pin to adjust the door latch to get proper fit and center it in the door latch mechanism.
  • Page 1061 Section 18: BODY • • Apply some Sika 206 G+P onto door frame. Apply some Sika 206 G+P onto door frame. • • Clean door lower panel using anti-silicone. Clean door upper panel using anti-silicone. • • Prepare door lower panel using a scratch Prepare door upper panel using a scratch pad “Scotch Brite”.
  • Page 1062 Section 18: BODY 11.2 BAGGAGE COMPARTMENT FLOOR NOTE Adjustment is made using shims on the side 11.2.1 Repair of Mantex Urethane Covering plates. A total of 8 shims per door must be used e.g. 4 on L.H. side and 4 on R.H. side or Minor Repair 2 on L.H.
  • Page 1063 Section 18: BODY Allow drying for at least 2 hours then repaint as per paragraph: Minor Repair. 11.2.2 Baggage Compartment Floor Installation Preparation and Installation Clean baggage compartment support structure using anti-silicone. Rear baggage compartment equipped with WCL Prepare baggage compartment Mantex floor. Glue spacers (790392) about 16-inch apart.
  • Page 1064 Section 18: BODY Using a triangular nozzle, apply “Simson” glue (685126) onto support structure. Rear baggage compartment without WCL. Carefully install panel onto support structure. Evenly distribute and install conforming weights (6 to 8) (80 to 100 lbs total) onto panel for at least 4 hours.
  • Page 1065 Section 18: BODY Apply some Simson glue to fill the gap. Rear baggage compartment without WCL. Front finishing joint Section 2 Flat joint in front of fuel tank access panel Remove masking tape. Smooth down joints using soapy water. 11.3 EVAPORATOR COMPARTMENT DOOR Use plastic spatula #682838 to perform radius 1.
  • Page 1066 Section 18: BODY 5. Respect the required gap between exterior finishing panels. 6. Check that the door swings freely and closes properly. It may be necessary to adjust the door latch to get proper fit and operation. FIGURE 37: CONDENSER DOOR 18638 FIGURE 36: EVAPORATOR DOOR 18637...
  • Page 1067 Section 18: BODY 12 ZONE 6 FIGURE 39: ZONE 6 18629 12.1 FRONT FENDER Front fender may be removed using the following procedure: Remove the nuts on the inside of the fender. Remove the fender from the vehicle. To reinstall, reverse the procedure.
  • Page 1068 Section 18: BODY 13.1 X3 SMOOTH SIDE PANEL REPLACEMENT PROCEDURE Material: √ √ √ Anti-silicone (682989) Scotchbrite gray (680226) Sika 221 gray CHIX cloth (682384) √ Sika 205 1liter (683097) √ Sika 252 black √ √ Blue cloth (682383) Equipment: Glue gun √...
  • Page 1069 Section 18: BODY SECTION 2 PREPARATION OF SURFACES 2.00 VEHICLE SURFACE PREPARATION Clean using "anti-silicone" until all clothes come clean. See PR000001 section A. Use the belt sander (grit coarse) Use a new paper on each vehicle side. Clean using "anti-silicone" until all clothes come clean.
  • Page 1070 Section 18: BODY Section B Sika 205 Apply CHIX cloth Allow drying Mandatory For a smooth surface (aluminum, stainless, 2 minutes Minimum steel, fiber glass (gelcoat side), etc.) time - Pour a porous surface (fiber glass (non 10 minutes gelcoat side), etc.) After 2 hours : Reactivate surface with Sika 205 If surface seems dusty, greasy or with finger marks, start Before applying any...
  • Page 1071 Section 18: BODY 3.05 Install 1/8 X ½” foam tape onto middle reinforcement then compress. 3.10 Apply Sika 252 Section A-A Section B-B Section C-C – Onto vehicle surface – Cut nozzle as per template – Use the guide for the application Bead must be continuous for the whole perimeter.
  • Page 1072 Section 18: BODY 3.20 Install pulling equipment at the other end of side panel Make a final adjustment in height Sand front of side panel 2" wide Make sure the equipment pulls along the Pull side panel so that panel moves 1/8” whole width of side panel Perform tig spot welding Quantity of "tig spot": 30 minimum.
  • Page 1073 Section 18: BODY Wear surgical gloves and smooth down the joint with your finger. SECTION 4 ENGINE AIR INTAKE PANEL INSTALLATION 4.00 Make sure that sealing of structure has been performed properly 4.05 Prepare vehicle surface as for side panel. Refer to step # 2.00 Refer to step # 2.05 4.10...
  • Page 1074 Section 18: BODY 5.00 * Finition Joint Install a protective tape onto the tubing above welding Apply Sika 205 Use a plastic spatula inside a Chix cloth to ensure that Sika 205 reaches as far as the corner. See PR000001 section B. Apply Sika 252 black at the junction of both tubing.
  • Page 1075 Section 18: BODY 14 BODY PANEL AND WINDOW SPACING FIGURE 42: BODY PANEL AND WINDOW SPACING 18631 PA1562...
  • Page 1076 Section 18: BODY 15.2 REMOVING FIXED SEATS 15 PASSENGER SEATS NOTE X3 coaches can be equipped with any of 3 basic Seats on one row are not interchangeable with seat models and installed in a variety of seating seats of the other row. arrangements: 1.
  • Page 1077 Section 18: BODY recommended, since the resulting fumes could be hazardous in the confines of the coach and the solvent could be detrimental to the foam padding of the seats. 15.3.3 Cleaning With Covers in Place The most effective and economical method to clean the fabric seat covers is by washing with either an approved foam upholstery cleaner or with a mild household detergent.
  • Page 1078 Section 18: BODY 16 TARABUS FLOOR COVERING REPAIR OR REPLACEMENT On X3 vehicles equipped with “Tarabus” covering, it is possible to replace or repair this covering. The purpose of this paragraph is to explain the steps to be followed to ensure the best results and adherence. MATERIAL Part No Description...
  • Page 1079 Section 18: BODY FIGURE 45: TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 46: APPLICATION OF SIKA 221 GRAY 18641 PA1562...
  • Page 1080 Section 18: BODY 16.1 FRONT STEPS REPLACEMENT PROCEDURE MATERIAL Part No Description 682989 Anti-silicone 683097 Sika 205 (1 liter) 685101 Sika Remover 208 683916 Sika 215 (1 liter) 1. Cut and remove damaged step(s). 2. Remove dirt and adhesive residue. NOTE In wintertime, condensation and cold temperature may greatly influence bonding parameters.
  • Page 1081 Section 18: BODY Section D Sika Primer 215 Shake bottle to mix product CHIX cloth Apply a thin layer 3. Allow drying Mandatory Minimum time : 20 minutes After 2 hours : Remove dust using damp cloth (pure water) Before applying any other If surface seems dusty, dust using damp cloth.
  • Page 1082 Section 18: BODY 3. Apply some Sika 252 onto the step; make sure to cover the whole surface of the step. Use a serrated spreader with 1/8-inch serration to spread Sika. 4. Apply a bead of Sika 221 onto the perimeter of the step. 5.
  • Page 1083 Section 18: BODY 16.2 WELDING OF JOINT BETWEEN WHITE SAFETY STRIP AND “TARABUS” FLOOR COVERING 1. Pre-heat welding torch; Set welding torch to position #4.5 (temperature of 500 °C), Heating time: 5 minutes. 2. Before welding, visually ensure that a 1 to 1.5 mm gap exists between white safety strip and “Tarabus”...
  • Page 1084 Section 18: BODY 4. Use chamfer knife. Be careful not to overcut or to cut to the side to prevent damaging “Tarabus” covering. 5. Add (about 6 inches) some length to the required length of filler bead to make the joint then cut. 6.
  • Page 1085 Section 18: BODY 9. Allow cooling down of filler bead (about 5 minutes). 10. Shave filler bead to make it level to the floor. Use supplied knife designed for that purpose. NOTE To facilitate the cut, you can spray some soapy water onto the joint. CAUTION The procedure for turning the torch off must absolutely be followed.
  • Page 1086 Section 18: BODY 16.3 REPAIR OF A WELDED JOINT NOTE In wintertime, condensation and cold temperature may greatly influenced bonding parameters. Working area must be at a temperature sufficient to prevent reaching condensation point. Mechanically preheat working area (heat lamp or heat gun) or wait until vehicle reaches room temperature. 1.
  • Page 1087 Section 18: BODY Twelve jacking points are located on the vehicle: three are located on each side of the frame and two are located under each axle. Refer to the following illustrations for the location of jacking points. FIGURE 52: JACKING POINTS ON DRIVE AXLE 11005 CAUTION Always unload or retract the tag axle before...
  • Page 1088 Section 18: BODY DANGER CAUTION To prevent damage to the vehicle structure, it Jack is intended for lifting only. Do not get is not recommended to tow the vehicle from under the vehicle or load for any reason the rear. In case of damage to the drive train unless it is properly supported with safety components, use a low bed semi-trailer to stands and securely blocked.
  • Page 1089 Section 18: BODY 2. Operate the engine when towing to maintain 2. Operate the engine when towing to maintain brake system air pressure. If the engine brake system air pressure. If the engine cannot be operated, connect an external air cannot be operated, connect an external air pressure line from the tow truck to the pressure line from the tow truck to the...
  • Page 1090 Section 18: BODY 19 SPECIFICATIONS Door cylinder Manufacturer ................................Bimba Type ................................Pneumatic I.D................................... 1½" ( mm) Stroke................................. 8" ( mm) Prévost number..............................780595 Damper Manufacturer ................................Koni Prévost number..............................780565 Lock cylinder (upper) Manufacturer ................................Bimba Type ....................... Air, single action, 1/8 NPT, hexagonal rod I.D.
  • Page 1091 Isringhausen Seat Model 6800/338 Bus Seat Model 6800/338 Premium LX Service Manual Read and understand this manual before servicing this seat. © Copyright Isringhausen 1999 Manual No. 7018081-02, Rel. Jun. 1999...
  • Page 1092 INTRODUCTION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX SERVICE AND REPAIR Proper service and repair are important to the safe, reliable operation of this seat. Service and repair should be preformed only by responsible persons who have been properly instructed and authorized to do so. The procedures recommend in this manual are safe effective methods for performing service and repair operations.
  • Page 1093 MODEL 6800/338 BUS TABLE of CONTENTS MODEL 6800/338 PREMIUM LX subject page subject page INTRODUCTION HEIGHTADJUSTMENT HANDLE GENERAL SAFETY HEIGHTADJUSTMENT CYLINDER AND CAM 11 TROUBLESHOOTING HORIZONTALADJUSTMENT SLIDE SET INSPECTION QUICK AIR RELEASE VALVE AND HANDLE REMOVALAND INSTALLATION QUICK AIR RELEASE VALVE - SUSPENSION 13 ARMREST RISER AND SUSPENSION BACKREST...
  • Page 1094 GENERAL SAFETY MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX In this manual safety messages will alert persons to a specific hazard, the degree or level of hazard seriousness, the probable consequences of involvement with the hazard, and how the hazard can be avoided. Safety messages will include the safety alert symbol, a signal word, and a word message.
  • Page 1095 MODEL 6800/338 BUS TROUBLESHOOTING MODEL 6800/338 PREMIUM LX Problem Cause Solution Page Armrest will not stay in position. Armrest control is defective. Replace armrest. Backrest will not adjust Teeth on backrest are defective. Replace backrest. and/or stay adjusted. Backrest seat latch is defective. Replace backrest seat latch.
  • Page 1096 INSPECTION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX CAUTION Avoid the risk of injury. Vehicle must be in a safe parked position before inspecting seat. Visually inspect the seat. Look for damaged or worn upholstery and parts. The seat should be clean and free of dirt and debris.
  • Page 1097 MODEL 6800/338 BUS INSPECTION MODEL 6800/338 PREMIUM LX Air supply Air supply to seat must 90 to 145 p.s.i. Critical fastener torque Seat to seat rails torque to 14.8 - 18.4 lb ft (20 - 25 N•m) Seat rails to suspension torque to 14.8 - 18.4 lb ft (20 - 25 N•m) Armrest to seat...
  • Page 1098 REMOVAL and INSTALLATION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX CAUTION Avoid the risk of injury. Vehicle must be in a safe parked position before working on the seat. NOTICE To remove seat from vehicle follow vehicle manufacturer's instructions. Armrest Set up •...
  • Page 1099 MODEL 6800/338 BUS REMOVAL and INSTALLATION MODEL 6800/338 PREMIUM LX Backrest assembly Set up • Backrest must be removed from seat (see Backrest) Premium XL Premium XL Removal • Premium XL - remove upholstery and backrest liner • Bus - remove cover, hog rings and wires.-- remove upholstery •...
  • Page 1100 REMOVAL and INSTALLATION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX Lumbar and bolster valve Set up • Cover must be removed from seat (see Covers front, LH and RH) Removal • Mark air line and remove them from valve • Press valve clips in and remove valve from cover Installation •...
  • Page 1101 MODEL 6800/338 BUS REMOVAL and INSTALLATION MODEL 6800/338 PREMIUM LX Seat pan assembly Set up • Vehicle must be in a safe parked position or seat removed from vehicle. Removal • Slide cushion assembly forward • Pry lever handle up to release cushion stop -- lift cushion off of glides Installation...
  • Page 1102 REMOVAL and INSTALLATION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX Seat pan assembly, lever and handle torque to 7.4 - 8.1 lb ft Set up • Seat cushion must be removed from (10-11 N•m) seat (see Cushion seat pan) Removal •...
  • Page 1103 MODEL 6800/338 BUS REMOVAL and INSTALLATION MODEL 6800/338 PREMIUM LX Height adjustment handle Set up • Vehicle must be in a safe parked position or seat removed from vehicle • Control cover must be removed (see Covers front, LH and RH) Removal •...
  • Page 1104 REMOVAL and INSTALLATION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX Horizontal adjustment slide set Set up • Seat frame must be removed (see Seat frame) Removal • Move horizontal adjustment forward or back to allow access to fasteners • Remove mounting fasteners Installation •...
  • Page 1105 MODEL 6800/338 BUS REMOVAL and INSTALLATION MODEL 6800/338 PREMIUM LX Quick air release valve - torque to suspension 15.9 - 19.5 lb in (1.8 - 2.2 N•m) Set up • Seat cushion must be removed from seat (see Cushion seat pan) Removal •...
  • Page 1106 REMOVAL and INSTALLATION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX Seat frame Set up • Seat cushion and backrest must be removed from seat (see Cushion seat pan and Backrest) • Shock absorber handle and cable must be removed. (see Adjustable shock absorber handle and cable - handle end)
  • Page 1107 MODEL 6800/338 BUS REMOVAL and INSTALLATION MODEL 6800/338 PREMIUM LX Backrest adjustment handle Set up • Vehicle must be in a safe parked position or seat removed from vehicle. Removal • Pull handle off Installation • Push handle on Tilt handle Set up •...
  • Page 1108 REMOVAL and INSTALLATION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX Air spring torque to Set up • Seat must be removed from 44.2 - 62 lb in vehicle (5 - 7 N•m) • Seat cushion must be removed do not over tighten from seat (see Cushion seat pan) Removal...
  • Page 1109 MODEL 6800/338 BUS REMOVAL and INSTALLATION MODEL 6800/338 PREMIUM LX Adjustable shock absorber handle and cable (handle end) Set up • Seat cushion must be removed from seat (see Cushion seat pan) Removal • Remove fasteners and move control, bracket, and cable up away from seat frame •...
  • Page 1110 REMOVAL and INSTALLATION MODEL 6800/338 BUS MODEL 6800/338 PREMIUM LX Distribution valve Set up • Seat cushion must be removed from seat (see Cushion seat pan) Removal • Mark and remove air lines from valve • Remove valve fastener and remove valve Installation •...
  • Page 1111 MODEL 6800/338 BUS PARTS MODEL 6800/338 PREMIUM LX © Copyright Isringhausen 1999 Manual No. 7018081-02, Rel. Jun. 1999...
  • Page 1112 RISER - 127 MM (STD, NEOPLAN, ORION VI, NEW FLYER) 03013P RISER - 156 MM (MCI 'E-SERIES' COACH) 03468 RISER KIT - 76 MM (PREVOST COACH) 111779P03 RISER - 127 MM (KW O W900 & T2000, MACK, NAVISTAR) 112256P02 RISER - 110 MM (PB - 379)
  • Page 1113 86506-00 Customer P/N: 860912 Seat Specification: LH controls, 16 degree restriction, Air lumbar/Manual valve (IPS5), Adjustable shock, Armrest-padded, Long air supply hose Property / User / Application: Prevost Car motor coach ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N Headrest Kit ------------...
  • Page 1114 SERVICE PARTS LIST ISRI P/N: 17518-00 Description: Backrest–517-LH-AL ISRI Illus. No.: C-024 Customer: Prevost Car Customer P/N: 860739 Specification: LH controls, Air lumbar, Poly foam ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N Backrest Frame 17734D01 860740 Backrest Foam 00849 864741 Kit – Air Lumbar Bag...
  • Page 1117 SERVICE PARTS LIST ISRI P/N: 14663-04 Description: Seat Pan-515 ISRI Illus. No.: D-008 Customer: Prevost Car Customer P/N: 860742 Specification: Poly foam, w/o upholstery ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N Seat Pan 17832P 860743 Seat Foam 00425 860744 Uph Clip See D15 Uph Rod –...
  • Page 1120 SERVICE PARTS LIST ISRI P/N: 02371-02 Description: Seat Frame-515-LH-AL/MV(RH) ISRI Illus. No.: E-059 Customer: Prevost Car Customer P/N: 861099 Specification: LH controls, double swivel bolt, controls – black w/symbol, Air lumbar/Manual valve-RH (IPS 5) ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N...
  • Page 1121 SERVICE PARTS LIST ISRI P/N: 02371-02 Description: Seat Frame-515-LH-AL/MV(RH) ISRI Illus. No.: E-059 Customer: Prevost Car Customer P/N: 861099 Specification: LH controls, double swivel bolt, controls – black w/symbol, Air lumbar/Manual valve-RH (IPS 5) ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N Bolt –...
  • Page 1122 SERVICE PARTS LIST ISRI P/N: 02371-02 Description: Seat Frame-515-LH-AL/MV(RH) ISRI Illus. No.: E-059 Customer: Prevost Car Customer P/N: 861099 Specification: LH controls, double swivel bolt, controls – black w/symbol, Air lumbar/Manual valve-RH (IPS 5) ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N E142 Washer –...
  • Page 1129 SERVICE PARTS LIST ISRI P/N: 17491 Description: Slide Set – “B” Style ISRI Illus. No.: J-006 Customer: Prevost Car Customer P/N: 860758 Specification: 90/60 slide stroke, double locking, bar handle up ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N Handle – Slide See J8 Slide –...
  • Page 1131 SERVICE PARTS LIST ISRI P/N: 17259-01 Description: Susp–Air ISRI Illus. No.: K-019 Customer: Prevost Car Customer P/N: Specification: Manual air, 100 mm stroke, Adjustable shock ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N Suspension Hdw Kit 95477-03 860770 Bumper / Bracket Asm...
  • Page 1132 SERVICE PARTS LIST ISRI P/N: 17259-01 Description: Susp–Air ISRI Illus. No.: K-019 Customer: Prevost Car Customer P/N: Specification: Manual air, 100 mm stroke, Adjustable shock ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N K155 Washer–Air Spring Mtg-Upr See K6 K156 O-Ring (Air Spring)
  • Page 1135 SERVICE PARTS LIST ISRI P/N: 92625-01 Description: Boot Kit-Susp–Air-AL ISRI Illus. No.: M-001 Customer: Prevost Car Customer P/N: Specification: ILLUS DESCRIPTION ISRI P/N CUSTOMER P/N Boot 00169 Boot Button – Small See M4 Boot Button – Large See M4 Hdw Kit – Boot Button...
  • Page 1137 119 Salisbury Road Sheffield, Massachusetts 01257 TEL: 413.229.8711 FAX: 413.229.8717 www.sheffieldplastics.com Makrolon Cleaning Instructions The Following techniques for cleaning Makrolon polycarbonate sheet are based on standard industry practice. To ensure acceptability of the results, always test a sample of the material with the cleaner and technique to be used.
  • Page 1143 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS HEATING AND AIR CONDITIONING....................4 AIR CIRCULATION ..........................4 ’ ..........................4 RIVER ’ A .......................... 4 ASSENGERS CENTRAL HVAC SYSTEM OPERATION .................... 5 ’ ......................5 RIVER ECTION PERATION ’ S ....................6 ASSENGERS ECTION PERATION...
  • Page 1144 Section 22: HEATING AND AIR CONDITIONING 7.3.1 Removal ..........................22 7.3.2 Installation ..........................23 ........................... 23 ONDENSER 7.4.1 Condenser Fan Motors......................23 7.4.2 Condenser Fan Motor Removal .................... 24 ..........................24 ECEIVER ..........................24 ILTER RYER 7.6.1 Replacement ......................... 24 7.6.2 Moisture Indicator........................
  • Page 1145 Section 22: HEATING AND AIR CONDITIONING 9.7.5 Installation ..........................44 ) ....................44 REHEATING YSTEM PTIONAL 9.8.1 Operation..........................45 9.8.2 Preheating System Timer...................... 45 9.8.3 Timer Operating Instructions (Webasto) ................46 9.8.4 Troubleshooting and Maintenance..................48 SPECIFICATIONS ........................... 49 ILLUSTRATIONS ’...
  • Page 1146 Section 22: HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING PASSENGERS’ AREA The coach’s interior is pressurized by its Fresh air enters the vehicle on the L.H. side, Heating, Ventilation, Air Conditioning (HVAC) through the recirculation damper located inside units. Air flow and controls divide the vehicle in the evaporator compartment door (Fig.
  • Page 1147 Section 22: HEATING AND AIR CONDITIONING FIGURE 3: CENTRAL HVAC SYSTEM AIR CIRCULATION 22308 The overhead compartment air registers are The driver’s HVAC section piping is paralleled used to control air flow for the passenger seats. with the passengers HVAC section piping. Both One register per seat direct air flow by pointing sections use the same refrigerant and coolant, or rotating register.
  • Page 1148 Section 22: HEATING AND AIR CONDITIONING NOTE To perform a test of the driver's section windshield defroster, it is possible to run the system without running the engine. The following 2% error chart and table can be used to troubleshoot the driver’s area air temperature sensor outside...
  • Page 1149 Section 22: HEATING AND AIR CONDITIONING NOTE Squeeze rubber hose located underneath the appropriate compartment to eliminate the accumulated water and dirt when you make routine maintenance. COIL CLEANING Check the external surface of the coil at regular intervals for dirt or any foreign matter. For the driver's HVAC unit, remove the grill and the access panels and back flush the coil from inside.
  • Page 1150 Section 22: HEATING AND AIR CONDITIONING For the condenser coil, back flush the coil (Fig. 11) every 6,250 miles (10 000 km) or twice a year, whichever comes first. CAUTION Use a water jet or water mixed with low air pressure to clean the coil.
  • Page 1151 Section 22: HEATING AND AIR CONDITIONING FIGURE 15: OVERHEAD COMPARTMENT FAN AIR FILTER 22201 HVAC SYSTEM PARTICULARITIES, TESTING AND TROUBLESHOOTING Before undertaking any troubleshooting on the HVAC system, study the appropriate wiring diagrams to get a complete understanding of the HVAC components circuitry,...
  • Page 1152 Section 22: HEATING AND AIR CONDITIONING when working on the heating system to remove HVAC SYSTEM AND TEST MODE FOR air pockets trapped in the system. ELECTRIC MOTORS When performing an A/C cooling test and having The test mode allows testing the motors and the water pump shut off in switch/sensor test electric contactors without the need to have the mode is required, just set the passenger set...
  • Page 1153 Section 22: HEATING AND AIR CONDITIONING HVAC SYSTEM TROUBLESHOOTING Problem/Symptom Probable Causes Actions No temperature control in the Problem with the temperature Instruct the driver to manually control the passenger area sensor located in the evaporator temperature by playing with the passenger set compartment air intake or the point.
  • Page 1154 Section 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions Check / reset circuit breaker CB1 Check / replace fuse F12 The A/C compressor clutch Module A52 is not powered or is Check the SYSTEM DIAGNOSTIC menu does not engage faulty of the message center display (MCD).
  • Page 1155 Section 22: HEATING AND AIR CONDITIONING All refrigerant cylinders are shipped with a heavy Other causes of inadequate cooling are dirty coils or filter. Dirt acts as insulation and metal screw cap. The purpose of the cap is to is also serves as a restriction to the air flow. protect the valve and safety plug from damage.
  • Page 1156 Section 22: HEATING AND AIR CONDITIONING FIGURE 16: REFRIGERANT CIRCUIT (CENTRAL AND AUXILIARY SYSTEMS) 22313_1 PA1562...
  • Page 1157 Section 22: HEATING AND AIR CONDITIONING 6.2.4 Precautions in Handling Refrigerant be made to correct the leaks by tightening Lines the connections beyond the recommended torque. The O-rings are designed to seal at All metal tubing lines should be free of the specified torque and overtightening the kinks, because of the resulting restrictions connection does not result in a satisfactory...
  • Page 1158 Section 22: HEATING AND AIR CONDITIONING ADDING REFRIGERANT (VAPOR CAUTION STATE) Use the suction service valve on the compressor The filter dryer must be changed each time a to add a small quantity of refrigerant to the line in the system is opened. system.
  • Page 1159 Section 22: HEATING AND AIR CONDITIONING 6.5.1 Double Sweep Evacuation Procedure Open the vacuum pump and the thermistor valves. Start the pump and evacuate to a Remove any remaining refrigerant from the system pressure of 2000 microns. system using refrigerant recovery machine.
  • Page 1160 Section 22: HEATING AND AIR CONDITIONING 10. After the second “sweep”, change the filter 7. Attach a charging hose to the R-134a tank. drier (if you have not done so) and Open the tank valve slightly permitting R- evacuate to 500 microns. 134a to escape thus purging the hose of air.
  • Page 1161 Section 22: HEATING AND AIR CONDITIONING 6.7.1 Determining Severity of Failure Install new or repaired compressor. The severity of compressor failure can be Change the filter dryer. categorized as minor or major. A failure is Circulate clean R-134a or nitrogen with the considered minor when the contamination is reclaimer clean...
  • Page 1162 Section 22: HEATING AND AIR CONDITIONING order to release pressure and tension on belts. 2. Remove the radiator fan driving mechanism belt (Refer to Section 05: Cooling). 3. Slip the old A/C compressor belts off and the new ones on. 4.
  • Page 1163 Section 22: HEATING AND AIR CONDITIONING 7.1.3 Pulley Alignment 7.1.6 Vertical Compressor Alignment In order to avoid skipping, disengagement and a Rest a short "angle and level indicator" on the premature wear of compressor belt, it is outer side face of the crankshaft pulley, adjust necessary to align compressor pulley with the the level indicator inclination at 0 and check if...
  • Page 1164 Section 22: HEATING AND AIR CONDITIONING compressed refrigerant vapor will be circulated Overcharge of oil. between the suction and discharge sides of the Discharge valves not seated properly (liquid head. The affected cylinder head will then have drainback during shutdown). a relatively even temperature across its surface and be neither as hot as the normal discharge Expansion valve not controlling properly.
  • Page 1165 Section 22: HEATING AND AIR CONDITIONING Open last L.H. side baggage compartment door. Pull the black release button located on the L.H. side in order to unlock open evaporator compartment door. Remove the evaporator motor and coil access panel. Identify the L.H. side discharge duct inside compartment and remove the Phillips head screws retaining the flexible member to duct.
  • Page 1166 Section 22: HEATING AND AIR CONDITIONING For details about electrical wiring, refer to “A/C In case of extreme pressure there will be a rise and Heat system” in the master wiring diagram. in the liquid receiver tank. A pressure relief valve will break at 450 psi (3103 kPa) and relieve the receiver tank pressure.
  • Page 1167 Section 22: HEATING AND AIR CONDITIONING detection of moisture in the system and when DANGER corrected by a desiccant charge, system contamination is greatly minimized. Cleaning products are flammable and may explode under certain conditions. Always LIQUID REFRIGERANT SOLENOID handle in a well ventilated area. VALVE The flow of liquid refrigerant to the driver’s and 7.6.2...
  • Page 1168 Section 22: HEATING AND AIR CONDITIONING 2. Take out the retaining screw at the top of the coil housing. The entire coil assembly can then be lifted off the enclosing tube. 3. Place the new coil and yoke assembly on the enclosing tube.
  • Page 1169 Section 22: HEATING AND AIR CONDITIONING superheat spring, causing the valve pin to move This ensures that the refrigerant leaving the in the opening direction. Conversely, as the evaporator is in a completely gaseous state when drawn into the suction side of the temperature of the refrigerant gas leaving the compressor.
  • Page 1170 Section 22: HEATING AND AIR CONDITIONING Example of readings taken at fig. 34: A/C pressure gauge Temperature on converted to remote bulb temperature at expansion valve fitting High Low- swing swing 40°F (4,4°C) 54°F 44°F (12,2°C) (6,6°C) Formula for superheat Average of low and 49°F-40°F=9°F high swing is 49°F...

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X3 45 2007