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PREVOST LE MIRAGE XLII BUS SHELLS Maintenance Manual

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COACH MANUFACTURER

MAINTENANCE MANUAL

LE MIRAGE XLII

BUS SHELLS

PA1553

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Troubleshooting

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Page 1 COACH MANUFACTURER MAINTENANCE MANUAL LE MIRAGE XLII BUS SHELLS PA1553...
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 AND ERTIFICATIONS 4.1.1 Engine ............................. 4 4.1.2 Transmission ........................... 5 4.1.3 Drive Axle ..........................5 4.1.4 Front Suspension ........................
Page 4: Foreword
Section 00: GENERAL INFORMATION 1. FOREWORD 2. SCHEMATICS This manual includes procedures for diagnosis, Vehicle AIR SCHEMATICS are provided at the service, maintenance and repair for components end of Section 12, "Brake". SUSPENSION AIR of the XLII series bus shell models as listed on SCHEMATICS are provided at the end of the front cover page.
Page 5 Section 00: GENERAL INFORMATION STEEL – STEEL WELDING CAUTION Before welding, disconnect electronic modules and battery terminals. 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.
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: Transmission
Section 00: GENERAL INFORMATION 4.1.4 Front Suspension FIGURE 4: ISS TYPICAL SERIAL & MODEL NUMBERS 4.1.5 Power Steering Pump FIGURE 1 : DETROIT DIESEL SERIES 60 00043 Power steering pump serial number is located on a tag on the pump (Fig. 5). The pump is 4.1.2 Transmission mounted on the engine beside the crankshaft The transmission identification plate is located...
Page 8: Dot Certification Label
Make sure correct vehicle Prevost Car Inc., comply with all Federal Motor identification number is given when ordering Vehicle Safety Standards at the time of replacement parts. Using the VIN when ordering manufacture. Information such as date of parts will facilitate processing.
Page 9: Figure 9 : Vehicle Identification Number
Section 00: GENERAL INFORMATION FIGURE 9 : VEHICLE IDENTIFICATION NUMBER 00050 YEAR CODE YEAR CODE 2000 2006 2001 2007 2002 2008 2003 2009 2004 2010 2005 2011 PA1553...
Page 10: 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 11: 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 12: Figure 13: Metric - Us Standard Conversion Table
Section 00: GENERAL INFORMATION FIGURE 13: METRIC - US STANDARD CONVERSION TABLE 00005 PA1553...
Page 13: Figure 14: Conversion Chart
Section 00: GENERAL INFORMATION FIGURE 14: CONVERSION CHART 00006 PA1553...
Page 15 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING PROCEDURE NO: PR060034 REVISION 3 2007-02-27 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 ENGINE ..............................3 ENGINE-MOUNTED COMPONENTS....................3 ......................4 LECTRONIC ONTROL ODULE N3 E ......................4 LECTRONIC NJECTOR ..............................4 VPOD 2.3.1 VPOD Removal ........................5 2.3.2 VPOD Installation ........................5 EGR H ........................5 YDRAULIC ALVE ....................
Page 32 Section 01: ENGINE ILLUSTRATIONS ) .................. 3 IGURE DETROIT DIESEL SERIES ENGINE TYPICAL ) ....................4 IGURE ELECTRONIC CONTROL MODULE ......................4 IGURE UNIT INJECTOR CROSS SECTION ..........................4 IGURE VPOD LOCATION ......................... 5 IGURE VPOD INSTALLATION & ....................5 IGURE EGR VALVE ACTUATOR ASSEMBLY...
Page 33: Engine
SECTION 01: ENGINE 1. ENGINE Refer DDEC Troubleshooting Guide published by Detroit Diesel for more complete This vehicle is powered by a 6-cylinder, four- information on diagnosis of components and cycle, Detroit Diesel series 60 engine equipped system problems. with an electronic control system (DDEC V). DDEC V (Detroit Diesel Electronic Control) Two engine displacements are used in the controls the timing and quantity of fuel injected...
Page 34: Electronic Control Module
Section 01: ENGINE 2.1 ELECTRONIC CONTROL MODULE Meters and injects the exact amount of fuel required to handle the load; The Electronic Control Module is mounted, on starter side engine (Fig. 2). Atomizes the fuel for mixing with the air in Considered the "Brain"...
Page 35: Vpod
SECTION 01: ENGINE 2.3.1 VPOD Removal 1. Remove airline from VPOD. 2. Unplug harness connection. 3. Remove two bolts and one stud holding VPOD assembly and bracket to engine block. 2.3.2 VPOD Installation Align VPOD assembly and bracket to threaded holes in engine block; install two FIGURE 6: EGR VALVE &...
Page 36: Turbo Boost Pressure Sensor
Section 01: ENGINE 2.7 TURBO BOOST PRESSURE SENSOR 2.10 AIR TEMPERATURE SENSOR The Turbo Boost Pressure Sensor is located on The Air Temperature Sensor (Fig. 1 & 7) located the intake manifold. This device is a pressure on the intake manifold provides input data to sensor that sends an electrical signal to the vary hot idle speed and injection timing.
Page 37: Oil Temperature Sensor
SECTION 01: ENGINE 2.13 OIL TEMPERATURE SENSOR When installed by the equipment manufacturer, the TPS should not require adjustment. If the The Oil Temperature Sensor (OTS) is installed TPS is suspected of being misadjusted, confirm behind the engine oil filters manifold (Fig. 1). that the sensor is installed in accordance with The OTS sends an electrical signal to the ECM manufacturer's...
Page 38: Diagnostic System Accessories (Dsa)
Section 01: ENGINE oil sensors exceeds 239°F (115°C). When NOTE sensors detect such temperatures, DDEC shuts Cruise control system will not accept speed the engine down after a 30 seconds grace settings, nor will the "Resume" switch operate period. This 30-second delay may be extended below 20 mph (32 km/h) and the engine speed another 30 seconds (if absolutely necessary) by must be above 1100 RPM.
Page 39: Ddec V Diagnostic Codes
SECTION 01: ENGINE 4. DDEC V DIAGNOSTIC CODES Active codes will be flashed on the stop engine telltale, followed by the inactive codes being 4.1 READING DIAGNOSTIC CODES - flashed on the check-engine telltale panel. The FLASHING LIGHT METHOD: cycle repeats itself until the operator depresses the stop engine override switch again.
Page 40 Section 01: ENGINE DDEC V Code DESCRIPTION EGR Valve Current too Low Throttle Plate Position Sensor Input Voltage High Blower Bypass Position Input Voltage High Relative Humidity Sensor Circuit Failed High Throttle Plate Position Sensor Input Voltage Low Blower Bypass Position Input Voltage Low Relative Humidity Sensor Circuit Failed Low Throttle Position Sensor Input Voltage High Throttle Position Sensor Input Voltage Low...
Page 41 SECTION 01: ENGINE DDEC V Code DESCRIPTION Aux. Output #13 Mechanical System Failure - Pin E-47 Aux. Output #14 Open Circuit (High Side) - Pin E-50 Aux. Output #14 Short to Ground (High Side) - Pin E-50 Aux. Output #14 Mechanical System Failure - Pin E-50 Aux.
Page 42 Section 01: ENGINE DDEC V Code DESCRIPTION Too Many CKP Sensor (missing CMP Sensor) Too few CKP Sensor (missing CKP Sensor) Coolant Level Low Intercooler Coolant Temperature High Intake Manifold Temperature High Engine Power Derate Due to Intake Manifold Temperature Coolant Temperature High Engine Power Derate Due to Coolant Temperature Air Inlet Temperature High...
Page 43 SECTION 01: ENGINE DDEC V Code DESCRIPTION TCI Temperature Circuit Failed High Turbo Compressor Out Temperature Sensor Input Voltage High A/D Conversion Fail Nonvolatile Checksum Incorrect EEPROM Write Error Out of Calibration Vehicle Speed Sensor Fault Other ECU Fault (This fault is logged in conjunction with another fault to indicate missing information from another ECU.) J1939 Data Link Fault...
Page 44 Section 01: ENGINE DDEC V Code DESCRIPTION Aux. Output #8 Mechanical System Not Responding Properly - Pin V-53 Aux. Output #9 Open Circuit – Pin V-54 Aux. Output #9 Short to Gnd – Pin V-54 Aux. Output #9 Mechanical System Failure – Pin V-54 Aux.
Page 45 SECTION 01: ENGINE DDEC V Code DESCRIPTION Turbo Overspeed Turbo Speed Sensor Input Failure – Abnormal Period Throttle Plate Position Above Normal Range Throttle Plate Position Below Normal Range Throttle Plate Position Erratic Throttle Plate Not Responding Air Filter Restriction Sensor Voltage High Air Filter Restriction Sensor Voltage Low Oil Filter Restriction Sensor Voltage High Oil Filter Restriction Sensor Voltage Low...
Page 46 Section 01: ENGINE DDEC V Code DESCRIPTION Sensor Supply Pins V-11/V-12 Voltage High Injector V (slope) Voltage Failed High Injector V (pull-in) Voltage Failed High RTC Backup Battery Voltage High Sensor Supply Voltage High, Pin E-26 Engine Overspeed With Engine Brake —...
Page 47 SECTION 01: ENGINE DDEC V Code DESCRIPTION — Anti-Theft Fault Present — Clock Module Abnormal Rate of Change — Clock Module Failure — Clock Module Abnormal Rate of Change — Clock Module Failure — Relative Humidity Above Range — Relative Humidity Below Range —...
Page 48 Section 01: ENGINE DDEC V Code DESCRIPTION — EGR Rate Sensor Failed Oil Level Sensor Input Voltage Low Crankcase Pressure Sensor Input Voltage Low Extended Crankcase Pressure Input Voltage Low Injection Control Pressure Sensor Input Voltage Low Exhaust Temperature Sensor Input Voltage Low —...
Page 49: Engine Oil Level
SECTION 01: ENGINE DDEC V Code DESCRIPTION Exhaust Port Temperature #3 High Exhaust Port Temperature #4 High Exhaust Port Temperature #5 High Exhaust Port Temperature #6 High Exhaust Port Temperature #7 High Exhaust Port Temperature #8 High Exhaust Port Temperature #9 High Exhaust Port Temperature #10 High Exhaust Port Temperature #11 High Exhaust Port Temperature #12 High...
Page 50: Engine Oil And Filter Change
Section 01: ENGINE decreased gradually increased with CAUTION experience on specific lubricants until the most practical service condition has been established. Clean end of tube before removing the dipstick Always refer to the lubricant manufacturer's to prevent oil contamination. recommendations (analysis of drained oil can be helpful).
Page 51: Recommended Engine Oil Type
SECTION 01: ENGINE 6. Lightly coat the filter gasket (seal) with clean Modification of drain interval may be necessary, engine oil. depending on fuel quality. Contact Detroit Diesel Corporation for further guidance. 7. Install the new filter on the adapter and tighten manually until the gasket touches the 8.
Page 52 Section 01: ENGINE FIGURE 15: BELT TENSIONER VALVE 12200 FIGURE 16: ELECTRIC FAN-CLUTCH CONNECTOR 010XX 4. Locate the belt tensioner pressure releasing valve (Fig. 15). Turn pressure releasing valve 13. Disconnect and remove the air intake duct handle counterclockwise in order to release mounted between the turbocharger outlet pressure in belt-tensioner air bellows and and the air cooler inlet (5, Fig.
Page 53: Power Plant Assy. Installation
SECTION 01: ENGINE 21. Disconnect the oil delivery hose from the 35. Inspect the power plant assembly to ensure valve located at the reserve tank drain that nothing will interfere when sliding out the (7, Fig. 17). cradle. Check for connections or hoses not mentioned in this list as some vehicles are 22.
Page 54: Valve Cover Removal
Section 01: ENGINE 5. Start engine for a visual check. Check fuel, oil, cooling, pneumatic and hydraulic system connections for leakage. Test operation of engine controls and accessories. FIGURE 17: ENGINE COMPARTMENT XLII MTH (TYPICAL) 01174 6. Adjust Jake brakes (if applicable), injectors 10.
Page 55: Jake Brake
SECTION 01: ENGINE 11. JAKE BRAKE Two rubber mounts are used at the front of the engine while two others are mounted on each Refer to both "The Jake Brake Troubleshooting side of the flywheel housing (Fig. 18). and Maintenance Manual" and "Installation It is recommended that new rubber mounts be Manual for Model 790 Engine Brakes"...
Page 56: Engine Troubleshooting Guide
Section 01: ENGINE 13. 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 57: Specifications
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 58 Section 01: ENGINE XL2 Entertainer & 40’ MTH Engine XL2 45’ MTH Engine (14.0L) (12.7L) 470 HP @1800 rpm; 1650 lb-ft @1200 rpm 445 HP @1800 rpm; 1550 lb-ft @1200 rpm 490 HP @1800 rpm; 1650 lb-ft @1200 rpm 450 HP @1800 rpm;...
Page 59 1.29 JAKE BRAKE 1.29 JAKE BRAKE The engine brake has been designed to fit on the Series 60 engine with no additional valve cover spacers. There are three styles of valve covers for the Series 60 engine. On engines equipped with a two-piece aluminum valve cover, it is NOT necessary to remove the lower valve cover to install the engine brake.
Page 60 SERIES 60 SERVICE MANUAL Engine Slave Piston Model Number Model Year Engine Brake Displacement Adjustment 6067WU40 Pre-1991 11.1L 760/760A 0.660 mm (0.026 in.) 6067GU40 Pre-1991 12.7L 760/760A 0.508 mm (0.020 in.) 6067WU60 1991 11.1L 760/760A 0.660 mm (0.026 in.) 6067GU40 1991 12.7L 0.660 mm (0.026 in.)
Page 61 1.29 JAKE BRAKE NOTE: All engines built after serial number 06R0004455 have the correct engine parts for engine brake installation. The model numbers have changed because of design changes in the engine brakes. NOTE: All Series 60 engines with serial numbers 06R0004455 or higher are Jake Brake ready. Do not install a Jake Brake on engines with lower serial numbers.
Page 62 SERIES 60 SERVICE MANUAL Energizing the engine brake effectively converts a power-producing diesel engine into a power-absorbing air compressor. This is accomplished through motion transfer using a master-slave piston arrangement which opens cylinder exhaust valves near the top of the normal compression stroke, releasing the compressed cylinder charge to exhaust.
Page 63 1.29 JAKE BRAKE The blowdown of compressed air to atmospheric pressure prevents the return of energy to the engine piston on the expansion stroke, the effect being a net energy loss, since the work done in compressing the cylinder charge is not returned during the expansion process. Exhaust blowdown occurs as the energized solenoid valve permits engine lube oil to flow under pressure through the control valve to both the master piston and the slave piston.
Page 64 SERIES 60 SERVICE MANUAL The Jake Brake is electronically controlled. Jake Brake control system wiring will vary depending on the vehicle manufacturer. For a general overview of the Jake Brake, see Figure 1-416 and see Figure 1-416a. 1. Ball Check Valve (Model 760 Only) 5.
Page 65 1.29 JAKE BRAKE 1. Solenoid Valve 12. Inner Control Valve Spring 2. Upper Seal 13. Washer 3. Center Seal 14. Retaining Ring 4. Lower Seal 15.J-Lash ® Screw 5. Master Piston 16. Locknut 6. Master Piston Pushrod 17. Slave Piston 7.
Page 66 SERIES 60 SERVICE MANUAL 1.29.1 Repair or Replacement of Jake Brake To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-417. Figure 1-417 Jake Brake Repair or Replacement Flowchart All information subject to change without notice. From Bulletin 16-60-99 1-529 6SE483 9901 Copyright ©...
Page 67 1.29 JAKE BRAKE 1.29.2 Removal of Model 760, 765, or 770 Jake Brake Remove the model 760, 765, or 770 Jake Brake as follows: NOTE: The following procedures apply to Model 760, 765, and 777 Jake Brakes. For Model 790 Jake Brake removal procedures, refer to section 1.29.6.
Page 68 SERIES 60 SERVICE MANUAL 1. Cylinder Head 4. Washers (3 each) 2. Jake Brake Assembly 5. Mounting Bolts (3 each) 3. Solenoid 6. Engine Brake Harness Figure 1-418 Jake Brake Assembly 5. Remove the nine mounting bolts and washers that secure the engine brake assemblies to the cylinder head.
Page 69 1.29 JAKE BRAKE 1.29.3 Disassembly of Model 760, 765, or 770 Jake Brake Remove the control valve as follows: To avoid personal injury, remove control valve covers carefully. Control valve covers are under load from the control valve springs. 1. Press down on control valve washer using an appropriate diameter rod to relieve spring pressure.
Page 70 SERIES 60 SERVICE MANUAL 2. Using retaining ring pliers, remove retaining ring. 3. Slowly remove cover until spring pressure ceases, then remove the two control valve springs and collar. See Figure 1-420. 1. Jake Brake Assembly 5. Washer 2. Control Valve 6.
Page 71 1.29 JAKE BRAKE Remove the slave piston adjusting screw as follows: 1. Loosen slave piston adjusting screw locknut. 2. Remove adjusting screw from housing. See Figure 1-421. 1. Jake Brake Assembly 2. Slave Piston Adjusting Screw Figure 1-421 Removing Slave Piston Adjusting Screw All information subject to change without notice.
Page 72 SERIES 60 SERVICE MANUAL Remove the solenoid valve as follows: NOTICE: To avoid possible engine damage, do not disassemble or tamper with the solenoid valve. 1. Disconnect solenoid valve harness. 2. Using a 7/8 in. socket and extension for former solenoids or a 3/4 in., 6 point socket and extension for current solenoids, unscrew solenoid valve.
Page 73 1.29 JAKE BRAKE Remove the accumulator as follows: The accumulator spring is under strong compression. To avoid possible personal injury if the accumulator spring is discharged, wear safety glasses and use caution when removing the retaining ring and cover. 1. Push down on the accumulator cover using the appropriate diameter rod, and remove the retaining ring.
Page 74 SERIES 60 SERVICE MANUAL 4. Use a magnet to remove the piston from the accumulator bore. See Figure 1-424. 1. Jake Brake Assembly 4. Retaining Ring 2. Piston 5. Washer 3. Spring Figure 1-424 Removing Piston from Accumulator Bore with Magnet All information subject to change without notice.
Page 75 1.29 JAKE BRAKE Remove the master piston as follows: 1. Remove the screw, washer, and master piston spring from the housing. 2. Remove the master piston. See Figure 1-425. NOTE: Use needle-nose pliers, if necessary. 1. Washer and Screw Assembly 3.
Page 76 SERIES 60 SERVICE MANUAL Remove the slave piston as follows: 1. Remove the screw and spring that retains the slave piston return spring. 2. Remove the bridge and the slave piston. See Figure 1-426. 1. Slave Piston Bridge 4. Return Spring 2.
Page 77 1.29 JAKE BRAKE 3. Loosen the leveling screw locknut and remove the leveling screw from the bridge. See Figure 1-427. 1. Slave Piston Bridge 2. Slave Piston Leveling Screw Figure 1-427 Removing the Leveling Screw from the Bridge The injector rocker arm contains a pin and roller for actuating the engine brake master piston.
Page 78 SERIES 60 SERVICE MANUAL 1.29.3.1 Cleaning of Model 760, 765, or 770 Jake Brake Clean the Jake Brake as follows: NOTE: Use an OSHA-approved cleaning solvent when washing parts. Be sure to coat parts with clean engine oil when reinstalling them. 1.
Page 79 1.29 JAKE BRAKE 1.29.3.2 Inspection of Model 760, 765, or 770 Jake Brake The Jacobs engine brake is typically a trouble-free device. However, inspections are necessary and some maintenance is required. Use the following procedures to keep the engine brake in top condition.
Page 80 SERIES 60 SERVICE MANUAL 6. Inspect the ball check valve (Model 760 only) for wear or damage. [a] If worn or damaged, replace ball check valve. Refer to Section 1.29.4. [b] If not worn or damaged, proceed with inspection. 7. Inspect slave piston components for excessive wear or damage. [a] If worn or damaged, replace slave piston component.
Page 81 1.29 JAKE BRAKE 1.29.4 Assembly of Model 760, 765, or 770 Jake Brake Install the control valve as follows: 1. Slip the control valve into the bore. See Figure 1-428. NOTE: Make sure the control valve collar is installed with the longer sleeve area facing up. If the collar is installed upside down, the engine brake cylinder will not operate.
Page 82 SERIES 60 SERVICE MANUAL Install the slave piston adjusting screw as follows: 1. Place the screw in the housing. See Figure 1-429. 1. Jake Brake Assembly 2. Slave Piston Adjusting Screw Figure 1-429 Installing the Slave Piston Adjusting Screw 2. Torque the slave piston adjusting screw locknut to 35 N·m (25 lb·ft). Install the solenoid valve as follows: NOTE: As of October 19, 1997, former solenoids have been replaced with the current improved...
Page 83 1.29 JAKE BRAKE 2. Install the upper and center seal rings on the solenoid valve body and the lower seal ring into the bottom of the bore in the housing. See Figure 1-430. 1. Seal Rings (3) 2. Solenoid Figure 1-430 Installation of Solenoid Valve Seal Rings 3.
Page 84 SERIES 60 SERVICE MANUAL Install the master piston as follows: 1. Apply clean lube oil to the piston. 2. Insert master piston into bore. See Figure 1-431. 1. Washer and Screw Assembly 3. Master Piston 2. Jake Brake Assembly 4. Master Piston Spring Figure 1-431 Inserting Master Piston into Bore 3.
Page 85 1.29 JAKE BRAKE On model 760 only, install the ball check valve as follows: 1. Install the ball check valve and spring. See Figure 1-432. 1. Ball Check Valve 3. Pipe Plug 2. Spring Figure 1-432 Installation of Ball Check Valve 2.
Page 86 SERIES 60 SERVICE MANUAL Install the slave piston as follows: 1. Install the screw from the slave piston side of the bridge. 2. Install the leveling screw locknut. 3. Install the bridge with the leveling screw toward the center of the housing. See Figure 1-433.
Page 87 1.29 JAKE BRAKE 4. Install the slave piston assembly torsion spring with the ends over the bridge. See Figure 1-434. Figure 1-434 Installing the Slave Piston Assembly Torsion Spring 5. Install the screw over the center part of the spring. NOTICE: While tightening the screw on the torsion spring, push the spring toward the slave piston assembly.
Page 88 SERIES 60 SERVICE MANUAL 1.29.5 Installation of Model 760, 765, or 770 Jake Brake Install the model 760, 765, or 770 Jake Brake as follows: NOTE: The following procedures apply to Model 760, 765, and 770 Jake Brakes. For Model 790 Jake Brake installation procedures, refer to section 1.29.10.
Page 89 1.29 JAKE BRAKE 4. Place the spacer bar on the exhaust manifold side of the cylinder head with the "OUT" markings adjoining each other and facing the exhaust manifold. See Figure 1-435, and see Figure 1-436. Figure 1-435 Spacer Bars with "Out" Marks Adjoined All information subject to change without notice.
Page 90 SERIES 60 SERVICE MANUAL Figure 1-436 Location of Spacer Bars 5. Place the three engine brake housings over the rocker shafts with the solenoid valves toward the camshaft side of the engine. NOTE: Be sure housings do not interfere with wiring harness. All information subject to change without notice.
Page 91 1.29 JAKE BRAKE NOTICE: Do not mix the rocker arm shaft bolts and the Jake Brake mounting bolts. If the rocker arm shaft bolt is mistakenly used to mount the Jake Brake housing, the longer shoulder on the bolt will block the oil supply to the Jake Brake on the camshaft side of the housing.
Page 92 SERIES 60 SERVICE MANUAL [d] The DDC bolt shoulder is much longer, 17.0 mm (0.669 in.) versus 4 mm (0.157 in.) than the Jake Brake bolt. See Figure 1-437. Figure 1-437 Jake Brake and DDC Bolt Identification All information subject to change without notice. From Bulletin 16-60-99 1-555 6SE483 9901 Copyright ©...
Page 93 1.29 JAKE BRAKE NOTICE: The model 760 uses two lengths of mounting bolts. Six 120 mm bolts should be installed on the exhaust side of the engine. Three 110 mm bolts should be installed on the camshaft side of the engine.
Page 94 SERIES 60 SERVICE MANUAL 7. On model 760, install one washer on the 110 mm (4.375 in.) bolt, and insert into brake housing at the camshaft side (one per housing). See Figure 1-439. 1. Jake Brake Housing Assembly 2. Mounting Bolt Figure 1-439 Installation of Brake Housing Bolts on Camshaft Side 8.
Page 95 1.29 JAKE BRAKE 10. On models 760A and 765, move the housing from side to side, and locate the housing in the center position of the movement. See Figure 1-440. Figure 1-440 Locating Center Position of Housing 11. On models 760B and 765A, move the housing from side to side, and locate as far toward the camshaft side of the engine as possible.
Page 96 SERIES 60 SERVICE MANUAL 1.29.5.1 Adjustment of Slave Piston on Model 760, 765, or 770 Jake Brake Make the following adjustment with the engine stopped and cold, and the oil temperature at 60 (140 F) or below. The exhaust valves on the cylinder must be in the closed position (rocker arm roller on the base circle of the camshaft).
Page 97 1.29 JAKE BRAKE 2. Back out the leveling screw in the slave piston assembly until the end of the screw is beneath the surface of the bridge in the slave piston assembly. See Figure 1-441. NOTE: The leveling screw is located in the bridge member of the slave piston assembly. 1.
Page 98 SERIES 60 SERVICE MANUAL 4. On models 760, 760A, 760B, 765, and 765A, turn the slave piston adjusting screw clockwise until a slight drag is felt on the feeler gage. See Figure 1-442. 1. Slave Piston Bridge 3. Feeler Gage 2.
Page 99 1.29 JAKE BRAKE 5. Perform the following additional steps on model 770: ® [a] Turn in the J-Lash adjusting screw until the solid side of the slave piston bridge assembly contacts the exhaust valve and the valve springs begin to compress. Turn in one additional turn.
Page 100 SERIES 60 SERVICE MANUAL 9. Turn the leveling screw clockwise until a slight drag is felt on the feeler gage. See Figure 1-443. 1. Feeler Gage 3. Rocker Arm Adjusting Screw 2. Slave Piston Leveling Screw Figure 1-443 Setting Clearance on Leveling Screw and Rocker Arm Adjusting Screw 10.
Page 101 1.29 JAKE BRAKE 1.29.6 Removal of Model 790 Jake Brake Assembly Remove the Model 790 Jake Brake as follows: To avoid injury from hot engine surfaces, stop the engine and allow it to cool ambient temperature before working on it. To avoid injury from accidental engine start-up, disable/disconnect power to the engine starting system.
Page 102 SERIES 60 SERVICE MANUAL 4. Remove the three (3) 140 mm long mounting bolts that secure the engine brake to the cylinder head. See Figure 1-443a. 1. Mounting Bolt — 170 mm Long 3. Stud Bolt 2. Mounting Bolt — 140 MM Long 4.
Page 103 1.29 JAKE BRAKE 1.29.6.1 Disassembly of Model 790 Jake Brake Instructions for disassembly of Model 790 Jake Brakes are incomplete at time of publication, but will be provided at a future date. For components of Model 790 Jake Brakes, see Figure 1-443b. 1.
Page 104 SERIES 60 SERVICE MANUAL 1.29.7 Cleaning of Model 790 Jake Brake Instructions for cleaning of Model 790 Jake Brake are incomplete at the time of publication, but will be provided at a future date. 1.29.8 Inspection of Model 790 Jake Brake Instructions for inspection of Model 790 Jake Brake are incomplete at the time of publication, but will be provided at a future date.
Page 105 1.29 JAKE BRAKE 3. Install six (6) 170 mm bolts through the housings into the rocker shafts in locations 1 through 6, and install two (2) nuts in locations 7 and 8. See Figure 1-443c. Figure 1-443c Housing Hold-Down Bolt Locations NOTICE: To ensure proper engine brake housing installation, Jake Brake mounting bolts (identified by a circle "J"...
Page 106 SERIES 60 SERVICE MANUAL 1.29.10.1 Set Slave Piston Lash The slave piston lash must be set after Jake Brake housings are installed. Adjustments must be made with the engine stopped and cold and the oil temperature at 60 C (140 F) or below.
Page 107 1.29 JAKE BRAKE NOTICE: Oil must be purged from the J-Lash adjusting screw. Oil remaining in the J-Lash screw will cause inaccurate clearance adjustment, which could result in damage to the engine or Jake Brake. If oil is below room temperature (below C or 60 F), wait at least two minutes for oil to be purged from the J-Lash adjusting screw.
Page 108 SERIES 60 SERVICE MANUAL 4. After torquing the adjusting screw lock nut, recheck lash setting. If lash is incorrect, repeat step 1 and step 2. NOTE: Once the engine brake has been run, you will not be able to check Jake Brake adjustment.
Page 109 Jacobs Engine Brake ™ Tune-Up Kit 790/795 Series P/N 29013 Information in this manual was current at time of printing and is subject to change without notice or liability. Refer to the Application guide, P/N 24770 for specific application information. Also refer to the Install Manual, P/N 29901 and the engine manual for specific installation instructions.
Page 110 Tune-up Kit Contents Model 790/795 Quantity Quantity Illus. Illus. Part Name per kit Part Name per kit 1 1024612 Solenoid, 12VDC S/L 26142 Slave Piston 1 1024619 Solenoid, 24VDC S/L 28379 Bridge, Slave Piston 20229 Seal, Solenoid Upper 28372 Spring, Inner Slave Piston 1082 Seal, Solenoid Center 28373...
Page 111 General Information Instructions NEVER REMOVE OR ADJUST ANY These instructions describe how to properly remove, ENGINE BRAKE OR COMPONENT WITH clean and reinstall Jacobs Engine Brake™ THE ENGINE RUNNING. components. For additional information on the 790/795 Series engine brakes, refer to the Series 60 Engine Service Manual, P/N 6SE483.
Page 112 Assemble Housings 1. Place the engine brake housings on the rocker shafts and spacer tubes with the solenoids on 1. Clean all parts in an approved cleaning solvent. the camshaft side of the engine and the slave Dry with compressed air. pistons over the exhaust valves.
Page 113 1. Back out the adjusting screws on the slave Bleed the engine brake housings. pistons until the slave piston does not touch the rocker arm. 1. Be sure wires are away from moving parts. 2. Insert the proper feeler gage between the slave 2.
Page 114 Jacobs Vehicle Systems Visit us on the Internet: 22 East Dudley Town Road www.jakebrake.com Bloomfield, CT 06002 P/N 29015 Rev. A ©2000 Jacobs Vehicle Systems, Inc. Printed in U.S.A. Rev. 10/00...
Page 115 Jake Brake Models 790, 795 & 797 Jake Brake Models 790, 795 & 797 ® ® for Detroit Diesel Series 60 ® Engines Year 2000 Production Engines and Beyond Features & Benefits 797 Series Designed in partnership with Detroit For engines manufactured 10/01/02- Diesel to yield a more simplified design, reducing weight while increasing performance &...
Page 116 Jake Brake Models 790, 795 & 797 Jake Brake Models 790, 795 & 797 ® ® for Detroit Diesel Series 60 ® Engines Technical Specifications How The Jake Brake Works: ® Height 4.2” 107 mm Energizing the engine brake effectively Length 19.6”...
Page 117 Jacobs Engine Brake ® Models 790/795/797 Information in this manual was current at time of printing and is subject to change without notice or liability. Refer to the Application guide, P/N 24770 for specific application information. Also refer to the Installation Manual, P/N 29901 and the Engine Manual for specific installation instructions.
Page 118 790/795/797 HOUSING ASSEMBLIES 790/795/797 KITS Model Model No. Description Description 28367 Front housing Assembly, 12 VDC, S/L 29240 Engine Brake Kit, 12 VDC 28368 Rear housing Assembly, 12 VDC, S/L 29020 Engine Brake Kit, 24 VDC 29017 Front housing Assembly, 24 VDC, S/L 790A 790A 790A...
Page 119 HOUSING ASSEMBLY 790/795/797 Illus. Qty per Part Name housing Solenoid 1024612(12VDC) -or- 1024619(24VDC) Seal, Solenoid Upper 20229 Seal, Solenoid Middle 1082 Seal, Solenoid Lower not required not required 2*/*** Master Piston 26932 31282 Pushrod - Master Piston 28791 Spring, Master Piston 28768 Washer- MP Retainer 29944...
Page 120 ATTACHING PARTS SERVICE PARTS 790/795/797 Illus. Quantity Part Name Part Name per kit 17671 Feeler gauge 0.026 IN. (0.660 mm) 29133 29133 29133 Attaching Parts Group Attaching Parts Group Attaching Parts Group 29133 29133 Attaching Parts Group Attaching Parts Group 16590 Screw, Rocker Adjusting 28346...
Page 121 SERIES 60 SERVICE MANUAL 2.15 ELECTRONIC ENGINE CONTROL The Detroit Diesel Electronic Control System (DDEC) controls fuel injection timing and output by the electronic unit injectors (EUI) on the Series 60 Diesel engine. DDEC controls throttle, gas valve and the ignition system on the Series 60G engine. The system also monitors several engine functions using electrical sensors which send electrical signals to the Electronic Control Module (ECM).
Page 122 ELECTRONIC ENGINE CONTROL 2.15 Figure 2-78a DDEC V Electronic Control Unit (Rev. 12/03) All information subject to change without notice. From Bulletin 21-60-03 2-151a 6SE483 0303 Copyright © 2003 DETROIT DIESEL CORPORATION...
Page 123 SERIES 60 SERVICE MANUAL 2.16A DDEC V ELECTRONIC CONTROL UNIT DDEC V provides an indication of engine and vehicle malfunctions. The ECU continually monitors the DDEC V system. See Figure 2-79a. Figure 2-79a DDEC V System Series 60 Diesel Engine (Rev.
Page 124 DDEC V ELECTRONIC CONTROL UNIT 2.16A Any faults that occur are stored as codes in the ECU’s memory. These codes can be accessed in any of three ways: ® 1. A DDDL can be used to read the codes. 2. A personal computer (PC) connected to the ECM through a translator device which converts J1708 to RS232 protocol can be used.
Page 125 SERIES 60 SERVICE MANUAL ® Figure 2-79b Detroit Diesel Diagnostic Link (DDDL) (Rev. 12/03) All information subject to change without notice. From Bulletin 22-60-03 2-151d 6SE483 0303 Copyright © 2003 DETROIT DIESEL CORPORATION...
Page 126 DDEC V ELECTRONIC CONTROL UNIT 2.16A The SAE Standard Communications of the DDEC V system are listed in Table 2-6a. The fan control inputs and outputs for DDEC V are listed in Table 2-6b. The engine brake control features of DDEC V are listed in Table 2-6c. DDEC V can identify faulty components and other engine-related problems by providing the technician with a diagnostic code.
Page 127 SERIES 60 SERVICE MANUAL DDEC V Barometric Pressure Sensor (Baro Sensor) Camshaft Position Sensor (CPM Sensor) Crankshaft Position Sensor (CKP Sensor) EGR Delta Pressure Sensor (EGR Delta Pressure) EGR Temperature Sensor Engine Coolant Temperature Sensor (ECT Sensor) Engine Oil Level (EOL Sensor) Engine Oil Pressure Sensor (EOP) Engine Oil Temperature Sensor (EOT) Fuel Restriction Sensor...
Page 128 DDEC V ELECTRONIC CONTROL UNIT 2.16A 2.16a.1 Repair or Replacement of the DDEC V Electronic Control Unit The DDEC V ECU is a sealed, nonserviceable unit. Tag defective ECU for recore. 2.16a.2 Removal of the DDEC V Electronic Control Unit Perform the following steps for ECU removal: 1.
Page 129 SERIES 60 SERVICE MANUAL 5. Turn the ignition to the "ON" position. Observe the DDDL for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel DDEC V Single ECM Troubleshooting Manual (6SE565). 1.
Page 130 DDEC V ELECTRONIC CONTROL UNIT 2.16A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Always start and operate an engine in a well ventilated area.
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Page 143 ® ONLY Motor Coach Power Choice...
Page 144 Why Is The Series 60 So Popular? Because It Offers Motor Coach Operators The Best Combination Of: ■ ■ Performance Warranty Satisfaction ■ Fuel Economy ■ Ratings Flexibility ■ ■ Low Cost Of Operation Electronic Controls ■ Reliability ■ Lightweight ■...
Page 145 Engines Registered Since 1/1/92 200,000 300,000 400,000 500,000 600,000 589,643 Detroit Diesel Series 60 388,610 CAT 3406 C15/C16 372,170 Cummins N14/ISX/SIG Based on R.L. Polk Registrations (through Nov. 2003) And The Tradition Carries On Into 2004 The EPA has regulated heavy- EPA Heavy-Duty Engine Emission Standards duty diesel engines since the 1970s.
Page 146 The Series 60 EGR ® The NOx Challenge How Does EGR Work? EGR Is The Best Solution 2002 emission regulations required EGR (Exhaust Gas Recirculation) is a reduction in oxides of nitrogen a simple concept. During certain EGR is the technology chosen by (NOx) to 2.5 g/hp-hr.
Page 147 When EGR Was Added To The Series 60, Additional Refinements Were Also Made To The Series 60’s Proven Design. ■ Improved Liner, Valve, Seat & Guide Materials ■ Compact Gear Train ■ High Performance ■ Single Cylinder Turbocharger Air Compressor ■...
Page 148 Base Engine Improvements Power Assembly ■ Piston — Enhance Combustion Piston Bowl ■ Fire Ring — Increase Thickness from 2.5 mm to 3.0 mm — Base Material and Face Coating Material Enhancements ■ Connecting Rod — 12.7L Common Rod with 14L —...
Page 149 What Is Being Said In The Field About Series 60 With EGR? “Our Driver Acceptance Is At The Highest Level I Can Remember.” Series 60 Engine Population “Fleet representatives, reporting their first impressions of new 729,058 lower-emission diesel engines, 700,000 692,410 gave them generally high marks 643,964...
Page 150 The Rapid Acceptance Of EGR Over 40,000 Units...
Page 151 How Well Are They Doing? After 250,000 Miles Of Operation DDC Wanted To See How The New Components Were Holding Up. See For Yourself. Main bearings did their job and show no wear. Upper no load main Cam bearings show minor polishing. bearings show no wear and lower load bearings look as good.
Page 152 More… Piston bushings only show typical polishing. Connecting rod bushing machining marks are still visible indicating minimal wear. Piston liner shows cross hatch pattern intact.
Page 153 Look At These Fuel Economy Results From Fleets That Ran Their Own SAE Fuel Economy Tests Series 60 w/EGR vs. ISX w/EGR Series 60 5.4% (12L) & 5.9% (14L) Better July 24, 2003 Fleet “A” Series 60 2.83% Better August 20, 2003 Fleet “B”...
Page 154 What’s New For 2004? The Series 60 Continues To Evolve. 2004 Series 60 Engine Hardware Enhancements ■ Unit Injector, Monotherm Piston ■ New Cold Pipe ■ DDEC V ■ Tube & Shell EGR Cooler ■ Cylinder Head – Better Air Flow For Improved Performance ■...
Page 155 ■ EGR Cooler – Tube In Shell Design For Improved Durability – Improved Efficiency – Simpler Stainless Steel Housing With Less Welding – 10 Lb. Weight Reduction ■ New Fuel Injector – Improved End Of Injection Quality And Faster Response Time For Better Efficiency –...
Page 156 More Benefits Of Variable Geometry Turbocharging ( VGT ) ■ Maximum engine power up to 12,000 feet ■ Improved engine braking ■ Improved engine driveability Boost Pressure Benefit With VGT Turbocharger Boost Pressure Bene it ith urbocharger and acceleration ■ Improved performance at high altitudes ■...
Page 157 425-515 HP The Most Complete Power Range In A Single Engine Package Big Power With each family show the prepro- 12.7L grammed horsepower range in a Maximum HP @ RPM Peak Torque @ RPM All The Other single engine. A simple electronic 445 HP @ 1800 RPM 1450 LB-FT @ 1200 RPM tool is all that is required to change...
Page 158 These Features Combine To Want To Produce The Economy, Durability Know More? And Performance The Series 60 Take A Look At The Engine Is Known For Simple Design Of The cylinder liner is cooled all The Engine. The the way to the top, using a One-Piece Cylinder patented DDC feature called top liner cooling.
Page 159 DDEC Engine Management Technology ■ ■ Every Series 60 engine is equipped Multiple hp ratings Droop adjustment with Detroit Diesel Electronic ■ ■ Three levels of engine braking Idle timer shutdown Controls (DDEC). DDEC ® is the ■ ■ Engine fan braking Air temperature shutdown most popular electronic control sys- ■...
Page 160 DDEC Electronic Technology Ordinary Diesel ProDriver Diagnostic Engines Have Link™ Software ProDriver DC is a dashboard- mounted display with data card Electronic Detroit Diesel Diagnostic Link is a extraction capabilities. It provides PC Windows ® based software Controls real time and summary information engine troubleshooting tool that on vehicle and engine operation, as includes a built-in service manual...
Page 161 IRIS – Infrared Information System The IRIS system consists of simple infrared transmitters and receivers (transceivers). One transceiver is mounted on the vehicle. Another transceiver is mounted at the loca- tion (or locations) where the vehicle IRIS - Infrared owner wants to extract information, Information System such as the entrance to the shop or the fuel island.
Page 162 What About Warranty? The Series 60 engine is covered by coverage is available from 3 years a standard warranty of two years, or 300,000 miles or as much as unlimited miles with 100% parts 5 years or 500,000 miles. and labor coverage, and 5 years or 500,000- mile.
Page 163 What Can The Series 60 You Expect Engine Will From The Continue To Series 60? Provide Coach Heavy-duty diesel engines produced in North America after October 1, Operators 2002, must meet new emission standards. The proven Detroit Diesel With The Best Series 60 engine, newly-equipped with a simple EGR system, meets Combination...
Page 164 A complete power range ■ in a common package Easy to change ■ horsepower settings ■ The choice of the top fleets The choice of those who ■ want big power Lightweight ■ Low cost per mile ■ Unaided cold starts ■...
Page 165 Simple design ■ Easy to service ■ Dozens of DDEC ■ features as standard equipment The complete ■ DDEC System ProDriver ® ■ Data Summaries ■ Optimized Idle ® ■ Fuel Economy ■ Incentive 1-800-445-1980 direct ■ line to support Customized warranties ■...
Page 166 Series 60 24-Hour Hot Line Phone 1-800-445-1980 13400 Outer Drive, West, Detroit, Michigan 48239-4001 Telephone 313-592-5000 www.detroitdiesel.com © Copyright 2004 Detroit Diesel Corporation. All rights reserved. Detroit Diesel, the spinning arrows design, DDC ® , DDEC ® and Series 60 ®...
Page 167 SECTION 03: FUEL SYSTEM CONTENTS FUEL SYSTEM DESCRIPTION ......................3 FUEL LINES AND FLEXIBLE HOSES ....................4 FUEL VALVES ............................. 4 FILTERS AND WATER SEPARATOR ....................4 ................... 4 ILTER ATER EPARATOR ERVICING ) ............... 5 ILTER ERVICING RIMARY AND ECONDARY 382 ........................
Page 168 Section 03: FUEL SYSTEM ILLUTRATIONS ........................ 3 IGURE FUEL SYSTEM SCHEMATIC ......................4 IGURE MANUAL SHUT OFF VALVES ..................... 5 IGURE FUEL FILTER WATER SEPARATOR ....................6 IGURE DAVCO FUEL PRO FUEL FILTER .................... 7 IGURE DAVCO FUEL PRO EXPLODED VIEW 6: 208 &...
Page 169: Fuel System Description
Section 03: FUEL SYSTEM FUEL SYSTEM 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 or a fuel filter/water separator (optional) before it enters the fuel pump. If the vehicle is equipped with the optional “Davco Fuel Pro 382”, it is designed to be the only fuel filter in the system, no secondary fuel filter is necessary.
Page 170: Fuel Lines And Flexible Hoses
Section 03: FUEL SYSTEM FUEL LINES AND FLEXIBLE HOSES To drain, loosen positive seal drain valve below separator, and tighten after water has been Make a visual check for fuel leaks at all engine- flushed out. mounted fuel lines and connections and at the fuel tank suction and return lines.
Page 171: Fuel Filter Servicing (Primary And Secondary )
Section 03: FUEL SYSTEM 7. Fill filter element/bowl assembly with clean diesel fuel and attach onto cover. Hand tighten an additional 1/3 to 1/2 turn after making full seal contact. 8. Open valves of the engine fuel supply line. 9. Run the engine and check for leaks. 4.2 FUEL FILTER SERVICING (PRIMARY AND SECONDARY) The primary and secondary fuel filters are...
Page 172: Davco Fuel Pro 382
Section 03: FUEL SYSTEM 3. Install new filters. Tighten until filter is snug against the gasket, with no side movement. Rotate an additional 1/2 turn by hand. 4. Open engine fuel supply line valves. CAUTION Mechanical tightening of the fuel filters is not recommended and may result in seal and/or cartridge damage.
Page 173: Fuel Tank
Section 03: FUEL SYSTEM FUEL TANK All XLII series motorhomes are equipped with a high-density cross-link polyethylene fuel tank. W0 and WE vehicles fuel tanks have a total capacity of 250 US gallons (945 liters) while W5 can be equipped with an optional 90 US gallons (341 Liters) auxiliary stainless steel tank forward of the standard 208 US gallons (787 liters) fuel tank.
Page 174: Main Fuel Tank
Section 03: FUEL SYSTEM 5.1.2 Auxiliary Fuel Tank (if so equipped) NOTE 1. Open the baggage compartment just forward It is possible to drain both tanks through only of condenser compartment, disconnect the one plug, but the other tank will not drain (2) hoses previously joining the tanks.
Page 175 Section 03: FUEL SYSTEM FIGURE 6: 208 US GAL. MAIN FUEL TANK & 90 US GAL. AUXILIARY FUEL TANK (OPTIONAL) (W5) 03028 FIGURE 7: 250 US GALLONS FUEL TANKS (MAIN TANK & TRANSVERSE FUEL TANK) (W0 & WE) 03029 PA1553...
Page 176: Fuel Tank Verification
3. Drill perforation with a 23/64" bit. Make sure drill hole is perfectly round. 4. Insert a screw (Prevost #500196) and a washer (Prévost #5001244) into anchor nut (Prévost #500331). 5. Place assembly in drill hole. Tighten screw by 10 complete turns.
Page 177: Fuel Pump Installation
Section 03: FUEL SYSTEM FUEL PUMP INSTALLATION FUEL OIL SPECIFICATIONS The fuel pump is driven off the rear of the air The quality of fuel oil used for high-speed diesel compressor. engine operation is a very important factor in obtaining satisfactory engine performance, long engine life and acceptable exhaust emission levels.
Page 178: General Recommendations
Section 03: FUEL SYSTEM 4. Inspect element cover gasket and replace if 9.4 AIR CLEANER RESTRICTION INDICATOR necessary. A resettable restriction indicator may be installed Whenever it becomes necessary to remove the on the engine air-intake duct, clearly visible from air cleaner assembly (dry type) for maintenance the rear engine compartment.
Page 179: Fuel Pedal
Section 03: FUEL SYSTEM FUEL PEDAL 5. Reconnect electronic foot pedal assembly's cable harness to the ECM connector. If The EFPA (Electronic Foot Pedal Assembly) potentiometer calibration is necessary (see connects accelerator pedal "FUEL PEDAL ADJUSTMENT" this potentiometer (a device that sends an electrical section).
Page 180: Specifications
Section 03: FUEL SYSTEM SPECIFICATIONS Davco FuelPro 382 Fuel Filter / Water Separator Element Supplier number .............................23521528 Prévost number ............................531437 Primary Fuel Filter / Water Separator (optional) (May be used instead of primary filter (never use with a primary filter). Make ................................
Page 181 Section 03: FUEL SYSTEM Air Cleaner Make ................................Nelson Prevost Number ............................530206 Service Part No ............................7182 8N Supplier number (element cartridge) ......................70337N Prévost number (element cartridge) ......................530197 Air Cleaner Restriction Indicator Make ..............................Donaldson Model ..............................RBX00-2220 Indicates .........................at 20" (508 mm) of water Prévost number ............................530161...
Page 183 SECTION 04: EXHAUST SYSTEM CONTENTS DESCRIPTION ............................2 MAINTENANCE ............................ 2 MUFFLER REMOVAL & INSTALLATION ..................4 FLEXIBLE TUBE INSTALLATION ....................... 4 BUS SHELLS HEAT BLANKETS......................4 ............................4 XHAUST 5.1.1 Installation on W5 Bus Shells....................4 5.1.2 Installation on W0 & WE Bus Shells ..................4 ILLUSTRATIONS 0 &...
Page 184 Section 04: EXHAUST SYSTEM DESCRIPTION The muffler is rubber mounted on the vehicle frame. This feature reduces the transmission of vibrations to the muffler thus resulting in extended life of muffler, brackets and other components. MAINTENANCE The exhaust system should be inspected periodically for restrictions and leaks. The exhaust systems are shown on figures 1 &...
Page 185 Section 04: EXHAUST SYSTEM FIGURE 2: EXHAUST SYSTEM INSTALLATION (W5) 04013 PA1553...
Page 186 Section 04: EXHAUST SYSTEM MUFFLER REMOVAL & INSTALLATION WARNING Make sure that muffler and components are cold before handling. 1. Remove bolts and clamps securing exhaust pipe bellows to the muffler. 2. Support the muffler from underneath vehicle. 3. Remove U-clamp retaining the tail pipe to the FIGURE 3: FLEXIBLE TUBE INSTALLATION 04003 muffler.
Page 187 SECTION 05: COOLING SYSTEM CONTENTS DESCRIPTION ............................3 MAINTENANCE ............................ 4 ....................4 EHICLES ITHOUT OOLANT ILTERS ....................4 EHICLES OOLANT ILTERS HOSES ..............................5 ....................5 ONSTANT ORQUE LAMPS 3.1.1 Installation ..........................5 3.1.2 Maintenance ..........................5 COOLANT ............................. 6 ......................
Page 188 Section 05: COOLING SYSTEM SPECIFICATIONS ........................... 17 ILLUSTRATIONS ..........................3 IGURE COOLING SYSTEM ......................4 IGURE SURGE TANK ENGINE COMP ......................5 IGURE CONSTANT TORQUE CLAMP ........................ 6 IGURE SURGE TANK SIGHT GLASS 5) ....................8 IGURE HEATER LINE SHUTOFF VALVES 0 &...
Page 189: Description
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 190: Maintenance
Section 05: COOLING SYSTEM concentration antifreeze/water solution. Drain, flush, thoroughly clean and refill the system every two years or every 200,000 miles (320 000 km), whichever comes first. For vehicle equipped with coolant filters, change the precharge element filter or the existing maintenance element filter for a new maintenance element filter.
Page 191: Hoses
Section 05: COOLING SYSTEM liner that covers the band slots to protect NOTE soft/silicone hoses from damage, and help In order to ensure the integrity of the system, maintain consistent sealing pressure. it is recommended that a periodic cooling This type of clamp is designed to automatically system pressure check be made.
Page 192: Coolant
Section 05: COOLING SYSTEM 4. COOLANT 4.4 COOLANT REQUIREMENTS The coolant provides a medium for heat transfer 4.1 COOLANT LEVEL VERIFICATION and controls the internal temperature of the Coolant level is correct when cold coolant is engine during operation. In an engine having visible through the surge tank sight glass proper coolant flow, some of the combustion (Fig.
Page 193: Inhibitors
TMC RP-329 “Type A”. Use Nalco Chemical Diesel “DDC Power Cool” (P/N 23512138) or Company nitrite test kits (CO-318). A factory Prestone AF977 (bulk) Prevost #685125, 72702 coolant analysis program is available through (3.78 L), 70119 (205L), 70102 (4L).
Page 194: Coolant Not Recommended
Section 05: COOLING SYSTEM 4.7.4 Vehicles With Coolant Filters CAUTION Change the coolant precharge element filter for a maintenance element filter at initial oil changes Always test the solution before adding water (see Specifications at the end of this section) or antifreeze.
Page 195: Vehicles Equipped With Small Hvac System
Section 05: COOLING SYSTEM 5.2 VEHICLES EQUIPPED WITH SMALL 4. Open drain cock at bottom of thermostat HVAC SYSTEM housing to drain the coolant trapped above the thermostats (1, Fig. 9). FIGURE 7: HEATER LINE SHUTOFF VALVES (W5) FIGURE 9: ENGINE COOLANT DRAIN COCKS 05088 5.
Page 196: Filling Cooling System
Section 05: COOLING SYSTEM NOTE CAUTION If for any reason, the coolant level drops below the surge tank level probe, the Check Drain water pump completely before extended Engine light will flash storage avoid possible water pump damage. 4. Stop engine and allow cooling. If freezing weather is anticipated and the 5.
Page 197: Cooling System Descalers
Section 05: COOLING SYSTEM Replace the coolant filter with a precharge NOTE element filter; in this case do not mix Apply air gradually. Do not exert more than inhibitors with antifreeze/water solution. 138 kPa (20 psi) air pressure. Too great a Dispose of spent fluids in an environmentally pressure may rupture a radiator tube.
Page 198: Radiator
Section 05: COOLING SYSTEM To replace a filter: 9.1 MAINTENANCE 1. Close the two filter shutoff cocks on the filter Inspect the exterior of the radiator core every mounting head and unscrew the old filter 25,000 miles (40 000 km) or once a year, whichever comes first.
Page 199: Maintenance
Section 05: COOLING SYSTEM 10.2 INSPECTION DANGER Set the starter selector switch in engine compartment to the "Off" position to prevent accidental starting of the engine. Check security of fasteners securing fan blade assembly to fan driving mechanism. FIGURE 12: MECHANICAL LOCKING DEVICE 05061 Check coupling installation between fan blade assembly and gearbox.
Page 200: Fan Gearbox
Section 05: COOLING SYSTEM 3. Drain gearbox. 4. Replace drain plug. 5. Remove the dipstick located on top of gearbox and wipe with a clean rag (Fig. 15). 6. Adjust level to ″Full″ mark using Mobil SHC 630 (Prévost #180217) synthetic oil. 7.
Page 201: Fan Drive Alignment
Section 05: COOLING SYSTEM assembly with two nuts (P/N 500709), (74, Fig. 18) at both anchoring locations. FIGURE 18: ANGLE SUPPORT 05014 CAUTION Tilt fan and check for clearance. 3. Using a straight edge, align the 3"V"pulley on gearbox central shaft pulley with engine pulley, while taking pulleys outer edge thickness FIGURE 16: REGULATOR VALVE 12200...
Page 202 Section 05: COOLING SYSTEM NOTE Use a straight edge to measure engine pulley's vertical angle (Fig. 20). 5. Check alignments again (steps 2, 3 & 4) then replace temporary anchoring nuts (P/N 500709) (74, Fig. 18) with four nuts (P/N 500714) (47, Fig. 18) and tighten using a wrench.
Page 203 The fan clutch is controlled by DDEC (not by thermoswitch). Fan Gearbox Make ............................Superior Gearbox Ratio...................................1:1 Prevost number ............................550789 Lubricating Oil..........................MOBIL SHC 630 Prevost number (Oil) ..........................683666 Fan Belt (gearbox-fan) Make ................................Dayco Type ................................Poly-V Qty ..................................1 W0 & WE MTH: Prevost number ............................506684...
Page 204 Section 05: COOLING SYSTEM Fan Belt (gearbox-motor) Make ................................Dayco Type ................................V belt Qty ..................................3 W0 & WE MTH: Prevost number ............................506691 W5 MTH: Prevost number ............................509822 Coolant Prevost Number ............................685125 MAINTENANCE ELEMENT FILTER Prevost number ............................550630 PRECHARGE ELEMENT FILTER Prevost number ............................550629...
Page 215 SECTION 06: ELECTRICAL CONTENTS GENERAL DESCRIPTION........................5 ..........................5 IRING IAGRAMS 1.1.1 Using Wiring Diagram ......................5 1.1.2 Testing Circuits........................6 ........................6 IZES AND OLORS ........................... 6 PARE IRES ........................7 LEANING ONNECTORS ........................... 7 IRCUIT REAKERS ..........................7 ULTIPLEX USES ............................
Page 216 Section 06: ELECTRICAL ................33 SSENTIAL UNCTIONS PERATE EHICLE 4.8.1 Available Functions ....................... 33 ..............33 OWER RIORITY ODULES REAKDOWN ERVICE 4.10 M ........................33 ULTIPLEX ODULES 4.10.1 CECM ............................ 33 4.10.2 MASTER ID ........................... 33 4.10.3 IO-A ............................33 4.10.4 IO-B ............................
Page 217 Section 06: ELECTRICAL EXTERIOR LIGHTING........................51 12.1 H ........................... 51 EADLIGHTS 12.1.1 Headlight Beam Toggle Switch ..................... 51 12.1.2 Maintenance .......................... 51 12.1.3 Headlight Adjustment ......................51 12.1.4 Sealed-Beam Unit ......................... 55 12.1.5 Front Turn Signal........................56 12.1.6 Optional Xenon Headlamp ....................56 12.2 S ..........
Page 218 Section 06: ELECTRICAL ........................... 21 IGURE JUMP STARTING ........................ 33 IGURE B MODULE REMOVAL ..................36 IGURE TWIN BOSCH ALTERNATORS INSTALLATION ..............36 IGURE ALTERNATORS AND ACCESSORIES MOUNTING TORQUES 22: 50 .................. 37 IGURE DN DELCO ALTERNATOR SECTIONAL VIEW ) ..................37 IGURE ALTERNATOR WIRING DIAGRAM DELCO...
Page 219: General Description
6, you will find the location, the b) At item CB systems are controlled through individual main Prevost number, the breaker function, the battery relays. One or two 24 volt self-rectified breaker ampere rating and the page on alternators are belt driven from the engine, and which to find the corresponding diagram.
Page 220: Testing Circuits
Section 06: ELECTRICAL b) In first column DEVICE ID, look for device Yellow Multiplex modules communication SW102. CAN-H (twisted with green) Green Multiplex modules communication c) At device SW102, find the fault message, CAN-L (twisted with yellow) the minimum condition to activate, other Orange Connected to multiplex outputs inputs involved in logic, the multiplex module...
Page 221: Cleaning Connectors
Section 06: ELECTRICAL CLEANING CONNECTORS and afterwards toggle yellow lever upwards to reset the circuit breaker and close the circuit. When the pins and sockets of connectors become dirty, clean them with a good quality MULTIPLEX FUSES solvent containing HFC 134A refrigerant as its The multiplex outputs are protected in current by active ingredient.
Page 222: Precautions
Section 06: ELECTRICAL PRECAUTIONS DANGER Green Orange Grey Black 30 14 Guides, not Prior to working on a system inside vehicle, Grey terminal Brown make sure to cut electrical power and air cavities Green supply. A component could be supplied with Yellow electricity even if the ignition switch is set to the OFF position and/or a component could...
Page 223 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 224: Xlii Motorhomes Electrical Compartments And Junction Boxes
Section 06: ELECTRICAL XLII MOTORHOMES ELECTRICAL COMPARTMENTS AND JUNCTION BOXES FIGURE 3: ELECTRICAL COMPARTMENTS (XLII-40 BUS SHELLS) 06647 FIGURE 4: ELECTRICAL COMPARTMENTS (XLII-45E BUS SHELLS) 06648 PA1553...
Page 225: Maintenance
Section 06: ELECTRICAL FIGURE 5: ELECTRICAL COMPARTMENTS (XLII-45 BUS SHELLS) 06646 MAINTENANCE Electronic Ground Stud; A Cortec VCI-238 corrosion inhibitor has been Rear Junction Box Temperature Sensor. sprayed in all electrical compartments to protect Rear Junction Box components from corrosion. The life expectancy this product five...
Page 226: Circuit Breakers
Section 06: ELECTRICAL Power Fan Clutch Spare CIRCUIT BREAKERS 24VI A54 Spare All manually-resettable circuit breakers are 24VI A54 Spare located in the engine compartment R.H. side 24VI R8 Spare 24 VI Customer Spare area. An identification decal is affixed on the Resistors inside face of the door.
Page 227: A/C Junction Box
Section 06: ELECTRICAL On all vehicles equipped with one or two slide- Diodes outs, breaker CB6 is installed on breaker panel Pre-heating Baggage in engine compartment R.H. side area (Fig. 7). It compartment -2 is accessible through engine R.H. side door and Pre-heating Baggage is identified as follows:...
Page 228: Engine Compartment
Section 06: ELECTRICAL Rear start (push button switch); Relays 24V Wake-up Engine ECU Prime pump switch. mode Power 12V Wake-up mode Fuses CECM Power Mirror Front start main Spare fuse switch Driver liquid Spare fuse solenoid valve Spare fuse 12VI Customer 24 volts Wake-up Driver’s seat mode...
Page 229: Battery Discharge Protection
Section 06: ELECTRICAL 3. Supplying current for a limited time, when are no filler caps in the cover. The battery is sealed, except for small vent holes in the cover. electrical demands of the equipment exceed The vents must not be restricted as they allow the power output of the alternator.
Page 230: Battery Removal And Installation
Section 06: ELECTRICAL FIGURE 14: BATTERIES CONNECTIONS 06649 BATTERY REMOVAL NOTE INSTALLATION When the battery cables have been removed batteries located engine from the batteries, wrap the battery terminals and cable ends with electric tape to prevent compartment R.H. side area (Fig. 13). accidental grounding.
Page 231: Battery Rating
Section 06: ELECTRICAL good or bad, charged or discharged. The test NOTE indicator is a built-in hydrometer in one cell that When reinstalling batteries, battery provides visual information for battery testing connections must be tightened to 13-15 lbf-ft (Fig. 15). (18-20) Nm).
Page 232: Visual Inspection
Section 06: ELECTRICAL 3. With an ammeter reading specified load, 3.5.1 Visual Inspection read voltage. The voltage should be at least 1. Check the outside of the battery for a broken 9.6 volts. Disconnect the load. If the or cracked cover or case that could permit voltmeter indicates 9.6 volts or more, the loss of electrolyte.
Page 233: Battery Charging
Section 06: ELECTRICAL temperature of 70ºF (21ºC), voltage reading DANGER should be less than 0.3 volt. If the voltage reading exceeds 0.3 volt, there is excessive resistance in this circuit. During charging of the batteries, an explosive gas mixture forms in each cell. Part of this gas 2.
Page 234: Battery Charging Guide
Section 06: ELECTRICAL gassing electrolyte occurs battery 3.6.1 Battery Charging Guide temperature exceeds 125ºF (52ºC), the charging Fast Charging Rate rate must be reduced or temporarily stopped to 20 amps @ 3-¾ hours allow cooling and to avoid damaging the battery. 30 amps @ 2-½...
Page 235: Cleaning And Inspection
Section 06: ELECTRICAL by using energy from a booster battery or the 5. Make sure the clips from one cable do not battery from another vehicle. inadvertently touch the clips on the other cable. Do not lean over the battery when making connections.
Page 236: Common Causes Of Battery Failure
Section 06: ELECTRICAL enough to prevent the batteries from moving, but TROUBLESHOOTING they should not be tightened to the point that If a battery is known to be good and then has not excessive strain is placed on the battery performed satisfactorily service...
Page 237: Troubleshooting And Testing The Multiplex Vehicles
Section 06: ELECTRICAL o Check battery equalizer connections. NOTE Voltmeter exceeds 30 volts dc When performing an electrical system diagnostic with the MCD (message center display), the o Check alternator output. message “No Response ModA41” indicates o Check voltage regulator. either module A41 is not responding due to a CAN link problem or module A41 is not o Check battery connections.
Page 238: Can Network
Section 06: ELECTRICAL CAN NETWORK spare CAN network. Refer to the vehicle wiring diagram and paragraph 4.6 for more information. The CAN link wiring is separated in sections and uses connectors that are not shared with other TEST MODE FOR SWITCHES AND circuits.
Page 239: Test Mode For Electric Motors
Section 06: ELECTRICAL Multi-function lever courtesy blinkers switch Prerequisite conditions for the motor test mode: Headlights switch, 2 positions A. The battery charger must be connected to a Multi-function lever headlights beam toggle 110-120 volt power supply. If not, the test will switch be interrupted when the voltage drops below Baggage compartment door lock/unlock switch...
Page 240: Test Sequence - Mth Equipped With Small Hvac System
Section 06: ELECTRICAL In the engine compartment, the sequence is In the engine compartment, the sequence is as follows: as follows: A/C compressor clutch activates 3 times. A/C compressor clutch activated 3 times. [5 seconds delay] Left compressor unloader activates 3 times. Radiator fan clutch is disengaged (fan can Right compressor unloader activates 3 times.
Page 241: Can Network Layout And Troubleshooting
Section 06: ELECTRICAL CAN NETWORK LAYOUT AND TROUBLESHOOTING Rear Junction Box Wiper control panel (right console) Termination resistor CAN network Termination resistor Front electrical compartment Evaporator compartment A/C Junction Box Plug Connector 563589 Socket Connector 563590 Wiper control Plug with integrated Termination Resistor 563593 panel Rear Junction Termination...
Page 242: Roadside Troubleshooting
Section 06: ELECTRICAL ROADSIDE 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 retry cranking. 2.
Page 243 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Many secondary functions The CECM module does not 1. Check / reset circuit breaker CB2 (2 (not essential for driving) receive 24 V power. from the bottom. Check / replace fuse not functioning (interior lighting, driver's area...
Page 244 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Defroster message “No Response functioning but no heat or ModA46, Active” indicates a power cooling available in the problem on the module. (A CAN driver area. network problem would show the same message but doesn't produce these symptoms).
Page 245 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions 2. Check / reset circuit breaker CB1. 3. Check / replace fuse F80. 4. Probe gray connector on module to see if it is powered. Engine is overheating and Module A52 is not powered 1.
Page 246 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Fire alarm telltale light Short-circuited fire sensor or Prior to start the vehicle, cycle the ignition and audible alarm always defective sensor key to the ON position, OFF position and ON and there is no fire or then ON position again and then start the high temperature in the vehicle.
Page 247: Essential Functions To Operate The Vehicle
Section 06: ELECTRICAL o Driver's area lighting, ESSENTIAL FUNCTIONS TO OPERATE THE VEHICLE o Tag axle activation, Even with a defective CECM (Chassis Electronic o Courtesy blinkers. Control Module) or a CAN network problem, Functions lost if A44 is removed and used as essential base functions are maintained to rear spare part: start the vehicle from the engine compartment...
Page 248: Replacing Io-A Or Io-B Modules
Section 06: ELECTRICAL 4.11.1 Replacing IO-A Or IO-B Modules this point the MasterID module has finished loading the program in the CECM. Set the ignition key to the ON position and leave it in that position at all time while Go to the engine compartment R.H.
Page 249: Twin Bosch Alternators Installation
Section 06: ELECTRICAL TWIN BOSCH ALTERNATORS INSTALLATION If the alternators needed to be removed, reinstall as follows. Refer to figure 20 for installation and to figure 21 for tightening specifications: 1. Install alternator mounting bracket (1, figure 20) to the gear case. Use the four flanged phosphor alloy bolts on the pulley end of the bracket and the flanged nuts at the transmission end of the bracket;...
Page 250 Section 06: ELECTRICAL FIGURE 20: TWIN BOSCH ALTERNATORS INSTALLATION FIGURE 21: ALTERNATORS AND ACCESSORIES MOUNTING TORQUES PA1553...
Page 251 Section 6: ELECTRICAL FIGURE 22: 50DN DELCO ALTERNATOR SECTIONAL VIEW 06493 FIGURE 23: ALTERNATOR WIRING DIAGRAM (DELCO) 06067 PA1553...
Page 252 Section 6: ELECTRICAL This oil-cooled alternator is self rectifying. All CAUTION current carrying members, windings, built-in diodes, and field coils are stationary. The only moving component is the rotor. The alternator is Since there are no brushes, slip rings, or a totally-enclosed unit, cooled and lubricated by rubbing seals, the alternator requires no engine oil.
Page 253: Charging System Troubleshooting
Section 6: ELECTRICAL CHARGING SYSTEM 7.2.1 Diode Checks TROUBLESHOOTING Each diode may be checked for shorts and opens as follows: The troubleshooting of the charging system is made easier by the use of a 12 and a 24 volt 1. Ensure the ignition key switch is set to the voltmeter, “BAT”...
Page 254 Section 6: ELECTRICAL FIGURE 25: VIEW OF RECTIFIER END FRAME WITH COVER REMOVED 06069 each diode lead and the ohmmeter positive lead NOTE to the end frame as shown in parts “D”, “E” and Use an ohmmeter with a single 1.5 volts cell. “F”.
Page 255: Field Winding Check
Section 6: ELECTRICAL Open Fields Connect the ohmmeter leads to two pairs of diode supports as shown in parts "A", "B", and "C" of figure 28. Correct polarity of the leads must be observed. The ohmmeter should indicate a low resistance. If an infinite or a high resistance is measured in either one or both checks, the stator windings are open.
Page 256: Diode Replacement (In End Frame)
Section 6: ELECTRICAL 160-180 lbf-in (18-20 Nm). If no other parts are NOTE to be replaced, refer to “DIODE END COVER When replacing a diode, make sure it is INSTALLATION” in this section. designed for a negative ground system. The diode can be identified by the symbol stamped FIELD REMOVAL on the diode case.
Page 257: Stator Replacement
Section 6: ELECTRICAL 4. Place insulating sleeve in inner side of the 3. Thoroughly clean silver solder field terminal stud hole in the end frame, and connection with a wire brush. insert the terminal stud through the sleeve. 4. Using a high grade energized rosin flux, Place two O-rings and insulating bushing coat the silver soldered connection with a over the terminal stud and push into hole in...
Page 258: Alternator Removal (Delco)
Section 6: ELECTRICAL ALTERNATOR REMOVAL (DELCO) 1. Place Rear Start Panel "Starter Selector Switch" in engine compartment to the "OFF" position. 2. Place the ignition key switch to the “OFF” position. 3. Remove alternator drive belt (see “ALTERNATOR DRIVE BELT”). NOTE When reinstalling drive belt, it is important to FIGURE 30: ALTERNATOR RETAINING BOLTS AND...
Page 259: Alternator Cleaning And Inspection
Section 6: ELECTRICAL 8. Separate the rotor assembly and drive end and the inner race is a press fit on to the frame from the stator assembly by removing rotor shaft, the bearing will probably be the attaching screws. damaged when the shaft is pressed out and need to be replaced with a new part.
Page 260: Alternator Reassembly
Section 6: ELECTRICAL ALTERNATOR DRIVE BELT CAUTION Removal When replacing the alternator on the vehicle, 1. Insert a ¾‘’ socket drive into the tensioning ensure that an alternator with the proper drive arm opening (Fig. 31). ratio is used. Installation of an alternator with 2.
Page 261: Troubleshooting Procedures
Section 6: ELECTRICAL components are mounted on a printed circuit Install a new voltage regulator by reversing panel board to form a completely static unit the procedure. containing no moving parts. Regulators of this NOTE type have only four terminals which are identified "GND."...
Page 262: Undercharged Battery
Section 6: ELECTRICAL 3. Note the voltage setting. It should be steady 1. Stop alternator, turn off all accessories and at 27.5 volts. disconnect battery ground cable. 4. If not, the desired setting can be obtained by 2. Disconnect all leads from the regulator and removing the plug from the voltage regulator from the alternator field.
Page 263: Overcharged Battery
Section 6: ELECTRICAL readings with published specifications in A) By changing the printed circuit board in the Delco-Remy Service Bulletin 1G-186, regulator. Unscrew the retaining screws on 1G-187, 1G-188. alternator the printed circuit and remove it. Install a defective if it does not produce rated output new printed circuit board.
Page 264: Adjusting Voltage
Section 6: ELECTRICAL Transistor TR2 = Change the ohmmeter to use engagement and/or disengagement problems. the low scale. EB should read low and high. BC Failure to do so will render the Warranty null should read low and high. EC should both read and void.
Page 265: Exterior Lighting
Section 6: ELECTRICAL 12. EXTERIOR LIGHTING contribute to a decrease in voltage. Check wiring and connections regularly and keep The circuit for exterior lights, as well as their battery properly charged. When a headlight control switches, relays and circuit breakers are burns out, a new bulb must be installed.
Page 266 Section 6: ELECTRICAL 5. Install “Hoopy 100” Aligner onto support rail (Fig. 45). 6. Using an Allen key on the front wheel, level Hoopy 100 aligner until spirit level bubble is centered (Fig. 46 and 47). 7. Install a calibration fixture in the axis of front axle wheel and one in the axis of rear axle wheel (Fig.
Page 267 Section 6: ELECTRICAL 1. Set the support rail (Prévost #29261) down (Fig. 43). Using shims, adjust its level to stabilize it. Use previous reference marks to ensure proper positioning. 2. Make sure that headlight assembly fixing screw is properly fastened (Fig. 40). NOTE Make sure that the vehicle is at proper height (suspension) and that air pressure is above 90...
Page 268 Section 6: ELECTRICAL High Beam Adjustment and the plane on which the vehicle rests, not the floor on which the screen rests (Fig. 49). 1. Turn ON high beam lights. 4. The nominal vertical aim position on lower 2. Press ALIGN TO LAMP and move aligner in beam headlights shall be adjusted based on front of first beam.
Page 269: Sealed-Beam Unit
Section 6: ELECTRICAL FIGURE 50: HIGH-INTENSITY ZONE (SHADED AREA) OF A PROPERLY AIMED UPPER BEAM ON THE AIMING FIGURE 53: AIM INSPECTION LIMITS FOR LOWER- SCREEN 7.6 M (25FT) IN FRONT OF VEHICLE 06503 BEAM HEADLIGHTS 06506 12.1.4 Sealed-Beam Unit Bulb Removal and Replacement 1.
Page 270: Front Turn Signal
Section 6: ELECTRICAL 7. Tilt headlight assembly up into its housing then secure using fixing screw. NOTE Make sure headlight assembly is properly positioned into its housing before securing using fixing screw. 8. Perform alignment procedure. NOTE The headlight aim must be checked and adjusted even if it was properly adjusted before the sealed beam unit was replaced.
Page 271: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights
Section 6: 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 272: Clearance, Identification And Marker Lights
Section 6: ELECTRICAL 1. Pry out the rubber seal with a small 12.4.1 Marker Light Removal and Replacement screwdriver. Pull on the LED unit and The side marker light is a sealed unit (LED) and disconnect it. should replaced assembly accordance with the following procedure: 2.
Page 273: Lamp Removal And Replacement
Section 6: ELECTRICAL 12.5.1 Lamp Removal and Replacement The gauge lights, panel lights, switch lights and indicator lights have different bulb Both docking and cornering sealed-beam units arrangement. Thus, the procedure to change a can be changed in accordance with the following defective bulb can vary according to the procedure: application.
Page 274: Drivers Area Lights
Section 6: ELECTRICAL 4. Replace the rear dashboard housing. 4. Install new bulb in the socket, then push and turn clockwise to lock bulb in position. 13.2 DRIVER’S AREA LIGHTS 5. Push the bulb socket in the reading lamp unit. Two halogen ceiling lights are installed over the stepwell and the driver’s area.
Page 275 Section 6: 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 276 Section 6: ELECTRICAL 15. SPECIFICATIONS Battery Make............................... Volvo Model............................... 20359831 Prévost Number ..........................563030 Type ............................Maintenance-free Terminal type ........................... Top Stud Group size..............................31 Volts ................................12 Load test amperage ..........................290 Reserve capacity (minutes) ........................195 Cold cranking (in amps) -At 0 F (-18 C)........................950 (each battery)
Page 277 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..............................60-100D Amperes ............................100 amps Prévost Number ..........................563334 Starter Make....................Mitsubishi Electric Corporation (MELCO)
Page 279 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 280 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 281 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 282 * 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 283 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 284 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 285 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 286 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 287: 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 288: 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 289: 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 290: 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 291: 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 292: 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 293: 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 294: 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 295: 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 296: 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 297: 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 298: 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 299: 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 300: 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 301: 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 302: 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 303: 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 304: 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 305 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 306: 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 307: 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 308: 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 309: 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 310: 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 311: 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 312: 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 313 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 314: 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 315: 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 316 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 317: 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 318: 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 319: 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 320: 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 321: Open Exciter Diode
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 322: 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 323: Open Negative Rectifier Diode
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 324: Shorted Exciter Diode
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 325: Shorted Positive Rectifier Diode
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 326: Shorted Negative Rectifier Diode
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 327: Open Phase Of Stator
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 329 ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § 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 330 © ¢ ¤ ¥ ¥ ¨ © ¢ ¤ ¥ ¥ ¨ 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 331 ¢ ¤ ¥ ¥ ¨ ¢ ¤ ¥ ¥ ¨ 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 332 ¢ ¤ ! ¥ ! ¥ " ¨ # ¢ ¤ ! ¥ ! ¥ " ¨ # 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 333 $ ¢ % ¤ & ¥ & ¥ ' ¨ ( $ ¢ % ¤ & ¥ & ¥ ' ¨ ( 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 334 ) ¢ 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 335 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 336 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 337 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 338 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 339 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 340 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 341 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 342 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 343 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 344 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 345 FAULT CODE MANUAL Created on 00-04-25 15:30 FAULT CODE MANUAL B7L, B7TL, B12 - 1 -...
Page 346 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 347 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 348: 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 349: 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 350: 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 351 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 352: 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 353 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 354: 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 355 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 356 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 357: 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 358: 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 359: 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 360: 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 361 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 362 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 363: 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 364 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 365 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 366: 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 367: Fault Codes, Retarder 133
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 368 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 369 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 371 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 372 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 373 SECTION 07: TRANSMISSION CONTENTS DESCRIPTION ............................3 ....................3 LLISON UTOMATIC RANSMISSION 1.1.1 Retarder (if applicable) ......................3 WELDING PROCEDURES ........................4 ALLISON TRANSMISSION MAINTENANCE..................4 ......................4 ANUAL LUID LEVEL HECK ............................ 4 HECK ............................5 HECK ............5 LUID EVEL HECK...
Page 374 Section 07: TRANSMISSION ......................11 IGURE ENGINE CRANKING POSITION ........................12 IGURE MODINE OIL COOLER ......................12 IGURE COOLER WITH RETARDER )................... 14 IGURE AIR PRESSURE REGULATOR TYPICAL ....................14 IGURE TRANSMISSION CONTROL MODULE PA1553...
Page 375: Description
Section 07: TRANSMISSION DESCRIPTION memory. It then looks at these adjustments and resets parameters, which allow XLII Series Bus Shells are provided with an transmission quickly compensate Allison automatic transmission. variations in load, terrain or environment and to adjust for clutch wear and engine power changes. ALLISON AUTOMATIC TRANSMISSION A Diagnostic Data Reader can be connected to The B500 or B500R (with retarder) Allison...
Page 376: Welding Procedures
Section 07: TRANSMISSION WELDING PROCEDURES These procedures are intended only for vehicles equipped with transmission electronic controls. When frame or other welding is required on the vehicle, precautions are to be taken to protect the electronic control components. Refer to section 00: GENERAL INFORMATION, paragraph 3: “Precautions to be observed before welding”...
Page 377: Cold Check
Section 07: TRANSMISSION when selecting the Gauge Mode (refer to the ‘’Operator’s Manual’’ for added information). 2. Park the vehicle on a level surface and shift to Neutral (N). Apply the parking brake and allow the engine to idle (500 - 800 rpm). FIGURE 4: COLD CHECK 07050 3.
Page 378: Importance Of Proper Fluid Level
Section 07: TRANSMISSION o Waiting time, vehicle must be stationary NOTE for at least 2 minutes to allow the oil to Failure to meet one of the above parameters settle; will stop the two minute countdown. One of o Engine at idle; the codes shown hereafter will indicate the cause of the countdown interruption.
Page 379: Oil Contamination
Section 07: TRANSMISSION • To be sure a fluid is qualified for use in Allison transmission, check for the DEXRON-III® license numbers on the container or consult the lubricant manufacturer. Consult your Allison Transmission dealer or distributor before using other fluid types. Customers may use TranSynd™/TES 295 equivalent and extend drain intervals.
Page 380 Section 07: TRANSMISSION TABLE 1 Recommended Fluid and Filter Change Intervals Using Dexron-III / Non-TranSynd /Non-TES 295/Mixture Severe General MTH equipped with retarder MTH without retarder Filters Filters Main Internal Lube/ Main Internal Lube/ Fluid Fluid Auxiliary Auxiliary 12,000 Miles 12,000 Miles Overhaul 12,000 Miles...
Page 381: Oil And Filter Change
Section 07: TRANSMISSION 3.11 OIL AND FILTER CHANGE 2. Remove the drain plug from under the transmission (Fig. 6) and allow the oil to drain Allison transmissions are factory fill with Castrol into a suitable container. Check the condition TranSynd fluid.
Page 382: Installation Of Allison Transmission Brackets
Section 07: TRANSMISSION Fluid loss with filter change only NOTE When changing main and lube filters at Quantities listed above are approximations and recommended intervals, approximate fluid loss do not include external oil cooler lines. for each filter as follows: Using the oil level dipstick filler tube, refill with Main filter = 2 quarts (1.9 liters) 24 US qts (23 liters) [28 US qts (26.5 liters) if...
Page 383 Section 07: TRANSMISSION NOTE CAUTION For more clearance between the tag axle and transmission, the tag axle may be unloaded Do not rotate alternator shaft clockwise to avoid and jacked up or retracted (if applicable). removing tension on belt. 3. Remove engine splash guards and protective 15.
Page 384: Transmission Oil Cooler Removal
Section 07: TRANSMISSION TRANSMISSION OIL COOLER REMOVAL 1. To drain the cooling system, proceed as per Section 05 ‘’Cooling’’, paragraph 5: Draining. If the cooling system is contaminated, flush TRANSMISSION WITHOUT RETARDER system as per Section 05 ‘’Cooling’’, Stop engine and allow engine to cool. Close paragraph 7: Flushing.
Page 385: Breather
Section 07: TRANSMISSION 3. Loose, dirty, or improperly adjusted throttle flywheel with the flexible plate hole facing the sensor linkage; access opening in the flywheel housing. 4. Damaged or loose oil lines; DANGER 5. Worn or frayed electrical harnesses, improper routing;...
Page 386: Troubleshooting
Section 07: TRANSMISSION 17. Install transmission dipstick and filler tube. involves specific diagnostic incident codes. The TCM is located in the coach rear junction box. 18. Install cross member under transmission. 19. Install engine splash guards. 20. Adjust the retarder pressure to 80 ± 3 psi with pressure regulator.
Page 387 Section 07: TRANSMISSION The TCM separately stores the active and inactive codes. An active code is any code that is current in the TCM decision-making process. Inactive codes are codes that are retained in the TCM memory and will not necessary affect the TCM decision-making process.
Page 388 Section 07: TRANSMISSION NOTE 9.1.5 Diagnostic Code Response The Diagnostic Display Mode can be entered The following responses are used in the for viewing codes at any speed. Codes can "Diagnostic Troubleshooting Code List and only be cleared when the output speed = 0 Inhibited Operation Description"...
Page 389 Section 07: TRANSMISSION 9.1.6 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 390 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P0732 Incorrect 2 Gear ratio DNS, Attempt 3 , then 5 P0733 Incorrect 3 Gear ratio DNS, Attempt 4 , then 6 P0734 Incorrect 4 Gear ratio DNS, Attempt 5 , then 3 P0735 Incorrect 5...
Page 391 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P2671 Actuator Supply Voltage 2 (HSD2) High DNS, SOL OFF (hydraulic default) P2685 Actuator Supply Voltage 3 (HSD3) Low DNS, SOL OFF (hydraulic default) P2686 Actuator Supply Voltage 3 (HSD3) High DNS, SOL OFF (hydraulic default) P2714 Pressure Control Solenoid 4 (PCS4) Stuck Off...
Page 392 Section 07: TRANSMISSION 10. SPECIFICATIONS ALLISON AUTOMATIC TRANSMISSION WITH OR WITHOUT RETARDER XLII BUS SHELLS Gross input power (maximum)....................525 HP (392 kW) Gross input torque (maximum) ..................1650 Lbf-ft (2237 Nm) Rated input speed (minimum-maximum) ..................1600-2300 rpm Mounting: Engine....................SAE #1 flywheel housing, flex disk drive Torque converter: Type ......................
Page 393 SECTION 09: PROPELLER SHAFT CONTENTS PROPELLER SHAFT ..........................2 ............................ 2 ESCRIPTION REMOVAL, DISASSEMBLY, REASSEMBLY AND INSTALLATION ..........2 CLEANING, INSPECTION AND LUBRICATION ................. 3 ....................... 3 LEANING AND NSPECTION ............................ 3 UBRICATION EXPLANATION OF COMMON DAMAGES..................3 TROUBLESHOOTING .......................... 3 SPECIFICATIONS..........................
Page 394 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 395 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 396 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 409 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 410: 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 411: 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 412: 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 413: 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 414 Section 11: REAR AXLES TAG AXLE ALIGNMENT Remove and reinstall all wheel mount sensors on the drive and tag axles (fig. 8); NOTE For an accurate alignment, the tag axle must be aligned with the drive axle. NOTE Reinstall wheel mount sensors as shown in figure 7. For example, the sensor from the right side of the front wheel is mounted on the right side of the tag axle.
Page 415: Axle Shaft Sealing Method
Section 11: REAR AXLES NOTE 3. Assemble components immediately to permit the silicone sealant to compress evenly Refer to Section 16, "Suspension", for proper between parts. torque tightening of the longitudinal radius rod support nuts. a. Place a new gasket, then install the axle shaft into the wheel hub and differential carrier.
Page 416: Purposes
Section 11: REAR AXLES 1. Shortening of wheelbase, thus allowing tighter The bearings are greased for life and there is no turning in tight maneuvering areas such as need or facility for re-lubrication parking lots or when making a sharp turn. Front and tag axle wheel hub bearings need to 2.
Page 417 Section 11: REAR AXLES under frame. Remove drive axle wheels (if CAUTION required, refer to Section 13, "Wheels, Hubs And Tires"). On vehicles equipped with an automatic 2. Exhaust compressed air from the air supply transmission (with or without the output system by opening the drain cock on each air retarder), move tag assembly very carefully.
Page 418: Specifications
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 4.88:1 Standard 4.56:1 Optional NOTE The drive axle alignment consists in aligning the axle with reference to the frame.
Page 419 SERVICE MANUAL GENERAL INFORMATION NDS Axle range place product photo here SPICER SPECIALITY AXLE DIVISION...
Page 420 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 421 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 422 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 423 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 424 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 426 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 427 Maintenance Manual NDS axles Lubrication and Maintenance NDS Axle range Issue D place product photo here SPICER SPECIALITY AXLE DIVISION...
Page 428 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 New tie rod...
Page 429 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 430 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) . WARNING! NEVER WORK UNDER A VEHICLE SUPPORTED ONLY BY JACKS! ALWAYS USE SUITABLE AXSLE STANDS!
Page 431 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 432 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 433 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 434 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 NDS2 issue A Page No.8...
Page 435 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 436 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. Brake disc thickness should be checked in accordance with manufacturers dimensional recommendations.
Page 437 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. 13 TP1632 If Heavy grooving is found as shown in Fig.
Page 438 Spicer SpecialityAxle Division - Technical Publications © Spicer Speciality Axle Division NDS2 issue A Page No.12...
Page 439 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 440 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) -------- Top lever bolts M24 x 3 grade 10.9 ---------- 751 - 830 lbs.ft ------- 1018 - 1125 NM --- (NDS 80)
Page 441 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 442 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 443 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 236 - 260NM...
Page 444 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 180 - 210NM...
Page 445 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 236 - 260NM...
Page 446 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, Kirkstall Leeds LS5 3NF...
Page 447 Maintenance manual Model NDS Hub and brake assembly With Knorr Bremse Disc brake Fitted to offset barrel swivel SPICER SPECIALITY AXLE DIVISION...
Page 448 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 449 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 450 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 451 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 452 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 453 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 454 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 455 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 456 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 457 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 458 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 459 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 460 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 461 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 462 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 463 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 464 Spicer Speciality Axle Division - Technical Publications TP1193 © Spicer Speciality Axle Division Page No.18 Manual No. NDS8...
Page 465 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 466 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 467 TP-9539 Revised 09-05 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 468 Table B: Axle Oil Speciﬁcations A.P.I. Viscosity ArvinMeritor Outside Gear Oil Type Speciﬁcation Grade Speciﬁcation Speciﬁcation Temperature ˚ ˚ Above +10 F (–12 85W/140 O76-A Above –15 ˚ F (–26 ˚ 80W/140 O76-B Above –15 ˚ F (–26 ˚ 80W/90 O76-D Petroleum with SAE J2360 Tested...
Page 469 Table C: Extended-Drain-Approved Synthetic Axle Oil Suppliers — United States Distributors Name of Lubricant Viscosity Manufacturer Hi-Tek Synthetic 75W/90, 80W/140 Industrial Oils Limited Imperial SGO 75W/90, 80W/140 IPAC Lubemaster Syn EP 75W/90, 80W/140 Lubemaster (A Division of Certiﬁed Labs) Maxtron GL 75W/90, 80W/140 Country Energy LLC Mobilube SHC...
Page 470 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 471 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 472 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 473 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS AIR SYSTEM ............................. 4 BRAKES ............................4 AIR RESERVOIRS..........................4 ..........................4 AINTENANCE 3.1.1 Wet (Main) Air Tank ........................ 4 3.1.2 Primary Air Tank........................5 3.1.3 Accessory Air Tank ......................... 5 3.1.4 Secondary Air Tank......................... 5 ............................
Page 474 Section 12: BRAKE AND AIR SYSTEM QUICK RELEASE VALVES (QR-1) ....................11 SPRING BRAKE VALVE (SR-7) ..................... 11 PRESSURE PROTECTION VALVE (PR-4) ..................12 LOW PRESSURE INDICATOR (LP-3).................... 12 SHUTTLE-TYPE DOUBLE CHECK VALVE (DC-4)............... 12 AIR HORN VALVE .......................... 12 AIR SYSTEM TROUBLESHOOTING .....................
Page 475 Section 12: BRAKE AND AIR SYSTEM ILLUSTRATIONS ......................4 IGURE AIR RESERVOIRS LOCATION ) ..................... 5 IGURE REAR VALVE LOCATION TYPICAL ......................5 IGURE FRONT SERVICE COMPARTMENT ........................6 IGURE ACCESSORY AIR FILTER ........................ 6 IGURE HALDEX AIR FILTER DRYER ....................
Page 476: Air System
Section 12: BRAKE AND AIR SYSTEM AIR SYSTEM The drive and tag axles are provided with spring- loaded emergency/parking brakes, which are The basic air system consists of an air applied automatically whenever the control valve compressor, reservoirs, valves, filters and supply pressure drops below 40 psi (275 kPa).
Page 477: Primary Air Tank
(Fig. 1). It is provided with a bottom drain valve. system provided by Prevost. Do not fill system Purge this reservoir every 12,500 miles (20 000 by any point on the system.
Page 478: Accessory Air Filter
Section 12: BRAKE AND AIR SYSTEM ACCESSORY AIR FILTER AIR GAUGES (PRIMARY, SECONDARY AND ACCESSORY) The air pressure gauges, located on the “Owner’s Manual”), dashboard (see connected to the DC-4 double check valve, located on the pneumatic accessory panel in the front service compartment.
Page 479: Air Filter Dryer Purge Tank
Section 12: BRAKE AND AIR SYSTEM Change cartridge every 100,000 miles (160 000 FLEXIBLE HOSES km) or once every two years, whichever comes A flexible hose is used normally where it is first. The air dryer may be purged for mainte- impractical to use copper or nylon tubing due to nance purposes using the remote drain valve constant flexing during operation, such as brake...
Page 480: Maintenance
Section 12: BRAKE AND AIR SYSTEM MAINTENANCE excessively grooved or pitted, it should be replaced. Replace any other part that appears Inspect all lines for cuts, swelling, kinks or other worn or damaged. After reassembly, adjust to damage or deterioration. Check for lines being the specified pressure setting and check for air pinched by other components.
Page 481: Air Compressor (Ba-921)
Section 12: BRAKE AND AIR SYSTEM 2. Turn the adjustment screw clockwise to 10.1 COMPRESSOR REMOVAL AND increase the pressure slowly until the re- INSTALLATION quired pressure setting is reached. Tighten 1. Exhaust compressed air from air system by the locking nut. opening the drain valve of each air tank.
Page 482: Flip-Flop Control Valve (Tw-1)
Section 12: BRAKE AND AIR SYSTEM 2. Access this valve by tearing out the finishing panel, which holds the controls in place (Fig. 9). 3. Disconnect the air tubes. 4. Remove the retaining screws. 5. Service or replace the valve. 6.
Page 483: Parking Brake Alarm Switch
Section 12: BRAKE AND AIR SYSTEM 15. PARKING BRAKE ALARM SWITCH 17. QUICK RELEASE VALVES (QR-1) Refer to the appropriate annexed booklet The quick release valve is located on the front (Bendix, SL-5 Stop Light Switch; reference no. axle service brakes air line and permit rapid SD-06-2501).
Page 484: Pressure Protection Valve (Pr-4)
Section 12: BRAKE AND AIR SYSTEM 19. PRESSURE PROTECTION VALVE (PR-4) Maintenance and repair information on the pressure protection valve is supplied in the applicable booklet annexed to this section under reference number SD-03-2010. The air system includes two pressure protection valves (Fig.
Page 485: Air System Troubleshooting
Section 12: BRAKE AND AIR SYSTEM 23. AIR SYSTEM TROUBLESHOOTING operation in the event that one circuit of the system fails. The primary circuit is connected to The following list has been designed to help in the drive and tag axle brakes, while the troubleshooting some of the most common secondary circuit is connected to the front axle problems in the air system and main causes.
Page 486: Caliper Maintenance
Section 12: BRAKE AND AIR SYSTEM since all pads are the same. Once removed, worn pads should be replaced in their original position. FIGURE 21: BRAKE PAD CHECK 12117 FIGURE 22: CLEARANCE INSPECTION 12119 3. Measure pad to rotor clearance: 25.1.2 Caliper Maintenance Place a long feeler gauge (long enough to Use the following procedure for brake calipers...
Page 487: Roadside Inspection For Knorr/Bendix Air Disc Brakes
Section 12: BRAKE AND AIR SYSTEM about 5 - 10 times (30 PSI or 2 bar), the 25.1.3 Roadside Inspection for Knorr/Bendix wrench should turn clockwise in small Air Disc Brakes increments if the adjuster is functioning The coach is equipped with air disc brakes and correctly (Figs.
Page 488: Checking Pad Wear
Section 12: BRAKE AND AIR SYSTEM CAUTION Do not apply brakes while pads are removed as this could cause over stroke damage to the adjusting mechanism. FIGURE 30: ROTOR AND PAD WEAR LIMITS 12113 25.1.7 Checking Caliper Guidance and Seal Condition Perform sliding test.
Page 489: Checking The Tappet Boots
Section 12: BRAKE AND AIR SYSTEM NOTE CAUTION Do not attempt to use thinner or alcohol to clean the pin without removing it as it may Any ingress of water and dirt will lead to damage the rubber bushing. corrosion and may affect the function of the actuation mechanism and adjuster unit.
Page 490: Brake Tools
Section 12: BRAKE AND AIR SYSTEM Total running clearance should be between 25.1.13 Torque specifications 0.020 and 0.035 inch (0.5 and 0.9 mm). Smaller For proper caliper maintenance, refer to the clearances may lead to overheating problems. following figures. FIGURE 34: RUNNING CLEARANCE 12116 25.1.11 Brake Tools FIGURE 36: TORQUE SPECIFICATION...
Page 491: Air Brake Troubleshooting
Section 12: BRAKE AND AIR SYSTEM 27. 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 492 Section 12: BRAKE AND AIR SYSTEM FIGURE 38: AIR-OPERATED BRAKING SYSTEM (W0 & WE) PA1553...
Page 493 Section 12: BRAKE AND AIR SYSTEM FIGURE 39: AIR-OPERATED BRAKING SYSTEM (W5) PA1553...
Page 494 Section 12: BRAKE AND AIR SYSTEM If discharge valves leak, pull head and Pressure Build-Up / Low Pressure Warning / correct or replace cylinder head. Cutoff Point Filter/Dryer Built-in Governor Cutout If drive is slipping, replace gear. CONDITION: Vehicle leveled, parking brake If inlet valves are stuck, open or leaking applied.
Page 495: Brake Air Chamber
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 496: Emergency/Parking Brake Manual Release
Section 12: BRAKE AND AIR SYSTEM NOTE Tag Axle When the diaphragm, spring, or both are 1. Block the wheels to prevent the vehicle from replaced, they should be replaced in the moving. corresponding chamber on the same axle. 2. Turn the release bolt counterclockwise to cage the power spring (approx.
Page 497: Brake Chamber Disassembly
Section 12: BRAKE AND AIR SYSTEM 28.5 BRAKE CHAMBER DISASSEMBLY 5. Remove clamp ring, remove and discard the existing diaphragm. Install the new dia- phragm squarely on body. DANGER 6. Reverse the procedure for assembly. Tap clamp ring to ensure proper seating. Check Spring brake chambers, on drive and tag for proper operation before placing vehicle axles contain an extremely high compressive...
Page 498: Troubleshooting And Testing
Section 12: BRAKE AND AIR SYSTEM NOTE The ABS system is inoperative at speeds under 4 mph (6 Km/h). Illumination of ABS telltale indicator at these speeds is normal. CAUTION Disconnect the ECU or pull the ABS fuse before towing vehicle. 29.1 TROUBLESHOOTING AND TESTING For troubleshooting and testing of the vehicle's...
Page 499: Sensor Installation
Section 12: BRAKE AND AIR SYSTEM Maintenance 29.2.4 Sensor Installation No specific maintenance is required for the The following procedure deals with sensor solenoid control valve. installation on the axle wheel hubs. Read procedure carefully before reinstalling a sensor, as its installation must comply with operational 29.2.3 Sensors tolerances and specifications.
Page 500 Section 12: BRAKE AND AIR SYSTEM FIGURE 46: ABS 4S/4M CONFIGURATION PA1553...
Page 501 Section 12: BRAKE AND AIR SYSTEM 30. FITTING TIGHTENING TORQUES ο Flare and Inverted Flare: Tighten assembly with a wrench until a solid feeling is encoun- tered. From that point, tighten 1/6 turn (Fig. 47). FIGURE 49: HOSE FITTING 12055 AB-Type Copper Piping: Hand tighten nut (Fig.
Page 502 Section 12: BRAKE AND AIR SYSTEM SPECIFICATIONS Air Compressor 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 503 Section 12: BRAKE AND AIR SYSTEM Quick Release Valve Make........................... Bendix Westinghouse Model..............................QR-1 Prévost number..........................641429 Spring Brake Valve Make........................... Bendix Westinghouse Model..............................SR-7 Prévost number.............................. Pressure Protection Valve Make........................... Bendix Westinghouse Model..............................PR-4 Nominal closing pressure....................70 psi (482 kPa) Prévost number..........................
Page 504 Section 12: BRAKE AND AIR SYSTEM Tag Axle Brake Chambers Make............................Knorr-Bremse Type ......................16 as service – 16 as emergency Prévost number..........................641308 Piggy Back (On Tag Brakes) Make............................Knorr-Bremse Type ...........................16 as emergency Prévost number..........................641431 Brake Lining (All Axles) Make............................
Page 505 Effective Date: 12/02/05 Bendix Air Disc Brake Pad Replacement on Prévost Car Vehicles Subject: Prévost 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 the potential brake performance degradation separating from the backing plate in many associated with use of non-approved, aftermarket...
Page 506 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 507 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 508 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 509 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 510 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 511 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 512 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 513 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 514 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 515 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 516 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 517 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 518 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 519 ¶ 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 520 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 521 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 522 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 523 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 524 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 525 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 526 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 527 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 528 16 BW2158 © Honeywell Commercial Vehicle Systems Company 4/2001. Printed in USA.
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 TW-1, TW-3, TW-4, TW-5 & TW-6 CONTROL VALVES *Formerly SD-03-64 REVERSED LEVER...
Page 538 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 539 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 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 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 546 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 547 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 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 *Formerly SD-03-69 QR AND QR-1 QUICK RELEASE VALVES QR-1 VALVE QR VALVE Brake Valve...
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 c. Install O-Ring in cover groove; install cover and tighten 1.
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 E-8P & E-10P DUAL BRAKE VALVES TREADLE TREADLE MOUNTING MOUNTING PLATE...
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 TP-5 TRACTOR MV-3 TRAILER CONTROL SLACK SPRING BRAKE SLACK (E-8P OR E-10P) QUICK...
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 - 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 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 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 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 UPPER BODY UPPER BODY LOWER LOWER BODY BODY BODY BODY ATTACHING...
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 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 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 11. Remove the relay piston (20), relay piston spring (21), 6.
Page 566 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 567 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 569 ® 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 570 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 571 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 572 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 573 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 574 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 575 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 576 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 577 SECTION 13: WHEELS, HUBS & TIRES CONTENTS WHEELS..............................2 WHEEL MAINTENANCE ........................2 ............................2 NSPECTION ........................3 INGLE HEEL EMOVAL ......................3 INGLE HEEL NSTALLATION DUAL WHEELS............................. 3 ........................3 UTER HEEL EMOVAL ........................... 3 NNER HEEL ......................3 NNER HEEL NSTALLATION...
Page 578: Wheel Maintenance
Section 13: WHEELS, HUBS & TIRES 1. WHEELS 2. WHEEL MAINTENANCE When the vehicle is provided with stud-mounted Wheel maintenance consists periodic wheels, wheel studs and nuts on the left side of inspections. Check all parts for damage and the vehicle have left-hand threads whereas make sure that wheel nuts are tightened to the those on the right side have right-hand threads.
Page 579: Dual Wheels
Section 13: WHEELS, HUBS & TIRES 2.2 SINGLE WHEEL REMOVAL 3. DUAL WHEELS 1. Stop engine and apply parking brake. 3.1 OUTER WHEEL REMOVAL 2. Loosen wheel nuts about one turn (do not Same as described in "Single Wheel Removal" remove the nuts).
Page 580 Section 13: WHEELS, HUBS & TIRES Repeat for each of the 10 "hex stud nut - inner 2. Spray Alcoa Cleaner (Prévost #683529) cap nut assemblies" according to the tightening evenly on cool outer surface of wheel. Let sequence in Figure 2. work 15-20 minutes (keep wet by spraying more Cleaner if necessary).
Page 581: Wheel Studs
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 582: Care Of Wheels
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 grease and paint (except for initial “E”...
Page 583: Bearing Adjustment
Section 13: WHEELS, HUBS & TIRES NOTE 4. Tighten lock check bearing 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, then the retaining 9.2 DISASSEMBLY AND REPAIR clip within the unit is damaged and a new unit 1.
Page 584: Tire Maintenance
Section 13: WHEELS, HUBS & TIRES 8. Assemble axle flange to axle using a new An under inflated tire builds up heat that can gasket. Apply sealant in stud area. After both cause sudden tire destruction, resulting in wheels have been assembled according to improper vehicle handling and possible loss of above procedure, fill the differential with the vehicle control.
Page 585: Tire Matching
Section 13: WHEELS, HUBS & TIRES WARNING Incorrect tire pressures cause increased tire wear and adversely affect road holding of the vehicle, which may lead to loss of vehicle control. FIGURE 7: TIRE LIFE / INFLATION PRESSURE 13010 WARNING Recommended tire inflation pressures and maximum allowable loads apply to speeds up to 65 mph (105 km/hr).
Page 586: Wheel Balancing
Section 13: WHEELS, HUBS & TIRES NOTE It is recommended that all tires on coach be of the same type. 11.3 WHEEL BALANCING Before balancing, wheels must be clean and free from all foreign matter. The tires should be in good condition and properly mounted. An unbalanced wheel can be due to a bent wheel or improper mounting.
Page 587 Section 13: WHEELS, HUBS & TIRES 12. SPECIFICATIONS DRIVE AXLE WHEELS Wheel size............................9" X 22.5" Wheel nut torque.................... 450 - 500 lbf-ft (610 - 680 Nm) Tire size............................ 315/80 R 22.5 STANDARD FRONT AND TAG AXLE WHEELS Wheel size............................9" X 22.5" Wheel nut torque....................
Page 589 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 590 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 591 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 592 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 593 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 595 truck and trailer ® Alcoa Dura-Bright Wheels More shine. Less maintenance. You said you wanted aluminum wheels that kept their brilliant good looks with as little effort as possible. And, we listened. Along with faster, easier cleaning and maintenance, Introducing the first aluminum wheels you don’t polish or you get all the advantages you’ve come to expect from scrub –...
Page 596 Dura-Bright ® Wheel Specifications Alcoa aluminum disc wheel mounting dimensions are consistent with SAE Recommended Practice J694 August ’98. Part numbers listed for all sizes are Dura-Bright ® brushed finish. Buffed finishes are indicated by changing the last digit of the part number listed to one of the following: For buffed outside only, part number should end in “1”...
Page 598 How to use this manual This manual is written in a style called structured text. LIMITED WARRANTY Throughout the manual you will find numbers which look FOR HEAVY DUTY TRUCKS, TRUCK TRAILERS, like this (See 3-1, page 18). These numbers are cross BUSES, RV and MOTORHOME WHEELS references to other sections of the manual.
Page 599 Table of Contents Section Number Page Number 1 Wheel Specifications....................2 2 Inspection......................5 Inspect thoroughly and frequently ..................5 Excessive heat damage ......................6 Dimension checks........................7 Cracked or damaged wheel checks ..................8 Mounting area ........................9 Corrosion..........................10 Stud holes ..........................11 Disc area ..........................11 Rim area ..........................12 2-10 Gutter area ...........................12 2-11 Rim flange wear ........................13 3 Alcoa 15°...
Page 600 Specifications Alcoa aluminum disc wheel mounting dimensions are consistent with SAE Recommended Practice J694 February 2001. Part numbers listed for all sizes are satin finish. 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.” For polished inside only, part number should end in “2.”...
Page 601 Specifications cont’d. TUBELESS WHEELS (round hand holes) ENGLISH UNITS continued Maximum Maximum Rear inner Rear inner Hub cover wheel load Wheel wt. Outset Inset inflation Valve Part Front outer cap nuts cap nuts Rear outer Lug nut system Item no. Wheel description in lbs.
Page 602: Specifications
Specifications cont’d. TUBELESS WHEELS (round hand holes) ENGLISH UNITS (METRIC UNITS) Maximum Maximum wheel load Wheel Outset Inset inflation Rear inner Rear inner Hub cover in lbs. wt. lbs. inches inches PSI—cold Valve Part Front outer cap nuts cap nuts Rear outer Lug nut system...
Page 603: Inspect Thoroughly And Frequently
Inspection Inspect Safe operation requires thorough examination of wheels and attaching hardware, at frequent intervals, both on and off the vehicle. thoroughly and frequently Wheels that have been in service need to be inspected at regular intervals to assure proper and safe performance. Like tires and other vehicle components that work hard, wheels will eventually wear out.
Page 604: Excessive Heat Damage
Excessive WARNING Excessive heat from fire, brake malfunction, wheel bearing heat damage failure or other sources may weaken the metal and cause the wheel/tire assembly to separate explosively. Exploding wheel/tire assembly can cause death or serious injury. WARNING Immediately and permanently remove from service any wheel that has been exposed to excessive heat.
Page 605: Dimension Checks
Dimension Open side circumference check checks WARNING Wheels that have been subjected to high pressure tire and rim separation, run flat, excessive heat or other physical damage may no longer have sufficient dimension and contour to retain tire bead while under pressure. WARNING Rims that lack proper dimension and contour can lead to explosive separation of tire and rim, causing injury or death.
Page 606: Cracked Or Damaged Wheel Checks
Dimension Tire wear or ride problems checks (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 3-5, page 22 for recommendations and instructions for demounting tubeless tires and 6-5, page 43 for recommendations and instructions for demounting tube-type tires).
Page 607: Mounting Area
Mounting area Stud hole cracks are usually caused by improper torquing (see 4-9, page 29 and 5-2, page 35), excessive loading or insufficient mounting flange support by the hub or brake drum. Remove wheel from service. Shown below are stud hole cracks emanating from stud hole to stud hole. Causes are: undersized diameter of wheel support surface (see specifications below), support surface not flat, incorrect attachment parts (see 4-12, page 34) and insufficient torque (see 4-9, page 29 and 5-2, page 35).
Page 608: Corrosion
Mounting area Support surface diameters (continued) Support surface (backup diameter) should be flat to the diameter recommended on the chart below: Number of Bolts Bolt Circle Mounting Type Backup Diameter Thread Size 11.25 inch U.S. Stud pilot 13.2-13.5 in. .750/1.125 in. 285.75mm Hub pilot 13.2-13.4 in.
Page 609: Stud Holes
Stud 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 610: Rim Area
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. Gutter area Projections on the side of the wheel gutter area on tube type wheels can cause uneven seating of the side and lock ring and chipping of the gutter.
Page 611: Rim Flange Wear
Rim flange wear 2-11 Irregular wear on the surface of the rim flange is caused by abrasion from the tire chafer and sidewall. Rim flange wear happens most often in applications with heavy or shifting loads. If you are experiencing excessive rim flange wear in your operation, consider using Alcoa Dura-Flange ®...
Page 612 STEP 2. After the wheel is separated from the tire, use a ball tape to verify the Rim flange circumference of the bead seat on the open side is acceptable (see 2-3, page 7). wear Check the wheel flange with the Alcoa Rim Flange Wear Gauge to determine if the wheels must be removed from service for excessive rim flange wear (continued) (photo 1 on page 13).
Page 613 Rim flange Edge Removal Procedures wear There are many tools available to remove the sharp edge on the wheel caused (continued) 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 614 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 wear care must be taken to remove metal as uniformly as possible and not to gouge the wheel (photo 7 on page 15).
Page 615 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 wear is still cut, perform the steps again to remove the sharp edge. Always remove the minimum amount of material necessary to eliminate the sharp edge.
Page 616: Alcoa 15° Drop Center Wheel For Tubeless Tires
Alcoa 15° Drop Center Wheel for Tubeless Tires Recommendations WARNING Damaged tires or wheels can lead to an explosive separation for mounting of tires and wheels. tubeless tires Explosive separation can result in 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 617: Mounting Tubeless Tires
Recommendations for mounting WARNING Use of a volatile or flammable material, such as ether or gasoline, as an aid to seating the tire beads on the wheel can lead to an tubeless tires uncontrolled pressure build-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 618 NOTICE: Alcoa aluminum 19.5"RW and non-symetrical well wide base wheels require tires be Mounting mounted and demounted over the disc side of the wheel only. For a free instruction wall chart, tubeless tires contact: Alcoa Inquiry Fulfillment, Markinetics Inc., P.O. Box 809, Marietta, OH 45750. continued WARNING Use of a volatile or flammable material, such as ether or gasoline,...
Page 619 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) 17.5HC 6.00HC 22.5 5.25, 6.00, 6.75 215/75R 17.5...
Page 620: Demounting Of Tubeless Tires
1. When hand demounting tires from wheels, placing aluminum wheels on a clean Recommendations wooden floor, or rubber mat is recommended. Additional care should be used when for demounting demounting Alcoa Dura-Bright ® surface treated wheels since minor nicks and scratches can not be polished out (see section 5-8, pages 37-38 for specific cautions, care and tubeless tires maintenance procedures).
Page 621: Wheel Installation
Wheel Installation Recommendations 1. For the same reason the best tires are run on the front axle, the best wheels also should be used on the front axle. for proper 2. Make sure all wheel cap nuts are properly torqued — check them often (see section 4-9, page 29). installation of If the wheel is loose, the holes will pound out (deform).
Page 622: Wheel Cap Nuts
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, WARNING causing injury or death.
Page 623: How To Measure Stud Standout
How to measure Stud standout is measured from the axle end mounting surface to the end of the stud. stud standout Exposed Drum shoulder End of End of stud stud Drum Stud Standout Stud Standout Mounting Mounting surface surface Outboard mounted drum Inboard mounted drum Stud located ball The nut seat for the stud located ball seat mounting system is a...
Page 624: Single Wheel, Stud Located, Ball Seat Mounting
Single wheel, Front wheels are mounted as singles and require 1.6" (1-39/64") minimum stud standout. Most vehicles have 1-1/8-inch studs on the front hubs. Alcoa single cap nuts, Part Nos. stud located, ball 5996R and 5996L, or equivalents, should be used. Some front hubs have 3/4-inch studs. seat mounting On these hubs, use Alcoa single cap nuts, Part Nos.
Page 625 Dualed wheels, 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). stud located, ball When changing types of brake drums be sure to check for excessive stud standout seat mounting (greater than 1.88"...
Page 626 Dualed wheels, DiscMate wheel spacers are recommended for use with Alcoa Dura-Bright surface ® treated wheels to protect the wheel contact surfaces from marring. DiscMate wheel steel inner/ spacers are placed between the contact surfaces of the Dura-Bright ® wheel and the aluminum outer brake drum and between the steel and aluminum wheels as shown below.
Page 627: Tightening Stud Located, Ball Seat Cap Nuts
Cap nut thread The actual length of thread engagement present in an assembled wheel can not always be determined by visual inspection or measurement of a tightened assembly. The relationship engagement, of the wheel cap nut seat to the end of the stud may vary. If there is any doubt that stud located enough thread engagement is present, the number of engaged threads may be counted.
Page 628 Tightening stud Stud located, ball seat mounting system. located, ball seat cap nuts It is recommended that stud threads on stud located mounting systems be lubricated with SAE 30W oil and torqued between 350 and 400 foot-pounds. If threads are not (continued) lubricated, torque to between 450 and 500 foot-pounds.
Page 629 Tightening stud After 50-100 miles of operation, torque should be rechecked. Loosen outer cap nuts on every other stud to check the torque on inner cap nuts, then retorque outer cap nuts. located, ball Repeat steps on remaining studs. Check torque frequently from then on. If nuts require frequent tightening, studs break frequently, or wheel nut seats are pounding out, seat cap nuts hardware and mounting practices should be reviewed.
Page 630 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 and wide base from steel to aluminum duals. Measure the hub pilot to make sure the hub has a minimum wheels, hub pilot length of 1.06-inch or 27mm for dualed wheels.
Page 631 Lubricate the hub pads or the wheel hub bore generously with a non-water-based Tightening lubricant. hub piloted mounting, Lube here two-piece flange nuts Lube Lube here (continued) 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 632: Incorrect Assemblies
Incorrect WARNING Use of two-piece flange nuts on ball seat wheels, ball seat cap nuts assemblies 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 WARNING and cracked wheels, conditions which can lead to injury or death.
Page 633: Proper Torque, Wheel Identification, Valves And Surface Maintenance
Proper Torque, Wheel Identification, Valves and Surface Maintenance Abuse can shorten the life of a wheel. Lack of care in changing a tire, heavy pounding Avoid abuse of the wheel rim, overloading, exposure to excessive heat or hitting curbs at high speed or a sharp angle can damage wheels.
Page 634: Lead Balance Weights (Clip On)
Lead balance weights for Alcoa wheels are available from your Alcoa Wheel Distributor. Lead balance With radial tires it may be necessary to temporarily reduce the tire pressure when weights (clip on) installing clip-on weights to allow 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 635: Maintenance Against Corrosion (Non Dura-Bright Surfaced Treated Wheels)
Maintenance The following information is for standard Alcoa forged aluminum wheels without the Dura-Bright ® surface treatment. See section 5-8, page 37 for specific instructions against corrosion on the care and clearing of Alcoa Dura-Bright ® surface treated wheels. (non-Dura-Bright ®...
Page 636: Identification
Dura-Bright ® d. Clean your Alcoa Dura-Bright ® wheels using the above procedures as frequently as required to maintain their appearance. Typical road soils, grime and brake dust trap surface treated moisture, which can cause corrosion over a period of time. These must be removed wheels cleaning regularly.
Page 637: Flat Base Wheel For Tube-Type Tires
Flat Base Wheel for Tube-type Tires Tube-type WARNING Mismatched rim/wheel components can lead to explosive wheel part separation of wheel components. interchangeability Explosive separation of wheel parts can cause serious injury WARNING or death. See chart below for matching components. The following is the Alcoa Aluminum Wheel inter- changeability information from the OSHA Multipiece Rim Matching Chart.
Page 638: Mounting Recommendations For Tubed Tires
1. Inspect the wheel for damage. Do not use a bent, cracked, damaged or severely Mounting corroded wheel. (See Section 2, page 5). recommendations 2. Inspect ring(s) for corrosion, bending or other damage and discard if any is apparent. for tubed tires 3.
Page 639: Mounting Of Tubed Tires
Mounting of When mounting Alcoa flat base wheels for tube-type tires you must use the proper side ring or side and lock ring required for each wheel. The table below lists the Alcoa tube-type tubed tires wheels currently in production and the proper side ring or side and lock ring identification recommended for each wheel.
Page 640: Demounting Recommendations For Tubed Tires
WARNING An inflated tire contains air under pressure which can be Demounting a dangerous explosive force. recommendations Explosive separation of a tire and wheel can cause serious injury or death. WARNING for tubed tires Follow proper service procedures to avoid injury or death. WARNING An aluminum wheel can be structurally weakened by uncontrolled excessive heat.
Page 641: Demounting Of Tubed Tires
Demounting of tubed tires NOTICE: Tire must be completely deflated and valve core removed before demounting. If manually breaking the tire beads from the wheel, Once the tool is inserted, pry down and out as it is important to use the proper tools. Tire tools illustrated.
Page 642: Osha Regulations
OSHA Regulations OSHA Sec. 1910.177 Servicing multi-piece and single piece rim wheels. Regulations (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 automobile tires or truck tires designated “LT”.
Page 643: Osha Regulations
OSHA Single piece rim wheel means the assemblage of single piece rim wheel with the tire and other components. Regulations Single piece wheel means a vehicle wheel consisting of one part, designed to hold the (continued) 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 644 OSHA 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 Regulations occurring at 150 percent of the maximum tire specification pressure for the (continued) type of rim wheel being serviced.
Page 645 OSHA When the tire has been driven underinflated at 80% or less of its recommended pressure, or Regulations (ii) When there is obvious or suspected damage to the tire or wheel components. (continued) (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.
Page 646 OSHA (10) Tires shall not be inflated above the maximum pressure recommended by the manufacturer to seat the tire bead firmly against the rim flange. Regulations (11) No heat shall be applied to a single piece wheel. (continued) (12) Cracked, broken, bent, or otherwise damaged wheels shall not be reworked, welded, brazed, or otherwise heated.
Page 647: 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 2-PIECE FLANGE NUT - A two-piece washer and nut combination used to secure hub piloted wheels.
Page 648 Glossary of LOCK RING - The third piece of a three rim assembly which positions and supports the side ring to the rim base. Common Terms MAXIMUM INFLATION - The highest amount of air pressure allowed, measured (continued) at normal ambient temperatures. mm - Abbreviation for millimeters.
Page 649: 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 650: Conversion Tables
Conversion Tables Inch Fraction, Decimal and Millimeter Equivalents Chart (Up to 1 inch)
Page 651: Conversion Factors
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 2.2050 Pounds Foot-pounds to Kilogram Meters Ft-lbs 0.13826 Kilogram Meters to Foot-pounds 7.23 Ft-lbs...
Page 652 Alcoa Wheel and Forged Products 1600 Harvard Avenue Cleveland, Ohio 44105 (800) 242-9898 www.alcoawheels.com Copyright © 2004 Alcoa Wheel and Forged Products All Rights Reserved Form E37-13584 Printed in USA 03/05/30M...
Page 653 SECTION 14: STEERING CONTENTS STEERING SYSTEM..........................3 ............................ 3 ESCRIPTION POWER STEERING GEAR ........................4 ............................ 4 ESCRIPTION ....................5 OWER TEERING EMOVAL ..................... 5 OWER TEERING NSTALLATION BLEEDING POWER STEERING HYDRAULIC SYSTEM..............5 HYDRAULIC PRESSURE TEST......................5 TROUBLESHOOTING .......................... 5 POWER STEERING HYDRAULIC PUMP ....................
Page 654 Section 14: STEERING ILLUSTRATIONS ......................3 IGURE STEERING SYSTEM AXLE SETUP ........................4 IGURE POWER STEERING GEAR ......................4 IGURE FRONT SERVICE COMPARTMENT .......................... 6 IGURE STEERING COLUMN ........................6 IGURE STEERING STOP SCREW ................... 7 IGURE DRAG LINK TO BELL CRANK CONNECTION ........................
Page 655: Steering System
Section 14: STEERING STEERING SYSTEM 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. 1). The steering linkage consists of tie rods connected to the bell crank and the steering arm at the left side of the bus shell, and to the idler arm and steering arm at the right side of the bus shell.
Page 656 Section 14: STEERING POWER STEERING GEAR FIGURE 3: FRONT SERVICE COMPARTMENT 14039 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 2: POWER STEERING GEAR 14035 applied to the steering wheel.
Page 657: Troubleshooting
Section 14: STEERING POWER STEERING GEAR REMOVAL NOTE vehicles equipped with SERVOCOMTRONIC unit, refer WARNING supplement repair manual SERVOCOM. The steering gearbox weighs approximately 100 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 DESCRIPTION steering gear.
Page 658: Maintenance
Section 14: STEERING MAINTENANCE Refer to the "ZF-SERVOCOM Repair Manual" and the "TRW - Power Steering Pump Service Manual" annexed to this section. STEERING WHEEL REMOVAL 1. Set the battery master switch located in the R.H. side rear service compartment, or the engine compartment to the "OFF"...
Page 659: Pitman Arm
Section 14: STEERING SERVOCOM Repair Manual" “ZF- 11. PITMAN ARM SERVOCOM Operating, Servicing/ 11.1 REMOVAL Maintenance Inspection Instructions” annexed to this section, under heading "Setting 1. Remove cotter pin, nut and washers from The Steering Limiter"). drag link ball stud at pitman arm. 2.
Page 660: Installation
Section 14: STEERING 7. You must use a puller to remove pitman arm. heading "Pitman arm removal". Adjust to the proper angle. 11.2 INSTALLATION 4. When adjustment is achieved, replace fixing nut and torque to 470-570 lbf-ft (637-773 1. Position pitman arm on sector gear shaft with Nm).
Page 661: Power Steering Reservoir And Filter
Section 14: STEERING Air in the hydraulic system will cause spongy At regular intervals, fluid level should be checked action and noisy operation. When a hose has in the reservoir and filter assembly. Furthermore, been disconnected or when fluid has been lost for the oil filter cartridge element in the power any reason, the system must be bled.
Page 662: Drag Link
Section 14: STEERING 12.3 POWER STEERING HYDRAULIC PUMP For maintenance of the power steering hydraulic pump, refer to the "TRW - Power Steering Pump Service Manual" annexed to this section. 13. DRIVING TIPS In order to maximize power steering pump service life, do not attempt to turn the steering wheel when the vehicle is stationary, and especially when service brakes are applied (wheel locking...
Page 663 Controlled flow rate ........................4.23 gpm (16 lpm) Inlet port..............................1 1/4 NPT Outlet port ..................3/4-16 straight thread SAE O’ ring boss conn. Supplier number ........................PS251615L10200 Prevost number ............................661009 Gasket - Supplier number ........................23516100 Gasket - Prevost number ...........................510488 PA1553...
Page 664 Oil capacity ..........................4 US qts (3.7 liters) Supplier number ............................91410A Prevost number ............................660982 Make ............................... Nelson Muffler Element filter - Supplier number ......................83804 E Element filter - Prevost number .........................660987 Power Steering Hydraulic Cylinder Make................................Hyco Supplier number..........................007-0300-0 Prévost number.............................661076...
Page 823 SECTION 16: SUSPENSION CONTENTS INTRODUCTION ............................ 4 STEERING LINKAGE ..........................4 ....................7 OWER TEERING YDRAULIC ....................... 7 TEERING INKAGE DJUSTMENT ........................7 ITMAN EMOVAL ........................ 7 ITMAN NSTALLATION ............................8 2.5.1 Adjustment..........................8 ......................8 RANK AND DLER 2.6.1 Bell Crank and Idler Arm Removal...................
Page 824 Section 16: SUSPENSION ......................21 HOCK BSORBER EMOVAL ..................... 21 HOCK BSORBER NSTALLATION SWAY BAR ............................21 ............................21 EMOVAL ..........................21 NSTALLATION REAR SUSPENSION ........................... 23 ........................... 24 PRINGS 8.1.1 Inspection ..........................24 8.1.2 Removal ..........................24 8.1.3 Installation ..........................24 .........................
Page 825 Section 16: SUSPENSION ILLUSTRATIONS ....................4 IGURE SUSPENSION AND STEERING LINKAGE ........................5 IGURE LOCATION OF CLAMPS ......................... 6 IGURE CLAMP POSITIONING ......................... 6 IGURE CLAMP POSITIONING ......................... 6 IGURE CLAMP POSITIONING ......................... 6 IGURE CLAMP POSITIONING ......................... 6 IGURE CLAMP POSITIONING .........................
Page 826 Section 16: SUSPENSION INTRODUCTION mounted to the steering gear, transfers the turning motion of the steering wheel to the The vehicle is provided with an air suspension steering arms. The hydraulic power cylinder system. The system consists of air springs, provides an added source of assistance and height control valves, tie rods, radius rods, sway being connected to the R.H.
Page 827 Section 16: SUSPENSION 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 (56° interfere with other parts. + 0°...
Page 828 Section 16: SUSPENSION FIGURE 6: CLAMP POSITIONING 16179 FIGURE 3: CLAMP POSITIONING 16169 FIGURE 7: CLAMP POSITIONING 16170 FIGURE 4: CLAMP POSITIONING 16178 FIGURE 8: CLAMP POSITIONING 16171 FIGURE 5: CLAMP POSITIONING 16172 PA1553...
Page 829 Section 16: SUSPENSION POWER STEERING HYDRAULIC PUMP WARNING Refer to the "TRW Power Steering Pump Service Manual" annexed at the end of Section Always wear approved eye protection when operating pullers. STEERING LINKAGE ADJUSTMENT NOTE CAUTION Whenever a steering linkage component has Do not drive pitman arm on or off pitman shaft been removed and replaced, check steering as this can damage the steering gear.
Page 830 Section 16: SUSPENSION 4. Install stud with nut and torque to 150-200 lbf-ft (203-271 Nm). Align nut with cotter pin slot (tighten) and install a new cotter pin. 5. Torque mounting clamp bolt nut to 40-60 lbf- ft (55-80 Nm), then test the adjustment. Front wheels should turn from right to left extremities without noticeable binding at drag link ends.
Page 831 Section 16: SUSPENSION FIGURE 11: BELL CRANK AND IDLER ARM 16109 NOTE Install grease retainer according to figure 11. Grease must be able to exit the bell crank or idler arm mechanism. For grease retainer installation use tool Prévost # 110683. 3.
Page 832 Section 16: SUSPENSION 2.7.1 Replacement 1. Remove cotter pins from bell crank and idler arm end of relay rod. Loosen nuts flush with end of studs. 2. Use a puller or place a sledge hammer behind the adjacent part to absorb shocks. Strike the studs with a brass hammer to loosen end assemblies.
Page 833 Section 16: SUSPENSION 2. Remove tie rod ball stud by tapping on 3. Remove bolts securing steering arm to steering arm and bell crank or idler arm with steering knuckle assembly. Remove steer- hammer, while using a sledge hammer to ing arm from steering knuckle.
Page 834 Section 16: SUSPENSION base grease NLGI No. 2 (Shell Retinax LX 6. Upper A-Arm Central Ball Joint: Lubricate or equivalent). at fitting until you see some grease on the relief valve nearby, every 6,250 miles (10 4. Swivel Assembly: Refer to DANA SPICER 000 km) with good quality lithium-base MAINTENANCE MANUAL NDS AXLES grease NLGI No.
Page 835 Section 16: SUSPENSION 3. BALL JOINTS FIGURE 15: BALL JOINTS LOCATION 16137 When the following characteristics are noted, 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 836 Section 16: SUSPENSION 3.1.3 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 FIGURE 18: UPPER A-ARM BALL JOINTS 16115 (Prévost # 611114)).
Page 837 Section 16: SUSPENSION FIGURE 19: LOWER A-ARM CENTRAL BALL JOINT FIGURE 20: UPPER A-ARM CENTRAL BALL JOINT 16116 3. Faultlessly apply grease by mechanical means to bracket-outer core and ball-inner FRONT END ALIGNMENT cone. Insert bracket outer cone in fixture Proper front end alignment must be maintained with distance ring and then use press tool to insure...
Page 838 Section 16: SUSPENSION FIGURE 21: STEERING LINKAGE MEASURE 16132 ALIGNMENT TERMINOLOGY 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 839 Section 16: SUSPENSION FRONT WHEEL CAMBER 4.4.1 Toe-In Check Positive camber is the outward inclination of the 1. Check the camber adjustment and adjust if wheels at the top, negative or reverse camber is necessary. the inward inclination of the wheels at the top. 2.
Page 840 Section 16: SUSPENSION FIGURE 22: FRONT END ALIGNMENT DIAGRAM 16133 ALIGNMENT SPECS (See Figure 22) Minimal Nominal Maximal Non- Converted Non- Converted Non- Converted Load converted converted converted WHEEL CAMBER -0.150 0.35 0.55 0.200 KING PIN INCLINATION 8° (not adjustable) CASTER 2.55 3.05...
Page 841 Section 16: SUSPENSION Variations from the specified caster will affect WARNING steering stability, cause wandering, wheel shimmy, and reduce returnability when pulling To prevent personal injury, do not apply more out of curves. than 10 psi (69 kPa) air pressure to the unmounted air spring.
Page 842 Section 16: SUSPENSION FIGURE 24: AIR SPRING AND SHOCK ABSORBER 16180 and none is permissible. Repair or replace 1. Compress air spring as necessary, then defective parts. aligning studs with their holes, position air spring between both the lower and upper 7.
Page 843 Section 16: SUSPENSION 3. Place the inner washer on shock absorber SHOCK ABSORBER REMOVAL pin (Fig. 25). 1. Remove the nut, washer and rubber joint 4. Install washer and rubber joint on shock from shock absorber mounting stud. Discard absorber mounting stud (lower side). the rubber joints.
Page 844 Section 16: SUSPENSION FIGURE 26: SWAY BAR (FRONT SUSPENSION) 16138D FIGURE 27: SWAY BAR (REAR SUSPENSION) 16014 PA1553...
Page 845 Section 16: SUSPENSION REAR SUSPENSION For a description of all these systems, refer to the appropriate heading in this section. FIGURE 28: REAR SUSPENSION COMPONENTS 16140 FIGURE 29: DETAILS OF REAR SUSPENSION 16106 FIGURE 30: TAG AXLE SUSPENSION 16107 PA1553...
Page 846 Section 16: SUSPENSION AIR SPRINGS 8.1.2 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 847 Section 16: SUSPENSION NOTE CAUTION To facilitate air spring installation, compress it manually then put a piece of tape over the air When a shock absorber is found defective, line threaded fitting. This prevents air from always replace with a new set on affected getting back into the bag and keeps it axle, except if there has been a recent re- compressed, thus enabling to place the bag in...
Page 848 Section 16: SUSPENSION a) Broken mounts; 4. Install the shock absorber eyes over the mounting pins, then the outer washers (with b) Extreme bushing wear; washer convex side facing the shock absorber rubber bushing) on each shock c) Shifted bushing or sleeve; extremity.
Page 849 Section 16: SUSPENSION 8.3.1 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 850 Section 16: SUSPENSION 8.3.5 Installation The front valve is mounted to the subframe at center of front sway bar and connected to the 1. Lightly spray the radius rod support with front air tank support (Fig. 38). The front height water.
Page 851 Section 16: SUSPENSION At this point, it should not be necessary to make When the desired height is obtained, tighten an adjustment under normal service conditions. clamp. However, if an adjustment is required, change Rear air springs clearance the position of the overtravel lever in relation to the overtravel control body.
Page 852 Section 16: SUSPENSION 10.1 LOADING POSITION 11. "LEVEL-LOW" LEVELING SYSTEM As the load increases and lowers the vehicle Bus shells are equipped with "LEVEL-LOW" body, the overtravel lever commands the height leveling system. The purpose of the "LEVEL- control valve to add air to air springs. LOW"...
Page 853 Section 16: SUSPENSION 11.1 PRINCIPLES OF OPERATION WARNING DOWN: Never move vehicle with selector knob in any The (front/rear right/rear left) control solenoid other position than the “DRIVE” position. valve supplies air to the (front/rear right/rear left) five-way three-position air control valve, which 11.2 MAINTENANCE bypasses the (front/rear right/rear left) height control valve, and opens a passage to allow the...
Page 854 Section 16: SUSPENSION 12.1 AIR TANK MAINTENANCE 12.1.3 Secondary Air Tank Ensure that the accessory air tank is purged This tank is located in front wheelhousing, during pre-starting inspection. A good practice is between air springs. The tank is installed to purge this tank at the end of every driving day vertically and is provided with a bottom drain by the remote air tank drain valve located in the...
Page 855 Section 16: SUSPENSION 12.1.5 Expansion Air Tank 13. HUB UNIT AND SWIVEL ASSEMBLY Two expansion tanks are located in front Refer to “DANA SPICER Service Manual wheelhousing. These air tanks are located General Information, Maintenance Manual behind secondary and accessory air tank. Also, Model NDS and Maintenance Manual NDS six expansion tanks are located near rear air Axles”...
Page 856 Section 16: SUSPENSION 14. TORQUE TABLE TORQUE (DRY) DESCRIPTION Lbf-ft Pitman Arm to Steering Gear Fixing Nut 470-570 637-773 Steering Gear to Mounting Bracket Bolts 365-405 495-550 Drag Link to Pitman Arm Stud Nut * 150-200 203-271 Drag Link to Bell crank Stud Nut * 150-200 203-271 Drag Link Socket End Clamp Bolt Nut...
Page 857 Section 16: SUSPENSION SPECIFICATIONS Front Axle Air Springs Make........................Goodyear Tire and Rubber Model............................... 1400 Type ..............................Mae West Diameter............................14.5 inches Air Inlet .............................1/2’’- 14 NPTF Supplier number..........................1R14-167 Prévost number........................... 630239 Tag Axle Air Springs (WE) Make........................Goodyear Tire and Rubber Model............................... 1200 Type ..............................Mae West Nominal diameter ........................
Page 858 Section 16: SUSPENSION Height control valve (Front) Make..............................Barksdale Quantity used ..............................1 Supplier number....................... 52321POAQ3-Q62 Prévost number........................... 630157 Height control valve (Rear) Make..............................Barksdale Quantity ................................. 2 Supplier number....................... 52321POAQ3-Q26 Prévost number........................... 630156 Radius rod bushing Make..............................Prévost Prévost number........................... 630021 Loctite Make..............................
Page 859 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 860 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 861 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 862 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 863 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 864 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 865 SECTION 18: BODY CONTENTS VEHICLE EXTERIOR ..........................6 VEHICLE STRUCTURE ........................9 VEHICLE EXTERIOR MAINTENANCE ....................9 ......................... 9 ORROSION REVENTION ................... 10 REVENTIVE AINTENANCE CHEDULE ......................10 NHIBITOR PPLICATION COMMON FIBERGLASS REPAIR PROCEDURE ................15 ....................15 EPAIR SING IBERGLASS LOTH ....................
Page 866 Section 18: BODY 6.5.4 Fuel Filler Door........................40 6 ............................40 6.6.1 Front Fender.......................... 40 7 ............................41 6.7.1 Side Panel for Vehicles Not Fitted With Slide-Out ..............41 6.7.2 Side Panel for Vehicles Fitted With Slide-Out............... 42 6.7.3 Side Crest..........................42 8 ............................
Page 867 Section 18: BODY 8.1.4 Rear View Mirrors........................64 8.1.5 Windshield Wipers......................... 65 8.1.6 Windshield ..........................65 8.1.7 Front face Body Panel......................66 8.1.8 Entrance Door ........................67 8.1.9 Front Electrical & Service Compartment Door ..............67 8.1.10 Upper Lateral Window......................68 8.1.11 Front Cap..........................
Page 868 Section 18: BODY 1............................20 IGURE ZONE ......................20 IGURE FRONT BUMPER REMOVAL ....................20 IGURE FRONT BUMPER RELEASE HANDLE )......................21 IGURE REAR VIEW MIRROR RAMCO ..................23 IGURE WINDSHIELD INSTALLATION USING ROPE ....................24 IGURE APPLICATION F SIKA BLACK ........................
Page 869 Section 18: BODY 6............................60 IGURE ZONE 7............................61 IGURE ZONE ........................... 62 IGURE WE MTH ZONING 1............................62 IGURE ZONE ....................63 IGURE FRONT BUMPER RELEASE HANDLE ......................63 IGURE FRONT BUMPER REMOVAL )......................64 IGURE REAR VIEW MIRROR RAMCO ..................
Page 870: Vehicle Exterior
Section 18: BODY VEHICLE EXTERIOR FIGURE 1: XL2-40 CONVERTED VEHICLE EXTERIOR VIEW (TYPICAL) 1. Engine air intake 12. Front electrical & service compartment 2. Engine compartment R.H. side door 13. Driver’s power window 3. Hinged rear fender 14. Evaporator compartment or Baggage 4.
Page 871 Section 18: BODY FIGURE 2: XL2-45 CONVERTED VEHICLE EXTERIOR VIEW (TYPICAL) 18362 Engine air intake 10. Reclining bumper Engine compartment R.H. side door 11. Front electrical & service compartment R.H. side rear service compartment 12. Front Slide-Out (Optional) Baggage compartment 13.
Page 872 Section 18: BODY FIGURE 3: XL2-45E CONVERTED VEHICLE EXTERIOR VIEW (TYPICAL) 18369 Engine air intake Reclining bumper 10. Front electrical & service compartment Engine compartment R.H. side door Baggage compartment 11. Evaporator compartment or Baggage compartment Condenser compartment or Baggage compartment 12.
Page 873: Vehicle Structure
Section 18: BODY VEHICLE STRUCTURE The operating environment the vehicle is subjected to will largely influence the amount of The body of the XLII vehicles is an integral dirt and corrosion that will accumulate over a structure made of 14, 16 and 18 gauge welded given period.
Page 874: Preventive Maintenance Schedule
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 875 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 and Air pressure system may be used, refer to annex 1 for dew point must be respected before applying rust surface temperature and dew point.
Page 876 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) PA1553...
Page 877 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 878 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 879: Common Fiberglass Repair Procedure
Section 18: BODY COMMON FIBERGLASS REPAIR If part is warped from original shape, use PROCEDURE clamping equipment to straighten the surface. Preheat area to be repaired with one or two heat All repairs to fiberglass parts consist of filling the lamps placed 18 to 24 inches (450-610 mm) damaged area with fiberglass cloth and resin or from repair.
Page 880: Typical Fiberglass Repair Procedure
Section 18: BODY 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. Apply the material with a putty knife or similar object, building material up to the desired contour.
Page 881: Common Painting Procedure
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 882: Painting
Section 18: BODY 5.3.1 Safety If you sand through to metal surface, first prime 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 883: W5 Mth Exterior Finishing And Body Repair
Section 18: BODY W5 MTH EXTERIOR FINISHING AND BODY REPAIR The following procedures explain the steps to be followed for proper repair, installation and replacement for various doors, panels and windows pertaining to W5 MTH. The paragraph divides the vehicle into zones to facilitate the search;...
Page 884: Zone 1
Section 18: BODY ZONE 1 FIGURE 11: ZONE 1 6.1.1 Front Bumper The front bumper can be tilted downward to give WARNING access to the bumper compartment. Pull the release handle located inside front service The compartment behind the bumper is not compartment to unlock.
Page 885: Headlights
Section 18: BODY 6.1.4 Rear View Mirrors CAUTION Your vehicle is equipped with two exterior mirrors. Do not exceed the crest dedicated surface. The mirrors may be equipped with an optional electric heating system which serves minimize ice and condensation on the mirror glass in extreme weather conditions.
Page 886: Windshield Wipers
Section 18: BODY NOTE adjustment, then push down on either of the button’s (4) sides to adjust the selected mirror Position the ball cup halves so the joint viewing angle. between them lies on the centerline of the arm. Ensure that the setscrews are not on the Disassembly joint between the cup halves.
Page 887 Section 18: BODY • Spray soapy water on a regular basis to A metal rod or screwdriver to clean the seal ease this operation. groove, • A filler insertion tool, Using the same type of plastic spatula, • repeat the same operation from inside of Goggles and protective gloves.
Page 888: Front Face Body Panel
Section 18: BODY When filler insertion is almost complete, Front Face Body Panel Removal cut filler leaving ¼” of excess length to Using a drill and a 1/8” drill bit remove the thwart filler contraction over time then rivets fixing the vertical molding. The insert filler into groove.
Page 889: Front Electrical & Service Compartment Door
Section 18: BODY Separate body panel from door. For gluing of driver’s window, refer to procedure PR290013 included at the end of this section. Remove from door surface Sika bead and double-face self adhesive tape residue gluing front electrical & service using a razor sharp window scraper.
Page 890: Front Cap
For gluing of upper lateral window, refer to held in place with adhesive. If ever it has to be procedure PR290016 included at the end of this replaced, make an appointment at a Prevost section. service center near you. For minor damages, refer to paragraph 4 "Common Fiberglass...
Page 891: Electric Awning Windows
Section 18: BODY 6.2.3 Electric Awning Windows Cut Sika bead until you come back to starting point, then you can remove the The electric awning windows are connected window by carefully pushing it out from the directly on the batteries 24 V DC terminal block. inside of vehicle.
Page 892 Section 18: BODY Fixing frame Screen Gas spring Frame Releasing bar keeper Track Proximity sensor magnet Vertical latch handle D-seal Window ajar sensor Spring Track release latch FIGURE 19: ELECTRIC AWNING WINDOW EXPLODED VIEW (FRAME) 18586 Actuators Horizontal latch handle Latch guide Proximity sensor Relay...
Page 893 Section 18: BODY Actuator Replacement Motor Replacement 1. Push the vertical latch handle downwards to 1. Push the vertical latch handle downwards to release the track and then unlatch the release the track and then unlatch the window using the horizontal latch handle. window using the horizontal latch handle 2.
Page 894: Electric Sliding Windows
Section 18: BODY Were the shipping blocks in place during installation? C: Failure to remove the shipping blocks after installation can create interference between sash and frame. Have the shipping blocks been removed after installation? D: The window is misaligned or not installed squarely. Is there interference with any coach parts? Is there proper clearance between the bottom of the outer glass and the belt-line trim / seal?
Page 895 Section 18: BODY FIGURE 22: REMOVING THE SASH 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 23) FIGURE 23: DISENGAGING THE BOTTOM OF THE SASH Installation 1. Align the leading edge of the slot on the lower cam follower block with the sash stop. Use the power toggle switch to obtain the correct alignment.
Page 896 Section 18: BODY Lower Cam Sash Stop Follower FIGURE 24: PROPER ALIGNMENT 2. Position the left hand lower corner of the sash over the front cam follower block (Figure 25) FIGURE 25: POSITIONING THE LOWER LEFT CORNER OF THE SASH 3.
Page 897: Zone 3
Section 18: BODY Correct Position Incorrect Position FIGURE 26: RELEASE LATCH PROPER POSITION 7. * Failure to confirm this step may lead to the sash becoming disengaged with the frame and could result in personal injury. 8. Operate the window to confirm that it opens and closes properly. Install the screen assembly.
Page 898: Rear Bumper
Section 18: BODY Remove damaged engine compartment Engine compartment doors may be adjusted for door from vehicle. proper fit by untightening hinge bolts: Install damaged door onto 1. Loosen the bolts, (1, 2 Fig. 28) holding the appropriate support. hinge to the vehicle structure to shift the door "UP or DOWN".
Page 899: Zone 4
Section 18: BODY ZONE 4 FIGURE 30: ZONE 4 6.4.1 Rear Fender 5. Check that the door swings freely and closes properly. It may be necessary to On the "XLII MTH" series vehicles, rear fenders adjust the door latch to get proper fit and are hinged for maintenance on brakes and operation.
Page 900: Engine Radiator Door
Section 18: BODY To adjust the latch mechanism (3, Fig. 31) and 5. Check that the door swings freely and the striker pin: closes properly. It may be necessary to adjust the door latch to get proper fit and 1. Open the door to access the striker pin. operation.
Page 901: Side Rear Service Compartment Door
Section 18: BODY 5. Respect the required gap between exterior adjust the door latch to get proper fit and finishing panels. operation. 6. Check that the door swings freely and To adjust the latch mechanism (3, Fig. 33) and closes properly. It may be necessary to the striker pin: adjust the door latch to get proper fit and operation.
Page 902: Baggage Compartment Doors
Section 18: BODY 6.5.1 Baggage Compartment Doors 1. Maintain the door halfway open by placing a wooden block between one of the panto- The baggage compartment doors on the vehicle graph arms and the upper frame. identical design. doors pantograph, vertical-lift type and are fully sealed. 2.
Page 903: Condenser Compartment Door
Section 18: BODY If the baggage door locks too tightly or too loosely, the position of the catch striker is misadjusted. To adjust, loosen the catch striker retaining bolts, position the striker correctly and tighten the retaining bolts. If the lower part of the baggage door does not close evenly with the side of the vehicle, adjust the lock plates by loosening their retaining bolts and positioning the locking plates correctly (Fig.
Page 904 Section 18: BODY For the installation of evaporator compartment Check that the door swings freely and door body panel, refer to procedure PR00133 closes properly. included at the end of this section. 6.5.4 Fuel Filler Door Open the fuel filler door. Loosen the screws holding the panel to hinge assembly.
Page 905 Section 18: BODY ZONE 7 FIGURE 42: ZONE 7 6.7.1 Side Panel for Vehicles Not Fitted With Slide-Out Removal Remove top and bottom finishing moldings. Insert Be careful not to damage the adjacent surfaces a screwdriver into snap-on finishing molding joint. You need to remove the finishing molding support Bend finishing molding enough to be able to fix a and rivets in the case of engine air intake panel.
Page 906 Section 18: BODY structure preparation before CAUTION installation of a ridged side panel, refer to procedure PR00027 included at the end of this Because most junction panels are only riveted section. and not spot welded, be careful when For gluing of ridged side panels, refer to removing a side panel not to damage adjacent procedure PR00028 included at the end of this panels.
Page 907 Section 18: BODY 6.8.1 Slide-Out Exterior Finishing Panels & Windows Refer to Maintenance Manual, Section 26: Paragraph 16 for the procedure on slide-out exterior finishing panels & windows. ZONE 9 FIGURE 44: ZONE 9 6.9.1 Slide-Out Exterior Finishing Panels & Windows Refer to Maintenance Manual, Section 26: Paragraph 16 for the procedure on slide-out exterior finishing panels &...
Page 908 Section 18: BODY 6.10 BODY PANEL AND WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE-OUT FIGURE 45: BODY PANEL & WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE-OUT PA1553...
Page 909 Section 18: BODY 6.11 BODY PANEL AND WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE-OUT FIGURE 46: BODY PANEL & WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE-OUT PA1553...
Page 910 Section 18: BODY W0 MTH EXTERIOR FINISHING AND BODY REPAIR FIGURE 47: W0 MTH ZONING ZONE 1 FIGURE 48: ZONE 1 7.1.1 Front Bumper Push the bumper back up firmly in place to lock The front bumper can be tilted downward to give in position.
Page 911 Section 18: BODY 7.1.2 Front Crest separate the bumper from the spare wheel compartment door. To install bumper, reverse Use a Chix cloth and anti-silicone to clean the removal procedure. the surface where the crest will be applied. WARNING CAUTION Front bumper is heavy.
Page 912 Section 18: BODY 7.1.3 Headlights Assembly Refer to Paragraph 12.1 Headlights, included in Mount the mirror arm base to the coach. Insert Section 06: Electrical of the Maintenance the ball stem into the mirror arm and tighten the Manual for complete information on headlights. socket setscrews.
Page 913 Section 18: BODY 7.1.6 Windshield mounted to the mirror head behind the mirror glass. For the removal or installation of windshield, you Turn pointer knob to the left for mirror head will need: adjustments and to the right for convex mirror •...
Page 914 Section 18: BODY Slide windshield into rubber seal groove Gradually insert filler into the rubber seal starting with the bottom curved side edge. groove ensuring to leave a 2 inch excess Using a plastic spatula, move the rubber length at the filler extremity. seal lip aside to gradually insert the wind- Every 6 inches or so, it is important to shield into the groove.
Page 915 Section 18: BODY First of all, pry loose the front face molding replaced because it will be damaged at using the lever. Save molding if only the removal. body panel needs to be changed. Remove interior finishing panel to access Using the Olfa knife, cut the Sika bead rub rail fixing bolts, then remove rub rail.
Page 916 From inside of vehicle, cut Sika bead held in place with adhesive. If ever it has to be around window perimeter using a “Zip replaced, make an appointment at a Prevost gun” while another person hold the win- service center near you. For minor damages, dow from the outside.
Page 917 Section 18: BODY 7.2.1 Upper Side Panel When you reach top corner, detach wire from the outside handle, secure it to a fish For structure preparation, refer to procedure wire or rod and thread it underneath the PR00035 included at the end of this section. aluminum molding behind the rivets.
Page 918 Section 18: BODY 7.2.3 Electric Awning Windows for making the Simson joint around fixed windows. For window or components replacement, refer to All these procedures are included at the end of paragraph 6.2.3. this section. 7.2.4 Electric Sliding Windows For sash removal or replacement, refer to paragraph 6.2.4.
Page 919 Section 18: BODY Engine Compartment Door Body Panel WARNING Removal For the removal of engine compartment door Be very careful when pulling the body panel, body panel, you will need: somebody could get hurt if the body panel suddenly detach from the door surface without Pneumatic “Zip gun”...
Page 920 Section 18: BODY 7.4.1 Rear Fender 5. Check that the door swings freely and closes properly. It may be necessary to On the "XLII MTH" series vehicles, rear fenders adjust the door latch to get proper fit and are hinged for maintenance on brakes and operation.
Page 921 Section 18: BODY 3. Adjust the door position depending on the 1. Open the door to access the striker pin. gap needed between exterior finishing 2. Slightly loosen the striker pin. panels. 3. Using a hammer, adjust the striker pin to 4.
Page 922 Section 18: BODY 2. Loosen jam nut and cap screw locking the horizontal member of the pantograph to the pivot pin. 3. Slide pantograph assembly to the right and remove assembly from the vehicle. 4. To install, perform the removal instructions in reverse.
Page 923 Section 18: BODY If the lower part of the baggage door does not Loosening the screws allows the evaporator close evenly with the side of the vehicle, adjust door assembly to be shifted "LEFT or the lock plates by loosening their retaining bolts RIGHT"...
Page 924 Section 18: BODY FIGURE 66: FUEL FILLER DOOR 03046 ZONE 6 FIGURE 67: ZONE 6 7.6.1 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 925 Section 18: BODY ZONE 7 FIGURE 68: ZONE 7 7.7.1 Ridged Side Panels Removal Remove top and bottom finishing moldings. Insert Be careful not to damage the adjacent surfaces a screwdriver into snap-on finishing molding joint. You need to remove the finishing molding support Bend finishing molding enough to be able to fix a and rivets in the case of engine air intake panel.
Page 926 Section 18: BODY structure preparation before For gluing of horizontal finishing molding, refer installation of a ridged side panel, refer to to procedure PR00208 included at the end of procedure PR00027 included at the end of this this section. section. 7.7.2 Side Crest For gluing of ridged side panels, refer to...
Page 927 Section 18: BODY 8.1.1 Front Bumper WARNING The front bumper can be tilted downward to give access to the bumper compartment. Pull the The compartment behind the bumper is not release handle located inside front service designed for storage. Never store loose compartment to unlock.
Page 928 Section 18: BODY Adjustment At the base of the mirror arm, loosen the mounting bolt to swing arm in or out. To pivot the mirror head, loosen the setscrews on each side of the ball stub at the base of the mirror head to facilitate the adjustment.
Page 929 Section 18: BODY the lens to release the Velcro. Disconnect the CAUTION heater grid at the two connectors. Connect the connectors of the new mirror’s grid Do not attach stick-on type convex mirror to the harness. Install the lens by positioning the accessories to the heated mirror glass.
Page 930 Section 18: BODY Windshield Installation At the top of windshield, clean surface between fiberglass and rubber extrusion NOTE using Sika 205 (Fig.75). Rubber seal may have to be replaced if it was Apply Sika 221 black between fiberglass used on several windshield replacements. and rubber extrusion Spray rubber seal with soapy water to Spray filler and rubber seal groove...
Page 931 Section 18: BODY 8.1.8 Entrance Door Front Face Molding Removal For the removal of entrance door body panel, you will need: Pneumatic “Zip gun” type tool; Razor sharp window scraper; Before removing body panel, you can to ease repair uninstall entrance door from vehicle.
Page 932 It is lateral window, you will need: held in place with adhesive. If ever it has to be replaced, make an appointment at a Prevost Pneumatic «Zip gun» type tool; service center near you. For minor damages, Razor sharp window scraper;...
Page 933 Section 18: BODY ZONE 2 FIGURE 77: ZONE 2 This procedure requires accuracy and it is 8.2.1 Upper Side Panel possible not to succeed on the first at- For structure preparation, refer to procedure tempt. From the inside of vehicle, a sec- PR00035 included at the end of this section.
Page 934 Section 18: BODY Using a ball peen hammer, hit one of the For the installation of awning or sliding window, window bottom corners from the outside. refer to procedure PR00038 included at the end of this section. Carefully push window out and lift it up sufficiently to separate it from the alumi- For gluing of lateral fixed window, refer to num molding.
Page 935 Section 18: BODY 4. Tighten the bolts. CAUTION 5. Check that the doors swing freely and close properly. It may be necessary to adjust the Do not damage painted surface. door latch to get proper fit and operation. Use a second person equipped with a pair To adjust the latch mechanism (4, Fig.
Page 936 Section 18: BODY ZONE 4 FIGURE 81: ZONE 4 8.4.1 Rear Fender On the "XLII MTH" series vehicles, rear fenders are hinged for maintenance on brakes and suspension. Each rear fender panel has two mechanical spring loaded holding devices fixing it to the vehicle’s structure.
Page 937 Section 18: BODY 3. Using a hammer, adjust the striker pin to center it in the door latch mechanism. 4. Tighten the striker pin. 5. Check door fit and operation. For gluing of engine compartment R.H. side door finishing molding, refer to procedure PR00210 included at the end of this section.
Page 938 Section 18: BODY 8.5.1 Baggage Compartment Doors 1. Maintain the door halfway open by placing a wooden block between one of the panto- The baggage compartment doors on the vehicle graph arms and the upper frame. identical design. doors pantograph, vertical-lift type and are fully sealed. 2.
Page 939 Section 18: BODY If the baggage door locks too tightly or too loosely, the position of the catch striker is misadjusted. To adjust, loosen the catch striker retaining bolts, position the striker correctly and tighten the retaining bolts. FIGURE 87: CONDENSER DOOR For the installation of condenser compartment door body panel, refer to procedure PR00131 included at the end of this section.
Page 940 Section 18: BODY For the installation of evaporator compartment Check that the door swings freely and door body panel, refer to procedure PR00133 closes properly. included at the end of this section. 8.5.4 Fuel Filler Door Open the fuel filler door. Loosen the screws holding the panel to hinge assembly.
Page 941 Section 18: BODY ZONE 7 FIGURE 91: ZONE 7 8.7.1 Smooth Side Panel Removal Remove finishing molding. Insert a screwdriver into Be careful not to damage the adjacent surfaces. snap-on finishing molding joint. Bend finishing molding enough to be able to fix a pair of locking pliers.
Page 942 Section 18: BODY Installation Procedures SMOOTH SIDE PANEL – STRUCTURE PREPARATION PR00072 SMOOTH SIDE PANEL – INSTALLATION PR00073 ENGINE AIR INTAKE PANEL - GLUING PR00074 SMOOTH SIDE PANEL – FINISHING JOINT PR00075 SMOOTH SIDE PANEL – GLUING MOLDINGS PR00214 SMOOTH SIDE PANEL – REAR MOLDING GLUING PR00215 SMOOTH SIDE PANEL –...
Page 943 Section 18: BODY BODY PANEL AND WINDOW SPACING FOR WE MTH FITTED WITH SLIDE-OUT FIGURE 93: BODY PANEL & WINDOW SPACING FOR WE MTH FITTED WITH SLIDE-OUT PA1553...
Page 944 Section 18: BODY VEHICLE JACKING POINTS The vehicle can be lifted by applying pressure under body jacking points or front and drive axle jacking points. When it is necessary to lift the vehicle, care should be taken to ensure that the pressure is applied only on the specified areas.
Page 945 Section 18: BODY capacity. When transporting a vehicle, apply parking brake and shut down the engine. Block all wheels and secure vehicle with tie-downs. Check that overall height will clear obstacles on the route to follow, and obtain required permits. The vehicle can also be towed by lifting the front axle or by towing from the front with all wheels FIGURE 99: JACKING POINTS ON TAG AXLE...
Page 946 Section 18: BODY 10.1 LIFTING AND TOWING 10.2 TOWING WITHOUT LIFTING The towed vehicle must be lifted from under the WARNING front axle only. The tow truck must be equipped with the proper lifting equipment to reach under When towing vehicle without lifting, use only a the front axle since no other lifting points are tow truck with a solid link tow bar and related recommended.
Page 947 MEMORANDUM SEALANT / GLUING PRODUCT PROCEDURE NO: PR000001 REVISION 14 2006-06-09 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) DISCARD WEAR WEAR AS PER P908 GLOVES SAFETY GLASSES Page 1 of 10...
Page 948 PROCEDURE NO: PR000001 REVISION 14 Section 1 Sealant / Gluing Products General Remarks Verify expiration Do not use Back and forth date straight from the bottle See section 3 - Without excessive dust (mind the ventilation). Work Place - Air blast forbidden. (Spray dust in the work environment and contaminate surfaces by oil in the pneumatic system).
Page 949 PROCEDURE NO: PR000001 REVISION 14 Section A Anti-silicone (or alcohol) Apply Dry immediately CHIX cloth Blue cloth Note: Do not use over long distances. Turn cloth over. Clean until Chix cloth comes out clean. Unacceptable Unacceptable Maximum acceptable Minimum time: Wait for product to evaporate Allow drying After 2 hours: Start cleaning operation again (Mandatory)
Page 950 PROCEDURE NO: PR000001 REVISION 14 Section C Sika Aktivator Glass Other material (plastic, paint, etc) Plastic Apply & spatula wipe CHIX cloth CHIX cloth immediately Leave ½" to 2" CHIX cloth between the 2 CHIX cloth clothes Allow to evaporate Do not use pads supplied in the box.
Page 951 PROCEDURE NO: PR000001 REVISION 14 Section D Sika Primer 206 G+P, 210-T or 215 Shake bottle to mix product Apply a thin layer CHIX cloth Uneven. Apply again locally onto missing areas after waiting Even application, no drips no miss. drying time Renewal Renewal...
Page 952 PROCEDURE NO: PR000001 REVISION 14 Section E Glass cleaner Spray (Essex, Spray Away or BLUE cloth Sika) Allow to evaporate Minimum time : Complete evaporation of product Mandatory After 2 hours : Start cleaning operation again Before applying any other If surface seems dusty, greasy or with finger marks, start product cleaning operation again.
Page 953 PROCEDURE NO: PR000001 REVISION 14 Section G Sanding Sand belt grit coarse Scotchbrite grey 7446 or SIA P-110 Smooth surface: Use orbital sander Use belt sander Ridged surface: Sand bottom of creases by hand Change paper or belt on a regular basis as per procedure. Important aspects to follow In the case of Stainless steel, eliminate reflection (mirror image).
Page 954 PROCEDURE NO: PR000001 REVISION 14 Section H Simson Primer M Apply CHIX cloth Allow to evaporate Mandatory Minimum time 10 minutes Maximum time; to follow If surface seems dusty, greasy or with finger marks, start Before applying any other operation again. product Section 2 Repair (Sika product or Simson) During winter season, condensation and cold can influence the gluing parameters.
Page 955 PROCEDURE NO: PR000001 REVISION 14 Section 3 Use of glue / sealant Section 3a) Sika Products Heating of Sika Ultrafast II Authorized oven: Sika F00549 c max). Minimum time 1hr. Maximum time 5hrs. Note: Cartridge may be heated up several times but keep in mind the maximum time. Glue Job time* Clamping time...
Page 956 PROCEDURE NO: PR000001 REVISION 14 Section 3b) Simson Product Open time Simson 70-03; 10 min maximum Cleaning Anti-silicone (sealant removal) Water or soapy water [Authorized soap: Transparent Liquid Sunlight #680339 (concentration Smoothing down ± 5%)]. Sealant joint may be painted or primed once the joint is dry to the touch. Paint Expiration Date BB.
Page 957 MEMORANDUM SEALANT/GLUE APPLICATION PROCEDURE NO: PR000001A REVISION 00 2006-06-09 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Section 1: Triangular Beads Application Section 2: Irrelevant Section 3: Finishing Joint around glass (aesthetic appearance) Page 1 of 4...
Page 958 PROCEDURE NO: PR000001A REVISION 00 Section 1 Triangular Beads Application Rules Nozzle must be as perpendicular to the surface as possible Nozzle must be positioned to follow the direction of movement (towards the rear not side) Bead Appearance Page 2 of 4...
Page 959 PROCEDURE NO: PR000001A REVISION 00 Section 2 Irrelevant Section 3 Finishing Joint around glass (aesthetic appearance) 3.00 Apply masking tape beside the joint.. EDGE OF RADIUS ABOUT 3 mm Glass side; apply about 3 mm from the edge for better sealant adherence. Fiberglass side;...
Page 960 PROCEDURE NO: PR000001A REVISION 00 Joint must be parallel (visually), straight and without notch. Notch Repeating notches Stepped sealant Cavity in the sealant joint due to the plastic spatula and/or sealant shrinking (Accepted). Page 4 of 4...
Page 961 PR00027 RIDGED SIDE PANEL – STRUCTURE PREPARATION Effective: 9052 REVISION 00 LVA077 Spec 15.0 DATE 06-08-31 Section 1 Structure Preparation Important: Before cleaning, make sure there is no paint, gravel guard or urethane residue. If necessary, remove using sander. 1.00 Structure Sanding A) Clean using anti-silicone in the direction of the arrows.
Page 962 PROCEDURE NO: PR00027 REVISION 00 1.05 Structure Cleaning Clean using anti-silicone Use white clothes #684009 for vertical backers. Page 2 of 3...
Page 963 PROCEDURE NO: PR00027 REVISION 00 1.10 Application of Sika 206 G+P onto structure A) Apply 3/4" wide masking tape in the center of vertical backers. - Make sure that grit blasting is uniform on the whole surface. B) Apply Sika 206 G+P Use white clothes #684009 for vertical backers.
Page 965 PR00028 RIDGED SIDE PANEL – GLUING Spec 15.0 Effective: 9052 REVISION 00 LVA173 DATE 06-08-31 LVA085 Section 1 Side Panel Pre-Adjustment 1.00 A) Install some kind of supports for temporary side panel holding. B) Install side panel in position 1, install a U-shape clamp to hold upper portion.
Page 966 PROCEDURE NO: PR00028 REVISION 00 Section 2 Preparation before Side Panel Gluing Important: Make sure that all bonding surfaces are clean and free of dust, residue or dry glue. If required, clean using a scraper or damp cloth. 2.00 Make sure that structure is sealed at the back of engine air intake panel location.
Page 967 PROCEDURE NO: PR00028 REVISION 00 Section 35 Side Panel Gluing 3.00 A) Apply Sika 221 grey to seal vertical "backers". Smooth down with a finger. Seal vertical backer upper and lower portions using Sika 221 grey B) If accessible, seal the back of vertical "backers" as indicated in picture.
Page 968 PROCEDURE NO: PR00028 REVISION 00 3.15 Install side panel in position 1 and rivet, install Curing time: 4 hours minimum engine air intake panel in position 2 and rivet. Check gap between 2 panels. Install side panels 3, 4, 5, 6 and rivet, making sure to check the gap 3-4.5mm between side panels Check adjustment with vertical "backers".
Page 969 PR00029 RIDGED SIDE PANEL GLUING – MTH FITTED WITH SLIDE-OUT Spec 15.0 Effective: 9064 REVISION 00 LVA173 DATE 06-09-07 LVA085 Section 1 Side Panel Pre-Adjustment 1.00 A) Install some kind supports temporary side panel holding. Measure height of 4 ridge from top of structural tubing, on backer located between side panels 4 and 5 (should be 320.5 mm).
Page 970 PROCEDURE NO: PR00029 REVISION 00 C) Locate junction panel between side panels 7 and Vertically: Follow chalk line. Horizontally: Centered with reference structural tubing Note: Temporary secure junction panel using a rivet #504108 and drill bit #30. D) Locate junction panel between side panels 2 and Vertically: As per dash 2 Horizontally: Centered with reference to slide- out structure.
Page 971 PROCEDURE NO: PR00029 REVISION 00 C) Side Panel # 5: JUNCTION PANEL LINE UP RIDGES Vertically: - Front installed onto junction panel located between side panels 4 and 5 - Rear line up with side panel # 7 ridges +/-1mm Horizontally: - gap of 3 mm +1.5/-0 with reference to side panel # 7, horizontal alignment of 1 mm max.
Page 972 PROCEDURE NO: PR00029 REVISION 00 F) Side Panel # 6: CENTER Horizontally: - Centered with reference to slide-out window panes +/-1 mm. Gap should be 9 mm +/-2, horizontal alignment of 2 mm max. Vertically: - Gap of 9 mm +/-2 with reference to side panels 7 and 8.
Page 973 PROCEDURE NO: PR00029 REVISION 00 Install junction panel between metal strips 9 and 10. Apply a VHB tape at the back. Vertically: Install junction panel 10 mm underneath side panels 2 and 3 Horizontally: Center junction panel between side panels 2 and 3.
Page 974 PROCEDURE NO: PR00029 REVISION 00 Section 3 Junction Panels Gluing 3.00 A) Remove all side panels with the exception of metal strips 9 and 10 and side panel # 7. B) Install large slide-out (front) front and rear junction panels. C) Install junction panel between side panels 5 and 7.
Page 975 PROCEDURE NO: PR00029 REVISION 00 C) Apply Sika 221 black onto structure where engine air intake panel will be located. D) Apply Sika 221 onto all junction panels perimeter. Make sure to fill creases. Rivet junction panels onto structure. Hand press junction panels to flatten Sika bead.
Page 976 PROCEDURE NO: PR00029 REVISION 00 Junction Panel 4-5 Junction Panel 5-7 Junction Panel 7-8 Junction Panel 2-3 Page 8 of 9...
Page 977 PROCEDURE NO: PR00029 REVISION 00 Section 4 Glue Application 4.00 A) Apply Sika 221 + Booster onto side panels. B) Curing time: 4 hours C) Seal corners between metal strips and structure using Sika 221 black. D) Seal side panel ridges using Sika 221 (vehicle, not slide-out).
Page 979 PR00030 RIDGED SIDE PANEL – SEALING JOINT Spec 15.0 Effective: 9052 REVISION 00 DATE 06-08-31 1.00 Sealing Side Panel Upper Portion A) If applicable, remove excess of Sika glue in the upper portion of side panels. B) Caution; - No Sika 205 on the front part of side panels (will stain the S/S).
Page 981 PR00031 RIDGED SIDE PANEL – SLIDE-OUT JUNCTION PANEL PREPARATION Effective: 9064 REVISION 00 Spec 15.0 LVA173 DATE 06-09-07 1.00 Junction Panel Preparation A) Clean using anti-silicone both junction panel sides. (See PR000001, Section A) B) Normally in the center of the junction panel, there is a ¾”...
Page 983 PR00035 STRUCTURE PREPARATION Spec 15.0 Effective: 9082 REVISION 01 LVA077 DATE 06-10-11 A) Clean structure using anti-silicone. 1.00 (See PR000001, Section A) B) Sand structure using Scotchbrite. (See PR000001, Section G) Page 1 of 2...
Page 984 PROCEDURE NO: PR00035 REVISION 01 C) Clean structure and window frames using anti- silicone. (See PR000001, Section A) D) Apply Sika 206G+P onto structure and window frames. (See PR000001, Section D) EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGES...
Page 985 PR00036 UPPER SIDE PANEL – GLUING OF NEOPRENE FOAM TAPES Effective: 9082 REVISION 01 DATE 06-10-11 1.00 Affix neoprene foam tape 3/16 x 1 onto structure where the side panel will be glued. Affix foam tape in the center of vertical and horizontal members. 1.05 Not fitted with slide-out Affix a double-face self adhesive tape 3/16″x1/4″...
Page 986 PROCEDURE NO: PR00036 REVISION 01 1.15 WE OR W5 Fitted with front slide-out Glue a neoprene foam tape 3/16x1/2 Glue a piece of window rubber seal at the top (in the curvature). Page 2 of 2...
Page 987 PR00037 LATERAL FIXED WINDOW RUBBER SEAL – GLUING Effective: 9055 REVISION 00 DATE 06-09-06 Gluing Vertical and Bottom Rubber Seals 1.00 A) Mark the position of each rubber seal. Draw a 13mm (about) long line in the center of the post.
Page 989 PR00038 AWNING OR SLIDING WINDOW INSTALLATION LVA050 Effective: 9055 REVISION 00 LVA081 DATE 06-09-01 Spec 15.0 Section 1 Awning Window Installation 1.00 Glue 2 stops onto the horizontal structure tubing or underneath the window. INSIDE OF VEHICLE VIEW A-A 1.03 Check that D.O.T.
Page 990 PROCEDURE NO: PR00038 REVISION 00 1.05 Interior of Frame Preparation (powder paint) A) Clean using anti-silicone. (See PR000001, Section A) B) Apply Sika Aktivator. (See PR000001, Section C) 1.07 Add a bead of Sika 252 on each side 1.10 Apply Sika 252 onto structure and onto 2 welding joints in the lower bottom corners.
Page 991 PROCEDURE NO: PR00038 REVISION 00 1.20 Install retaining support inside the vehicle. Tighten as per the following sequence. Note: One person should push the window from outside the vehicle while another one tightens the frame from inside. A) Manually open the window and smooth down 1.25 the excess of Sika.
Page 992 PROCEDURE NO: PR00038 REVISION 00 Section 2 Sliding Window Installation 2.00 Interior of Frame Preparation (powder paint) A) Clean using anti-silicone. (See PR000001, Section A) B) Apply Sika Aktivator. (See PR000001, Section C) 2.05 Apply Sika 252 onto structure and onto 2 welding joints in the lower bottom corners.
Page 993 PROCEDURE NO: PR00038 REVISION 00 2.15 Install retaining support inside the vehicle. Tighten as per the following sequence. Note: One person should push the window from outside the vehicle while another one tightens the frame from inside. 2.20 A) From inside the vehicle, add a bead of Sika 252 or 255 in the window upper corners as required.
Page 995 UPPER SIDE PANEL PR00041 GLUING LVA166 REVISION 01 Effective: 9082 Spec 15.0 DATE 06-11-10 D470604-2-1, D470605-2-1 1.00 Fiberglass Panel Preparation Clean using anti-silicone. (See PR000001, Section A) Apply 206 G+P primer. (See PR000001, Section D) Apply Sika 221 black + Booster onto structure. 1.05 Triangular bead at the top (Use the applicator) = 25mm x 15mm...
Page 996 PROCEDURE NO: PR00041 REVISION 01 Install panel on the vehicle. Make sure it is well Distance between panel and windows = 1.15 centered before pressing against 8±2mm structure. Use go-nogo #31133. Note: If you are not sure if the glue is cured, verify with a finger that it is “Tack Free”.
Page 997 PROCEDURE NO: PR00041 REVISION 01 A) Compress bottom of panel starting by the 1.20 center. B) Install a curved jig at each panel end or other mean of compressing the panel. Curing time = 90 minutes minimum C) Check panel alignment (flatness) with adjacent panel or windows 2mm max at the front and 3mm max at the rear.
Page 999 PR00043 LATERAL FIXED WINDOW – GLUING LVA050 Effective: 9055 REVISION 00 LVA075 DATE 06-09-05 LVA081 Spec 15.0 Fixed Window Installation 1.00 Window Preparation Bonding surface must be clean. If it is greasy, clean using anti-silicone as per PR000001, Section A and/or use a scraper to remove glue residue.
Page 1000 PROCEDURE NO: PR00043 REVISION 00 D) Compress bottom of window using two “Quick Grip”. Compress top of window. Note: If necessary, use hands to compress window to reach required flatness. E) Install a curved jig at each window end or other mean of compressing the window.
Page 1001 PROCEDURE NO: PR00043 REVISION 00 Appendix Exterior Tolerance: 1- A gap of 8±2mm with an out of parallelism of 3mm max. Take measurements about 230mm from window extrusion and approximately 25mm from bottom of window. 2- A gap of 4mm is the maximum distance between two windows.
Page 1003 PR00044 LATERAL FIXED WINDOW – JOINT LVA075 Effective: 9055 REVISION 00 Spec 15.0 DATE 06-09-06 Simson Joint Around Fixed Windows A) Smooth down, using a brush, excess of glue 1.00 inside the vehicle all around the window. B) Single Glass: Add a bead of Sika 252 or 255 if necessary to get a joint of 10-12 mm.
Page 1004 PROCEDURE NO: PR00044 REVISION 00 Slide-out Page 2 of 2...
Page 1005 PR00045 LATERAL FIXED HALF-WINDOW – GLUING LVA050 Effective: 9055 REVISION 00 LVA081 DATE 06-09-06 Spec 15.0 Fixed Half-Window Installation 1.00 Window Frame Exterior Preparation Awning or Sliding (powder paint) A) Clean using anti-silicone. (See PR000001, Section A) B) Apply Sika Aktivator. (See PR000001, Section C) 1.05 Half-Window Preparation...
Page 1006 PROCEDURE NO: PR00045 REVISION 00 1.15 Half- Window Installation Apply Sika 255 or Ultrafast onto half-window perimeter. Triangular bead = 20mm X 10mm C) Line up half-window sides with sliding or awning window sides before pressing half- window against structure. Important: Never raise a window once it has been pressed against the structure because the joint would be too damaged.
Page 1007 PROCEDURE NO: PR00045 REVISION 00 G) Install suction cup puller 6" from bottom of half- window in order to compress the bead. Compression time= 8 hours minimum (30 minutes with Ultrafast) Important: Make sure that half-window flatness with reference to the adjacent windows remains acceptable.
Page 1009 LATERAL FIXED WINDOW BEHIND DRIVER PR00046 GLUING Spec 15.0 Effective: 9082 REVISION 01 DATE 06-11-07 1.00 Window Preparation Bonding surface must be clean. If it is greasy, clean using anti-silicone as per PR000001, Section A before proceeding with steps A) & B). A) Clean using glass cleaner.
Page 1011 PR00072 SMOOTH SIDE PANEL – STRUCTURE PREPARATION Effective: 9062 REVISION 00 Spec 15.0 LVA174 DATE 06-09-13 1.00 Structure Preparation (S/S) Clean using anti-silicone (See PR000001, Section A) Sand using belt sander (See PR000001, Section G) Sand using “grit coarse belt”. Change paper on a regular basis. Clean using anti-silicone (See PR000001, Section A) Apply Sika 205.
Page 1013 PR00073 SMOOTH SIDE PANEL – INSTALLATION Spec 15.0 Effective: 9062 REVISION 00 Spec 36.0 DATE 06-09-13 LVA174 Section 1 Smooth Side Panel Preparation 1.00 Smooth Side Panel Preparation (S/S) A) Clean using anti-silicone (See PR000001, Section A) B) Sand using belt sander (See PR000001, Section G) Sand using “grit coarse belt”.
Page 1014 Section 2 Smooth Side Panel Gluing 2.00 Apply and compress foam tape 1/8’’ x 1/2’’ as per SECTION A-A indications. A) Clean using anti-silicone 2.05 (See PR000001 section A) B) Apply and compress foam tape 1/8’’ x1/2’’ onto mid reinforcement. 2.10 A) Use supports to hold up side panel weight.
Page 1015 Reinforcement Bar Installation WE Slide-out 2.20 A) Bolt 1 bar in the box-frame. B) Install cylinder in the centre. C) Bolt the 2 bar in the box-frame. A) Apply Sika 252 onto structure. 2.25 (Watertight Joint) Section A-A Section B-B Section C-C WE ‘’Slide Out’’...
Page 1016 Section A-A Section B-B 2- Position side panel 6±1mm from vertical tubing. 2.30 Rear of vehicle A) Sand back of side panel 2 inches wide for TIG- arc welding. B) Make 36 “TIG spots. WE A) Install pulling equipment at the other end of 2.35 side panel.
Page 1017 B) Perform TIG-arc welding Make 36 TIG spots WE C) Remove pulling equipment D) Remove pressure from slide-out reinforcement bar. E) Remove protective film from double-face self adhesive tape. F) Compress top and bottom section of side panel A) Cut excess of side panel. Make sure that cut is 2.50 parallel with tubing.
Page 1019 PR00074 ENGINE AIR INTAKE PANEL – GLUING Spec 15.0 Effective: 9062 REVISION 00 LVA174 DATE 06-09-13 Engine Air Intake Panel Gluing 1.00 Make sure that sealing of structure has been performed properly 1.05 Engine Air Intake Panel Preparation (S/S) Entertainer 1.10 Install foam tape 1/8"...
Page 1020 PROCEDURE NO: PR00074 REVISION 00 Apply a bead of 252 onto structure as per picture 1.20 Important: Make sure bead is continuous Triangular bead: 10mm x 8mm 3.30 * Panel Installation Install 2 supports onto structure and lay down panel. Adjust supports so that panel is 2±1mm lower than tubing.
Page 1021 PR00075 SMOOTH SIDE PANEL – FINISHING JOINT Spec 15.0 Effective: 9062 REVISION 00 DATE 06-09-13 Finishing Joint A) Apply Sika 205 1.00 Use a plastic spatula inside a Chix cloth to ensure that Sika 205 reaches as far as the corner.
Page 1023 PR00131 CONDENSER COMPARTMENT DOOR - ASSEMBLY Effective: 9064 REVISION 00 Spec 15.0 LVA175 DATE 06-09-19 Condenser Compartment Door 1.00 Apply some masking tape to protect the hinge (to prevent staining with Sika 206 G+P). 1.05 S/S Frame Preparation + EDGE A) Clean using anti-silicone.
Page 1025 PR00133 EVAPORATOR COMPARTMENT DOOR – ASSEMBLY Effective: 9064 REVISION 00 Spec 15.0 LVA176 DATE 06-09-19 Door Assembly 1.00 Drilling Back Panel Install back panel onto frame and drill 1.05 Back Panel Clean frame using anti-silicone. (See PR000001, Section A) Apply Sika 205 onto body panel and frame perimeter.
Page 1026 PROCEDURE NO: PR00133 REVISION 00 Apply Sika 205 aound the opening in the frame (See PR000001, Section B) Apply Sika 221 gey onto the perimeter Bead diameter, about 4mm Lay down back panel and rivet 1.10 Install latch Caution: Install the tip of the latch towards the top Page 2 of 7...
Page 1027 PROCEDURE NO: PR00133 REVISION 00 1.15 Damper Apply foam tape 1/16x1/2 underneath damper Install and rivet Install filter. 1.20 A/C Junction Box Install A/C junction box. Install 3 tie-mount and rivet 1.25 * Marker Light Grommets Install grommets Page 3 of 7...
Page 1028 PROCEDURE NO: PR00133 REVISION 00 1.35 Install insulating pieces. 1.40 Body Panel Adjustment Install and adjust lower and upper body panels. Make sure that the 2 panels are flush one compared other. Check hinge squareness with regards to panels. Hold down using clamps. Drill 6 holes into lower body panel.
Page 1029 PROCEDURE NO: PR00133 REVISION 00 1.55 E-Coat Upper Body Panel Preparation Clean using anti-silicone. (See PR000001, Section A) 1.60 S/S Frame Preparation A) Apply masking tape onto hinge B) Clean using anti-silicone. + edge (See PR000001, Section A) C) Sand using Scotchbrite. (See PR000001, Section G) D) Clean using anti-silicone.
Page 1030 PROCEDURE NO: PR00133 REVISION 00 1.65 Grid Installatione Apply Sika 221 grey around the opening Install grid Apply Sika 221 grey again aroud the grid. 1.70 Body Panel Installation A) Apply some butyl tape onto the frame and remove protective tape (liner) B) Apply Sika 221 grey onto lower body panel and frame.
Page 1031 PROCEDURE NO: PR00133 REVISION 00 D) Apply Sika 221 + booster onto upper body panel. E) Install upper body panel. Compress glue using hands. Make sure that upper portion of body panel rests perfectly against the frame. Remove protective tape from hinge. Hold down body panel using masking tape.
Page 1033 PR00177 BAGGAGE COMPARTMENT DOOR – BODY PANEL INSTALLATION MTH 9070 REVISION 00 Spec 15.0 Effective: LVA171 DATE 06-10-06 Section 1 Baggage Door Back Panel Positioning 1.00 Position back panel. Apply masking tape to hold it in place. 1.05 Drill using a #11 drill bit. 1.10 Remove masking tape and back panel.
Page 1034 PROCEDURE NO: PR00177 REVISION 00 Section 3 Door Structure Sealing 3.00 A) Apply Sika 205 around door handle pipe exterior ends (#1 & #2). (See PR000001, Section B) B) Apply Sika 221 around door handle pipe exterior ends (#1 & #2) 3.05 A) Apply Sika 205 at the top of the handle (handle exterior side)
Page 1035 PROCEDURE NO: PR00177 REVISION 00 B) Apply Sika 221 Into the 4 interior corners of the frame. Bead diameter = Ø3/16" 3.25 Hinged Door Frame (Slide-Out) A) Apply Sika 205 from the interior of the frame, hinge side. (See PR000001, Section B) B) Apply Sika 221.
Page 1036 PROCEDURE NO: PR00177 REVISION 00 Section 5 Insulation Installation (optional) 5.00 Install pieces of insulation onto door structure. 5.05 A) Apply some green tape onto the joint between the two pieces of insulation. B) Apply some green tape in order to hold the electric motor cable into the insulation cavity.
Page 1037 PROCEDURE NO: PR00177 REVISION 00 6.05 SS Body Panel Preparation A) Clean using anti-silicone. (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 206 G+P. (See PR000001, Section D) 6.10 E-Coat Body Panel Preparation Clean using anti-silicone.
Page 1038 PROCEDURE NO: PR00177 REVISION 00 6.20 A) Apply Sika 221+ booster. Triangular bead = 8mm wide X 9mm high. Important: There should be no more than 18 minutes between the beginning of the glue application and the panel installation onto the frame.
Page 1039 PROCEDURE NO: PR00177 REVISION 00 6.35 A) If necessary, install door handle onto frame to install the rivets B) Drill door structure using a #30 drill bit using the holes in the body panel pleats. Rivet body panel onto structure. Important: If equipped with a smooth body panel, soak rivets into Sika 221 before riveting.
Page 1040 PROCEDURE NO: PR00177 REVISION 00 7.05 A) Remove lower body panel B) Grind metal burrs from the top of the frame and also at the back of the body panel. C) Remove blue paper from the body panel ends (so that the holes are free) and also at the top (so that the portion inserted underneath the upper panel is free).
Page 1041 PROCEDURE NO: PR00177 REVISION 00 7.20 Insert a rivet into each hole and rivet starting from the top. Note: Make sure the rivet shank does not excess its head. Section 8 Body Panel Replacement Procedure UPPER BODY PANEL REMOVAL 8.00 Remove door lock and handle.
Page 1042 PROCEDURE NO: PR00177 REVISION 00 Appendix 1 Replacement/Repair A1.00 Remove part. See PR000001, Section 2. Preparation and gluing. See PR000001, Section 2 and/or do procedure again. Page 10 of 10...
Page 1043 PR00198 FRONT BUMPER PANEL - GLUING Spec 15.0 9090 REVISION 00 Effective : Engineering Change : DATE 06-10-16 1.00 S/S Frame Preparation A) Clean using anti-silicone. (See PR000001, Section A) B) Use Scotchbrite to sand frame. (See PR000001, Section G) C) Clean using anti-silicone.
Page 1044 PROCEDURE NO: PR00198 REVISION 00 1.15 A) Apply double face self adhesive tape 1/16 x 1/4 onto perimeter of frame. B) Apply Sika 252. 1.20 A) Remove protective film from double face self adhesive tape and lay down panel onto frame. B) Press panel against frame to compress the glue and double-face self adhesive tape.
Page 1045 PR00208 RIDGED SIDE PANEL – GLUING OF HORIZONTAL FINISHING MOLDING 9090 REVISION 00 Spec 15.0 Effective: L00014 DATE 06-10-20 Section 1 Rear Cap and Engine Air Intake Snap-on Finishing Molding Installation 1.00 Snap-On Finishing Molding Pre positioning SNAP-ON FINISHING MOLDING A) Position snap-on finishing molding and put a pencil mark underneath the snap-on finishing molding where indicated (onto engine air intake...
Page 1046 PROCEDURE NO: PR00208 REVISION 00 1.05 Sealing the cavity A) Clean using anti-silicone Section View (See PR000001, Section A) B) Apply Sika 205. (See PR000001, Section B) C) If necessary, apply masking tape onto each cavity side to pick up the excess. D) Fill the cavity with Sika 221 or 252.
Page 1047 PROCEDURE NO: PR00208 REVISION 00 1.20 Snap-On Finishing Molding Installation A) Position snap-on finishing molding as per chalk CHALK LINE line of step 1.00 B). Position snap-on finishing molding “flush” with the edge of the engine air intake panel. B) Pre-drill using a 1/8" dia. bit. Drill using a #11 drill bit and rivet.
Page 1048 PROCEDURE NO: PR00208 REVISION 00 Section 2 Corner Molding Gluing 2.00 (S/S) Corner Molding Preparation A) Clean using anti-silicone. (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 205. (See PR000001, Section B) 2.05 Apply Sika 252.
Page 1049 PROCEDURE NO: PR00208 REVISION 00 3.15 A) Glue finishing molding. 3.20 B) Compress molding with a nylon block. Section 4 Vehicle Preparation 4.00 Vehicle Preparation (S/S) A) Clean using anti-silicone side panels and gutters, under masking tape. Section A-A Section B-B (See PR000001, Section A) B) Sand using orbital sander.
Page 1050 PROCEDURE NO: PR00208 REVISION 00 5.15 Sealing cavities A) Fill cavities with Sika 221 or 252. Section A-A Section B-B B) Smooth down the joint with a plastic spatula. Important: There must be no more than 15 minutes between the start of cavity filling and the installation of molding.
Page 1051 PROCEDURE NO: PR00208 REVISION 00 Section 6 Upper & Lower Finishing Moldings Preparation 6.00 A) Position rear upper lower finishing moldings onto vehicle. B) Draw a line onto moldings in line with the joint between the 2 and 3 side panels. Cut the excess of molding and file down the end.
Page 1052 PROCEDURE NO: PR00208 REVISION 00 Section 7 Upper Finishing Molding Installation 7.00 A) Apply foam tape 1/4″x1/4″. B) Make 3-100mm (+/- 25) long clearings in the bottom foam tape. C) W5 Fitted With Slide-out Upper Finishing Molding in front of slide- out.
Page 1053 PROCEDURE NO: PR00208 REVISION 00 Section 8 Lower Finishing Molding Installation 8.00 A) Apply foam tape 1/4″x1/4″. B) Make 3-100mm (+/- 25) long clearings in the bottom foam tape. 8.05 Apply Sika 252. Do not apply Sika in front of the previous clearings.
Page 1055 PR00210 ENGINE RADIATOR DOOR MOLDING OR ENGINE COMPARTMENT R. H. SIDE DOOR MOLDING – GLUING MTH 9090 Sepc 15.0 REVISION 00 Effective: DATE 06-10-17 1.00 Door Preparation (SS) A) Clean using anti-silicone (See PR000001 section A) B) Sand using Scotchbrite. CHALK LINE (See PR000001, Section G) C) Clean using anti-silicone...
Page 1056 PROCEDURE NO: PR00210 REVISION 00 1.10 A) W5 W0 Apply Sika 252. B) WE Apply 252. 1.15 A) W5 W0 Position and glue the molding underneath the chalk line making sure it is lined up with the horizontal side molding (maximum 1mm) B) WE Position and glue the molding making sure it is Line up moldings...
Page 1057 PR00211 ENGINE COMPARTMENT DOORS MOLDING – GLUING MTH 9090 REVISION 00 Spec 15.0 Effective: DATE 06-1017 1.00 Door Preparation (SS) A) Clean using anti-silicone (PR000001 Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone (PR000001 Section A) D) Apply Sika 205 (PR000001 Section B) Door Preparation (Primer)
Page 1058 PROCEDURE NO: PR00211 REVISION 00 1.10 W5 W0 Apply Sika 252. WE X3 Apply Sika 252 1.15 A) Apply corner molding so that it is level and lined up (maximum 1mm) with engine compartment R.H. side door molding or radiator door molding.
Page 1059 PR00212 FRONT FACE MOLDING – GLUING Spec 15.0 MTH 9090 REVISION 00 Effective : Engineering Change: DATE 06-10-17 1.00 Mark molding position onto front face using a felt-tip pen (refer to side moldings for proper height). 1.05 Molding Preparation (SS) A) Clean using anti-silicone.
Page 1060 PROCEDURE NO: PR00212 REVISION 00 1.20 Apply Sika 252 MTH: Onto front face. Triangular bead = 8mm 1.25 A) Affix moldings Note: Affix moldings so that the joint falls on the center of the vertical molding. Vertical Molding B) Compress moldings using hands. C) Use masking tape to hold moldings in place during curing process.
Page 1061 PR00213 ENTRANCE DOOR OR FRONT ELECTRICAL& SERVICE COMPARTMENT DOOR MOLDING– GLUING MTH 9090 Spec 15.0 REVISION 00 Effective: Engineering Change: DATE 06-10-17 1.00 Molding Preparation A) Clean using anti-silicone. (See PR000001, Section A) B) Use Scotchbrite to sand molding. (See PR000001, Section G) C) Clean using anti-silicone.
Page 1062 PROCEDURE NO: PR00213 REVISION 00 1.15 MTH: Glue 3-50mm long pieces of foam tape 1/16 x 1/2 onto the door. 1.20 Apply Sika 252 onto the door Triangular bead = 8mm 1.25 Molding Installation Line up with front and side moldings Even within 1mm.
Page 1063 PR00214 SMOOTH SIDE PANEL – GLUING MOLDINGS Spec 15.0 MTH 9090 REVISION 00 Effective: L00016 DATE 06-10-18 1.00 A) Temporarily position front vertical molding and mark horizontal moldings (top & bottom) with a pencil B) Remove vertical molding and cut the excess of horizontal moldings C) If required, straighten horizontal moldings using a grinder.
Page 1064 PROCEDURE NO: PR00214 REVISION 00 1.15 Front Fender Preparation (SS) A) Clean using anti-silicone. (See PR000001, Section A) B) Sand using a Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 205. (See PR000001, Section B) Front Fender Preparation (E-coat) Clean using anti-silicone.
Page 1065 PROCEDURE NO: PR00214 REVISION 00 1.25 Apply Sika 252. 1.30 Molding Installation A) Position top of the molding even with (1mm maximum) top of horizontal finishing molding. B) Drill molding using a #30 drill bit and rivet. C) Seal rivet heads using Sika 221. 1.35 Seal top of molding using Sika 252.
Page 1067 PR00215 SMOOTH SIDE PANEL – REAR MOLDING GLUING MTH 9090 REVISION 00 Spec 15.0 Effective: L00016 DATE 06-10-18 1.00 A) Measure the distance between upper and lower horizontal finishing moldings, where the vertical molding will be installed. B) If required, cut the excess. 1.05 Molding Preparation (aluminum) A) Sand using a Scotchbrite.
Page 1068 PROCEDURE NO: PR00215 REVISION 00 1.20 Apply Sika 252 onto molding. 1.25 A) Glue molding 6mm from side panel. Important: Make sure that molding hides Sika 221 bead. B) Compress molding with hands. MOLDING ENGINE AIR INTAKE PANEL EDGE OF SIDE PANEL Page 2 of 2...
Page 1069 PR00216 SMOOTH SIDE PANEL – PROTECTION OF UNPRIMED TIG WELDING SPOTS MTH 9090 REVISION 00 Spec 15.0 Effective: DATE 06-10-20 Applicable only if there is no primer on the TIG welding spots (before gluing vertical moldings) 1.00 A) Apply masking tape on each side of the welding spots.
Page 1071 PR00217 SMOOTH SIDE PANEL – GLUING SLIDE-OUT VERTICAL MOLDING MTH 9090 REVISION 00 Spec 15.0 Effective: DATE 06-10-18 1.00 Vehicle Preparation (primer) Important: If there is no primer on top of welding spots, perform PR00216. Clean using anti-silicone. (See PR000001, Section A) Sand using a Scotchbrite.
Page 1072 PROCEDURE NO: PR00217 REVISION 00 Apply Sika 252 black Apply moldings. Distance of 9mm+/-2 with reference to slide-out panel and line up at the top with fiberglass or lateral fixed window behind driver. If applicable, clean up the excess with Sika 208. Adjust evenness of moldings if required.
Page 1073 PR00220 SMOOTH SIDE PANEL – CUTTING HORIZONTAL FINISHING MOLDING AT SLIDE-OUT LEVEL MTH 9090 REVISION 00 L00015 Effective: DATE 06-10-20 1.00 Cutting Upper Horizontal Finishing Molding A) Wait 24 hours before cutting horizontal molding at ‘’Slide-Out’’ level. CUT HERE B) Using a circular saw, cut molding even with the box-frame and structure.
Page 1075 ENTRANCE DOOR ASSEMBLY PROCEDURE (MTH) PROCEDURE NO: PR280020 REVISION 14 2004-06-11 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ √ Scotchbrite grey (680226) Sika 206 G+P 1 liter (683446) √ √ Anti-silicone (682989) Silver sealant (680462) √ √ √ Tack cloth Blue Loctite Sika 221 grey √...
Page 1076 PROCEDURE NO: PR280020 REVISION 14 Section 1 Motor Installation 1.00 Install plastic piece onto power window motor. 1.05 Install electric motor onto door frame. Section 2 Door Assembly 2.00 Power Window Frame Preparation (E-Coat) Clean bonding area using anti-silicone. (See PR000001, Section A) 2.05 Window Preparation A) Clean using glass cleaner.
Page 1077 PROCEDURE NO: PR280020 REVISION 14 2.10 Affix double-face self adhesive tape 1/8 x 1/4 onto power window frame. Peel back from tape where it comes in contact with window pane. 2.15 A) Apply Sika 255 onto frame. B) Affix the frame onto window pane. C) Secure assembly using clamps.
Page 1078 PROCEDURE NO: PR280020 REVISION 14 2.25 Fiberglass Preparation (LPLT) A) Sand using Scotchbrite. (See PR000001, Section G) B) Clean using tack cloth C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 206 G+P. (See PR000001, Section D) 2.30 Fiberglass Preparation (beige primer) A) Sand using Scotchbrite.
Page 1079 PROCEDURE NO: PR280020 REVISION 14 2.40 Apply Sika 255 onto door frame. Note: Leave a gap at the bottom (about 50mm) for water dripping. 2.45 Apply Sika 255 onto window pane. 2.50 Lay down and center window pane onto door frame. Window pane must extend 1mm at the frame top.
Page 1080 PROCEDURE NO: PR280020 REVISION 14 2.55 A) Lay down and center fiberglass panel onto door frame (panel exceeds 3mm at the frame bottom and sides). B) Compress panel using hands. 2.60 A) If needed, readjust window pane so that it is even with panel.
Page 1081 PROCEDURE NO: PR280020 REVISION 14 3.05 Steel Sheet Preparation (SS) A) Clean using anti-silicone. (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 205. (See PR000001, Section B) 3.10 Affix double-face self adhesive tape (1/16 x ½) 3mm from panel edge.
Page 1082 PROCEDURE NO: PR280020 REVISION 14 3.20 A) Lay down and center lower body panel onto fiberglass panel and then, compress body panel using hands. B) Lay down and center upper body panel onto fiberglass panel and then, compress body panel using hands. C) Drill 2 holes and rivet.
Page 1083 PROCEDURE NO: PR280020 REVISION 14 5) Position & fasten wiper using screws. Exterior Window Wper D) Insert pane in the frame. E) Fix window pane to its support. Note: Apply some blue “loctite” to the screws. Interior Window Wiper Installation Interior Window Wper 1) Position window wiper.
Page 1084 PROCEDURE NO: PR280020 REVISION 14 4.15 Do the finishing joints (See Section 5, steps 5.15 & 5.20). 4.20 Install “Keyless” pad. 4.25 Install locking plates. 4.30 Lock Installation A) If necessary, put together the lock. Calfeutrant 285198 B) Install lock. Note: Make sure that lock is even with door once fixed.
Page 1085 PROCEDURE NO: PR280020 REVISION 14 C) Remove existing piece on top of lock (will not be used) and replace with the new one. piece D) Glue some “Strip calk” onto the new piece. 4.35 Insert a plastic grommet into the frame. 4.40 A) Cut pneumatic tubing.
Page 1086 PROCEDURE NO: PR280020 REVISION 14 C) Fix the locking cylinder. 4.50 * Door Handle Installation A) Clean using anti-silicone. The handle perimeter (where the gasket will be glued). (See PR000001, Section A) B) Glue the gasket onto the handle. C) Install door handle. Parallel Note: Make sure that door handle is parallel with fiberglass panel.
Page 1087 PROCEDURE NO: PR280020 REVISION 14 4.70 Water Deflector Gluing A) Use Scotchbrite to sand fiberglass panel and deflector bonding surfaces. (See PR000001 section G) B) Clean bonding surfaces using anti-silicone. (See PR000001, Section A) C) Apply double face self adhesive tape 1/8 x 1/4 onto deflector.
Page 1088 PROCEDURE NO: PR280020 REVISION 14 4.80 Membrane Installation Clean door frame where membrane will be glued, using anti-silicone. (See PR000001, Section A) Peel back from the membrane with the exception of the area where the mechanism is located (prevent mechanism from bonding to the membrane).
Page 1089 PROCEDURE NO: PR280020 REVISION 14 4.82 Interior Finishing Panel Installation DRILL 5/32’’ Unscrew lock guide. Install finishing panel and fasten guide on top of panel using screws. Drill 8-1/8" dia. holes and fasten panel using screws. Drill 1-5/32” dia. hole 4.85 Closing Plate Installation Clean using anti-silicone.
Page 1090 PROCEDURE NO: PR280020 REVISION 14 Peel the back of double-face self adhesive tape then compress ‘’Norryl’’ molding. 4.90 Install door handle plastic cover, door handle then hinges. 4.92 Perform power window, light and electric lock final testing. 4.95 Glue some blue protective paper onto the door interior.
Page 1091 PROCEDURE NO: PR280020 REVISION 14 5.07 A) Clean using anti-silicone the area to be sealed. (See PR000001, Section A) B) Apply masking tape around the area to be sealed. C) Apply Sika 255 at each exterior window wiper end (S/S portion). D) Smooth down the joint with your finger then WIPER remove masking tape.
Page 1092 PROCEDURE NO: PR280020 REVISION 14 Section 6 Replacement / Repair 6.00 Remove part. See PR000001, Section 2. Preparation and gluing. See PR000001, Section 2 and/or do procedure again. Page 18 of 18...
Page 1093 FRONT ELECTRICAL & SERVICE COMPARTMENT DOOR ASSEMBLY PROCEDURE NO: PR280021 REVISION 18 2006-02-17 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ √ Scotchbrite grey (680226) Sika 206 G+P 1 liter (683446) √ √ Anti-silicone (682989) Silver sealant (680462) √ √ CHIX cloth (682384) Simson 70-03 grey √...
Page 1094 PROCEDURE NO: PR280021 REVISION 18 Section 1 Door Assembly 1.00 A) Position fiberglass panel onto door frame. B) Mark bonding areas onto fiberglass panel. 1.10 Door Frame Preparation (S/S) A) Clean using anti-silicone. 90° (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone.
Page 1095 PROCEDURE NO: PR280021 REVISION 18 1.20 Window Frame Preparation Clean using anti-silicone bonding area (top and edges) (See PR000001, Section A) 1.22 Affix a double-face self adhesive tape 1/32 x 1/4 onto the whole window frame perimeter. 1.25 Fix window frame onto door frame. Section View Door frame Important: Make sure that top of window frame is...
Page 1096 PROCEDURE NO: PR280021 REVISION 18 1.35 Position fiberglass panel onto door frame and Door compress using hands. Use a ruler. Frame 3 mm All around Fiberglass Panel 1.40 Perform steps in section 3. 1.45 A) Door Exterior: Install appropriate number of c- clamps and wooden blocks all around.
Page 1097 PROCEDURE NO: PR280021 REVISION 18 C) Check fiberglass panel flatness using a 24" ruler (must be within 2mm). Rule 1.50 Important : Make sure window pane slides perfectly within its frame. 1.55 If necessary, clean up the excess all around door frame using Sika 208.
Page 1098 PROCEDURE NO: PR280021 REVISION 18 1.65 Window Wipers Gluing Anti-friction side A) Apply glue #680066 into fiberglass groove and affix window wiper. Important: Anti-friction side must be on window pane side. B) Apply Sika 252 into the window wiper corners, from the inside.
Page 1099 PROCEDURE NO: PR280021 REVISION 18 1.85 Power Window Installation A) Insert 2 seals in power window frame. B) Apply some “loctite” glue #680066 at the intersection of the 2 seals and also sparingly in order to fix the seals to the window frame. C) Clean window using glass cleaner.
Page 1100 PROCEDURE NO: PR280021 REVISION 18 Section 2 Door Finishing 2.00 Install docking lamp and reflector. 2.10 Membrane Installation A) Clean door frame where membrane will be glued, using anti-silicone. (See PR000001, Section A) B) Peel back from the membrane with the exception of the area where the mechanism is located (prevent mechanism from bonding to Leave the...
Page 1101 PROCEDURE NO: PR280021 REVISION 18 2.15 Interior Finishing Panel Installation A) Position top of interior finishing panel even with top of window frame. B) Drill 12-#30 holes and screw in panel. Do not drill (will be done during latch cover installation) 2.20 Interior Finishing Molding (Norryl) Installation...
Page 1102 PROCEDURE NO: PR280021 REVISION 18 Section 3 Gluing of SS Body panels 3.00 * Fiberglass Preparation (LPLT) A) Sand using Scotchbrite. (See PR000001, Section G) B) Clean using anti-silicone. (See PR000001, Section A) C) Apply Sika 206 G+P. (See PR000001, Section D) 3.05 Body Panels Preparation (S/S) A) Cut and remove from the appropriate areas on...
Page 1103 PROCEDURE NO: PR280021 REVISION 18 3.10 Affix double-face self adhesive tape 1/16 x 1/2. AFFIX NEAR THE EDGE 3.15 Apply Sika 252 onto panels. Page 11 of 12...
Page 1104 PROCEDURE NO: PR280021 REVISION 18 B) Position and glue bottom body panel. C) Position and glue upper body panel. D) Compress body panels using hands. E) Drill 2-#30 holes and rivet. F) Seal rivets using silver sealant. Finishing Joint 3.20 * A) Apply Simson 70-03 Fill in the space between body panels and fiberglass panel at the indicated location.
Page 1105 ENTRANCE DOOR OR FRONT ELECTRICAL & SERVICE COMPARTMENT DOOR INSTALLATION PROCEDURE PROCEDURE NO: PR280022 REVISION 10 2006-06-04 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ Anti-silicone (682989) √ √ Chiffon CHIX (682384) Sika 215 1 liter (683916) √ Chiffon Bleu (682383) √...
Page 1106 PROCEDURE NO: PR280022 REVISION 10 Section 3 Entrance Door or Front Service Door Final Adjustment 3.00 Door Adjustment with reference to front face Line up each door groove with front face groove within 3mm max. Aligning door pleats with front fender pleats Line door pleats with front fender pleats within 2mm max.
Page 1107 PROCEDURE NO: PR280022 REVISION 10 Section 4 Gluing Entrance Door and Service Door Seal 4.00 A) Clean using anti-silicone seal bonding surface Service Door Entrance Door (See PR000001, Section A) B) Apply Sika 205. (See PR000001, Section B) 4.05 * Gluing Service Door Seal A) Apply Simson 70-03 black at the seal 4 corners, each side of the tape.
Page 1108 PROCEDURE NO: PR280022 REVISION 10 4.10 * Gluing Entrance Door Seal A) Apply Simson 70-03 black at the seal 4 corners, each side of the tape. B) Glue seal 4 corners. Upper corners: Press corners against door frame. Lower corners: Glue 10mm lower than bottom of door frame (may vary depending on seal length).
Page 1109 PROCEDURE NO: PR280022 REVISION 10 Section 6 Collage du cache penture intérieur 6.00 Interior Hinge Cover Preparation (ABS) Clean using anti-silicone. (See PR000001, Section A) Apply Sika 215. (See PR000001, Section D) 6.05 Hinge Preparation (E-Coat) Clean using anti-silicone. (See PR000001, Section A) 6.10 Apply Sika 252 black.
Page 1111 ENGINE COMPARTMENT DOOR BODY PANEL INSTALLATION PROCEDURE NO: PR280032 REVISION 4 2006-05-30 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ √ Anti-silicone (682989) Scotchbrite grey (680226) √ CHIX cloth (682384) √ Blue cloth (682383) √ √ Sika 205 1liter (683097) Sika 252 black √...
Page 1112 PROCEDURE NO: PR280032 REVISION 4 Section 1 Stainless Steel Body Panel Gluing MTH 1.00 Make sure that panel is in perfect shape before gluing. Verify especially the corners by lifting the blue paper. Remove blue paper from the adhesion side. Stainless Steel Panel 1.05 Clean using anti-silicone...
Page 1113 PROCEDURE NO: PR280032 REVISION 4 1.10 Door Preparation Painted door (clear coat of polyurethane) Clean using anti-silicone See PR000001 section A. Primed door (beige primer) Sand using Scotchbrite See PR000001 section G. Clean using anti-silicone See PR000001 section A. 1.15 Install double-face self...
Page 1114 PROCEDURE NO: PR280032 REVISION 4 1.20 Apply Sika 252 onto body panel. 1.25 Lay down stainless steel body panel onto fiberglass door. Note: Be careful upon installing the upper or lower small body panel. Make sure that drip hole is in the bottom.
Page 1115 PROCEDURE NO: PR280032 REVISION 4 Appendix 1 Replacement A1.00 Remove body panel A1.05 See PR000001 section 2. A1.10 For gluing procedure, refer to section 1. Page 5 of 5...
Page 1117 DRIVER’S WINDOW GLUING PROCEDURE PROCEDURE NO: PR290013 REVISION 22 2006-06-16 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ √ Scotchbrite grey (680226) Sika 206 G+P 1 liter (683446) √ Anti-silicone (682989) √ CHIX cloth (682384) √ √ √ Blue cloth (682383) Glass cleaner (683926) Sika 221 black + booster √...
Page 1118 PROCEDURE NO: PR290013 REVISION 22 Section 1 Window Installation 1.00 There should be no Primer 206G+P in this zone. If required, apply some masking tape. 1.05 Structure Preparation A) Clean using anti-silicone. (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone.
Page 1119 PROCEDURE NO: PR290013 REVISION 22 2.02 There should be no glue in this zone. If required, apply some masking tape. 2.05 Install 3 positioning shims onto structure. 2.10 Window Pane Preparation EDGE A) Clean using glass cleaner interior surface and edges.
Page 1120 PROCEDURE NO: PR290013 REVISION 22 2.20 A) Press window against the shims B) Install suction cup puller in the center of window, from the inside. C) Compress window using hands and adjust puller. Line up window exterior (flatness) with adjacent surfaces.
Page 1121 PROCEDURE NO: PR290013 REVISION 22 Section 3 Finishing Joint (esthetic) 3.00 * See PR000001A section 3 for details of finishing joint A) Apply Sika 205 into cavity. (See PR000001, Section B) B) Fill cavity with Sika 255 Appendix 1 Replacement/Repair A1.00 Remove part.
Page 1123 FRONT FACE UPPER LATERAL WINDOWS GLUING PROCEDURE PROCEDURE NO: PR290016 REVISION 18 2006-06-16 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ Sika 206 G+P 1 liter (683446) Anti-silicone (682989) √ √ CHIX cloth (682384) √ √ Blue cloth (682383) Glass cleaner (683926) √...
Page 1124 PROCEDURE NO: PR290016 REVISION 18 Section 1 Windows Installation 1.00 A) Remove markers lights. B) If applicable, remove excess of sealant and urethane from bonding areas. Use an air gun to clean up. 1.02 Structure Preparation (primer 206 G+P) Reactivate Sika 206G+P primer as per PR000001 section D.
Page 1125 PROCEDURE NO: PR290016 REVISION 18 1.15 Apply masking tape onto window pane. Interior Exterior 1.20 A) Glue 4 stops #790392 onto fiberglass. STOPS Glue all stops half of their length B) Affix a double-face self adhesive tape 1/8’’ x 1/8’’ onto fiberglass structure perimeter.
Page 1126 PROCEDURE NO: PR290016 REVISION 18 1.25 Install shims at the bottom of window. A) Install window into the opening to check the 1.30 R.H. side window pane curvature with reference to the front cap. L.H. side: Align front of window with front of driver’s window.
Page 1127 PROCEDURE NO: PR290016 REVISION 18 1.40 Install window. Compress window all around in order to glue it to the double-face self adhesive tape. Make sure to respect flatness in the indicated area, must be flush within 2mm. FLATNESS AREA A) Install suction cup puller in the window center 1.45 from inside of vehicle.
Page 1128 PROCEDURE NO: PR290016 REVISION 18 1.60 A) Apply Sika 255 from inside of vehicle (make two joints). B) Smooth down the joints and remove masking tape. INTERIOR VIEW 1.65 Reinstall markers light. Appendix 1 Replacement/Repair A1.00 Remove part. See PR000001, Section 2. Preparation and gluing.
Page 1129 FRONT FENDER BODY PANEL PROCEDURE NO: PR470024 REVISION 10 2006-04-25 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: Alcohol (680536) √ Scotchbrite grey (680226) √ Anti-silicone (682989) √ √ CHIX cloth (682384) Sika 221 grey √ √ Blue cloth (682383) Sika 221 black + booster √...
Page 1130 PROCEDURE NO: PR470024 REVISION 10 Section 1 Surface Preparation 1.00 A) Check the state of the parts bonding surface (visually and with a scraper. Remove blue paper from the body panels bonding side. B) Check plate flatness. Use a hammer if necessary to prevent the plate from exceeding the structure surface.
Page 1131 PROCEDURE NO: PR470024 REVISION 10 1.20 A) Apply Sika 252 black onto structure. B) Smooth down the joint with a finger or spatula to prevent bumps. Section 2 Smooth Body Panel Gluing 2.00 Apply a foam tape onto body panel and peel back. 2.05 A) Apply Sika 221 + booster onto panels..
Page 1132 PROCEDURE NO: PR470024 REVISION 10 2.10 * A) Body panel adjacent to baggage compartment door. Install body panel in the best possible position. Allow the panel to float on the glue. Make the FOLLOW CURVATURE final adjustment and then press body panel using hands.
Page 1133 PROCEDURE NO: PR470024 REVISION 10 2.35 Finishing Joint A) Apply masking tape onto body panel edge and structure. B) Apply Sika 221 grey in order to fill the space between body panel and structure. C) Smooth down the joints with a finger and soapy water.
Page 1134 PROCEDURE NO: PR470024 REVISION 10 3.10 * A) Body panel adjacent to baggage compartment door. Install body panel in the best possible position. Allow the panel to float on the glue. Make the LINE UP RIDGES final adjustment and then press body panel using hands.
Page 1135 PROCEDURE NO: PR470024 REVISION 10 C) Seal lower body panel rivets using silver sealant. 3.35 Finishing Joint A) Apply masking tape onto body panel edge and structure B) Apply Sika 221 grey in order to fill the space between body panel and structure. C) Smooth down the joints with a finger and soapy water.
Page 1136 PROCEDURE NO: PR470024 REVISION 10 Section 4 Front Fender With Reference To Body Panel 4.00 Front fender with reference to body panel. Out of alignment between body panel ridge and front fender ridge ± 2mm. 2mm maximum between body panel and front fender Appendix 1 Repair A1.00...
Page 1137 REAR FENDER BODY PANEL PROCEDURE NO: PR470046 REVISION 5 2006-02-21 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ √ √ Anti-silicone (682989) Scotchbrite grey (680226) Sika 206 G+P 1 liter (683446) √ √ CHIX cloth (682384) Sika 221 + booster √ Blue cloth (682383) √...
Page 1138 PROCEDURE NO: PR470046 REVISION 5 Section 1 S/S Structure Preparation A) Clean using anti-silicone. 1.00 (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 206 G+P. (See PR000001, Section D) Section 2 E-Coat (black) Body Panel Preparation Clean using anti-silicone.
Page 1139 PROCEDURE NO: PR470046 REVISION 5 Section 3 S/S Body Panel Preparation A) Clean using anti-silicone. 3.00 (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 206 G+P. (See PR000001, Section D) 3.05 Apply double-face self adhesive tape 1/16 x 1/2 6mm from panel edges and remove protective tape...
Page 1140 PROCEDURE NO: PR470046 REVISION 5 Section 4 Docking Lamp casing Preparation 4.00 * SMC Lamp Casing Preparation A) Sand using Scotchbrite. (See PR000001, Section G) B) Clean using anti-silicone. (See PR000001, Section A) C) Apply Sika 206 G+P. (See PR000001, Section D) 4.10 Apply double-face self adhesive tape 1/16 x 1/2.
Page 1141 PROCEDURE NO: PR470046 REVISION 5 5.10 SMOOTH BODY PANEL GLUING Apply Sika 221 + booster. 5.15 RIDGED BODY PANEL GLUING Apply Sika booster. 5.20 Install body panels Compress for 4 hours minimum. 5.25 RIDGED BODY PANELS Apply Sika 252 to fill the ridges.
Page 1143 S/S FRONT FACE BODY PANEL GLUING PROCEDURE PROCEDURE NO: PR470047 REVISION 3 2006-02-15 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) Material: √ Scotchbrite grey (680226) √ Anti-silicone (682989) √ CHIX Cloth(682384) √ √ Blue Cloth (682383) Sika 205 1litre (683097) Sika Remover 208 (685101) √...
Page 1144 PROCEDURE NO: PR470047 REVISION 3 1.00 Check condition of panels. 1.05 S/S Panel Preparation Bottom A) Clean using anti-silicone. (See PR000001, Section A) B) Sand using Scotchbrite. (See PR000001, Section G) C) Clean using anti-silicone. (See PR000001, Section A) D) Apply Sika 205. (See PR000001, Section B) 1.10 * Fiberglass Preparation...
Page 1145 PROCEDURE NO: PR470047 REVISION 3 B) Draw a line on the side of each panel for reference (left and right). Draw another line in the center of the 2 previous lines to define center piece positioning. 1.20 Center Piece Installation A) Apply double-face tape 1/32 x ¼...
Page 1146 PROCEDURE NO: PR470047 REVISION 3 B) Apply Sika 252. C) Position and glue side panels with reference to the lines draw at step 1.15b) (make sure tolerance of ±1.5mm is met). Compress side panel using a blackboard eraser. Note: Position side panel before compressing double-face tape..
Page 1147 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS HEATING AND AIR CONDITIONING....................5 AIR CIRCULATION WITH CENTRAL HVAC SYSTEM ............... 5 ’ ..........................5 RIVER ............................. 5 ABIN AIR CIRCULATION WITH SMALL HVAC SYSTEM ................5 SMALL HVAC SYSTEM OPERATION ....................6 CENTRAL HVAC SYSTEM OPERATION ....................
Page 1148 Section 22: HEATING AND AIR CONDITIONING 9.3.2 Installation ..........................24 9.3.3 Checking Operation of Brush in Holder ................24 9.3.4 Brush Wear Inspection and Replacement ................24 9.3.5 Seating Brushes ........................25 9.3.6 Brush Holder Adjustment ...................... 26 9.3.7 Checking Commutator......................27 ...........................
Page 1149 Section 22: HEATING AND AIR CONDITIONING 11.1 C ......................44 ENTRAL EATING YSTEM 11.1.1 Draining Heating System....................... 44 11.1.2 Filling Heating System......................47 11.1.3 Bleeding Heating System ...................... 47 11.1.4 Soldering ..........................47 11.1.5 Driver’s Hot Water Pneumatic valve Assembly..............47 11.1.6 Central Hot Water Pneumatic Valve Assembly..............
Page 1150 Section 22: HEATING AND AIR CONDITIONING ..................39 IGURE LOOSENING THE DISCHARGE SIDE CONNECTOR S CAP ..........................39 IGURE ROTATING MAGNETIC CLUTCH ..................IGURE REFRIGERANT CIRCUIT SMALL SYSTEM ......................41 IGURE SMALL A C SYSTEM REAR COMPONENTS ..........................41 IGURE COMPRESSOR OIL LABEL ............................41 IGURE DRAINING THE OIL ........................41...
Page 1151: Cabin Area
Section 22: HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING areas (Refer to the Owner's Manual for more details). The recirculation REC button is located The vehicle interior is pressurized by its Heating, on the HVAC control module. Press down the Ventilation and Air Conditioning (HVAC) system.
Page 1152: S Unit Operation
Section 22: HEATING AND AIR CONDITIONING FIGURE 3: CENTRAL HVAC SYSTEM AIR CIRCULATION 22334 SMALL HVAC SYSTEM OPERATION DRIVER’S UNIT OPERATION Only the temperature in the driver’s area is The temperature control in the driver’s area is controlled by the HVAC control module mounted provided directly by the L.H.
Page 1153 Section 22: HEATING AND AIR CONDITIONING Using the Up/Down type switch sets the fan speed and the speed chosen is illustrated on the window display. NOTE Upon starting, if the outside temperature is above 32°F (0°C) and then drops below 32°F (0°C), the compressor will keep running up to a temperature of 15°F (-9°C) to prevent condensation from forming on the windows.
Page 1154: Coil Cleaning
Section 22: HEATING AND AIR CONDITIONING circuit breakers panel (refer to Section 06, Multiplex Module (evaporator compartment) “Electrical System” in this manual for details). I/O-B Relays (evaporator compartment) The condenser coil mounted on the opposite side of the evaporator is ventilated by two axial 24V Condenser fan R.H.
Page 1155: Driver ' S Hvac
Section 22: HEATING AND AIR CONDITIONING For the cabin HVAC unit evaporator, remove the evaporator motor & coil access panel. Back flush the coil (Fig. 10 & 11) every 12,500 miles (20 000 km) or once a year, whichever comes first. FIGURE 12: CONDENSER COIL CLEANING 22243A CAUTION...
Page 1156: Hvac
Section 22: HEATING AND AIR CONDITIONING FIGURE 15: CABIN HVAC UNIT AIR FILTERS 22179 CAUTION FIGURE 13: ACCESS TO DRIVER'S HVAC UNIT AIR Do not use high pressure water jet to avoid FILTERS 22172 damaging filter. CAUTION Be sure not to reverse filter upon installation. HVAC SYSTEM PARTICULARITIES,...
Page 1157 Section 22: HEATING AND AIR CONDITIONING HVAC SYSTEM AND TEST MODE FOR NOTE ELECTRIC MOTORS When starting the A/C compressor wait 5 The test mode allows testing the motors and seconds before checking pressures in order to electric contactors without the need to have the give the system a chance to build its pressure.
Page 1158 Section 22: HEATING AND AIR CONDITIONING There is also a « Pressure switch » adjusted to 350 PSI that acts to stop the compressor in the instance that the Multiplex module fails. HVAC SYSTEM TROUBLESHOOTING Problem/Symptom Probable Causes Actions No temperature control in the Problem with the temperature Driver must manually control the temperature cabin area...
Page 1159 Section 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions Check / reset circuit breaker CB7 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 1160 Section 22: HEATING AND AIR CONDITIONING Do not expose the eyes to liquid refrigerant. The success of the air conditioning system depends on retaining the conditioned air within the vehicle. All windows and intake WARNING vents should be closed. An opening of approximately 8 in (5162 mm ) could easily...
Page 1161 Section 22: HEATING AND AIR CONDITIONING possibility of infection. The mineral oil will also help in absorbing the refrigerant. 8.2.4 Precautions in Handling Refrigerant Lines All metal tubing lines should be free of kinks, because of the resulting restrictions on the flow of refrigerant. A single kink can greatly reduced the refrigeration capacity of the entire system.
Page 1162 Section 22: HEATING AND AIR CONDITIONING FIGURE 16: REFRIGERANT CIRCUIT (CENTRAL SYSTEM) 22247 PA1553...
Page 1163: Pumping Down
Section 22: HEATING AND AIR CONDITIONING The use of the proper wrenches when WARNING making connections on O-ring fittings is important. The use of improper wrenches To prevent any injury, when air conditioning may damage the connection. The opposing system must be opened, refer to previous fitting should always be backed up with a paragraph “Precautions...
Page 1164: Adding Refrigerant (V Apor State )
Section 22: HEATING AND AIR CONDITIONING Wait until pressure gauge reaches 1 to 2 psi 8.5.1 Double Sweep Evacuation Procedure (7 to 14 kPa). To accelerate procedure, Remove any remaining refrigerant from the lightly open compressor suction valve until system using refrigerant recovery...
Page 1165 Section 22: HEATING AND AIR CONDITIONING FIGURE 17: DOUBLE SWEEP EVACUATION SET-UP PA1553...
Page 1166: Charging System
Section 22: HEATING AND AIR CONDITIONING CHARGING SYSTEM CAUTION When a system has been opened or if there are any questions about the air or moisture in the The evacuation of the system must be made system, evacuate the system. Charging of an by authorized and qualified personnel only.
Page 1167: Compressor
Section 22: HEATING AND AIR CONDITIONING Check compressor oil level to ensure filter dryer again and replace the moisture- compressor is not overcharged with oil. liquid indicator. Sometimes a significant amount of oil is After approximately 7 days of operation, pumped out of the compressor to other recheck the compressor oil for cleanliness parts of the system when a compressor...
Page 1168: Pulley Alignment
Section 22: HEATING AND AIR CONDITIONING 9.1.4 Horizontal Compressor Alignment NOTE 1. Rest an extremity of the straight edge Both belts must always replaced against the upper part of the outer face of simultaneously to ensure an equal distribution compressor pulley, positioning the other end of load on each of them.
Page 1169: Compressor Maintenance
Section 22: HEATING AND AIR CONDITIONING 9.1.6 Compressor Maintenance Cause: For the maintenance of the A/C compressor, Improperly torqued cylinder head bolts. see the Carrier Compressor “WORKSHOP Severe liquid refrigerant floodback. MANUAL MODEL TWIN PORT COMPRESSOR” included at the end of this Oil slugging caused by an overcharge of oil section.
Page 1170 Section 22: HEATING AND AIR CONDITIONING Disconnect the electrical motor speed control connections on the motor plate. From under the vehicle, remove the eight bolts retaining the evaporator fan motor support. Remove the complete unit from the evaporator compartment (Fig. 23 & 24). CAUTION Never support evaporator motor by its output shafts while moving it.
Page 1171 Section 22: HEATING AND AIR CONDITIONING Replace the brushes if less than ¾ inch (19 mm). New brush length is 1-¼ inch. To replace brushes, proceed as follows: 1. Set ignition key switch to the “OFF” position. 2. Remove the protective screen band from the motor housing by pulling down the spring loaded fastener.
Page 1172 Section 22: HEATING AND AIR CONDITIONING CAUTION If grinding is not carried out or is carried out in an incorrect way, the brush may seat against a restricted zone only, which will create a high amperage situation for the commutator as for the brushes and could seriously damage the motor.
Page 1173 Section 22: HEATING AND AIR CONDITIONING motors. If the pressure rises to 170 psi, the motors will switch to high speed. For details about electrical wiring, refer to “A/C and Heat system” in the master wiring diagram. FIGURE 29: EVAPORATOR MOTOR 22321 CAUTION FIGURE 30: CONDENSER FAN MOTOR...
Page 1174 Section 22: HEATING AND AIR CONDITIONING Remove the brush holder ring. complete unit and replace with a new unit of the same type according to this procedure: Finally, separate the following parts: brush holders, brush boxes, terminal board, 1. Isolate the refrigerant in the receiver tank by bearings, etc.
Page 1175: Valve
Section 22: HEATING AND AIR CONDITIONING safe. A color indication of light blue to light violet cap is removed. To manually open valve, turn indicates the caution range of moisture level. stem ½ turn counterclockwise. To manually For positive protection, the drying of the system close valve, turn stem clockwise until tight should be continued until the color of the against seat.
Page 1176 Section 22: HEATING AND AIR CONDITIONING sleeve in the bonnet enters the mating hole temperature leaving the evaporator and moves in the body. the valve pin in the opening direction. Opposed to this force, on the under side of the diaphragm 4.
Page 1177 Section 22: HEATING AND AIR CONDITIONING vaporization refrigerant. continues along in the evaporator and remains at the same pressure. However, its temperature increases due to the continued absorption of heat from the surrounding atmosphere. The degree which refrigerant superheated is related to the amount of refrigerant being fed to the evaporator and the load to which the evaporator is exposed.
Page 1178 Section 22: HEATING AND AIR CONDITIONING Example of readings taken at fig. 36: Disconnect the external equalizer line from the under side of the power head, and A/C pressure gauge Temperature on unclamp the remote control bulb from the converted to remote bulb evaporator coil outlet line.
Page 1179 Section 22: HEATING AND AIR CONDITIONING 9.10 TROUBLESHOOTING 9.10.1 Expansion Valve PROBABLE CAUSE PROBABLE REMEDY LOW SUCTION PRESSURE-HIGH SUPERHEAT XPANSION ALVE IMITING Gas in liquid line due to pressure drop in the line Locate cause of line flash and correct by use of or insufficient refrigerant charge.
Page 1180: Valve
Section 22: HEATING AND AIR CONDITIONING 9.10.2 A/C TROUBLE CAUSE Low suction pressure and frosting at dryer outlet. Clogged filter. Low Oil Level. Check for oil leaks and for leaking oil seal. Do not attempt to check oil level unless system has been stabilized at least 20 minutes.
Page 1181 Section 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE An evaporator just does a proper cooling job without sufficient air. Shortage of air can be caused by the following: Dirty filters; or Dirty coils. Testing condenser pressure. Note: R-134A pressure is function of the temperature variation. Example, for an exterior temperature of 100°F.
Page 1182 Section 22: HEATING AND AIR CONDITIONING 9.11 TEMPERATURES & PRESSURES VAPOR-PRESSURE TEMPERATURE PRESSURE °F °C -100 -73.3 27.8 191.7 -67.8 26.9 185.5 -62.2 25.6 176.5 -56.7 23.8 164.1 -51.1 21.5 148.2 -45.6 18.5 127.6 -40.0 14.7 101.4 -34.4 67.6 26.2 12.4 43.4 11.6...
Page 1183: Compressor
Section 22: HEATING AND AIR CONDITIONING VAPOR-PRESSURE TEMPERATURE PRESSURE °F °C 82.2 385.9 2660.8 87.8 433.6 2989.7 93.3 485.0 3344.1 98.9 540.3 3725.4 9.12 LEAK TESTING NOTE Some methods such as nitrogen pressure and This gas is put into the suction and discharge soap, and electronic sniffer can be used for leak shutoff valves at the compressor.
Page 1184 Section 22: HEATING AND AIR CONDITIONING * Never store refrigerant cylinder in direct sunlight, near flame, where temperature exceeds 40°C (104°F). Always store refrigerant cylinder in a cool dry place. * Never throw or strike refrigerant cylinder and never handle roughly. 10.3.3 PAG Oil Handling FIGURE 37: SELTEC TM-16HD COMPRESSOR Whenever a part replacement has to be done on...
Page 1185: Compressor Removal
Section 22: HEATING AND AIR CONDITIONING For complete system recovery, any of the High Slacken bolts A (Refer to figure 39). and Low service ports can be used (Refer to fig. Remove bolts B & C (Refer to figure 39). 38, 42 &...
Page 1186 Section 22: HEATING AND AIR CONDITIONING FIGURE 42: REFRIGERANT CIRCUIT (SMALL SYSTEM) 22336 PA1553...
Page 1187: Compressor Oil Change
Section 22: HEATING AND AIR CONDITIONING Check oil for contamination. Refer to PARAGRAPH 10.8: “COMPRESSOR OIL CONTAMINATION”. Tighten the oil drain plug with a new o-ring lightly coated with clean compressor oil to specified torque. Torque: 13-15 Nm (9.4-10.8 Lbf-ft) Add new compressor oil through the suction-side connector with the amount specified on the label (180 ml).
Page 1188: Oil Addition
Section 22: HEATING AND AIR CONDITIONING 3. Supply with new oil as specified in Charge the system with the proper amount of refrigerant through the service port near paragraph 10.6: “COMPRESSOR OIL check valve using recommended CHANGE”. charging procedures. 10.9 OIL RETURN OPERATION Remove the hoses.
Page 1189 Section 22: HEATING AND AIR CONDITIONING Check the compressor for leaks using a leak detector. NOTE Never leave the compressor upside down for longer than 30 seconds. This is because the oil inside the compressor will enter the cylinders, causing liquid compression which will damage the compressor’s suction and delivery valves.
Page 1190: Condenser Coil
Section 22: HEATING AND AIR CONDITIONING 10.13 CONDENSER COIL 11. HEATING SYSTEM The condenser coil, for vehicles equipped with a As seen earlier in this section, the vehicle small A/C system is mounted on the outer face of interior is pressurized by its Heating, Ventilation engine radiator.
Page 1191 Section 22: HEATING AND AIR CONDITIONING FIGURE 50: CENTRAL HEATING SYSTEM COMPONENTS 22338 PA1553...
Page 1192 Section 22: HEATING AND AIR CONDITIONING FIGURE 53: HEATER LINE SHUTOFF VALVES 05070 On XLII-45 vehicles, the valves are located in engine compartment. One is on the L.H. side of compartment in front of the radiator and the other valve is located under the radiator fan gearbox (Fig.
Page 1193 Section 22: HEATING AND AIR CONDITIONING 11.1.4 Soldering Before soldering any part of the system, make sure the area is well ventilated. Use (stay clean) flux sparingly and apply solder (95-5 round wire 1/8 inch [3,1 mm]). After completing repairs, test for leaks.
Page 1194 Section 22: HEATING AND AIR CONDITIONING The driver’s heater water valve requires a minimum amount of maintenance. The valve should be free of dirt sediment that might interfere with operation. other maintenance is needed unless a malfunction occurs. Pneumatic Water Valve Disassembly a) Shut off air supply pressure and electrical current pilot...
Page 1195 Section 22: HEATING AND AIR CONDITIONING Pneumatic Water Valve Disassembly 2. Check that there is no restriction to the air a) Shut off air supply pressure and electrical escaping from current pilot solenoid valve. actuator casing. Disconnect wires. 3. Make sure that pilot b) The water valve need not be removed solenoid valve...
Page 1196 Section 22: HEATING AND AIR CONDITIONING b) Tighten the nipple in place in the body Pilot Solenoid Valve cavity as per figure 59. Fasten pilot a) No maintenance is needed unless a solenoid vale to the pneumatic water malfunction occurs. valve.
Page 1197 Section 22: HEATING AND AIR CONDITIONING Removal c. Annealed brush spring This can be detected by noting the a) Stop engine and allow engine coolant time resiliency of the spring. Annealing is to cool. caused by failing to tighten the brush caps properly, thus not providing a b) Close shutoff...
Page 1198 Section 22: HEATING AND AIR CONDITIONING FIGURE 61: WATER RECIRCULATING PUMP (CENTRAL HVAC SYSTEM) 22091 ITEM DESCRIPTION QTY. Housing O-Ring Washer SS Rotor Assembly Shaft SS Screw, Cap Hex Soc. Head 8-32 X 3/8 Adaptor Drive Magnet Motor Assembly 24V Brush PA1553...
Page 1199 Section 22: HEATING AND AIR CONDITIONING Installation 11.2.2 Filling Heating System a) Apply gasket cement to the line flanges, a) Ensure that the drain hose is reconnected put the two gaskets in place, and connect and the manual vent is closed. water lines to the pump at the flange b) Open the surge tank filler cap and slowly connections.
Page 1200 Section 22: HEATING AND AIR CONDITIONING FIGURE 62: CEILING OF THE SPARE WHEEL COMPARTMENT FIGURE 63: HEATER LINE SHUTOFF VALVES (W5) PA1553...
Page 1201 Section 22: HEATING AND AIR CONDITIONING FIGURE 64: HEATER LINE SHUTOFF VALVES (WE & W0) PA1553...
Page 1202 Section 22: HEATING AND AIR CONDITIONING FIGURE 65: SMALL HEATING SYSTEM COMPONENTS 22337 PA1553...
Page 1203 : 1880 rpm nominal Insulation .............................Class F Motor Life ...........................20 000 hours Brush life ............................10 000 hours Motor Prevost number......................... 563008 Brush Prevost number ........................562951 Condenser fan motors Make.............................US MOTOR Type ..............................TF-12 Voltage ............................28.5 V DC Current draw ............................. 20 amps Horsepower..............................
Page 1204 Oil pressure at 1750 rpm ..................15 to 30 psi (103-207 kPa) Oil capacity........................ 1.13 U.S. gal (4,3 liters) Weight ..........................142 lbs (64,5 kg) Approved oils -Castrol............................SW 68 (POE) Prevost number, option R-134a ......................950314 A/C Compressor (Small system) Make……………………………………………………………………………………………………………..Selte Model………………………………………………………………………………………………………...TM- 16HD Weight ...........................
Page 1205 C)................... 5.15 – 5.69 ohms Prevost number........................... 950204 Compressor V belts Make..............................Dayco Model (matching set of 2) ........................BX97 Prevost number (with Delco 270/300 Amp Alternator) ............... 506664 Compressor V belt Make..............................Dayco Model..............................BX100 Prevost number (with two BOSH Alternators) ..................506681 Condenser coil (Central system) Make...........................
Page 1206 Voltage .............................. 24 V DC Amperage draw..........................0.67 amps Watts ................................16 Prevost number (without coil) ......................95-0054 Coil Prevost number..........................950055 Repair kit Prevost number ........................950056 Driver’s hot water pneumatic valve Make..............................Burkert Type ............................Normally open Voltage .............................. 24 V DC Prevost number...........................
Page 1207 Section 22: HEATING AND AIR CONDITIONING Prevost number........................... 871381 Seal kit, Water Side..........................871389 Seal kit, Actuator Side......................... 871388 Seal kit, Pilot Solenoid Valve ......................871390 Water recirculating pump Make.............................M.P. pumps Voltage .............................. 24 V DC Prevost number........................... 871342 Driver’s expansion valve Prevost number...........................
Page 1209 Compressor WORKSHOP MANUAL MODEL 05G TWIN PORT COMPRESSOR 62--11052 Rev A...
Page 1210 WORKSHOP MANUAL MODEL 05G TWIN PORT COMPRESSOR...
Page 1211 SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions.
Page 1212 SPECIFIC WARNING AND CAUTION STATEMENTS The statements listed below are specifically applicable to this unit and appear elsewhere in this manual. These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein. WARNING Do not operate compressor unless suction and discharge service valves are open. WARNING Midseat service valves or by other means relieve pressure in replacement compressor before removing plugs.
Page 1213: Paragraph Number Page
TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY SUMMARY ..............Safety-1 GENERAL SAFETY NOTICES .
Page 1214 PARAGRAPH NUMBER Page COMPRESSOR RUNNING GEAR REASSEMBLY ........3.8.1 Seal End Main Bearings .
Page 1215: Table 1-1. Compressor Reference Data
SECTION 1 DESCRIPTION 1.1 INTRODUCTION 1.3 COMPRESSOR REFERENCE DATA This workshop manual covers the Carrier Transicold Table 1-1. Compressor Reference Data Model Twin Port compressors. These compressors are designed for refrigeration (trailer) or air conditioning (bus & rail) applications. (See Model 05G-37CFM 05G-41CFM...
Page 1216 COMPRESSOR WITH MOUNTING FLANGE (ULTRA TYPE SHOWN) COMPRESSOR WITHOUT MOUNTING FLANGE 1. Discharge Service Valve 7. Oil Level Sight Glass 2. High Pressure Connection 8. Bottom Plate 3. Low Pressure Connection 9. Oil Drain Plug 4. Suction Service Valve 10. Oil Pump (See Figure 1-3) 5.
Page 1217 1.4 DETAILED DESCRIPTION 1.4.1 Service Valves The suction and discharge service valves used on the compressor are equipped with mating flanges for connection to flanges on the compressor. These valves are provided with a double seat and a gauge connection, which allows servicing of the compressor and refrigerant lines (See Figure 1-1).
Page 1218 When the pressure behind the piston has been reduced 1.5 COMPRESSOR UNLOADERS sufficiently, the valve spring will force the piston bypass The compressor is equipped with unloaders for capacity valve back, opening the gas bypass from the discharge control. This consists of a self-contained, cylinder head manifold to the suction manifold.
Page 1219 The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened. Sealing Cap Pressure Differential Adjustment Screw Control Set Point Adjustment Nut Poppet Valve Piston Bypass Valve 1.
Page 1220 SECTION 2 COMPRESSOR REPLACEMENT 2.1 COMPRESSOR REMOVAL 2.2.1 Installing Compressor Unloaders a. Remove the three socket head capscrews holding Refer to the operation and service manual covering the piston plug to cylinder head of the replacement equipment in which the compressor is installed for compressor.
Page 1221 g. Recheck compressor oil level. 2.2.2 INSTALLING COMPRESSOR h. Check operation of compressor unloaders (if installed). WARNING Midseat service valves or by other means relieve pressure replacement compressor before removing plugs. CAUTION The high capacity oil pump must be set to rotate in the same direction as the crankshaft.
Page 1222 SECTION 3 COMPRESSOR MAINTENANCE c. Inspect suction and discharge valve seats (on valve 3.1 SHAFT SEAL RESERVOIR plate). The shaft seal reservoir will accumulate up to 3.5 d. If unloaders are installed, inspect operation of ounces of oil. It should be serviced (checked and unloader.
Page 1223 1 Capscrew 5 Lockwasher 9 Valve Plate Gasket 2 Cylinder Head 6 Discharge Valve Backer 10 Suction Valve 3 Cylinder Head Gasket 7 Discharge Valve 11 Suction Valve Spring 4 Capscrew 8 Valve Plate 12 Dowel Pin Figure 3-2. Cylinder Head & Valve Plate e.
Page 1224 3.5.1 Removal 3.5.3 Reassembly Remove eight capscrews and remove the oil pump a. Install the pump end thrust washer on the two dowel bearing head assembly, gasket and thrust washer. (See pins located on the bearing head. (See Figure 3-5.) Figure 3-5.) CAUTION Ensure that thrust washer does not fall off...
Page 1225: Bottom Plate, Strainer, And Connecting Rod Caps
b. Lubricate the end of the crankshaft with clean oil. NOTE c. Using two long screwdrivers, pry out the shaft seal but Do not touch the sealing surfaces with your do not damage the gasket surface or the crankshaft. fingers. If the sealing surfaces become (See Figure 3-8) contaminated, clean with isopropyl alcohol and...
Page 1226: Crankshaft And Seal End Thrust Washer
be installed during compressor reassembly. (See Figure 3-11) d. Push the piston rods down so that the piston rings ex- tend below the cylinders. Remove and discard piston rings. Use only new rings when reassembling the compressor. (See Figure 3-12.) 3.7.2 Crankshaft and Seal End Thrust Washer 1 Bottom Plate 2 Oil Strainer...
Page 1227: Compressor Running Gear Reassembly
d. Measure side clearance between ring and ring groove in piston. Maximum dimensions are provided in Table 3-2. e. If parts are worn beyond limits, replace them in matched sets as specified above. f. Coat piston pins with compressor oil and reassemble pistons, pins, and connecting rods in matched sets.
Page 1228: Adding Oil
c. The compressor will be fitted with double ring pistons. be checked by using a small piece of stiff wire to en- sure that the spring mechanism can be depressed. Compression Ring Compression Ring Figure 3-18. Piston Rings Figure 3-19. Installing Pistons d.
Page 1229: Table 3-1. Torque Values
Table 3-1. Torque Values SIZE TORQUE RANGE THREADS THREADS USAGE USAGE DIAMETER DIAMETER FT-LB PER INCH (INCHES) 1/16 27 (pipe) 5.5 to 7 0.8 to 1.0 Crankshaft Center Web Plug 27 (pipe) 8 to 16 1.1 to 2.2 Oil Return Check Valve -- Crankcase 7/16 8 to 14 1.1 to 1.9...
Page 1230: Table 3-2. Wear Limits
Table 3-2. Wear Limits MAXIMUM WEAR MAXIMUM WEAR FACTORY MAXIMUM FACTORY MAXIMUM FACTORY MINIMUM FACTORY MINIMUM BEFORE REPAIR PART NAME PART NAME INCHES INCHES INCHES SEAL END End Play (Seal Removed) 0.034 0.8636 .013 0.3302 Main Bearing Diameter 1.8760 47.6504 1.8754 47.6352 .002...
Page 1231 INDEX Compresor Replacemant, 2-1 Service Valves, 1-3 Compressor Refernce Data, 1-1 Shaft Seal Maintenance, 3-3 Compressor Valves, 1-3 Shaft Seal Reservoir, 1-3 Cylinder Head and Valve Plate Maintenance, 3-1 Suction Strainer, 3-7 Lubrication System, 1-3 Torque Values, 3-8 Oil, 1-1 Oil Level, 2-2 Oil, Adding, 3-7 Oli Pump Maintenance, 3-2...
Page 1232 Carrier Transport Air Conditioning North America Central America 50 Grumbacher Road Carrier Transicold and Mexico York PA 17402 USA 700 Olympic Drive Ejercito Nacional No. 418 Carrier Transicold Division, Tel: 1- -800- -673- -2431 Athens, GA 30601 USA Piso 9, Torre Yumal Carrier Corporation Fax: 1- -717- -764- -0401 Tel: 1- -706- -357- -7223...
Page 1233 Compressor SERVICE PARTS LIST MODEL 05G TWIN PORT COMPRESSOR 62--11053 Rev B...
Page 1234 Service Parts List Model 05G Twin Port Compressor CONTENTS INTRODUCTION ........... . . MODEL CHART .
Page 1235: Twin Port Compressor
INTRODUCTION This parts list identifies service replacement parts for the 05G Twin Port Compressors listed in the Model Chart below. To find replacement parts, determine the major group in which the replacement parts are located (refer to the Table of Contents) and turn to the appropriate page for the illustrated parts breakdown of the replacement parts.
Page 1236: General Notes
GENERAL NOTES To find replacement parts consult table of contents, and turn to the appropriate page for the illustrated breakdown of replacement parts. The following letter designations are used to classify parts throughout this list. As Required Non-Stock Assembly - order components listed under the assembly. Not Sold Separately - order next higher assembly or kit.
Page 1237: Crankcase And Suction Service Valve
CRANKCASE AND SUCTION SERVICE VALVE 14 15 Item Part Number Description Crankcase 17-44037-00 Plug, O-Ring, 7/16-20 - Includes: 42-00243-07 O-Ring 17-10218-00 Sight Glass, Oil Level - Includes: 17-10218-02 Gasket (Fiber) 17-44021-00 Gasket (Metal) 17-44015-00 Bearing, Main Seal End (Requires Line Boring) 17-44005-00 Strainer, Suction 17-31062-00...
Page 1238: Compressor Base Group - Ultra Style
COMPRESSOR BASE GROUP - ULTRA STYLE Item Part Number Description 17-44026-00 Plate, Bottom, Aluminum, (Ultra Style Compressors) 17-44117-00 Capscrew, Hex Head, 3/8-16 x 2-1/4 Inches Long - SAE Grade 8 17-44037-00 Plug, O-Ring, 7/16-20 - Includes: 42-00243-07 O-Ring 17-40020-00 Oil Filter Screen Assembly 17-40021-00 Tube, Oil Suction 17-44011-00...

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