PREVOST LE MIRAGE XLII BUS SHELLS Maintenance Manual
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PREVOST LE MIRAGE XLII BUS SHELLS Maintenance Manual

PREVOST LE MIRAGE XLII BUS SHELLS Maintenance Manual

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COACH MANUFACTURER
MAINTENANCE MANUAL
LE MIRAGE XLII
BUS SHELLS
PA1564
ST
(1
EDITION)

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Summary of Contents for PREVOST LE MIRAGE XLII BUS SHELLS

  • Page 1 COACH MANUFACTURER MAINTENANCE MANUAL LE MIRAGE XLII BUS SHELLS PA1564 EDITION)
  • Page 2 PA1564 1 edition Date: July, 2007 Starting from vehicle: 8-9277 Featuring: DDC S60-2007 engine with Aftertreatment System...

  • 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: Section 00: General Information

    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 PA1564...

  • 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 PA1564...

  • Page 13: Figure 14: Conversion Chart

    Section 00: GENERAL INFORMATION FIGURE 14: CONVERSION CHART 00006 PA1564...
  • 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 ..........................3 YSTEM ............................3 ARNESSES ENGINE OVERVIEW..........................4 ..........................5 ENSORS ..........................6 THER ENSORS )..................... 6 OTOR ONTROL ODULE ) ..................6 OMMON OWERTRAIN ONTROLLER ENGINE-RELATED COMPONENTS....................6 ) & T ........

  • Page 32: Figure 7 : Engine Compartment

    Section 01: ENGINE ILLUSTRATIONS ) ............3 IGURE VEHICLE INTERFACE HARNESS GENERAL APPLICATION SHOWN 2007 ) ................5 IGURE DETROIT DIESEL SERIES ENGINE TYPICAL ) ..................... 6 IGURE MOTOR CONTROL MODULE ..............................6 IGURE 1587 1939 ......6 IGURE THE CPC COMMUNICATES OVER THE J AND J DATA LINKS TO THE VEHICLE ....................

  • Page 33: Engine

    SECTION 01: ENGINE 1. ENGINE unit, the Motor Control Module (MCM), this system has a chassis-mounted control unit for This vehicle is powered by a 6-cylinder, four- vehicle engine management, the Common cycle, Detroit Diesel series 60 engine equipped Powertrain Controller (CPC). The connection to with an electronic control system (DDEC VI).

  • Page 34: Engine Overview

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

  • Page 35: Ddec Vi Sensors

    SECTION 01: ENGINE 24- Water pump 25- EGR cooler 26- Oil filter (2) 27- Crankcase breather tube 28- EGR tube FIGURE 2: DETROIT DIESEL 2007 SERIES 60 ENGINE (TYPICAL) 01150 2.1 DDEC VI SENSORS • Camshaft Position Sensor (CMP Sensor): •...

  • Page 36: Other Sensors

    Section 01: ENGINE 2.2 OTHER SENSORS 2.4 COMMON POWERTRAIN CONTROLLER (CPC) • Engine Coolant Level Sensor (ECL The CPC is the interface between the MCM and Sensor): Senses coolant level for engine the vehicle/equipment for engine control and protection (mounted on coolant surge tank). manages other vehicle/equipment functions.

  • Page 37: Ddec Vi Diagnostics

    SECTION 01: ENGINE 4. DDEC VI DIAGNOSTICS Position Sensor (TPS). The (TPS) is a device, which sends an electrical signal to the Motor 4.1 DIAGNOSTIC SYSTEM Control Module (MCM). The TPS varies in voltage depending on how far the pedal is Diagnostics is a standard feature of DDEC VI.

  • Page 38: Stop Engine Warning Light (Rsl)

    Section 01: ENGINE code has been stored in the MCM memory. 4.2 READING DIAGNOSTIC CODES – This light also has a 5-second bulb check when FLASHING LIGHT METHOD: the ignition is first turned on. DDEC VI makes use of two types of codes: Active and inactive.

  • Page 39: Ddec Vi Cpc Diagnostic Codes List

    SECTION 01: ENGINE NOTE NOTE Active codes are flashed in ascending The listed codes may not be used in all numerical flash code order. Inactive codes are applications. A default value in the normal flashed in most recent to least recent order. operating range is used by the MCM to provide for engine operation if a sensor failure is present.
  • Page 40 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2113 J1939 Wheel-Based Vehicle Speed Signal from Source#3 is missing 2113 Vehicle Speed Sensor Drifted High Error (VSS signal not plausible) 2114 Accelerator Pedal Learn Error 2114 Accelerator Pedal Circuit Failed High 2114 Accelerator Pedal Circuit Failed Low 2114...
  • Page 41 SECTION 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2615 J1939 ETC1 Message is missing 2132 J1939 Transmission Output Shaft Speed Signal is erratic 2132 J1939 Transmission Output Shaft Speed Signal is missing 2615 MCM Engine Hours Data not received or stopped arriving 2615 MCM Engine Hours Data increasing at an...
  • Page 42 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2141 J1939 Service Brake Switch Signal from Source #2 is erratic 2141 J1939 Service Brake Switch Signal from Source #2 is missing 2141 J1939 Service Brake Switch Signal from Source #3 is erratic 2141 J1939 Service Brake Switch Signal from Source #3...
  • Page 43 SECTION 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2151 ECAN ID_1629 Diagnostic Message Reporting an Unknown MUID 2151 Incorrect MCM System ID Received 2151 MCM System ID Not Received or Stopped Arriving 2151 ECAN Link Circuit Failure 2151 XFLASH Static Fault Code Memory Page Read Write Failure 2615 20ms ECU OS Task Locked in an Endless Loop...
  • Page 44 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2222 Digital Output 2 10 Circuit Failed High (CEL / AWL Lamp) 2222 Digital Output 2 10 Circuit Failed Low (CEL / AWL Lamp) 2223 Digital Output 3 12 Circuit Failed High 2223 Digital Output 3 12 Circuit Failed Low 2224...
  • Page 45 SECTION 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 1590 2615 Adaptive Cruise Control Device Reporting Error 1624 2615 J1939 TCO1 Message is missing 1624 2315 J1939 Tachograph Vehicle Speed Signal is erratic 1624 2315 J1939 Tachograph Vehicle Speed Signal is missing 1663 2321 Optimized Idle Safety Loop Faulted...

  • Page 46: Ddec Vi Mcm Diagnostic Codes List

    Section 01: ENGINE 4.4 DDEC VI MCM DIAGNOSTIC CODES LIST PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1111 EGR Valve Position Circuit Failed Low 1111 EGR Valve Position Circuit Failed High 1111 EGR Valve Position Feedback Failed 1111 EGR Valve Position Feedback Failed (High Box) 1111 EGR Valve Position Feedback Failed (Low Box) 1111...
  • Page 47 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1215 Rail Pressure Governor (High Side) Error 1215 Rail Pressure Governor (Low Side) Error 1221 Battery Voltage Low 1221 Battery Voltage High 1222 Ambient Temperature Circuit Failed Low 1222 Ambient Temperature Circuit Failed High 1223 Fuel Temperature Circuit Failed Low 1223...
  • Page 48 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1322 Water Pump 1 Circuit Failed Open 1331 Turbo Compound Valve Circuit Failed Low 1331 Turbo Compound Valve Circuit Failed High 1331 Turbo Compound Valve Circuit Failed Open 1335 Turbo Brake Sleeve Circuit Failed Low 1335 Turbo Brake Sleeve Circuit Failed High 1335...
  • Page 49 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1453 Smart Remote Actuator 2, Temperature Fault 1453 Smart Remote Actuator 2, Failsafe Mode, Motor On 1453 Smart Remote Actuator 2, Restricted Operability 1453 Smart Remote Actuator 2, Temperature Warning 1453 Smart Remote Actuator 2, Internal Test Running 1453 Smart Remote Actuator 2, Unknown Error Code...
  • Page 50 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1243 Injector Cylinder #2 Needle Control Valve Abnormal Rate of Change Injector Cylinder 2, Nozzle Control Valve or Spill Control Valve, Jammed 1243 Closed Injector Cylinder 2, Nozzle Control Valve or Spill Control Valve, Jammed 1243 Open or Leakage 1243...
  • Page 51 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1255 Engine Starter Relay Circuit Failed Low 1255 Engine Starter Relay Open Circuit 1255 Starter Electronic Fault / ECU internal (Main) 1255 Engine Starter Relay - Starter Does Not Engage 1255 Engine Starter Relay Shorted to High Source 1255 Engine Starter Relay Jammed...
  • Page 52 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1188 1325 Waste Gate Circuit Failed Low 1188 1325 Waste Gate Circuit Failed High 1188 1325 Waste Gate Circuit Failed Open 1432 Smart Remote Actuator 1 (Wastegate), No Failsafe Mode, Motor Off 1188 1432 Smart Remote Actuator 1 (Wastegate), Failsafe Mode, Motor Off...
  • Page 53 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 2631 1515 Charge Air Cooler Outlet Pressure Circuit Failed High 2659 1515 EGR Flow Target Error Diagnostic - Low Flow 2659 1515 EGR Flow Target Error Diagnostic - High Flow 2791 1521 EGR Valve Circuit Failed Low 2791...
  • Page 54 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3246 1532 DPF Oulet Temperature Circuit Failed Low 3246 1532 DPF Oulet Temperature Circuit Failed High 3246 1532 Abnormal DPF Temperature Rise b) 3246 1532 DPF Outlet Temperature High 3246 1532 DPF Outlet Temperature Sensor Stuck 3246 1532...
  • Page 55 SECTION 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3563 1551 Ambient and Inlet Manifold Pressure Difference (Low Box) 3563 1551 Ambient and Inlet Manifold Pressure Difference (High Box) 3563 1551 Inlet Manifold Pressure Failed Low 3563 1551 Inlet Manifold Pressure Failed High 3563 1551 Inlet Manifold Pressure Sampling Range Failed...
  • Page 56 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3662 1614 Injector Cylinder #4 Spill Control Valve ("Amplifier"), Valve Shorted Circuit 3663 1615 Injector Cylinder #5 Spill Control Valve Abnormal Operation Injector Cylinder #5 Spill Control Valve ("Amplifier") Abnormal Rate of 3663 1615 Change...

  • Page 57: Engine Oil Level

    SECTION 01: ENGINE "Full" mark on the dipstick is reached then close 5. ENGINE OIL LEVEL the valve. Check oil reserve tank level and pour oil in the reserve tank if necessary (Fig. 9). MAINTENANCE Check the oil level daily with the engine stopped.
  • Page 58 Section 01: ENGINE levels of contamination and/or overheating. 6. Lightly coat the filter gasket (seal) with clean Change intervals may be decreased or gradually engine oil. increased with experience on specific lubricants 7. Install the new filter on the adapter and until the most practical service condition has tighten manually until the gasket touches the been established.

  • Page 59: Recommended Engine Oil Type

    SECTION 01: ENGINE 7. RECOMMENDED ENGINE OIL TYPE NOTE No parts within the MCM are serviceable. If To provide maximum engine life, lubricants shall found defective, replace the MCM as a unit. meet the following specifications: SAE Viscosity Grade: 15W-40 API Classification: CJ-4. 1.
  • Page 60 Section 01: ENGINE 6. Disconnect and remove the engine-air intake 18. Disconnect the steel-braided airline from the duct mounted between air cleaner housing A/C compressor air bellows. and turbocharger inlet (Fig.12). 19. Remove the power steering pump, leaving the supply and discharge hoses connected to CAUTION it (Fig.
  • Page 61 SECTION 01: ENGINE close to yoke. On right side: close to the solenoid valve of the output retarder. 33. From under the vehicle, disconnect the propeller shaft as detailed in Section 09, under heading "Propeller Shaft Removal". 34. Inspect the power plant assembly to ensure that nothing will interfere when sliding out the cradle.

  • Page 62: Power Plant Assy. Installation

    Section 01: ENGINE 10. VALVE COVER REMOVAL NOTE Check if any spacer(s) have been installed Refer to the series 60 Detroit diesel service between power plant cradle and vehicle rear manual for injectors and valves adjustment. subframe, and if so, note position of each Wait until engine is cold prior to working on washer for reinstallation purposes.
  • Page 63 SECTION 01: ENGINE FIGURE 13: POWER PLANT CRADLE INSTALLATION 01140 PA1564...

  • Page 64: 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 65: Specifications

    SECTION 01: ENGINE step 3 with diagnostic code in hand, contact your note 1 Detroit Diesel service REFERENCES center -Operator's Manual chap. 3,4 & 8 -Detroit Diesel pamphlet "DDEC III/IV diagnostic codes and MPSI reader functions" -8V92 series engine, switch is located in service compartment voir note 1...
  • Page 66 Section 01: ENGINE Capacity Oil reserve tank ......................... 8.4 US qts (8.0 L) Engine oil level quantity Oil Pan Capacity, Low Limit ....................26 quarts/25 liters Oil Pan Capacity, High Limit .....................32 quarts/30 liters Total Engine Oil Capacity with Filters ................38 quarts/36 liters Lubricating oil filter elements Make....................
  • Page 67 SECTION 03: FUEL SYSTEM CONTENTS FUEL SYSTEM DESCRIPTION ......................3 FUEL LINES AND FLEXIBLE HOSES ....................4 FUEL VALVES ............................4 FILTERS AND WATER SEPARATOR ....................5 ..................5 ILTER ATER EPARATOR ERVICING ) ................ 5 ILTER ERVICING RIMARY AND ECONDARY 382 ........................
  • Page 68 Section 03: FUEL SYSTEM ILLUTRATIONS ......................... 3 IGURE FUEL SYSTEM SCHEMATIC ..........................4 IGURE FUEL FILTERS ....................4 IGURE MANUAL SHUT OFF VALVES LOCATION 382 ................4 IGURE MANUAL SHUT OFF VALVE WITH DAVCO PRO ...................... 5 IGURE FUEL FILTER WATER SEPARATOR ....................

  • Page 69: 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 (fuel-filter/water-separator) before it enters the MCM and the fuel pump. If the vehicle is equipped with the optional “Davco Fuel Pro 382”, this one replaces the primary fuel filter.

  • Page 70: Fuel Lines And Flexible Hoses

    Section 03: FUEL SYSTEM FUEL LINES AND FLEXIBLE HOSES displacement fuel pump (located close to the fuel tank) prevents fuel flow when not activated. Make a visual check for fuel leaks at all engine- mounted fuel lines and connections and at the fuel tank suction and return lines.

  • Page 71: Filters And Water Separator

    Section 03: FUEL SYSTEM FILTERS AND WATER SEPARATOR 3. Separate bowl from filter element. Clean bowl and O-ring groove. The fuel system is equipped with primary and secondary fuel filters for additional protection of NOTE the injectors. A fuel-filter/water-separator may Bowl is reusable, do not discard.

  • Page 72: Davco Fuel Pro 382

    Section 03: FUEL SYSTEM 6. Open engine fuel supply line shut-off valves. MAINTENANCE CAUTION The primary and secondary fuel filters are of a spin-on type and must be replaced every Mechanical tightening of the fuel filters is not 12,500 miles (20 000 km) or once a year, recommended and may result in seal and/or whichever comes first.
  • Page 73 Section 03: FUEL SYSTEM 11. Open the shut-off valve; 12. Start engine, raise rpm for 2-3 minutes, hand tighten collar again; 13. After the air is purged and with the engine still running, slowly loosen the vent cap on the filter cover. The fuel level in the cover will start falling.

  • Page 74: Fuel Tank

    Section 03: FUEL SYSTEM FUEL TANK 5.1.1 Main Fuel Tank All XLII series motorhomes are equipped with a 1. Open the condenser door and remove the high-density cross-link polyethylene fuel tank. fuel tank access panel. The rear baggage compartment fuel tank access panel may WE vehicles fuel tanks have a total capacity of also be removed to facilitate access to 250 US gallons (945 liters) while W5 can be...

  • Page 75: Transverse Fuel Tank

    Section 03: FUEL SYSTEM 3. From inside the baggage compartment just 3. Unscrew clamps retaining L.H. side filler tube forward of condenser compartment, slightly to the fuel tank, then disconnect tube and raise the strap and pull out auxiliary fuel tank remove it.

  • Page 76: Fuel Tank Verification

    OFF position prior to working on the vehicle. Before working under air-suspended 4. Insert a screw (Prevost #500196) and a vehicle, it is strongly recommended to support washer (Prevost #5001244) into anchor nut the body at the recommended jacking points. (Prevost #500331).

  • Page 77: Priming Fuel System

    Section 03: FUEL SYSTEM 3. Start the engine and check for leaks. NYLON WASHER SCREW FUEL PUMP INSTALLATION The fuel pump is driven off the rear of the air compressor. FUEL TANK INTERIOR ANCHOR NUT FIGURE 10: FUEL TANK REPAIR 03014 PRIMING FUEL SYSTEM The problem with restarting a diesel engine that...

  • Page 78: Fuel Specifications

    Section 03: FUEL SYSTEM 4. Seat the fuel pump squarely against the air CAUTION compressor. Pilot the flange on the pump body, in the opening in the rear cover of the Owners of 2007 and later model year on- compressor. Install three mounting bolts and highway diesel engine must refuel only with tighten them to 22-28 Lbf-ft (30-38 Nm).

  • Page 79: Air Cleaner (Dry Type)

    Section 03: FUEL SYSTEM 1. Keep the air cleaner housing tight on the air AIR CLEANER (DRY TYPE) intake pipe; The vehicle is equipped with a dry-type replaceable element air cleaner, located in the 2. Make sure the correct filters are used for replacement;...

  • Page 80: Fuel Cooler

    Section 03: FUEL SYSTEM FUEL COOLER 11.1 FUEL PEDAL ADJUSTMENT The fuel cooler serves to cool the surplus diesel The EFPA contains a throttle position sensor fuel after it has exited the cylinder head, on its that varies the electrical signal sent to the ECM. The sensor must be adjusted whenever an way back to the fuel tank.

  • Page 81: Specifications

    03035 SPECIFICATIONS Davco Fuel Pro 382 Fuel Filter / Water Separator Element Prevost number ............................510795 Racor Primary Fuel Filter / Water Separator (optional) (May be used instead of regular primary filter (never use with a primary filter). Make ................................Racor Type ............................
  • Page 82 Optional (W5) ........................90 US gallons (341 liters) Air Cleaner Make ................................Nelson Prevost Number ............................530206 Service Part No ............................7182 8N Prevost number (element cartridge) ......................530197 Air Cleaner Restriction Indicator Make ..............................Donaldson Model ..............................RBX00-2220 Indicates .........................at 20" (508 mm) of water Prevost number ............................530161...
  • Page 83 SECTION 04: EXHAUST SYSTEM CONTENTS EXHAUST AND AFTERTREATMENT SYSTEM OVERVIEW ............. 2 ..........................2 AINTENANCE ....................3 LEXIBLE OUPLING NSTALLATION AFTERTREATMENT DEVICE (ATD) ....................3 ..................4 IESEL ARTICULATE ILTER EMOVAL DIFFUSER ASSEMBLY........................5 ........................5 IFFUSER DJUSTMENT ..........................6 AINTENANCE ..........................

  • Page 84: Section 04: Exhaust System

    Section 04: EXHAUST SYSTEM 1.1 MAINTENANCE EXHAUST AND AFTERTREATMENT SYSTEM OVERVIEW Inspect the exhaust system periodically for restrictions and leaks. Figure 1 presents the Detroit Diesel’s workhorse behind clean major components of the exhaust system. emissions technology exhaust Exhaust leaks are commonly the result of loose Aftertreatment Device (ATD) which replaces clamp bolts, corroded or punctured pipes.

  • Page 85: Flexible Coupling Installation

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

  • Page 86: Diesel Particulate Filter (Dpf) Removal

    Section 04: EXHAUST SYSTEM WARNING HOT EXHAUST During stationary regeneration, exhaust gases temperature may reach up to 1200°F (650°C) at the DPF outlet. Do not direct at combustible materials. Before initiating stationary regeneration, make sure that the DPF outlet diffuser is clear of objects and that no one is working near outlet...

  • Page 87: Diffuser Assembly

    Section 04: EXHAUST SYSTEM CAUTION FRAGILE - HANDLE WITH CARE Use extreme care when handling DPF cartridge as it could be damaged or destroyed by dropping or sudden impact. Clean remanufactured DPF cartridge will be available through Detroit Diesel on an exchange basis.

  • Page 88: Maintenance

    3.3 DIFFUSER ADAPTER diffuser adapter (Prevost #040710) available through Prevost Parts to permit connection with current exhaust gas collecting system. FIGURE 8: DIFFUSER POSITION ADJUSTMENT 04015_2 4. Tighten the clamp securing the diffuser assembly to the ATD.
  • Page 89 SECTION 05: COOLING SYSTEM CONTENTS DESCRIPTION ............................3 MAINTENANCE ............................ 4 ....................4 EHICLES ITHOUT OOLANT ILTERS ....................4 EHICLES OOLANT ILTERS HOSES ..............................5 ..............5 ONSTANT ORQUE LAMPS OOLANT INES 3.1.1 Installation ..........................5 3.1.2 Maintenance ..........................6 (CAC)..........
  • Page 90 Section 05: COOLING SYSTEM 13.1.2 Mechanical Locking....................... 15 13.2 M ..........................16 AINTENANCE 13.3 I ............................ 16 NSPECTION 13.4 F ......................16 EMOVAL NSTALLATION FAN RIGHT ANGLE GEARBOX..................... 17 14.1 M ..........................17 AINTENANCE 14.2 O ........................... 17 HANGE 14.3 R ........................

  • Page 91: Section 05: Cooling System

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

  • Page 92: Maintenance

    Section 05: COOLING SYSTEM element filter. If the vehicle is not equipped with filters recommended inhibitor concentration to the antifreeze/water solution. NOTE Do not add inhibitors to the antifreeze / water solution if vehicle is equipped with a coolant filter. Coolant must discarded...

  • Page 93: Hoses

    Section 05: COOLING SYSTEM This type of clamp is designed to automatically NOTE adjust its diameter to compensate for the normal Any measurable drop in pressure may indicate expansion/contraction of a hose and metal a leak. Whenever the oil pan is removed, the connection that occurs during vehicle operation cooling system should be pressure checked as and shutdown.

  • Page 94: Constant

    Section 05: COOLING SYSTEM 3.1.2 Maintenance shutdown, the screw tip will adjust according to the temperature and pressure changes. The constant-torque clamps contain a "Visual torque check“ feature. When the tip of the screw Checking for proper torque should be done is extending ¼"...

  • Page 95: Coolant Level Sensor

    Section 05: COOLING SYSTEM Select and maintain coolant in order to meet the following basic requirements: • Provide for adequate heat transfer. • Provide protection from cavitation damage. • Provide a corrosion and erosion resistant environment within the cooling system. •...

  • Page 96: Inhibitors

    Section 05: COOLING SYSTEM NOTE Recommended phosphate free coolants: Above SCA values with Detroit Diesel #7se298 • Prevost #685125; or TMC RP-329 “Type A”. Use Nalco Chemical • Detroit Diesel “DDC Power Cool” (P/N Company nitrite test kits (CO-318). A factory 23512138);...

  • Page 97: Coolant Not Recommended

    Section 05: COOLING SYSTEM 5.7.4 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 98: Vehicles Equipped With Small Hvac System

    Section 05: COOLING SYSTEM 6.2 VEHICLES EQUIPPED WITH SMALL 4. Open drain cock at bottom of thermostat HVAC SYSTEM housing to drain the coolant trapped above the thermostats (Fig. 8). 5. Open the radiator drain cock (Fig. 16). FIGURE 12: HEATER LINE SHUTOFF VALVES (W5) FIGURE 14: WATER PUMP DRAIN PLUG 05093 6.

  • Page 99: Flushing

    Section 05: COOLING SYSTEM 2. Refill cooling system from the surge tank 2. Refill with clean water. filler cap inlet with a recommended ethylene glycol-based antifreeze and water solution of CAUTION the required concentration. Add Detroit Diesel selected product cooling system If the engine is hot, fill slowly to prevent rapid inhibitors (if required).

  • Page 100: Spin-On Coolant Filter

    Section 05: COOLING SYSTEM through pump. Reverse flushing 9. SPIN-ON COOLANT FILTER accomplished by hot water, under pressure, The optional engine cooling system filter is used being forced through the cooling system in a to filter out impurities such as scale or sand from direction opposite to the normal flow of coolant, the coolant and it also eliminates the process of loosening and forcing deposits out.

  • Page 101: Radiator

    “The CAC is considered acceptable if it can hold PRECHARGE ELEMENT FILTER 30 psi (206 kpa) gauge pressure with less than Prevost number: 550629 5 psi (34.5 kpa) loss in 15 seconds after turning off the hand valve.” MAINTENANCE ELEMENT FILTER...

  • Page 102: Drive Pulley And Universal Joint Shaft

    Section 05: COOLING SYSTEM 12.1 DRIVE PULLEY AND UNIVERSAL JOINT SHAFT To disconnect the universal shaft, proceed as follow: WARNING Set the ignition to the OFF position and remove the key from the contact switch to prevent accidental starting of the engine. 1.

  • Page 103: Locking Radiator Fan For Emergency Operation

    Section 05: COOLING SYSTEM comparing data from engine coolant engine is overheating, execute the following temperature, charge air temperature, Allison procedure: transmission oil temperature and small A/C High 1. Set the ignition key to the ON position. side pressure to a set of calibration data. The 2.
  • Page 104 Section 05: COOLING SYSTEM 4. Turn the fan blades in order to position the 13.3 INSPECTION locking plate bores over the rotor’s threaded sockets. DANGER 5. Screw in and tighten the spare bolts (Fig. 21). Set the starter selector switch in engine compartment to the "Off"...
  • Page 105 Section 05: COOLING SYSTEM 3. Remove the drain plug located underneath the right angle gearbox case and allow the oil to drain into a suitable container. 4. Replace the seal and screw the drain plug back in (torque: 26 lbf-ft). 5.
  • Page 106 COOLING FAN DRIVE BELT bolts as specified. Make: Dayco Type: 14PK2605 15. COOLING FAN DRIVE BELT Prevost number: 550926 15.1 MOUNTING THE DRIVE BELT To install the cooling fan drive belt, proceed as follow: WARNING Set the ignition to the OFF position and remove the key from the contact switch to prevent accidental starting of the engine.
  • Page 107 Fully open ............................202°F (95°C) Cooling Fan Drive Belt Make ................................Dayco Type ............................Poly-Rib 14PK2605 Qty ..................................1 Prevost number ............................550926 Coolant Prevost Number ............................685125 DDC (Power Cool) ..........................23512138 Prestone (Heavy Duty)..........AF977 (bulk), 72702 (3.78 L), 70119 (205L), 70102 (4L) Corrosion Inhibitor and Coolant Stabilizer Supplier number..Detroit Diesel......................23507857...
  • Page 109 Postfach / P.O.Box 1430 D - 88672 Markdorf Tel.: + 49 7544 / 964 0 Fax: + 49 7544 / 6218 Internet: http://www.linnig.com Mail: webinfo@linnig.com Reparaturanleitung LINNIG Drehschwingungsdämpfer LDD (außer LDD12) Austausch Gummidämpfer 127.032 mit EB0112 Repair instructions LINNIG Torsional vibration damper LDD (except LDD12) Replacement of the rubber damper 127.032 with EB0112 Instrucciones de servicio LINNIG Polea antivibratoria LDD (excepto LDD12)
  • Page 110 Lieferumfang / Delivery / Volumen de suministro Ersatzteilbaugruppe / Assembly group / Juego de refacciones EB0112 6 × 127.032 Gummidämpfer Rubber damper Amortiguadores de goma 6 × 50.099 3 × 65.003 Zyl.-Schraube IN-STAR LIKO-Schraube Socket head cap screw IN-STAR LIKO-screw Tornillo cabeza allen Tornillo IN-STAR LIKO 4 ×...
  • Page 111 4 Zyl.-Schrauben M5 Remove 4 socket head Retire los 4 tornillos M5 bzw. 3 IN-STAR LIKO- cap screws M5 resp. 3 o 3 tornillos M6 IN- Schrauben M6 am IN-STAR LIKO-screws STAR LIKO de la tapa Deckel entfernen. M6 on the cover. de la polea.
  • Page 112 4 bzw. 6 neue Zyl.- Protect 4 resp. 6 new Aplicar Loctite 270 Schrauben 50.099 mit socket head cap screws o equivalente a los Loctite 270 versehen und 50.099 with Loctite 270 4 o 6 tornillos M8 4 bzw. 6 neue and attach the 4 resp.
  • Page 113 SECTION 06: ELECTRICAL CONTENTS GENERAL DESCRIPTION........................4 ..........................4 IRING IAGRAMS 1.1.1 Using Wiring Diagram ......................4 1.1.2 Testing Circuits........................5 ........................5 IZES AND OLORS ........................... 5 PARE IRES ........................6 LEANING ONNECTORS ........................... 6 IRCUIT REAKERS ..........................6 MULTIPLEX FUSES ............................
  • Page 114 Section 06: ELECTRICAL ................32 SSENTIAL UNCTIONS PERATE EHICLE 4.8.1 Available Functions ....................... 32 ..............32 OWER RIORITY ODULES REAKDOWN ERVICE 4.10 M ........................32 ULTIPLEX ODULES 4.10.1 CECM ............................ 32 4.10.2 MASTER ID ........................... 32 4.10.3 IO-A ............................32 4.10.4 IO-B ............................
  • Page 115 Section 06: ELECTRICAL LIGHT BULB DATA ........................45 SPECIFICATIONS ........................... 46 ILLUSTRATIONS ........................5 IGURE WIRE IDENTIFICATION ..................7 IGURE MULTIPLEX MODULE CONNECTORS PIN ) ................. 9 IGURE ELECTRICAL COMPARTMENTS XLII E BUS SHELLS )................9 IGURE ELECTRICAL COMPARTMENTS XLII BUS SHELLS ........................

  • Page 116: 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 117: 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 118: 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 119: 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 120 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 121: Xlii Motorhomes Electrical Compartments And Junction Boxes

    Section 06: ELECTRICAL XLII MOTORHOMES ELECTRICAL COMPARTMENTS AND JUNCTION BOXES FIGURE 3: ELECTRICAL COMPARTMENTS (XLII-45E BUS SHELLS) 06648 FIGURE 4: ELECTRICAL COMPARTMENTS (XLII-45 BUS SHELLS) 06646 PA1564...

  • Page 122: Maintenance

    Section 06: ELECTRICAL Spare 12V Wake-up MAINTENANCE A Cortec VCI-238 corrosion inhibitor has been Spare 12V Wake-up sprayed in all electrical compartments to protect Spare 12V Wake-up components from corrosion. The life expectancy this product five years, Lugg. Lock/Unlock 24V Excitation recommended to reapply it every five years.

  • Page 123: Circuit Breakers

    Section 06: ELECTRICAL On all vehicles equipped with central A/C, NOTE breakers CB4, CB5 and CB8 are installed on When ignition key switch is set to the "OFF" breaker panel in engine compartment R.H. side position, electrical supply from area (Fig. 6). They are accessible through batteries is cut off, with the exception of the engine R.H.

  • Page 124: Front

    Section 06: ELECTRICAL Evaporator Compartment Front Electrical & Service Compartment Multiplex Module Multiplex Modules VECF Vehicle Electrical I/O-A I/O-B Center Front I/O-A Relays ABS-ECU I/O-A 24V Condenser fan Water pump Master ID I/O-B ZF Steering Ctrl I/O-B 24V Condenser fan Pre-heating Keyless I/O-B...

  • Page 125: Engine Compartment (Rear Start Panel)

    Section 06: ELECTRICAL ENGINE COMPARTMENT (REAR BATTERIES START PANEL) vehicle provided with four The rear start panel is located over the engine in maintenance-free 12 volt heavy-duty batteries the engine compartment. Switches to start and connected in series-parallel (Fig. 13). The stop the engine from inside the engine top-mounted negative and positive terminals are compartment are mounted on that panel.

  • Page 126: Battery Discharge Protection

    Section 06: ELECTRICAL The battery has four (4) major functions: o Preheater and water recirculating pump; 1. Providing a source of current for starting the o Radio memory; engine. o CECM; 2. Stabilizing the voltage in the electrical o Cluster memory. system.

  • Page 127: Battery Rating

    Section 06: ELECTRICAL FIGURE 13: BATTERIES CONNECTIONS 06649 BATTERY RATING NOTE When reinstalling batteries, battery Each of the 12 volt batteries used on the vehicle connections must be tightened to 13-15 lbf-ft has the following rating: (18-20) Nm). A torque wrench is required to Reserve capacity: 195 minutes ensure an accurate tightening torque.

  • Page 128: Battery Testing

    Section 06: ELECTRICAL BATTERY TESTING The maintenance-free battery has a strong ability to withstand the damaging effects of overcharge. The test indicator in the cover is used only to determine if the battery can be tested in case of a cranking problem. The test indicator in the battery cover is to be used with accepted diagnostic procedures only.

  • Page 129: Testing Battery Cables

    Section 06: ELECTRICAL be detected with a low-reading voltmeter as follows: DANGER To prevent the engine from starting, the DDEC engine circuits, which are protected by breakers (CB-1 & CB-2) located in the circuit breaker panel, must be deenergized during these tests;...

  • Page 130: Battery Charging

    Section 06: ELECTRICAL BATTERY CHARGING On rare occasions, such as those that occur following prolonged cranking, the green dot in The batteries used on this vehicle can be the test indicator may still be visible when the charged either on or off the vehicle; however, battery is obviously discharged.

  • Page 131: Battery Charging Guide

    Section 06: ELECTRICAL content to increase, the charging current will likewise increase. Charger Capacity For example, a charger which can supply only 5 amperes will require a much longer period of charging than a charger that can supply 30 amperes or more. 3.6.2 Emergency Jump Starting With Auxiliary (Booster) Battery.

  • Page 132: Cleaning And Inspection

    Section 06: ELECTRICAL replace the battery. Do not attempt jump charging system of the booster vehicle or of starting when indicator is illuminated. If the the boosted vehicle. test indicator is dark and has a green dot in the center, failure to start is not due to a NOTE discharged battery and the cranking system Jumper cables must withstand 500 cranking...

  • Page 133: Troubleshooting

    Section 06: ELECTRICAL 4. Dirt and electrolyte on top of the batteries determine if the battery voltage is too high or too causing a constant drain. low. 5. Hardened battery plates, due to battery NOTE being in a low state of charge over a long period of time.

  • Page 134: Probing Voltage On The Multiplex Circuits

    Section 06: ELECTRICAL system. With the SYSTEM DIAGNOSTIC menu, module inputs/outputs can draw an erroneous highlight FAULT DIAGNOSTIC then conclusion. highlight ELECTRICAL SYSTEM to request a Inactive Multiplex output = Residual voltage of diagnostic of the electrical system from the 18% to 33% of supply voltage.

  • Page 135: Spare Can

    Section 06: ELECTRICAL The telltale panel module and HVAC module are SWITCHES AND SENSORS SUPPORTED linked to the CECM by a CAN connection. In BY THE SWITCH/SENSOR TEST MODE case of a CAN connection default, the telltale HVAC control unit driver’s section ON/OFF panel LCD display shows "CAN", and on the A/C door ajar open sensor HVAC control unit, the temperature display...

  • Page 136: Test Mode For Electric Motors

    Section 06: ELECTRICAL o A beep can be heard indicating the motor test vehicle is traveling to check the A/C compressor pressure values, but no beep can be heard. mode has started. In test mode, with the parking brake applied and Using the test mode: the cabin area (passenger) set point set to a value higher than 64°F (18°C), the circulator...

  • Page 137: Test Sequence - Mth Equipped With Small Hvac System

    Section 06: ELECTRICAL Driver's unit refrigerant solenoid valve activates 3 times. Driver's unit hot water pneumatic valve cycles 3 times. Closing of the fresh air dampers. This ends the test. Activate the dashboard Telltale Light Test switch one time to leave the motor test mode.

  • Page 138: 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 139: 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 140 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 141 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 142 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 143 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 144: 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 145: 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 146 Section 06: ELECTRICAL FIGURE 19: TWIN BOSCH ALTERNATORS INSTALLATION FIGURE 20: ALTERNATORS AND ACCESSORIES MOUNTING TORQUES PA1564...

  • Page 147: Twin Bosch Alternators Installation

    Section 6: ELECTRICAL Possible Alternators Arrangement NOTE Use Polyrex EM grease (684922) when W5 with central HVAC system repacking the bearings. Grease comes in 14.1 2x Bosch 24V-140A oz (400gr) cartridges. 2x Bosch 24V-140A + 1 aux. Bosch 24V-140A 2x Bosch 24V-140A + 1 aux. Bosch 14V-200A TWIN BOSCH ALTERNATORS W5 with small HVAC system INSTALLATION...

  • Page 148: Alternator Drive Belt

    Section 6: ELECTRICAL MAINTENANCE Check for wear and proper tension every 6,250 miles (10 000 km) or twice a year, whichever comes first. FIGURE 23: DELCO 24V-75A WITH SMALL HVAC SYSTEM FIGURE 25: ALTERNATOR DRIVE BELT 01180 BATTERY EQUALIZER VoltMaster Battery Equalizer Owner’s Manual (100 amps) is annexed at the end of this section.

  • Page 149: Engine Block Heater

    Section 6: ELECTRICAL diagrams are located in the technical publication CAUTION box. HEADLIGHTS Do not engage starter for more than 15 seconds at a time. If engine does not start Each headlight assembly consists of two within 15 seconds, release ignition key and let headlamp module 90 mm (3½...

  • Page 150: Headlight Adjustment

    Section 6: ELECTRICAL maximum allowable road illumination. When 2. The four movable vertical tapes should be using mechanical aiming devices, follow located on the screen at the left and right manufacturer’s instructions. limits called for in the specification with reference to centerlines ahead of each Headlight aim should be checked after installing headlight assembly.

  • Page 151: Sealed-Beam Unit

    Section 6: ELECTRICAL FIGURE 32: AIM INSPECTION LIMITS FOR UPPER-BEAM HEADLIGHTS 06505 8. The inspection limits in the vertical direction for low-beam headlights or the low beam of dual-beam headlight, shall described in Table 1. In the horizontal FIGURE 29: ALIGNMENT OF HEADLIGHT AIMING SCREEN direction, the left edge of the high-intensity 06502...

  • Page 152: Front Turn Signal

    Section 6: ELECTRICAL 2. Remove the headlight screw fixing the CAUTION headlight assembly, then tilt headlight assembly down (Fig. 27 and 28). During this step, avoid contacting the bulb with 3. Partially unfasten back plate fixing screws, the fingers not to alter the bulb life. then remove signal lamp.

  • Page 153: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights

    Section 6: ELECTRICAL 4. Remove connector from headlamp bulb by To protect the ballast, a counter in the electronic turning counterclockwise. safety system ensures that a defective lamp can only be switched off 7 times consecutively after 5. Unscrew the three Phillips head screws, pull a successful ignition, after which the device is the retainer and bulb out.

  • Page 154: Center Stoplights And Cyclops Light Removal And Replacement

    Section 6: ELECTRICAL CLEARANCE, IDENTIFICATION 2. Remove the lamp support retaining screws (2), and then from the outside, remove the MARKER LIGHTS lamp and its support. vehicle equipped with marker, identification and clearance lights (LED). The 3. From the outside, install the new lamp with clearance lights are mounted at each corner of its support then fasten the retaining screws.

  • Page 155: Docking And Cornering Lights

    Section 6: ELECTRICAL DOCKING AND CORNERING LIGHTS 4. Install the new bulb, reconnect the light unit and replace in its proper position. MTH vehicles are provided with two halogen sealed-beam units that serve as cornering lights. They are mounted on the vehicle as follows: one CAUTION is mounted on the front L.H.

  • Page 156: Telltale Light Replacement

    Section 6: ELECTRICAL 10.1.2 Telltale Light Replacement CAUTION Telltale module is non-serviceable and must be replaced as a unit. The lens is fragile. Be very careful when removing and handling. 1. Unscrew and remove the top dashboard panel. 3. Install a new fluorescent tube, rotating the 2.
  • Page 157 11. LIGHT BULB DATA When replacing a light bulb, special attention must be paid to the voltage rating (refer to light bulb data hereafter). LIGHT BULB DATA APPLICATION PREVOST TRADE OR WATTS OR VOLTS PART NO. SAE NUMBER CANDLE...
  • Page 158 Section 6: ELECTRICAL LIGHT BULB DATA APPLICATION PREVOST TRADE OR WATTS OR VOLTS PART NO. SAE NUMBER CANDLE POWER EXTERIOR LIGHTING Exterior compartment 562278 6429 10 W (except engine) Engine compartment 930383 SEALED 25 W INTERIOR LIGHTING 2721 MFX Instrument cluster lights...
  • Page 159 Section 6: ELECTRICAL 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) Model Number..........................M009T82479...
  • Page 161 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 162 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 163 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 164 * 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 165 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 166 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 167 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 168 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 169: 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 170: 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 171: 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 172: 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 173: 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 174: 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 175: 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 176: 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 177: 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 178: 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 179: 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 180: 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 181: 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 182: 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 183: 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 184: 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 185: 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 186: 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 187 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 188: 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 189: 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 190: 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 191: 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 192: 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 193: 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 194: 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 195 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 196: 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 197: 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 198 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 199: 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 200: 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 201: 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 202: 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 203: 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 204: 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 205: 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 206: 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 207: 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 208: 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 209: 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 211 ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § 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 212 © ¢  ¤  ¥  ¥  ¨  © ¢  ¤  ¥  ¥  ¨  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 213  ¢  ¤  ¥  ¥  ¨   ¢  ¤  ¥  ¥  ¨  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 214  ¢ ¤ ! ¥ ! ¥ " ¨ #  ¢ ¤ ! ¥ ! ¥ " ¨ # 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 215 $ ¢ % ¤ & ¥ & ¥ ' ¨ ( $ ¢ % ¤ & ¥ & ¥ ' ¨ ( 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 216 ) ¢ 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 217 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 218 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 219 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 220 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 221 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 222 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 223 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 224 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 225 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 226 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 227 ELECTRONIC MONITOR EM-70D Owner’s Manual GENERAL The EM-70D Electronic Monitor is a device designed to monitor several critical functions in the electrical system of a vehicle that operates on a 24 volt system. It will also monitor the 12 volt service when using a Vanner VoltMaster Battery Equalizer which supplies 12 volt service from a 24 volt source.
  • Page 228 INSTALLATION SCHEMATIC QUICK CONNECTS +24V IGN SW +24V IGN. SW. VANNER +12VDC +12V Model EM70D +24VDC +24V ELECTRICAL SYSTEM MONITOR BATT LOW BATT. LOW BATT HIGH BATT. HIGH BATT. BATT BALANCE BALANCE POWER ON LED POWER ON WARNING LAMP DEFINITIONS—LAMPS WILL GLOW UNDER FOLLOWING CONDITIONS: BATTERY LOW BATTERY BALANCE 1.
  • Page 229 FAULT CODE MANUAL Created on 00-04-25 15:30 FAULT CODE MANUAL B7L, B7TL, B12 - 1 -...
  • Page 230 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 231 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 232: 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 233: 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 234: 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 235 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 236: 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 237 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 238: 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 239 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 240 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 241: 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 242: 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 243: 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 244: 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 245 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 246 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 247: 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 248 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 249 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 250: 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 251: 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 252 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 253: Fault Codes, Vecu (Mid 144)

    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 255 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 256 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 257 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 258 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 PA1564...

  • Page 259: 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 260: 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 261: Hot 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 262: 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 263: Oil Contamination

    Section 07: TRANSMISSION • To be sure a fluid is qualified for use in Allison transmission, check for the DEXRON-III® or DEXRON- VI® 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 264 Section 07: TRANSMISSION TABLE 1 Recommended Fluid and Filter Change Intervals Using Dexron-III / Dexron-VI / 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...

  • Page 265: 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 266: 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 267 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 268: 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 269: 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 270: 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 271: Diagnostic Codes - Allison 4

    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 272: Diagnostic Code Response

    Section 07: TRANSMISSION 9.1.5 Diagnostic Code Response NOTE The following responses are used in the The Diagnostic Display Mode can be entered "Diagnostic Troubleshooting Code List and for viewing codes at any speed. Codes can Inhibited Operation Description" table only be cleared when the output speed = 0 command safe operation when diagnostic codes and no output speed sensor failure is active are sent.

  • Page 273: Diagnostic Troubleshooting Codes (Dtc) List - Allison 4

    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 274 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 275 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 276 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 277 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 278: Propeller Shaft

    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 279: Cleaning, Inspection And Lubrication

    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 280: Specifications

    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 293 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 294: 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 295: 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 296: 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 297: 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 298 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 299: Axle Shaft Sealing Method

    Section 11: REAR AXLES 3. Assemble components immediately to permit NOTE the silicone sealant to compress evenly Refer to Section 16, "Suspension", for proper between parts. torque tightening of the longitudinal radius rod a. Place a new gasket, then install the axle support nuts.

  • Page 300: Retracting Tag Axle For Repair 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 301: Tag Axle Alignment

    Section 11: REAR AXLES 1. Raise vehicle by its jacking points on the CAUTION body (fig. 5 or see Section 18, "Body" under heading: "Vehicle Jacking Points"). Place jack On vehicles equipped with an automatic under frame. Remove drive axle wheels (if transmission (with or without the output required, refer to Section 13, "Wheels, Hubs retarder), move tag assembly very carefully.
  • Page 302 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 303 BACK / RETOUR SERVICE MANUAL GENERAL INFORMATION NDS Axle range place product photo here SPICER SPECIALITY AXLE DIVISION...
  • Page 304 BACK / RETOUR 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 305 BACK / RETOUR 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 306 BACK / RETOUR 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.
  • Page 307 BACK / RETOUR 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...
  • Page 308 BACK / RETOUR 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 310 BACK / RETOUR APPLICATION POLICY Capability ratings, features and specifications vary depending upon the model type of service. Applications approvals must be obtained from Spicer Speciality axle division. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice.
  • Page 311 BACK / RETOUR Maintenance Manual NDS axles Lubrication and Maintenance NDS Axle range Issue D place product photo here SPICER SPECIALITY AXLE DIVISION...
  • Page 312 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications MANUAL ISSUE SHEET Page No. Issue Description / Alteration Reason Date New Manual Nov. 99 Mileage interval altered Updated spec. Mar.2000 Mileage interval altered Updated spec. Mar.2000 Tie rod torques added New tie rod Mar.2000 Tie rod torques added...
  • Page 313 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications LUBRICATION AND ROUTINE MAINTENANCE FOR NDS AXLE RANGE SECTION 1 LUBRICATION GREASING PERIODS 1.1.1 ON HIGHWAY APPLICATIONS Pressure lubricate every 6 months or 30000 miles (48000 km) A more frequent lubrication cycle is required for axles used in on/off highway, refuse, or other severe service applications.
  • Page 314 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 2 ROUTINE MAINTENANCE Hub bearing check should be carried out every 30000 miles (48000 km) Before commencing checks, apply parking brake, raise wheels off ground and support axle on stands. and remove brake drum (if fitted) .
  • Page 315 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 2 ROUTINE MAINTENANCE Cont. Check permissible slackness in swivel (king) pins every 30000 miles (48000 km) as follows :- Aspects to be considered are :- Lateral slackness. Vertical slackness. Before commencing checks, apply parking brake, raise wheels off ground and support axle on stands. Checking lateral slackness Whilst this is being carried out the brake must be applied.
  • Page 316 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 2 ROUTINE MAINTENANCE Cont. Every 6 months inspect ball joints for corrosion as follows :- NOTE:- INSPECTION OF BALL JOINTS IS IMPORTANT, ESPECIALLY THOSE IN OLDER VEHICLES. DAMAGED SEALING BOOTS, SALT ON ROADS IN WINTER AND CLIMATIC CONDITIONS CAN CAUSE LOSS OF THE CORROSION PROTECTION COATING APPLIED DURING MANUFACTURE.
  • Page 317 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 3 CARE OF WHEELS AND FIXING FACES (ALL AXLES WITH SPIGOT FIXING) At approximately 100 miles after fitting wheels, wheel nut torque should be checked with wheel ends in " cold " condition ( ie not after prolonged braking.). If any relaxation of original torque (see specification) has occured, re-tighten.
  • Page 318 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications WHEELNUT TIGHTENING TORQUE SEQUENCE 6 - STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 8 - STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 10 - STUD FIXING © Spicer Speciality Axle Division Page No.8 NDS2 issue A...
  • Page 319 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SECTION 4 Guidance standards for acceptable brake drum crazing (if fitted). Every 30000 miles (48000 km) or whenever brake drums are removed for axle maintenance purposes they should be checked for crazing. Brake drums with crazing in excess of that shown in fig.6 below, and which are of Spicer Speciality axle division manufacture should not be re introduced into service.
  • Page 320 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications EVALUATION OF BRAKE DISC SURFACE TP1627 Upon removal of brake disc Fig. 9. It's surface should be checked for defects. Inspection should cover both sides of the braking surface as well as the outer diameter of the disc.
  • Page 321 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications TP1631 EVALUATION OF BRAKE DISC SURFACE CONTINUED Grooving - Scoring can be light or heavy, If light grooving is found as shown in Fig. 13 then the disc can continue to be used. Fig.
  • Page 322 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications © Spicer Speciality Axle Division Page No.12 NDS2 issue A...
  • Page 323 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / AXLE BED TIGHTENING TORQUES Fig.No.17 PART N DESCRIPTION ----------------------------------- TIGHTENING TORQUE ---- 1 ------- Brake backplate nut 1/2" UNF ---------------- 85 - 103 lbs.ft -------- 115 - 140 NM ------- (All axles) 2 ------- Brake backplate stud 1/2"...
  • Page 324 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / AXLE BED TIGHTENING TORQUES Fig.No.18 PART N DESCRIPTION ----------------------------------- TIGHTENING TORQUE ---- 6 ------- Swivel top cap ------------------------------------- 25 - 75 lbs.ft ---------- 34 - 102 NM -------- (All axles) 7 ------- Swivel top cap lubricator ----------------------- 10 - 15 lbs.ft ---------- 14 - 20 NM ---------- (All axles) 9 ------- Top lever bolts M20 x 2.5 grade 10.9 ------- 433 - 479 lbs.ft ------- 587 - 649 NM ------- (NDS 35/41/56) -------- Top lever bolts M20 x 2.5 grade 12.9 ------- 520 - 575 lbs.ft ------- 705 - 780NM ------- (NDS 56)
  • Page 325 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / HUB END TIGHTENING TORQUES Fig.No.19 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM...
  • Page 326 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications SWIVEL / HUB END TIGHTENING TORQUES Fig.No.20 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM...
  • Page 327 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications 9< Fig.No.21 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM Hub flange retaining bolt M14 x 1.5 ---------------------------- 174 - 192 lbs.ft...
  • Page 328 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications Fig.No.22 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM Brake air cylinder retaining nuts M16 X 1.5 ------------------ 133 - 155 lbs.ft...
  • Page 329 BACK / RETOUR Spicer SpecialityAxle Division - Technical Publications Fig.No.23 PART N DESCRIPTION TIGHTENING TORQUE Wheel nut M18 x 1.5 ----------------------------------------------- 235 - 260 lbs.ft 318 - 352NM Wheel nut M20 x 1.5 ----------------------------------------------- 285 - 315 lbs.ft 386 - 427NM Wheel nut M22 x 1.5 ----------------------------------------------- 475 - 525 lbs.ft 644 - 712NM Hub flange retaining bolt M14 x 1.5 ---------------------------- 174 - 192 lbs.ft...
  • Page 330 BACK / RETOUR APPLICATION POLICY Capability ratings, features and specifications vary depending upon the model type of service. Applications approvals must be obtained from Spicer Speciality Axle Division. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice.
  • Page 331 Maintenance manual Model NDS Hub and brake assembly With Knorr Bremse Disc brake Fitted to offset barrel swivel SPICER SPECIALITY AXLE DIVISION...
  • Page 332 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 333 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 334 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 335 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 336 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 337 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 338 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 339 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 340 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 341 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 342 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 343 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 344 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 345 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 346 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 347 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 348 Spicer Speciality Axle Division - Technical Publications TP1193 © Spicer Speciality Axle Division Page No.18 Manual No. NDS8...
  • Page 349 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 350 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 351 TP-9539 Revised 06-07 Approved Rear Drive Axle Lubricants Technical Bulletin CAUTION You must fill Meritor axles with Meritor-specified lubricants only. Do not fill an axle with non-approved lubricants, which will void Meritor’s warranty. Damage to axle components also can result. To avoid axle component damage, fill Meritor axles with approved lubricants only.
  • Page 352 Table B: Axle Oil Specifications A.P .I. Viscosity ArvinMeritor Outside Gear Oil Type Specification Grade Specification Specification Temperature 85W/140 O76-A Above +10°F (–12°C) 80W/140 O76-B Above –15°F (–26°C) 80W/90 O76-D Above –15°F (–26°C) 75W/90 O76-E Above –40°F (–40°C) Petroleum with SAE J2360 Tested GL-5 From –40°F (–40°C)
  • Page 353 Table C: Extended-Drain-Approved Synthetic Axle Oil Suppliers — United States Distributors Name of Lubricant Viscosity Manufacturer Gibraltar Syn-Gear 75W/90, 80W/140 David Weber Oil Company Gulf Syngear 75W/90, 80W/140 Gulf Oil Hi-Tek Synthetic 75W/90, 80W/140 Industrial Oils Limited Imperial SGO 75W/90, 80W/140 IPAC Lubemaster Syn EP 75W/90, 80W/140...
  • Page 354 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 355: Specifications

    For Meritor R-170 Axles Equipped Lubrication Analysis ® With Traction Equalizer Recommendations Meritor’s R-170 axles with Traction Equalizer Meritor recommends using a lubricant analysis normally operate with either standard petroleum, program. Perform lubricant analysis at semi-synthetic or full-synthetic oils. regularly-scheduled preventive maintenance intervals.
  • Page 356 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 357 TP-96105 Revised 07-03 ® Applying Loctite Ultra Grey Flange Sealant 5699/Meritor Maintenance Part Number 2297-Z-7098 Manual Update TP-96105 Revised 1 Maintenance Manual Update 07-03 Hazard Alert Messages Clean the surfaces where you will apply the silicone gasket material. Remove all oil, grease, dirt and moisture. Figure 1. Read and observe all Warning and Caution hazard alert messages in Dry both surfaces.
  • Page 358 Maintenance Manuals The information in this Technical Bulletin updates the following Maintenance Manuals. Title Date Tandem Axle Forward Rear Drive 09-88 Units Single-Reduction Hypoid Drive 08-79 Unit Tandem Axle Forward Rear Drive 03-91 Units Double-Reduction Differential 08-84 Carriers Hypoid Planetary Two-Speed 08-90 Differential Carriers Heavy-Duty Front Drive Steer...
  • Page 359 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS AIR SYSTEM ............................. 5 BRAKES ............................5 AIR RESERVOIRS..........................5 ..........................5 AINTENANCE 3.1.1 Wet (Main) Air Tank ........................ 5 3.1.2 Primary Air Tank........................6 3.1.3 Accessory Air Tank ......................... 6 3.1.4 Secondary Air Tank......................... 6 ............................
  • Page 360 Section 12: BRAKE AND AIR SYSTEM SPRING BRAKE VALVE (SR-7) ..................... 12 PRESSURE PROTECTION VALVE (PR-4) ..................13 LOW PRESSURE INDICATOR (LP-3).................... 13 SHUTTLE-TYPE DOUBLE CHECK VALVE (DC-4)............... 13 AIR HORN VALVE .......................... 13 AIR SYSTEM TROUBLESHOOTING ..................... 14 BRAKE OPERATION ........................14 AIR BRAKES ...........................
  • Page 361 Section 12: BRAKE AND AIR SYSTEM 30.1.4 Bendix® M-32QR Pressure Modulator Valves (PMV)............30 30.2 6S/5M C ......................31 ONFIGURATION 30.3 ................... 31 DVANCED TABILITY ONTROL ® 30.4 ................31 ENDIX TEERING NGLE ENSOR 30.4.1 Removal of the steering angle sensor................... 31 FITTING TIGHTENING TORQUES ....................
  • Page 362 Section 12: BRAKE AND AIR SYSTEM ....................... 27 IGURE ABS MODULATOR VALVE ........................ 28 IGURE ABS SENSOR LOCATION ..........................28 IGURE SPRING CLIP ......................29 IGURE M CONFIGURATION ..........................32 IGURE HOSE FITTINGS ..........................33 IGURE HOSE FITTING ..........................33 IGURE HOSE FITTING ..........................

  • Page 363: Section 12: Brake And 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 364: 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 365: Filter Element Replacement

    Section 12: BRAKE AND AIR SYSTEM ACCESSORY AIR FILTER AIR GAUGES (PRIMARY, SECONDARY AND ACCESSORY) The air pressure gauges, located on the dashboard (see “Owner’s Manual”), connected to the DC-4 double check valve, located on the pneumatic accessory panel in the front service compartment.

  • Page 366: 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 367: 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 368: 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 369: 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 370 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 installed on this vehicle (Bendix, SL-5 Stop Light Switch; reference no. is used on Low Buoy rear release system. It SD-06-2501).
  • Page 371 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 372 Section 12: BRAKE AND AIR SYSTEM operation in the event that one circuit of the 23. AIR SYSTEM TROUBLESHOOTING 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 373 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 374 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 375 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 376 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 377 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 378 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 379 Section 12: BRAKE AND AIR SYSTEM FIGURE 38: AIR-OPERATED BRAKING SYSTEM (WE) PA1564...
  • Page 380 Section 12: BRAKE AND AIR SYSTEM FIGURE 39: AIR-OPERATED BRAKING SYSTEM (W5) PA1564...
  • Page 381 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 382 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 383 Section 12: BRAKE AND AIR SYSTEM Tag Axle NOTE 1. Block the wheels to prevent the vehicle from When the diaphragm, spring, or both are moving. replaced, they should be replaced in the corresponding chamber on the same axle. 2. Turn the release bolt counterclockwise to cage the power spring (approx.
  • Page 384 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 385 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 FIGURE 42: ABS ECU LOCATION...
  • Page 386 Section 12: BRAKE AND AIR SYSTEM procedure carefully before reinstalling a sensor, 29.2.3 Sensors as its installation must comply with operational The sensors are mounted on the front and drive tolerances and specifications. axle wheel hubs (Fig. 44). The inductive sensors consist essentially of a permanent magnet with a 1.
  • Page 387 Section 12: BRAKE AND AIR SYSTEM FIGURE 46: ABS 6S/5M CONFIGURATION PA1564...
  • Page 388 Section 12: BRAKE AND AIR SYSTEM 30.1.2 The EC-60 30. AUTOMATIC TRACTION CONTROL (ATC) controller’s ATC function utilizes the following components: – ELECTRONIC STABILITY PROGRAM (ESP) • Drive axle traction control valve; In addition to the ABS function, advanced models of Bendix EC-60 controllers provide an •...
  • Page 389 SAS-60 sensor. Yaw stability counteracts the tendency of a The SAS-60 sensor installed on Prevost vehicle to spin about its vertical axis. During vehicles is the 90° connector. operation, if the friction between the road surface and the tires is not sufficient to oppose lateral (side) forces, one or more of the tires can 30.4.1 Removal of the steering angle sensor...
  • Page 390 Section 12: BRAKE AND AIR SYSTEM Diagnostics: Steering Angle Sensor Calibration The steering angle sensor is only operational in The steering angle sensor calibration can only conjunction with Advanced ECU. be achieved when the sensor is powered by the independent diagnostics can be performed on Advanced ABS ECU.
  • Page 391 Section 12: BRAKE AND AIR SYSTEM Fitting Pipe Number of additional size diameter turns required following (inches) hand tightening 1 ¼ 3/16 1 ¼ FIGURE 50: HOSE FITTING 12056 1 ¼ Pipe Tightening: All connections must be hand 5/16 1 ¾ tightened.
  • Page 392 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 393 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..........................642015 Pressure Protection Valve Make........................... Bendix Westinghouse Model..............................PR-4 Nominal closing pressure....................70 psi (482 kPa) Prévost number..........................
  • Page 394 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 395 Effective Date: 12/02/05 Bendix Air Disc Brake Pad Replacement on Prevost Car Vehicles Subject: Prevost Car and Bendix Spicer Foundation Brake • Shear testing of the friction material adhesion LLC are issuing this product notification about resulted in the friction material completely...
  • Page 396 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 397 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 398 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 399 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 400 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 401 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 402 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 403 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 404 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 405 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 406 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 407 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 408 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 409 ¶ 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 410 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 411 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 412 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 413 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 414 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 415 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 416 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 417 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 418 16 BW2158 © Honeywell Commercial Vehicle Systems Company 4/2001. Printed in USA.
  • Page 427 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 428 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 429 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 435 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 436 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 437 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 447 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 448 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 449 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 450 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 451 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 452 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 453 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 454 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 455 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 456 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 457 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 459 ® 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 460 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 461 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 462 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 463 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 464 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 465 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 466 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 467: Introduction

    ® Bendix EC-60 ABS / ATC Controllers (Advanced Models) ® ™ See SD-13-4863 for Standard and Premium Controllers TABLE OF CONTENTS PAGE General System Information Introduction ....... . 1 Components .

  • Page 468: Components

    The ESP system only functions within the limits of Sensor physics. Clamping 90° Speed Sleeve ESP functionality mitigates potential vehicle stability Sensors incidents, but cannot prevent them in all cases. Other factors such as driving too fast for road, traffic or weather Straight Speed conditions, oversteering, an excessively high vehicle Center Sensors...

  • Page 469: Ecu Mounting

    Input Sensors PMVs ESP/ Blink Retarder Serial Communication Voltage Codes J1587 J1939 Off-Road Mud/Snow Relay 12 VDC 4/5/6 CHART 1 - EC-60 ADVANCED CONTROLLER FEATURES ™ ECU MOUNTING The Bendix EC-60 advanced cab-mounted controller is ® ™ not protected against moisture, and must be mounted in an environmentally protected area.

  • Page 470: Controller Inputs

    Diagnostic Blink Code Switch A momentary switch that grounds the ABS Indicator Lamp output is used to place the ECU into the diagnostic blink code mode and is typically located on the vehicle’s dash panel. Optional ABS Off-Road Switch and Indicator Lamp Operation Advanced EC-60 controllers use an optional dash-...

  • Page 471: Controller Outputs

    Bendix YAS-60 Yaw Rate/Lateral Acceleration 2. When full ABS operation is not available due to ® ™ presence of a DTC on the ECU. Sensor 3. If the ECU is unplugged or has no power. The Yaw Rate/Lateral Acceleration Sensor is used to provide the controller an indication of vehicle lateral 4.

  • Page 472: Power-Up Sequence

    (If you need to know if this EC-60 controller uses a serial ™ communications message to operate the lamp, e-mail ABS System Power Application ABS@bendix.com, specifying the ECU part number, or call Status Indicators 1-800-AIR-BRAKE and speak to the Bendix TechTeam.) 2.0 2.5 3.0 (sec.) SAE J1708/J1587 Serial Communications Powered Vehicle ABS...

  • Page 473: Abs Operation

    The EC-60 controller will perform a PMV chuff test on all With the EC-60 advanced controller, at the completion of ™ installed modulators in the following order: the second round of PMV & TCV chuff tests, the controller (if configured to do so) will perform a test to cross-check the •...

  • Page 474: Atc Operation

    WARNING: The ABS off-road mode should not be The ATC/ESP dash lamp illuminates: used on normal, paved road surfaces because vehicle 1. During power up (e.g. when the vehicle is started) for stability and steerability may be reduced. The ABS approximately 2.5 seconds and turns off after the self Indicator Lamp will flash slowly to indicate to the driver test is completed, providing no diagnostic trouble codes...

  • Page 475: Advanced Abs With Stability

    Bendix Smart ATC Traction Control ® ™ 5. When certain diagnostic trouble code conditions are detected. The EC-60 controller has an additional feature known as ™ Smart ATC traction control. Smart ATC traction control ™ ™ Optional ATC Mud/Snow (Off-Road) Mode monitors the accelerator pedal position (using J1939) to In some road conditions, the vehicle operator may desire help provide optimum traction and vehicle stability.

  • Page 476: Yaw Control

    IMPORTANT SAFETY INFORMATION ABOUT THE BENDIX STABILITY SYSTEM ® ® ESP May Reduce The Vehicle Speed Automatically ESP can make the vehicle decelerate automatically. ESP can slow the vehicle with or without the operator applying the brake, and even when the throttle is being applied.

  • Page 477: Dynamometer Test Mode

    To Maximize The Effectiveness Of ESP: The Dynamometer Test Mode may be activated by pressing and releasing the diagnostic blink code switch five times or • Loads must be properly secured at all times. by using a hand-held or PC-based diagnostic tool. •...

  • Page 478: Abs Partial Shutdown

    SYSTEM IMPACT DURING ACTIVE Brake Demand Pressure Sensor Diagnostic Trouble Code TROUBLE CODES ESP is disabled. ABS and ATC remain active. ABS PARTIAL SHUTDOWN Load Sensor Diagnostic Trouble Code Depending on which component the trouble code is ESP is disabled. ABS and ATC remain active. detected, the ABS, ATC, and ESP functions may be fully or partially disabled.
  • Page 479 Troubleshooting: General SAFE MAINTENANCE PRACTICES certain all components and systems are restored to their proper operating condition. WARNING! PLEASE READ AND FOLLOW 11. For vehicles with Antilock Traction Control (ATC), THESE INSTRUCTIONS TO AVOID PERSONAL the ATC function must be disabled (ATC indicator INJURY OR DEATH: lamp should be ON) prior to performing any vehicle When working on or around a vehicle, the following...

  • Page 480: Steering Angle Sensor Calibration

    For further information, contact either the vehicle Installation: manufacturer, Bendix or your local authorized Bendix 1. Obtain a new sensor. The sensor is not repairable in dealer. the field. 1. Position and secure the EC-60 controller in the original ™ 2.
  • Page 481 BRAKE DEMAND SENSOR CALIBRATION Diagnostics: The yaw rate sensor is only operational in conjunction with Calibration must be performed under the following conditions: an Advanced ABS ECU. No independent diagnostics can • After servicing any pressure sensor related DTCs be performed on the sensor. •...
  • Page 482 Troubleshooting: Blink Codes and Diagnostic Modes ECU DIAGNOSTICS BLINK CODES The EC-60 controller contains self-testing diagnostic Blink codes allow a technician to troubleshoot ABS ™ circuitry that continuously checks for the normal operation problems without using a hand-held or PC-based diagnostic of internal components and circuitry, as well as external tool.
  • Page 483 DIAGNOSTIC MODES Blink Code Timing The ECU responds with a sequence of blink codes. The In order to communicate with the ECU, the controller has overall blink code response from the ECU is called a several modes that the technician can select, allowing “message.”...
  • Page 484 Using blink codes, the technician may review all inactive 1st Number System Power trouble codes stored on the ECU. The ABS indicator 12 Volts lamp will display inactive diagnostic blink codes when the 2nd Number Wheel Speed Sensors diagnostic blink code switch is depressed and released two 4 Sensors times.
  • Page 485 Troubleshooting: Using Hand-Held or PC-Based Diagnostic Tools USING HAND-HELD OR PC-BASED vehicle. (See Figure 15.) If there are multiple diagnostic trouble codes on the ABS system, the RDU tool will display ™ DIAGNOSTICS one diagnostic trouble code first, then once that Diagnostic Troubleshooting and diagnostic trouble code clearing (as Trouble Code has been repaired and cleared, the next code well as reconfiguration) may also be carried out using...
  • Page 486 LED Diagnostic Trouble Codes LFT - Left ECU - ABS Controller RHT - Right SEN - Wheel Speed DRV - Drive Axle Sensor ADD - Additional MOD - Pressure Modulator STR - Steer Axle Valve VLT - Power TRC - Traction Control Example: If the Diagnostic LEDs...
  • Page 487 Active or Inactive Diagnostic Trouble Codes: INDEX How to interpret the first digit of messages received when Active or Inactive Diagnostic Trouble Code Mode Blink Go Here for Troubleshooting Tests Code Number 1 ....... . No faults (1,1) 2 .
  • Page 488 Troubleshooting Diagnostic Trouble Codes: Wheel Speed Sensors 1st. Blink Location Code Left Steer Axle Sensor Right Steer Axle Sensor Left Drive Axle Sensor Right Drive Axle Sensor Left Additional Axle Sensor Right Additional Axle Sensor 2nd. Diagnostic Blink Trouble Code Code Description Repair Information Excessive...
  • Page 489 Speed Sensor Repair Tests: 1. Take all measurements at ECU harness connector pins in order to check wire harness and sensor. Probe the connector carefully so that the terminals are not damaged. 2. Wheel speed sensor measurements should read: Location Measurement Sensor 1500 - 2500 Ohms...
  • Page 490 Troubleshooting Diagnostic Trouble Codes: Pressure Modulator Valves 1st. Blink Location Code Left Steer Axle Right Steer Axle Left Drive Axle Right Drive Axle Left Additional Axle Right Additional Axle Trailer PMV 2nd. Diagnostic Blink Trouble Code Code Description Repair Information Release Verify no continuity between PMV leads and ground.
  • Page 491 Pressure Modulator Valve Repair Tests: 1. Take all measurements at ECU harness connector pins in order to check wire harness and PMV. Probe the connector carefully so that the terminals are not damaged. 2. Pressure modulator resistance should read: Location Measurement Release to Common 4.9 to 5.5 Ohms...
  • Page 492 Troubleshooting Diagnostic Trouble Codes: Traction Control Valves 1st. Blink Location Code Drive Axle Traction Control Valve Steer Axle Traction Control Valve 2nd. Diagnostic Blink Trouble Code Code Description Repair Information TCV Solenoid Verify 7 to 19 ohms between TCV and TCV common. Verify no continuity between Shorted to TCV leads and ground.
  • Page 493 Troubleshooting Diagnostic Trouble Codes: Power Supply 1st. Blink Location Code Power Supply 2nd. Diagnostic Blink Trouble Code Code Description Repair Information Battery Voltage Measure battery voltage under load. Check vehicle battery and associated components. Too Low Check for damaged wiring. Check for damaged or corroded connectors and connections. Battery Voltage Measure battery voltage under load.
  • Page 494 Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications 1st. Blink Location Code J1939 2nd. Diagnostic Blink Trouble Code Code Description Repair Information J1939 Serial Link Loss of communications between the EC-60 controller and other devices connected ™ to the J1939 link. Check for damaged or reversed J1939 wiring. Check for corroded or damaged connectors.
  • Page 495 Troubleshooting Diagnostic Trouble Codes: 1st. Blink Location Code 2nd. Diagnostic Blink Trouble Code Code Description Repair Information ECU (02) ECU (10) ECU (11) ECU (12) ECU (13) 2-24: Check for damaged or corroded connectors. Check for damaged wiring. ECU (14) Clear trouble codes.
  • Page 496 Troubleshooting Diagnostic Trouble Codes: Miscellaneous 1st. Blink Location Code Miscellaneous 2nd. Diagnostic Blink Trouble Code Repair Information Code Description Stop Lamp Switch ECU has not detected the presence of the stop lamp switch since ignition power was applied (note that stop lamp Not Detected switch input may be applied to the EC-60 controller using either hardwire input or J1939).
  • Page 497 Miscellaneous Troubleshooting (continued) For all tests below, take all measurements at ECU Retarder Relay harness connector pins in order to check wire harness 1. Measure resistance between retarder disable output of and sensor. Probe the connector carefully so that the EC-60 controller and voltage / ground.
  • Page 498 Troubleshooting Diagnostic Trouble Codes: Steering Angle Sensor (SAS-60 sensor) ™ 1st. Blink Location Code Steering Angle Sensor 2nd. Diagnostic Blink Trouble Code Repair Information Code Description SAS has not been calibrated. Perform SAS calibration procedure. SAS Not Calibrated SAS calibration procedure is underway. SAS Calibration in Progress SAS signal incorrect.
  • Page 499 Troubleshooting Diagnostic Trouble Codes: Steering Angle Sensor (SAS-60 sensor) ™ (continued) Looking into wire harness connector Steering Angle Sensor Tests 5. Follow the prompts to perform a calibration of the Steering Angle Sensor. 1. Measure resistance between input voltage and ground at the sensor wiring harness connector.

  • Page 500: Yaw Rate/Lateral Acceleration Calibration

    Troubleshooting Diagnostic Trouble Codes: Yaw Rate Sensor (YRS) 1st. Blink Location Code Yaw Rate Sensor 2nd. Diagnostic Blink Trouble Code Repair Information Code Description YRS Signal YRS signal incorrect. Verify proper installation of the YRS. Verify proper wiring between the ECU and the YRS. Out of Range Check YRS output.
  • Page 501 Troubleshooting Diagnostic Trouble Codes: Yaw Rate Sensor (YRS) (continued) Looking into wire harness connector Yaw Rate Sensor Tests 5. Follow the prompts to perform a calibration of the Yaw Rate Sensor. 1. Measure resistance between input voltage and ground at the sensor wiring harness connector. 6.
  • Page 502 Troubleshooting Diagnostic Trouble Codes: Lateral Acceleration Sensor (LAS) 1st. Blink Location Code Lateral Acceleration Sensor 2nd. Diagnostic Blink Trouble Code Repair Information Code Description LAS signal incorrect. Verify proper installation of the YRS/LAS. Verify proper wiring LAS Signal between the ECU and the YRS/LAS. Check YRS/LAS output. Perform LAS calibration Out of Range procedure.
  • Page 503 Troubleshooting Diagnostic Trouble Codes Brake Demand/Load Sensors 1st. Blink Location Code Brake Demand/Load Sensors 2nd. Diagnostic Blink Trouble Code Repair Information Code Description PS1 Open or Check wiring between Brake Demand Sensor (primary brake circuit) and ECU. Verify Shorted operation of pressure sensor. PS2 Open or Check wiring between Brake Demand Sensor (secondary brake circuit) and ECU.

  • Page 504: Connectors

    EC-60 Controller Wire Harness Connector Part ™ Numbers and Pin Assignments: ADVANCED CAB CONNECTOR CONNECTOR CONNECTOR CONNECTOR Advanced Cab Model EC-60 Controller ™ Advanced cab models utilize four AMP connectors for wire harness connections. X1 Connector Pin Assignments Pin Designation Pin Designation Pin Designation Ground...
  • Page 505 Troubleshooting: Wiring ABS/ATC WIRING WARNING: All wires must be carefully routed to avoid contact with rotating elements. Wiring must be properly ECU Wiring Harness Connectors secured approximately every 6 to 12 inches using UV The Advanced EC-60 controller is designed to interface ™...
  • Page 506 ABS Component Connector Wire Wire Seal/ Terminal Terminal Terminal Plug Lock Crimp Tool Controller Harness 927768-9 17-Way AMP 1 - 2.5 mm MCP 2.8 (X1) X1-12 & 18 967634 1718091-1 Controller Harness 18-Way AMP 968874 MCP 2.8 (X2) 8-968974-1 2.5 - 4 mm Controller Harness 15-Way AMP...
  • Page 507 Troubleshooting: Wiring (Continued) Max. Gap (Sensor to Exciter) Mounting Block .015 Inches Speed Sensor Mounting Block WS-24 speed sensor ™ 100 Tooth (typical) Speed Sensor Exciter Ring 100 Tooth Exciter Brake Drum Ring WS-24 Speed Sensor ™ 90° Speed Sensors Hub Assembly Sensor Straight Speed...
  • Page 508 Troubleshooting: Wiring Schematic FIGURE 20 - STANDARD CAB WIRING SCHEMATIC REVISED 5/31/05...

  • Page 509: Glossary

    Glossary ABS — Antilock Brake System. J1587 — The SAE heavy duty standard diagnostic data link. ABS Event — Impending wheel lock situation that causes the J1708 — An SAE standard which defines the hardware and ABS controller to activate the modulator valve(s). software protocol for implementing 9600 baud heavy vehicle data links.
  • Page 510 Appendix A: J1587 SID and FMI Codes and Their Bendix Blink Code Equivalents General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) - ..-..No DTCs ......1 ..1 ..No DTCs 1.
  • Page 511 General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) 53 ..4 ..Pressure Modulator Valve DTCs ..17 ..1 ..AA Right PMV REL Solenoid Shorted to Ground 66 .
  • Page 512 General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) 22 ..7 ..Miscellaneous DTCs ....12 ..11 ..Wheel Speed Sensors Reversed on an Axle 102.
  • Page 513 General Bendix Blink Code Diagnostic Trouble Code Description (J1587) (J1587) Equivalent(s) (1st Digit) (2nd Digit) 103..2 ..Yaw Rate Sensor DTCs ... . . 22 ..12 ..YRS Plausibility Check (Ref Yaw Rate) 103.
  • Page 514 BW2429 ©2005 Bendix Commercial Vehicle Systems LLC • All Rights Reserved • 5/05 • Printed in U.S.A. REVISED 5/31/05...
  • Page 515 ® Bendix ® M-32 ™ and M-32QR ™ AntiLock Modulators Delivery Port ™ M-32 (Casting has Modulator Supply Port ™ M-32QR 2, DEL) Modulator* (Casting has 1, SUP) Supply Port (Casting has 1, SUP) Electrical Connector Electrical * All M-32QR modulators ™...
  • Page 516 Front Axle Systems Rear Axle System Wheel Control Wheel Control Axle Control Wheel Control Service Brake Chamber To Antilock To Antilock To Antilock Controller To Antilock Controller Controller Controller M-32QR ™ ™ ™ M-32 or M-32QR ™ ™ M-32 or M-32QR Modulator Modulator Modulator...
  • Page 517 Brake Supply Delivery Brake Supply Delivery Valve Bias Port Port Valve Port Port Valve Brake Brake Chamber Chamber Supply or Hold Supply or Hold Diaphragm Diaphragm Spring Spring Exhaust Exhaust Valve Valve ™ ™ M-32 M-32QR Modulator Modulator Exhaust Exhaust Exhaust Exhaust Port...
  • Page 518 Brake Supply Delivery Brake Supply Delivery Bias Valve Port Port Valve Port Port Valve Brake Brake Chamber Chamber Supply or Hold Supply or Hold Diaphragm Diaphragm Open Open Spring Spring Exhaust Exhaust Valve Valve Open Open ™ M-32 ™ M-32QR Modulator Modulator Exhaust...
  • Page 519 Brake Supply Delivery Brake Supply Delivery Bias Valve Port Port Valve Port Port Valve Brake Brake Chamber Chamber Supply or Hold Supply or Hold Diaphragm Diaphragm Closed Spring Spring Exhaust Exhaust Valve Valve Open ™ ™ M-32 M-32QR Solenoid Solenoid Solenoid Solenoid Energized:...
  • Page 520 PREVENTIVE MAINTENANCE OPERATION TEST To properly test the function of the modulator will require two GENERAL (2) service technicians. Perform the tests and inspections presented at the 1. Park the vehicle on a level surface and block or chock prescribed intervals. If the modulator fails to function as the wheels.
  • Page 521 Source Hold Exhaust 43 Threaded (Metric) Connector Twist-Lock Connector (Bayonet Connector) FIGURE 10: M-32 AND M-32QR MODULATORS CONNECTOR VIEWS ™ ™ 2. Stop the engine and remove ignition key when size, type and strength as original equipment and working under or around the vehicle. When be designed specifically for such applications and working in the engine compartment, the engine systems.
  • Page 522 Port Designation Supply Delivery 2 Exhaust 3 Electrical Control Source Hold Exhaust 43 FIGURE 11: M-32 AND M-32QR MODULATORS DIN SYMBOL ™ ™ MODULATOR INSTALLATION TECHNICAL INFORMATION 1. Install all air line fittings and plugs, making certain thread Supply Port (from brake, relay or quick Porting sealing material does not enter the valve.
  • Page 523 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 524: 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 525: Single Wheel Removal

    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 526: Aluminum Wheel Anti-Corrosion Protection

    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 527: 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 528: Hub Mounted 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 doubt, renew.

  • Page 529: Drive Axle Wheel Hubs

    Section 13: WHEELS, HUBS & TIRES 4. Tighten lock check bearing NOTE adjustment. Replace the axle shaft using a If original bearing unit is re-fitted, and end-float new gasket. is measured at 1 mm, with hub not fully tightened to correct torque, then the retaining 9.2 DISASSEMBLY AND REPAIR clip within the unit is damaged and a new unit 1.

  • Page 530: Changing A Flat Tire

    Section 13: WHEELS, HUBS & TIRES 8. Assemble axle flange to axle using a new NOTE gasket. Apply sealant in stud area. After both Bus Shells vehicles, before being converted, wheels have been assembled according to are not at their maximum weight and tire above procedure, fill the differential with the pressures are adjusted at lower level than the recommended lubricant to the proper factory...
  • Page 531 Section 13: WHEELS, HUBS & TIRES Running tires at optimal pressure reduce tire wear, improve safety and fuel economy. NOTE It is more accurate to use the TPMS display to set the tire pressures than a pressure gauge. The TPMS target pressures are factory set to equal the prevailing tire pressure at delivery time.

  • Page 532: Tire Matching

    Section 13: WHEELS, HUBS & TIRES NOTE WARNING It is recommended that all tires on coach be of the same type. Incorrect tire pressures cause increased tire wear and adversely affect road holding of the vehicle, which may lead to loss of vehicle 11.3 WHEEL BALANCING control.
  • Page 533 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 535 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 536 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 537 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 538 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 539 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 541 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 542 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 544 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 545 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 546 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 547 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 548: 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 549: Inspection

    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 550: 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 551: 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 552: 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 553: 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 554: 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 555: 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 556: 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 557: 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 558 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 559 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 560 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 561 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 562: 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 563: 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 564 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 565: Rim Width To Tire Matching

    Rim width to tire Rim to tire matching chart for medium and heavy trucks. matching Tire Size Tire Size Approved Approved (for both radial (for both radial Rim Widths Rim Widths and bias tires) and bias tires) 17.5HC 6.00HC 22.5 5.25, 6.00, 6.75 215/75R 17.5...

  • Page 566: 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 567: 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 568: 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 569: 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 570: 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 571 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 572 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 573: Cap Nut Thread Engagement, Stud Located Wheels, Ball Seat Mounting

    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 574 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 575: Single, Dualed And Wide Base Wheels, Hub Piloted Mounting, Two-Piece Flange Nuts

    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 576: Tightening Hub Piloted Mounting, Two-Piece Flange Nuts

    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 577 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 578: 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 579: 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 580: 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 581: 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 582: 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 583: 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 584: 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 585: 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 586: 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 587: 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 588: 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 589: 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 590 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 591 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 592 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 593: 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 594 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 595: 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 596: Conversion Tables

    Conversion Tables Inch Fraction, Decimal and Millimeter Equivalents Chart (Up to 1 inch)

  • Page 597: 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 598 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 599 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 600 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 601: 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 602: Power Steering Gear

    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 603: Power Steering Gear Removal

    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 604: Steering Wheel

    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 605: Steering Linkage Adjustment

    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 606: 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 607: 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 608: 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 609: Torque Specifications

    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 PA1564...
  • Page 610 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 611 Design Operation Maintenance Inspection R R R R ZF Servocom Types 8090, 8095, 8097 and 8098 ZF Lenksysteme GmbH D-73522 Schwäbisch Gmünd Telephone (07171) 31-0 Fax (07171) 31-4396 8090 I 04/06 e...
  • Page 612 Table of Contents / Safety Note Table of contents Page Safety note ..............Design and operation .

  • Page 613: Design And Operation

    Design and Operation II. Design and operation Design The housing of the ZF Servocom steering gear houses the steering valve, the steering cylinder and a complete manual steering gear. The oil flow and the pressure required by the steering gear is supplied by an engine-driven pump. To achieve this, the oil is taken in from the oil tank and fed back to the tank via the pump and the steering gear.
  • Page 614 Design and Operation The steering valve consists of the valve rotor (C) which is carried in a needle bearing in the worm and is provided with six control grooves on the circumference, and of the valve sleeve (D) on the worm.
  • Page 615 Design and Operation 2.1 Forward steering motion to the right (piston with right-handed thread) Fig. 2 Valve rotor in operating position Steering wheel turned clockwise J Inlet slot K Inlet slot L Return slot M Return slot N Axial groove O Axial groove P Return groove Operating pressure...
  • Page 616 Design and Operation Forward steering motion to the left (piston with right-handed thread) Fig. 3 Valve rotor in operating position Steering wheel turned counter-clockwise Inlet slot Inlet slot Return slot M Return slot Axial groove Axial groove Return groove Operating pressure Return line pressure When the steering wheel is turned to the left, the piston will shift to the left (Fig.
  • Page 617 Design and Operation Operation of the hydraulic steering limitation The hydraulic steering limitation prevents a steering to the lock stops at full hydraulic pressure. It, thus, protects the pump and the steering linkage and prevents high oil temperatures. A double-acting steering limiting valve with spring-loaded valve pins (T and U) is arranged in the longitudinal direction in the piston (B).

  • Page 618: Servicing Work

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

  • Page 619: Maintenance

    Servicing Work Maintenance Maintenance intervals: We recommend to carry out the following work within the scope of the general maintenance work.¡ 2.1 Test driving During the test drive, in particular look out for the following chacteristics: return to neutral sticking increased friction play 2.2 Checking and inspecting for external leakproofness/damages...
  • Page 620 Servicing Work For vehicles with ZF Servocom RAS (Rear Axle Steering System) Check the oil level in the straight ahead driving position. If the oil level is above the top mark, there may be a leakage in the master cylinder of the ZF Servocom RAS steering.

  • Page 621: Inspection

    Servicing Work 3 Inspection Attention: The inspection intervals depend on how the vehicle is used. Therefore, the table below distinguishes between different kinds of use which may, though, be overlapping. For the sake of increased traffic safety, we recommend to inspect the steering system in accor- dance with the inspection intervals listed below.
  • Page 622 Servicing Work - starting from date of manufacture/repair 1/94 Kind of use Ist inspection Further inspections Inspection on the vehicle Inspection on the vehicle Long-distance vehicles 600 000 km after a further Coaches with high mileages 300 000 km, ea. Buses 300 000 km every 300 000 km...
  • Page 623 Servicing Work Attention: Below is a list of all work that has to be carried out on the steering gear within the scope of the safety inspection (SP). This list represents the currently valid status and is not subject to the Updating Service. 3.5 Steering gear play (part of SP) Start the engine Rotate the steering gear to the straight ahead driving position.

  • Page 624: Oil Change And Bleeding

    Servicing Work Oil change and bleeding 4.1 Oil change 4.1.1 Draining the oil Note: An oil change is only required if steering gear units were repaired or replaced. Do not use any drained oil to refill the system. Avoid any blending of oils. 4.1.2 Draining the steering system Jack the steered axle up.
  • Page 625 Servicing Work To achieve a quick draining, open the one among the components referred to above which is lowest in the installed position. Rotate the steering gear manually from lock to lock until no more oil is draining. Unscrewed components must be screwed in again at the following tightening torques: Screw plug (55): 40 Nm (M16x1.5) 50 Nm (M18x1.5)
  • Page 626 Servicing Work 4.3 Bleeding For steering gear versions with automatic bleeding: Steering gear versions with automatic bleeding do not have any bleed scews. These steering gears automatically bleed any air remaining within the steering system. Note: Automatic bleed valves operate in the idle pressure range only; therefore, any unnecessary pres- sure build-up should be avoided.
  • Page 627 Servicing Work Versions with bleeder (57): With the engine running, open the bleeder (57) until nothing but oil is coming out (Fig. 7). Afterwards, close the bleeder again until it is oil-tight. On versions without automatic bleeding (installed position horizontal, steering output shaft in the bottom position) the topmost screw/set screw (20 and 128, respectively) can be used for bleeding.

  • Page 628: Setting The Hydraulic Steering Limitation

    Servicing Work Setting the hydraulic steering limitation A setting of the steering limitation is necessary if or when a new or repaired steering gear is fitted or new screws (20 and 128) were fitted to the automatically adjusting steering limitation or alterations to or adjustments of the front axle were carried out.
  • Page 629 Servicing Work ° ° Test temperature: 50 C ±10 S Rigid axle: Relieve the axle by jacking it up or place it on swivel plates. ¡ S Single-wheel suspension: Place the steered wheels on swivel plates. S With the engine running at idling speed, rotate the steering gear to the lock stop. Upon reaching the lock stop, overcome the return force of the steering valve by rotating the steer- ing wheel further for a short time (5 sec.
  • Page 630 Servicing Work Proceed as described above for the setting of the second lock stop. Note: At variance with the setting described above, the vehicle manufacturer may specify a different way of adjustment, e.g. by inserting a spacer to ensure that, when the steering limitation responds, a distance dimension “C”...
  • Page 631 Servicing Work Fig. 13 Initial position Sliding bushes not yet adjusted 5.2.1 Operating mode of the automatically adjusting steering limitation In the end positions, the valve piston tappets run up against the sliding bushes (20 and 128, respectively) and open the steering limiter valves (U and T, respectively). The opening of the steering limiter valve is determined by the position of the sliding bushes on the screws (20 and 128).
  • Page 632 Servicing Work For vehicles with single-wheel suspension: Place the wheels on swivel plates. Rotate the steering wheel, with and without hydraulic assistance, to the maximum lock stop. This will cause the piston to push the sliding bush on the screw (20 and 128) up to the required cut-off position (Fig.

  • Page 633: Repair Of External Leakages

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

  • Page 634: Replacing And Setting The Switch (222) And The Potentiometer

    Replacing and Setting the Switch (222) and the potentiometer (232) V. Replacing and setting the switch (222) and the potentiometer (232) Replacing the switch (222) Unscrew the switch (222) and replace it by a new one (tightening torque: 50 Nm). Starting from mid-position, rotate the steering gear to the left and to the right.
  • Page 635 Replacing and Setting the Switch (222) and the potentiometer (232) Fitting the potentiometer (232) again Check whether the steering gear is in mid-position. Fit an O ring (232.1) to the potentiometer (232). Place the deep groove of the potentiometer (232) drive on the carrier (230). Note: The slider of the potentiometer (232) being spring-loaded, it will return to its initial position when disassembled.
  • Page 636 Replacing and Setting the Switch (222) and the potentiometer (232) Setting the potentiometer (232) to steering gear mid-position Connect tools [6] and [7] and the Multimeter measuring instrument as shown in Fig. 20. Fig. 20 Tool [7] Cable colour green black Tool [6] blue...

  • Page 637: Removal And Re-Installation Of The Steering Gear

    Removal and Re-Installation of the Steering Gear VI. Removal and re-installation of the steering gear Removing the steering gear Thoroughly clean the steering gear and its immediate surroundings, in particular the pipe connections. Drain the oil as described in Chapter III.. Take a note of the pressure and return lines‘...
  • Page 638 Removing and Re-Installing the Steering Gear Re-installing the steering gear Attention: To guarantee a safe operation of the steering system, maximum cleanliness is an absolute must when re-installating all units that are part of the system. Note: To avoid malfunctions caused by foreign bodies or impurities in the oil circuit of the steering gear, the plugs in the ports of the steering gear, the oil pump, the steering cylinder, the valves etc.
  • Page 639 Removal and Re-Installation of the Steering Gear Fig. 23 mark housing mark protecting cap protecting cap steering input shaft mark mark steering drop arm sector shaft Place the steering gear into the mounting bracket and fasten it with screws. Note: Make sure that the position of the fitting bolt is correct.
  • Page 640 Removal and Re-Installation of the Steering Gear Additionally, for vehicles with adjustable driver’s workplace: Put the universal joint on without damaging the steering gear seal. Tighten the clamping screw (M10x1,25) applying a torque of 48+5 Nm. Relieve the tool, e.g. the ratchet belt (see Fig. 22), cautiously and remove it. Move the steered wheels of the vehicle to the straight ahead driving position.
  • Page 641 Removal and Re-Installation of the Steering Gear Peen the locking nut (50) as shown in Fig. 24. ¡ Fig. 24 at least 1.5 Put the drag link or the tie rod into place and tighten it. ¡ Rotate the steering gear to the left until reaching the stop. Take off the drag link or the tie rod.
  • Page 642 Removal and Re-Installation of the Steering Gear 2.14 Connect the pressure and return lines between the pump, the steering gear and the steering cylinder according to the notes taken on the removal. Fill the steering system with oil and bleed it. See Chapter III.

  • Page 643: Special Tools

    Special Tools VII. Special tools Note: The tools described below are universal tools. For special applications, special tools recom- mended by the vehicle manufacturer may therefore be necessary. Ordering ref. No. Tool [1] ZF Servotest 600 tester 7418 798 600 Tool [2] Dial with pointer 7418 798 452...
  • Page 644 Special Tools Ordering ref. No. Tool [6] Adapter cable 7418 798 567 Tool [7] Servotronictest tester 7418 798 545 Instructions on Design, Operation, Maintenance and Inspection...

  • Page 645: Troubleshooting

    Troubleshooting VIII. Troubleshooting Troubleshooting on the steering system, incl. checking the hydraulic functions Checking the play of the input shaft bearing in the steering column By moving (shaking) the steering wheel sideward to and fro, check whether there is any play. If so, replace or repair the steering column/the bearing.
  • Page 646 Troubleshooting Checking the straight ahead driving position of the steering gear and the vehicle Attention: Steering gears equipped with an automatically adjusting hydraulic steering limitation must not be rotated to the end positions if the steering linkage had been removed previously. Vehicles with single-wheel suspension: Place the wheels of the steered axle on swivel plates.
  • Page 647 Troubleshooting Checking the belt tension of the pump drive Check the tension of the drive belt. ¡ Even at maximum pump pressure, the drive belt must transmit the power without any slip. Checking the hydraulic functioning of pump and steering gear 1.6.1 Installing tool [1] (ZF Servotest tester) For the implementation of the pressure and leakage oil tests described below, it is necessary to distinguish 2 kinds (variants Œ...
  • Page 648 Troubleshooting Fit tool [1] (ZF Servotest) to variants Œ Œ Œ Œ or     in such a way that the readings can be seen from the driver’s seat. Check the oil level and bleed the steering system - see Chapter III. °...
  • Page 649 Troubleshooting 1.6.3 Checking the flow rate of the ZF pump Note: Specified values for flow rate, test pressure and test speed: see table below. Designations and operation of tool [1] (ZF Servotest power steering tester 6..): see separate operating instructions for ZF Servotest 6..
  • Page 650 Troubleshooting Minimum values Pump speed r.p.m. Minimum values Pump speed r.p.m. Instructions on Design, Operation, Maintenance and Inspection...
  • Page 651 Troubleshooting 1.6.4 Checking the hydraulic steering limitation 1.6.4.1 Manually adjustable hydraulic steering limitation Vehicles with a rigid axle: Jack the steered axle up. ¡ Vehicles with single-wheel suspension: Place the wheels of the steered axle on swivel plates. Rotate the steering wheel clockwise. When the axle stop and the lock stop, respectively, are reached, continue to rotate the steering wheel until a positive stop is reached.
  • Page 652 Troubleshooting 1.6.5 Checking the maximum pressure and the leakage oil of the steering gear For steering systems with pressure relief ahead of tool [1]: Variant Œ Œ Œ Œ Between the lock stops, insert tool [3] or approx. 15 mm thick thrust pads (Fig. 28) en- suring that the steering motion is stopped 1/2 to 3/4 steering wheel turn before reaching the axle stop/lock stop.
  • Page 653 Troubleshooting 1.6.7 Checking the steering gear play Prerequisite for the test described below: Tool [4] The transmission parts between the steering wheel and the road wheel must be free from play. Versions with leaf spring: Lock the LH front wheel (the RH front wheel if the vehicle is RH steered) in the straight ahead driving position by fitting tool [4] be- tween the wheel rim (rear and front) and the...
  • Page 654 Troubleshooting Troubleshooting Troubleshooting aid Fault Cause Remedial action Noise Air in the oil Bleed steering system ¢ Oil level too low Top up with oil Pump defective Repair © Replace © Replace © Stiff operation to either side Oil level too low Repair leakage Top up with oil ¢...
  • Page 655 Troubleshooting Fault Cause Remedial action Self-centring hampered Stiff operation of axle/ Repair ¡ axle guide components Steering gear/steering column Eliminate fitted twisting ¡ in twisted position Stiff operation of steering column Eliminate stiff operation ¡ Steering gear defective Repair © Replace ©...
  • Page 656 Troubleshooting Fault Cause Remedial action Internal malfunction Check potentiometer (see be- low) No tripping of potentiometer Replace steering gear © (232) Wrong operation of poten- Wrong setting Set potentiometer £ tiometer (232) Wrong cabling Check cabling £ Cap screws (223 and 235) loose Check and tighten £ Potentiometer (232) mounted in- Check £...

  • Page 657: Key To Numbers In Figures And Exploded Drawing

    Key to Numbers in Figures and Exploded Drawing IX. Key to numbers in figures and exploded drawing Set screw/screw 20.1 O ring 20.9 Screw Collar nut Valve insert O ring Screw O ring Valve insert Sealing ring Screw plug Bleeder Set screw/screw 128.1 O ring 128.9 Screw...

  • Page 658: Maintenance Report

    Maintenance Report for ZF Servocom Steering Gears Original for duplicating Customer: ........Steering gear version: .

  • Page 659: Inspection Report

    Inspection Report for ZF Servocom Steering Gears Original for duplicating Customer: ........Steering gear version: .
  • Page 761 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 762 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 763 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 764: Steering Linkage

    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 765 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 766 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 PA1564...
  • Page 767 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 768: Steering

    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 769 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 770: Relay Rod

    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 771: Steering Arms

    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 772 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 773: Ball Joints

    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 774: Assembly

    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 775: Upper A-Arm Central Ball Joint

    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 776: Alignment Terminology

    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 777: Camber

    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 778 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 779: Major Damage

    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 780 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 781: Sway Bar

    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 782 Section 16: SUSPENSION FIGURE 26: SWAY BAR (FRONT SUSPENSION) 16138D FIGURE 27: SWAY BAR (REAR SUSPENSION) 16014 PA1564...

  • Page 783: Rear Suspension

    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 PA1564...

  • Page 784: Air Springs

    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 785: Shock Absorbers

    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 786: Installation

    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 787: Inspection

    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 788: Installation

    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 789 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 790: Loading Position

    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 791: Principles Of Operation

    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 792: Air Tank Maintenance

    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 793 Section 16: SUSPENSION • 12.1.5 Expansion Air Tank Apply parking brake, raise wheels off the ground and support axle on stands. When Two expansion tanks are located in front the wheels are raised, they should revolve wheelhousing. These air tanks are located quite freely without roughness.
  • Page 794 Section 16: SUSPENSION • Place a set-square with its stock on ground and its blade against tire wall. • Place a mark on ground to indicate position of stock end. • Insert a lever through bottom cut-out of wheel and lever it upwards thus moving set- square outwards.
  • Page 795 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 796 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 Prévost number........................... 630239 Tag Axle Air Springs (WE) Make........................Goodyear Tire and Rubber Model............................... 1200 Type ..............................Mae West Nominal diameter ........................
  • Page 797 Section 16: SUSPENSION Height control valve (Rear) Make..............................Barksdale Quantity ................................. 2 Prévost number........................... 630156 Radius rod bushing Make..............................Prévost Prévost number........................... 630021 Loctite Make..............................Loctite Prévost number........................... 680039 Sway bar bushing (Front Suspension) Make..............................Prévost Prévost number........................... 630020 Sway bar bushing (Drive Axle) Make..............................Prévost Prévost number...........................
  • Page 799 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 800 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 801 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 802 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 803 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 804 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 805 SECTION 18: BODY CONTENTS VEHICLE EXTERIOR ..........................5 VEHICLE STRUCTURE ........................7 VEHICLE EXTERIOR MAINTENANCE ....................7 ......................... 7 ORROSION REVENTION ..................... 8 REVENTIVE AINTENANCE CHEDULE ......................8 NHIBITOR PPLICATION COMMON FIBERGLASS REPAIR PROCEDURE ................13 ....................13 EPAIR SING IBERGLASS LOTH ....................
  • Page 806 Section 18: BODY 6.5.4 Fuel Filler Door........................38 6 ............................38 6.6.1 Front Fender.......................... 38 7 ............................39 6.7.1 Side Panel for Vehicles Not Fitted With Slide-Out ..............39 6.7.2 Side Panel for Vehicles Fitted With Slide-Out............... 40 6.7.3 Side Crest..........................40 8 ............................
  • Page 807 Section 18: BODY TOWING THE VEHICLE ........................63 ........................64 IFTING OWING ......................64 OWING ITHOUT IFTING ILLUSTRATIONS )..............5 IGURE XLII CONVERTED VEHICLE EXTERIOR VIEW TYPICAL )..............6 IGURE XLII E CONVERTED VEHICLE EXTERIOR VIEW TYPICAL ........................14 IGURE FIBERGLASS REPAIR ........................
  • Page 808 Section 18: BODY ....................45 IGURE FRONT BUMPER RELEASE HANDLE ......................45 IGURE FRONT BUMPER REMOVAL )......................46 IGURE REAR VIEW MIRROR RAMCO ..................48 IGURE WINDSHIELD INSTALLATION USING ROPE ....................48 IGURE APPLICATION F SIKA BLACK ........................49 IGURE VIEW OF FRONT FACE 2............................

  • Page 809: Vehicle Exterior

    Section 18: BODY VEHICLE EXTERIOR FIGURE 1: XLII-45 CONVERTED VEHICLE EXTERIOR VIEW (TYPICAL) Engine air intake 11. Reclining bumper Engine compartment R.H. side door 12. Front electrical & service compartment 13. Driver’s power window Hinged rear fender Baggage compartment 14. Evaporator compartment or Baggage compartment Fuel filler door 15.
  • Page 810 Section 18: BODY FIGURE 2: XLII-45E CONVERTED VEHICLE EXTERIOR VIEW (TYPICAL) 18369 Engine air intake 10. Rear-view mirror Engine compartment R.H. side door 11. Reclining bumper Hinged rear fender 12. Front electrical & service compartment Baggage compartment 13. Driver’s power window Fuel filler door 14.

  • Page 811: 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 812: 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 813 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 814 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) PA1564...
  • Page 815 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 816 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 817: Common Fiberglass Repair Procedure

    Section 18: BODY COMMON FIBERGLASS REPAIR If part is warped from original shape, use clamping equipment to straighten the surface. PROCEDURE 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 818: 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 819: 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 820: Painting

    Section 18: BODY If you sand through to metal surface, first prime 5.3.1 Safety with Standox “Etch Primer (ST-11858)” then with Care should be exercised in storing, handling, Standox “Non Stop Fill Primer (ST-11000)”. mixing, and applying paint and chemicals listed in this manual.

  • Page 821: 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 822: Zone 1

    Section 18: BODY ZONE 1 FIGURE 10: 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 823: 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 824: Windshield Wipers

    Section 18: BODY adjustment, then push down on either of the NOTE 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 825 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 •...

  • Page 826: 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 827: Front Electrical & Service Compartment Door

    Section 18: BODY Separate body panel from door. gluing front electrical & service compartment door horizontal finishing molding, Remove from door surface Sika bead and refer to procedure SAV00213 included at the double-face self adhesive tape residue end of this section. using a razor sharp window scraper.

  • Page 828: Front Cap

    It is held in place with adhesive. If ever it has to be replaced, make an appointment at a Prevost service center near you. For minor damages, refer to paragraph 4 "Common Fiberglass Repair procedure"...

  • Page 829: Electric Awning Windows

    Section 18: BODY Cut Sika bead until you come back to All these procedures are included at the end of starting point, then you can remove the this section. window by carefully pushing it out from the inside of vehicle. 6.2.3 Electric Awning Windows The electric awning windows are connected...
  • Page 830 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 18: ELECTRIC AWNING WINDOW EXPLODED VIEW (FRAME) 18586 Actuators Horizontal latch handle Latch guide Proximity sensor Relay...
  • Page 831 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 832: 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 833 Section 18: BODY FIGURE 21: REMOVING THE SASH 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 22) FIGURE 22: 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 834 Section 18: BODY Lower Cam Sash Stop Follower FIGURE 23: PROPER ALIGNMENT 2. Position the left hand lower corner of the sash over the front cam follower block (Figure 24) FIGURE 24: POSITIONING THE LOWER LEFT CORNER OF THE SASH 3.

  • Page 835: Zone 3

    Section 18: BODY Correct Position Incorrect Position FIGURE 25: 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 836: 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. 27) holding the appropriate support. hinge to the vehicle structure to shift the door "UP or DOWN".

  • Page 837: Zone 4

    Section 18: BODY ZONE 4 FIGURE 29: 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 838: Engine Radiator Door

    Section 18: BODY To adjust the latch mechanism (3, Fig. 30) 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 839: 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. 32) and closes properly. It may be necessary to the striker pin: adjust the door latch to get proper fit and operation.

  • Page 840: 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 841: 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 842 Section 18: BODY For the installation of evaporator compartment Check that the door swings freely and door body panel, refer to procedure SAV00133 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 843 Section 18: BODY ZONE 7 FIGURE 41: 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 844 Section 18: BODY structure preparation before CAUTION installation of a ridged side panel, refer to procedure SAV00027 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 SAV00028 included at the end of this panels.
  • Page 845 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 43: 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 846 Section 18: BODY 6.10 BODY PANEL AND WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE-OUT FIGURE 44: BODY PANEL & WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE-OUT PA1564...
  • Page 847 Section 18: BODY 6.11 BODY PANEL AND WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE-OUT FIGURE 45: BODY PANEL & WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE-OUT PA1564...
  • Page 848 Section 18: BODY WE MTH EXTERIOR FINISHING AND BODY REPAIR FIGURE 46: WE MTH ZONING ZONE 1 FIGURE 47: ZONE 1 7.1.1 Front Bumper The front bumper can be tilted downward to give access to the bumper compartment. Pull the release handle located inside front service compartment to unlock.
  • Page 849 Section 18: BODY For gluing of front bumper panel refer to procedure SAV00198 included at the end of this section. 7.1.2 Front Crest Use a Chix cloth and anti-silicone to clean the surface where the crest will be applied. CAUTION Do not exceed the crest dedicated surface.
  • Page 850 Section 18: BODY 7.1.3 Headlights Assembly Refer to Paragraph 9.1 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 851 Section 18: BODY Mirror Control 7.1.5 Windshield Wipers Refer to Paragraph 23.7 Windshield Wipers and The remote control pointer knob(s) for the Washers, included in Section 23: Accessories of mirrors is (are) mounted on the L.H. side control Maintenance Manual complete panel.
  • Page 852 Section 18: BODY Spray rubber seal with soapy water to Spray filler and rubber seal groove ease windshield insertion. generously with soapy water. Insert rope into rubber extrusion leaving Using the special filler insertion tool, insert enough length at each corner to make a the filler into the rubber seal groove.
  • Page 853 Section 18: BODY Front Face Molding Removal 7.1.8 Entrance Door 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 854 It is held in place with adhesive. If ever it has to be For the removal of driver’s window or upper replaced, make an appointment at a Prevost lateral window, you will need: service center near you. For minor damages, refer to paragraph 4 "Common Fiberglass...
  • Page 855 Section 18: BODY ZONE 2 FIGURE 54: ZONE 2 This procedure requires accuracy and it is 7.2.1 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- SAV00035 included at the end of this section.
  • Page 856 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 SAV00038 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 857 Section 18: BODY 5. Check that the doors swing freely and close CAUTION properly. It may be necessary to adjust the door latch to get proper fit and operation. Do not damage painted surface. To adjust the latch mechanism (4, Fig. 56) and Use a second person equipped with a pair the striker pin: of locking pliers to pull the body panel as...
  • Page 858 Section 18: BODY ZONE 4 FIGURE 58: ZONE 4 7.4.1 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 859 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 SAV00210 included at the end of this section.
  • Page 860 Section 18: BODY 7.5.1 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 861 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 64: CONDENSER DOOR For the installation of condenser compartment door body panel, refer to procedure SAV00131 included at the end of this section.
  • Page 862 Section 18: BODY For the installation of evaporator compartment Check that the door swings freely and door body panel, refer to procedure SAV00133 closes properly. included at the end of this section. 7.5.4 Fuel Filler Door Open the fuel filler door. Loosen the screws holding the panel to hinge assembly.
  • Page 863 Section 18: BODY ZONE 7 FIGURE 68: ZONE 7 7.7.1 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 864 Section 18: BODY Installation Procedures SMOOTH SIDE PANEL – STRUCTURE PREPARATION SAV00072 SMOOTH SIDE PANEL – INSTALLATION SAV00073 ENGINE AIR INTAKE PANEL - GLUING SAV00074 SMOOTH SIDE PANEL – FINISHING JOINT SAV00075 SMOOTH SIDE PANEL – GLUING MOLDINGS SAV00214 SMOOTH SIDE PANEL – REAR MOLDING GLUING SAV00215 SMOOTH SIDE PANEL –...
  • Page 865 Section 18: BODY BODY PANEL AND WINDOW SPACING FOR WE MTH FITTED WITH SLIDE-OUT FIGURE 70: BODY PANEL & WINDOW SPACING FOR WE MTH FITTED WITH SLIDE-OUT PA1564...
  • Page 866 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 867 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 76: JACKING POINTS ON TAG AXLE...
  • Page 868 Section 18: BODY LIFTING AND TOWING 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 869 MEMORANDUM SEALANT / GLUING PRODUCT PROCEDURE NO: SAV000001 REVISION 14 2006-06-09 GLUING PROCEDURE (QUALIFIED PERSONNEL ONLY) DISCARD WEAR WEAR AS PER P908 GLOVES SAFETY GLASSES Page 1 of 10...
  • Page 870 PROCEDURE NO: SAV000001 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 871 PROCEDURE NO: SAV000001 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 872 PROCEDURE NO: SAV000001 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 873 PROCEDURE NO: SAV000001 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 874 PROCEDURE NO: SAV000001 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 875 PROCEDURE NO: SAV000001 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 876 PROCEDURE NO: SAV000001 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 877 PROCEDURE NO: SAV000001 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 878 PROCEDURE NO: SAV000001 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 879 MEMORANDUM SEALANT/GLUE APPLICATION PROCEDURE NO: SAV000001A 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 880 PROCEDURE NO: SAV000001A 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 881 PROCEDURE NO: SAV000001A 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 882 PROCEDURE NO: SAV000001A 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 883 SAV00027 RIDGED SIDE PANEL – STRUCTURE PREPARATION Effective: 9052 REVISION 01 LVA077 Spec 15.0 DATE 06-09-19 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 884 PROCEDURE NO: SAV00027 REVISION 01 1.05 Structure Cleaning A) Clean using anti-silicone Use white clothes #684009 for vertical backers. B) Apply 3/4" wide masking tape in the center of vertical backers. - Make sure that grit blasting is uniform on the whole surface.
  • Page 885 PROCEDURE NO: SAV00027 REVISION 01 1.10 Apply foam tape 1/8 x 1/4 in the center of side panel horizontal supports and at each end if needed. Page 3 of 3...
  • Page 887 SAV00028 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 888 PROCEDURE NO: SAV00028 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 889 PROCEDURE NO: SAV00028 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 890 PROCEDURE NO: SAV00028 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 891 SAV00029 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 892 PROCEDURE NO: SAV00029 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 893 PROCEDURE NO: SAV00029 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 894 PROCEDURE NO: SAV00029 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 895 PROCEDURE NO: SAV00029 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 896 PROCEDURE NO: SAV00029 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 897 PROCEDURE NO: SAV00029 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 898 PROCEDURE NO: SAV00029 REVISION 00 Junction Panel 4-5 Junction Panel 5-7 Junction Panel 7-8 Junction Panel 2-3 Page 8 of 9...
  • Page 899 PROCEDURE NO: SAV00029 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 901 SAV00030 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 903 SAV00031 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 SAV000001, Section A) B) Normally in the center of the junction panel, there is a ¾”...
  • Page 905 SAV00035 STRUCTURE PREPARATION Spec 15.0 Effective: 9082 REVISION 01 LVA077 DATE 06-10-11 A) Clean structure using anti-silicone. 1.00 (See SAV000001, Section A) B) Sand structure using Scotchbrite. (See SAV000001, Section G) Page 1 of 2...
  • Page 906 PROCEDURE NO: SAV00035 REVISION 01 C) Clean structure and window frames using anti- silicone. (See SAV000001, Section A) D) Apply Sika 206G+P onto structure and window frames. (See SAV000001, Section D) EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGES...
  • Page 907 SAV00036 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 908 PROCEDURE NO: SAV00036 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 909 SAV00037 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 911 SAV00038 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 912 PROCEDURE NO: SAV00038 REVISION 00 1.05 Interior of Frame Preparation (powder paint) A) Clean using anti-silicone. (See SAV000001, Section A) B) Apply Sika Aktivator. (See SAV000001, 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 913 PROCEDURE NO: SAV00038 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 914 PROCEDURE NO: SAV00038 REVISION 00 Section 2 Sliding Window Installation 2.00 Interior of Frame Preparation (powder paint) A) Clean using anti-silicone. (See SAV000001, Section A) B) Apply Sika Aktivator. (See SAV000001, Section C) 2.05 Apply Sika 252 onto structure and onto 2 welding joints in the lower bottom corners.
  • Page 915 PROCEDURE NO: SAV00038 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 917 UPPER SIDE PANEL SAV00041 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 SAV000001, Section A) Apply 206 G+P primer. (See SAV000001, Section D) Apply Sika 221 black + Booster onto structure. 1.05 Triangular bead at the top (Use the applicator) = 25mm x 15mm...
  • Page 918 PROCEDURE NO: SAV00041 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 919 PROCEDURE NO: SAV00041 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 921 SAV00043 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 SAV000001, Section A and/or use a scraper to remove glue residue.
  • Page 922 PROCEDURE NO: SAV00043 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 923 PROCEDURE NO: SAV00043 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 925 SAV00044 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 926 PROCEDURE NO: SAV00044 REVISION 00 Slide-out Page 2 of 2...
  • Page 927 SAV00045 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 SAV000001, Section A) B) Apply Sika Aktivator. (See SAV000001, Section C) 1.05 Half-Window Preparation...
  • Page 928 PROCEDURE NO: SAV00045 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 929 PROCEDURE NO: SAV00045 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 931 LATERAL FIXED WINDOW BEHIND DRIVER SAV00046 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 SAV000001, Section A before proceeding with steps A) & B). A) Clean using glass cleaner.
  • Page 933 SAV00072 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 SAV000001, Section A) Sand using belt sander (See SAV000001, Section G) Sand using “grit coarse belt”. Change paper on a regular basis. Clean using anti-silicone (See SAV000001, Section A) Apply Sika 205.
  • Page 935 SAV00073 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 SAV000001, Section A) B) Sand using belt sander (See SAV000001, Section G) Sand using “grit coarse belt”.
  • Page 936 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 SAV000001 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 937 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 938 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 939 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 941 SAV00074 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 942 PROCEDURE NO: SAV00074 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 943 SAV00075 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 945 SAV00131 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 947 SAV00133 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 SAV000001, Section A) Apply Sika 205 onto body panel and frame perimeter.
  • Page 948 PROCEDURE NO: SAV00133 REVISION 00 Apply Sika 205 aound the opening in the frame (See SAV000001, 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 949 PROCEDURE NO: SAV00133 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 950 PROCEDURE NO: SAV00133 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 951 PROCEDURE NO: SAV00133 REVISION 00 1.55 E-Coat Upper Body Panel Preparation Clean using anti-silicone. (See SAV000001, Section A) 1.60 S/S Frame Preparation A) Apply masking tape onto hinge B) Clean using anti-silicone. + edge (See SAV000001, Section A) C) Sand using Scotchbrite. (See SAV000001, Section G) D) Clean using anti-silicone.
  • Page 952 PROCEDURE NO: SAV00133 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 953 PROCEDURE NO: SAV00133 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 955 SAV00177 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 956 PROCEDURE NO: SAV00177 REVISION 00 Section 3 Door Structure Sealing 3.00 A) Apply Sika 205 around door handle pipe exterior ends (#1 & #2). (See SAV000001, 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 957 PROCEDURE NO: SAV00177 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 SAV000001, Section B) B) Apply Sika 221.
  • Page 958 PROCEDURE NO: SAV00177 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 959 PROCEDURE NO: SAV00177 REVISION 00 6.05 SS Body Panel Preparation A) Clean using anti-silicone. (See SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 206 G+P. (See SAV000001, Section D) 6.10 E-Coat Body Panel Preparation Clean using anti-silicone.
  • Page 960 PROCEDURE NO: SAV00177 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 961 PROCEDURE NO: SAV00177 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 962 PROCEDURE NO: SAV00177 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 963 PROCEDURE NO: SAV00177 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 964 PROCEDURE NO: SAV00177 REVISION 00 Appendix 1 Replacement/Repair A1.00 Remove part. See SAV000001, Section 2. Preparation and gluing. See SAV000001, Section 2 and/or do procedure again. Page 10 of 10...
  • Page 965 SAV00198 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 SAV000001, Section A) B) Use Scotchbrite to sand frame. (See SAV000001, Section G) C) Clean using anti-silicone.
  • Page 966 PROCEDURE NO: SAV00198 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 967 SAV00208 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 968 PROCEDURE NO: SAV00208 REVISION 00 1.05 Sealing the cavity A) Clean using anti-silicone Section View (See SAV000001, Section A) B) Apply Sika 205. (See SAV000001, 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 969 PROCEDURE NO: SAV00208 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 970 PROCEDURE NO: SAV00208 REVISION 00 Section 2 Corner Molding Gluing 2.00 (S/S) Corner Molding Preparation A) Clean using anti-silicone. (See SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 205. (See SAV000001, Section B) 2.05 Apply Sika 252.
  • Page 971 PROCEDURE NO: SAV00208 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 SAV000001, Section A) B) Sand using orbital sander.
  • Page 972 PROCEDURE NO: SAV00208 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 973 PROCEDURE NO: SAV00208 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 974 PROCEDURE NO: SAV00208 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 975 PROCEDURE NO: SAV00208 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 977 SAV00210 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 SAV000001 section A) B) Sand using Scotchbrite. CHALK LINE (See SAV000001, Section G) C) Clean using anti-silicone...
  • Page 978 PROCEDURE NO: SAV00210 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 979 SAV00211 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 (SAV000001 Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone (SAV000001 Section A) D) Apply Sika 205 (SAV000001 Section B) Door Preparation (Primer)
  • Page 980 PROCEDURE NO: SAV00211 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 981 SAV00212 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 982 PROCEDURE NO: SAV00212 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 983 SAV00213 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 SAV000001, Section A) B) Use Scotchbrite to sand molding. (See SAV000001, Section G) C) Clean using anti-silicone.
  • Page 984 PROCEDURE NO: SAV00213 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 985 SAV00214 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 986 PROCEDURE NO: SAV00214 REVISION 00 1.15 Front Fender Preparation (SS) A) Clean using anti-silicone. (See SAV000001, Section A) B) Sand using a Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 205. (See SAV000001, Section B) Front Fender Preparation (E-coat) Clean using anti-silicone.
  • Page 987 PROCEDURE NO: SAV00214 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 989 SAV00215 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 990 PROCEDURE NO: SAV00215 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 991 SAV00216 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 993 SAV00217 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 SAV00216. Clean using anti-silicone. (See SAV000001, Section A) Sand using a Scotchbrite.
  • Page 994 PROCEDURE NO: SAV00217 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 995 SAV00220 SMOOTH SIDE PANEL – CUTTING HORIZONTAL FINISHING MOLDING AT SLIDE- OUT LEVEL MTH 9090 L00015 REVISION 00 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 997 ENTRANCE DOOR ASSEMBLY PROCEDURE (MTH) PROCEDURE NO: SAV280020 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 998 PROCEDURE NO: SAV280020 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 SAV000001, Section A) 2.05 Window Preparation A) Clean using glass cleaner.
  • Page 999 PROCEDURE NO: SAV280020 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 1000 PROCEDURE NO: SAV280020 REVISION 14 2.25 Fiberglass Preparation (LPLT) A) Sand using Scotchbrite. (See SAV000001, Section G) B) Clean using tack cloth C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 206 G+P. (See SAV000001, Section D) 2.30 Fiberglass Preparation (beige primer) A) Sand using Scotchbrite.
  • Page 1001 PROCEDURE NO: SAV280020 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 1002 PROCEDURE NO: SAV280020 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 1003 PROCEDURE NO: SAV280020 REVISION 14 3.05 Steel Sheet Preparation (SS) A) Clean using anti-silicone. (See SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 205. (See SAV000001, Section B) 3.10 Affix double-face self adhesive tape (1/16 x ½) 3mm from panel edge.
  • Page 1004 PROCEDURE NO: SAV280020 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 1005 PROCEDURE NO: SAV280020 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 1006 PROCEDURE NO: SAV280020 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 1007 PROCEDURE NO: SAV280020 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 1008 PROCEDURE NO: SAV280020 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 SAV000001, 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 1009 PROCEDURE NO: SAV280020 REVISION 14 4.70 Water Deflector Gluing A) Use Scotchbrite to sand fiberglass panel and deflector bonding surfaces. (See SAV000001 section G) B) Clean bonding surfaces using anti-silicone. (See SAV000001, Section A) C) Apply double face self adhesive tape 1/8 x 1/4 onto deflector.
  • Page 1010 PROCEDURE NO: SAV280020 REVISION 14 4.80 Membrane Installation Clean door frame where membrane will be glued, using anti-silicone. (See SAV000001, 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 1011 PROCEDURE NO: SAV280020 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 1012 PROCEDURE NO: SAV280020 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 1013 PROCEDURE NO: SAV280020 REVISION 14 5.07 A) Clean using anti-silicone the area to be sealed. (See SAV000001, 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 1014 PROCEDURE NO: SAV280020 REVISION 14 Section 6 Replacement / Repair 6.00 Remove part. See SAV000001, Section 2. Preparation and gluing. See SAV000001, Section 2 and/or do procedure again. Page 18 of 18...
  • Page 1015 FRONT ELECTRICAL & SERVICE COMPARTMENT DOOR ASSEMBLY PROCEDURE NO: SAV280021 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 1016 PROCEDURE NO: SAV280021 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 SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone.
  • Page 1017 PROCEDURE NO: SAV280021 REVISION 18 1.20 Window Frame Preparation Clean using anti-silicone bonding area (top and edges) (See SAV000001, 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 1018 PROCEDURE NO: SAV280021 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 1019 PROCEDURE NO: SAV280021 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 1020 PROCEDURE NO: SAV280021 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 1021 PROCEDURE NO: SAV280021 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 1022 PROCEDURE NO: SAV280021 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 SAV000001, 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 1023 PROCEDURE NO: SAV280021 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 1024 PROCEDURE NO: SAV280021 REVISION 18 Section 3 Gluing of SS Body panels 3.00 * Fiberglass Preparation (LPLT) A) Sand using Scotchbrite. (See SAV000001, Section G) B) Clean using anti-silicone. (See SAV000001, Section A) C) Apply Sika 206 G+P. (See SAV000001, Section D) 3.05 Body Panels Preparation (S/S) A) Cut and remove from the appropriate areas on...
  • Page 1025 PROCEDURE NO: SAV280021 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 1026 PROCEDURE NO: SAV280021 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 1027 ENTRANCE DOOR OR FRONT ELECTRICAL & SERVICE COMPARTMENT DOOR INSTALLATION PROCEDURE PROCEDURE NO: SAV280022 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 1028 PROCEDURE NO: SAV280022 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 1029 PROCEDURE NO: SAV280022 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 SAV000001, Section A) B) Apply Sika 205. (See SAV000001, 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 1030 PROCEDURE NO: SAV280022 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 1031 PROCEDURE NO: SAV280022 REVISION 10 Section 6 Collage du cache penture intérieur 6.00 Interior Hinge Cover Preparation (ABS) Clean using anti-silicone. (See SAV000001, Section A) Apply Sika 215. (See SAV000001, Section D) 6.05 Hinge Preparation (E-Coat) Clean using anti-silicone. (See SAV000001, Section A) 6.10 Apply Sika 252 black.
  • Page 1033 ENGINE COMPARTMENT DOOR BODY PANEL INSTALLATION PROCEDURE NO: SAV280032 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 1034 PROCEDURE NO: SAV280032 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 1035 PROCEDURE NO: SAV280032 REVISION 4 1.10 Door Preparation Painted door (clear coat of polyurethane) Clean using anti-silicone See SAV000001 section A. Primed door (beige primer) Sand using Scotchbrite See SAV000001 section G. Clean using anti-silicone See SAV000001 section A. 1.15 Install double-face self...
  • Page 1036 PROCEDURE NO: SAV280032 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 1037 PROCEDURE NO: SAV280032 REVISION 4 Appendix 1 Replacement A1.00 Remove body panel A1.05 See SAV000001 section 2. A1.10 For gluing procedure, refer to section 1. Page 5 of 5...
  • Page 1039 DRIVER’S WINDOW GLUING PROCEDURE PROCEDURE NO: SAV290013 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 1040 PROCEDURE NO: SAV290013 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 SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone.
  • Page 1041 PROCEDURE NO: SAV290013 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 1042 PROCEDURE NO: SAV290013 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 1043 PROCEDURE NO: SAV290013 REVISION 22 Section 3 Finishing Joint (esthetic) 3.00 * See SAV000001A section 3 for details of finishing joint A) Apply Sika 205 into cavity. (See SAV000001, Section B) B) Fill cavity with Sika 255 Appendix 1 Replacement/Repair A1.00 Remove part.
  • Page 1045 FRONT FACE UPPER LATERAL WINDOWS GLUING PROCEDURE PROCEDURE NO: SAV290016 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 1046 PROCEDURE NO: SAV290016 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 SAV000001 section D.
  • Page 1047 PROCEDURE NO: SAV290016 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 1048 PROCEDURE NO: SAV290016 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 1049 PROCEDURE NO: SAV290016 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 1050 PROCEDURE NO: SAV290016 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 SAV000001, Section 2. Preparation and gluing.
  • Page 1051 FRONT FENDER BODY PANEL PROCEDURE NO: SAV470024 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 1052 PROCEDURE NO: SAV470024 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 1053 PROCEDURE NO: SAV470024 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 1054 PROCEDURE NO: SAV470024 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 1055 PROCEDURE NO: SAV470024 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 1056 PROCEDURE NO: SAV470024 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 1057 PROCEDURE NO: SAV470024 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 1058 PROCEDURE NO: SAV470024 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 1059 REAR FENDER BODY PANEL PROCEDURE NO: SAV470046 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 1060 PROCEDURE NO: SAV470046 REVISION 5 Section 1 S/S Structure Preparation A) Clean using anti-silicone. 1.00 (See SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 206 G+P. (See SAV000001, Section D) Section 2 E-Coat (black) Body Panel Preparation Clean using anti-silicone.
  • Page 1061 PROCEDURE NO: SAV470046 REVISION 5 Section 3 S/S Body Panel Preparation A) Clean using anti-silicone. 3.00 (See SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 206 G+P. (See SAV000001, Section D) 3.05 Apply double-face self adhesive tape 1/16 x 1/2 6mm from panel edges and remove protective tape...
  • Page 1062 PROCEDURE NO: SAV470046 REVISION 5 Section 4 Docking Lamp casing Preparation 4.00 * SMC Lamp Casing Preparation A) Sand using Scotchbrite. (See SAV000001, Section G) B) Clean using anti-silicone. (See SAV000001, Section A) C) Apply Sika 206 G+P. (See SAV000001, Section D) 4.10 Apply double-face self adhesive tape 1/16 x 1/2.
  • Page 1063 PROCEDURE NO: SAV470046 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 1065 S/S FRONT FACE BODY PANEL GLUING PROCEDURE PROCEDURE NO: SAV470047 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 1066 PROCEDURE NO: SAV470047 REVISION 3 1.00 Check condition of panels. 1.05 S/S Panel Preparation Bottom A) Clean using anti-silicone. (See SAV000001, Section A) B) Sand using Scotchbrite. (See SAV000001, Section G) C) Clean using anti-silicone. (See SAV000001, Section A) D) Apply Sika 205. (See SAV000001, Section B) 1.10 * Fiberglass Preparation...
  • Page 1067 PROCEDURE NO: SAV470047 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 1068 PROCEDURE NO: SAV470047 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 1069 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS HEATING AND AIR CONDITIONING....................4 AIR CIRCULATION WITH CENTRAL HVAC SYSTEM ............... 4 ’ ..........................4 RIVER ............................. 4 ABIN AIR CIRCULATION WITH SMALL HVAC SYSTEM ................4 SMALL HVAC SYSTEM OPERATION ....................5 CENTRAL HVAC SYSTEM OPERATION ....................
  • Page 1070 Section 22: HEATING AND AIR CONDITIONING 9.3.1 Removal ..........................23 9.3.2 Installation ..........................23 9.3.3 Checking Operation of Brush in Holder ................23 9.3.4 Brush Wear Inspection and Replacement ................24 9.3.5 Seating Brushes ........................24 9.3.6 Brush Holder Adjustment ...................... 25 9.3.7 Checking Commutator......................
  • Page 1071 Section 22: HEATING AND AIR CONDITIONING SPECIFICATIONS ........................... 52 ILLUSTRATIONS ’ ..........................4 IGURE DRIVER S AIR CIRCULATION ........................4 IGURE CABIN AREA RECIRCULATION DAMPER ......................5 IGURE CENTRAL HVAC SYSTEM AIR CIRCULATION .......................5 IGURE SMALL HVAC SYSTEM CONTROL MODULE ......................5 IGURE CENTRAL HVAC SYSTEM CONTROL MODULE ..........................6 IGURE EVAPORATOR COMPARTMENT...
  • Page 1072 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 1073 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 1074 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 1075 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 1076 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 1077 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 1078 Section 22: HEATING AND AIR CONDITIONING NOTE When performing an A/C cooling test and having the water pump shut off in switch/sensor test When starting the A/C compressor wait 5 mode is required, just set the passenger set seconds before checking pressures in order to point temperature to the minimum 64°F (18°C) give the system a chance to build its pressure.
  • Page 1079 Section 22: HEATING AND AIR CONDITIONING 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 on L.H. side of by playing with the cabin set point. Set above sensor located 22°C (72°F) to heat and below 22°...
  • Page 1080 Section 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions Select FAULT DIAGNOSTIC ELECTRICAL SYSTEM. The message “Voltage Module A52, Value too Low, Active” confirms a power problem on the module Check / reset circuit breaker CB7 Check / replace fuse F65 Evaporator fan not Circuit breaker CB4 tripped Check / reset circuit breaker CB4...
  • Page 1081 Section 22: HEATING AND AIR CONDITIONING The refrigeration load is not constant and varies. It is also affected by outside WARNING temperature, relative humidity, passenger load, compressor speed, the number of stops, etc. One of the most important precautions when handling refrigerant consists in protecting the compressor will...
  • Page 1082 Section 22: HEATING AND AIR CONDITIONING 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 1083 Section 22: HEATING AND AIR CONDITIONING FIGURE 16: REFRIGERANT CIRCUIT (CENTRAL SYSTEM) 22247 PA1564...
  • Page 1084 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 1085 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 1086 Section 22: HEATING AND AIR CONDITIONING FIGURE 17: DOUBLE SWEEP EVACUATION SET-UP PA1564...
  • Page 1087 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 1088 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 1089 Section 22: HEATING AND AIR CONDITIONING 9.1.4 Longitudinal Compressor Alignment NOTE 1. Rest an extremity of a straight edge of Both belts must always replaced approximately 46 inches (117 cm) against simultaneously to ensure an equal distribution the upper part of the outer face of crankshaft of load on each of them.
  • Page 1090 Section 22: HEATING AND AIR CONDITIONING Even cylinder head temperature. Cause: Improperly torqued cylinder head bolts. Improperly positioned gasket at assembly. Warped cylinder head. Severe liquid refrigerant floodback. Blown Valve Plate Gaskets Symptom: Loss of unit capacity at medium and low temperatures.
  • Page 1091 Section 22: HEATING AND AIR CONDITIONING Cause: Unloader body stem bent. Foreign material binding unloader piston or plunger. MAGNETIC CLUTCH Refer to Carrier service information entitled “Housing-Mounted Electric Clutch” at the end of this section for the description and maintenance of the magnetic clutch.
  • Page 1092 Section 22: HEATING AND AIR CONDITIONING For best results, remove oil and grease from commutator before applying brush seater. Grinding is generally done on the machine itself, in accordance with various processes' and conformably to the importance and the type of machines: a) Grinding with...
  • Page 1093 Section 22: HEATING AND AIR CONDITIONING CAUTION CAUTION If grinding with a honing stone, you must After grinding with the sandpaper or the disconnect the time delay in order to keep the honing stone, it is necessary to remove the motor in 1 speed.
  • Page 1094 Section 22: HEATING AND AIR CONDITIONING (3/8 inch) between the brush face and a 9.4.1 Condenser Fan Motors reference line passing through the center of Two fan motors (Fig. 31), 28.5 V - (0.6 HP - 0.42 the 2 bolts on the motor housing. kW) and cages are installed in the condenser compartment on R.H.
  • Page 1095 Section 22: HEATING AND AIR CONDITIONING Unscrew the flange retaining screws on the shaft end side (opposite to the commutator end frame), and separate flange from frame (Fig. 31). Remove flange and armature assembly by pushing bearing shaft toward commutator end frame. Separate flange from armature.

  • Page 1096: Valve

    Section 22: HEATING AND AIR CONDITIONING COLOR INDICATOR LIGHT BLUE PINK TEMPERATURE VIOLET (ppm) (ppm) (ppm) 75°F (24°C) Below 5 5-15 Above 15 100°F (38°C) Below 10 10-30 Above 30 125°F (52°C) Below 15 15-45 Above 45 p.p.m.= parts per million (moisture content) Since temperature changes affect the solubility, color change will also vary with the refrigerant temperature.
  • Page 1097 Section 22: HEATING AND AIR CONDITIONING Carefully lift the bonnet assembly off (upper EXPANSION VALVE part of the valve) so that plunger will not fall out. The diaphragm can now be lifted out. 9.8.1 Cabin HVAC Unit The expansion valve for the cabin HVAC unit is NOTE a thermo-sensitive valve with a remote control The above procedure must be followed before...
  • Page 1098 Section 22: HEATING AND AIR CONDITIONING F (-11.1 to -8.8 C) of superheat at the increases due to the continued absorption of evaporator outlet. heat from the surrounding atmosphere. The degree which refrigerant This ensures that the refrigerant leaving the superheated is related to the amount of evaporator is in a completely gaseous state refrigerant being fed to the evaporator and the...
  • Page 1099 Section 22: HEATING AND AIR CONDITIONING pressures table (page 35). Likewise check Example: Suction pressure 30 psi (207 kPa) the temperature reading at the remote bulb converted to 32 F (0 C) on chart. If temperature at the same 2-minute intervals and record reading is 40 F (4,4 C), subtract 32...
  • Page 1100 Section 22: HEATING AND AIR CONDITIONING TROUBLESHOOTING 9.9.1 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 1101: Valve

    Section 22: HEATING AND AIR CONDITIONING 9.9.2 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 1102 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 1103: Temperatures & Pressures

    Section 22: HEATING AND AIR CONDITIONING 9.10 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 1104: Torch Brazing

    Section 22: HEATING AND AIR CONDITIONING VAPOR-PRESSURE TEMPERATURE PRESSURE °F °C 87.8 433.6 2989.7 93.3 485.0 3344.1 98.9 540.3 3725.4 9.11 TORCH BRAZING Adjust flame so that the top of the cone is approximately level or within one-half inch Use an electrode containing 35% silver. above the plate.

  • Page 1105: Oil Addition

    Section 22: HEATING AND AIR CONDITIONING 10.2.2 When the compressor is inoperable Remove the hoses. Evacuate the system (Refer to paragraph 10.3 OIL ADDITION 10.2.3). The chart below shows the approximate amount Slacken bolts A (Refer to figure 38). of oil to be added to the system when replacing a component.
  • Page 1106 Section 22: HEATING AND AIR CONDITIONING FIGURE 39: REFRIGERANT CIRCUIT (SMALL SYSTEM) 22350 PA1564...

  • Page 1107: Central Heating System

    Section 22: HEATING AND AIR CONDITIONING 11. HEATING SYSTEM As seen earlier in this section, the vehicle interior is pressurized by its Heating, Ventilation and Air Conditioning (HVAC) system. Two heating systems are available: Central Heating System and Small Heating System. The vehicle interior should always be slightly pressurized to prevent cold and moisture from entering.
  • Page 1108 Section 22: HEATING AND AIR CONDITIONING FIGURE 42: CENTRAL HEATING SYSTEM COMPONENTS 22338 PA1564...
  • Page 1109 Section 22: HEATING AND AIR CONDITIONING FIGURE 43: 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 1110 Section 22: HEATING AND AIR CONDITIONING 11.1.4 Soldering The driver’s heater water valve requires a minimum amount of maintenance. The valve Before soldering any part of the system, make should be free of dirt sediment that might sure the area is well ventilated. Use (stay clean) interfere with operation.
  • Page 1111 Section 22: HEATING AND AIR CONDITIONING 2. Check that there is no restriction to the air escaping from actuator casing. 3. Make sure that pilot solenoid valve operates properly. 11.1.6 Central Hot Water Pneumatic Valve Assembly Description The flow of hot water to the vehicle's central heater core is controlled by a 3-way pneumatic water valve assembly.
  • Page 1112 Section 22: HEATING AND AIR CONDITIONING Pneumatic Water Valve Disassembly a) Shut off air supply pressure and electrical current pilot solenoid valve. Disconnect wires. b) The water valve need not be removed from the line. Unscrew nipple, the actuator casing, tube, spindle and closure member can be removed (Fig.
  • Page 1113 Section 22: HEATING AND AIR CONDITIONING 11.1.7 Water Recirculating Pump b) Close shutoff valves. Refer "05 COOLING" under heading "Draining This vehicle provided with water Cooling System" for location of valves. recirculating pump which is located in the evaporator compartment (Fig. 50). The water c) Disconnect the electrical wiring from the recirculating pump consists of a centrifugal motor.
  • Page 1114 Section 22: HEATING AND AIR CONDITIONING caps properly, thus not providing a good low resistance contact between the terminal and the brush tube. Replace brushes showing evidence of annealed springs. d. Frayed or broken pigtail An improperly installed brush may have the pigtail (shunt) pinched under the terminal or between the coils of the spring.
  • Page 1115 Section 22: HEATING AND AIR CONDITIONING FIGURE 51: 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 PA1564...

  • Page 1116: Small Heating System

    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 1117 Section 22: HEATING AND AIR CONDITIONING FIGURE 52: CEILING OF THE SPARE WHEEL COMPARTMENT FIGURE 53: HEATER LINE SHUTOFF VALVES (W5) PA1564...
  • Page 1118 Section 22: HEATING AND AIR CONDITIONING FIGURE 54: HEATER LINE SHUTOFF VALVES (WE) PA1564...
  • Page 1119 Section 22: HEATING AND AIR CONDITIONING FIGURE 55: SMALL HEATING SYSTEM COMPONENTS 22337 PA1564...
  • Page 1120 : 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 1121 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..............................Sanden Model..............................SD7H Prevost number........................... 950436 Approved oil .........................
  • Page 1122 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 1123 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 1125 Compressor WORKSHOP MANUAL MODEL 05G TWIN PORT COMPRESSOR 62--11052 Rev A...
  • Page 1126 WORKSHOP MANUAL MODEL 05G TWIN PORT COMPRESSOR...
  • Page 1127 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 1128 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 1129: Paragraph Number Page

    TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY SUMMARY ..............Safety-1 GENERAL SAFETY NOTICES .
  • Page 1130 PARAGRAPH NUMBER Page COMPRESSOR RUNNING GEAR REASSEMBLY ........3.8.1 Seal End Main Bearings .

  • Page 1131: 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 1132 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 1133 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 1134 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 1135 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 1136 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 1137 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 1138 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 1139 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 1140 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 1141 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 1142: Pistons, Rods, And Rings

    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 1143: 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 1144: Bottom Plate, Strainer, And Connecting Rod Caps

    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 1145: 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 1146: 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 1147 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 1148 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 1149 Compressor SERVICE PARTS LIST MODEL 05G TWIN PORT COMPRESSOR 62--11053 Rev B...
  • Page 1150 Service Parts List Model 05G Twin Port Compressor CONTENTS INTRODUCTION ........... . . MODEL CHART .

  • Page 1151: Introduction

    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 1152: 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 1153: 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 1154: 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...
  • Page 1155 COMPRESSOR BASE GROUP - STANDARD (NON-ULTRA) STYLE Item Part Number Description 17-44035-00 Plate, Bottom, Aluminum, (Non-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...

  • Page 1156: Bearing Head And Oil Pump

    BEARING HEAD AND OIL PUMP Item Part Number Description 17-10308-00 Capscrew, Hex Head, 3/8-16 x 1-1/4 Inches Long - SAE Grade 5 17-44137-00 Oil Pump and Bearing Head - Includes: 17-44037-00 Plug, O-Ring, 7/16-20 - Includes: 42-00243-07 O-Ring 17-44139-00 O-Ring, Pump Cover Plate 17-40204-00 Pin, Roll, 1/8 x 1/2 Inch 17-55009-01...

  • Page 1157: Crankshaft, Rod And Piston Group

    CRANKSHAFT, ROD AND PISTON GROUP Flat (Bus) Contoured (Truck/Trailer) Item Part Number Description 17-44045-01 Piston, 05G37 CFM, Flat, Standard - Includes: 17-44045-03 Piston, 05G37 CFM, Flat, .020 Inch Oversize - Includes: 17-44121-01 Piston, 05G41 CFM, Flat, Standard - Includes: 17-44122-01 Piston, 05G41 CFM, Flat, .020 Inch Oversize - Includes: 17-44070-00 Piston, 05G37 CFM, Contoured, Standard - Includes:...

  • Page 1158: Shaft End Group

    SHAFT END GROUP Trailer Clutch Bus Clutch Shaft Mount (If Present) or No Clutch Grease- Groove *NOTE: Early production trailer compressors may have had the snap ring style clutch hub. Should the hub require replacement, it must be converted to the threaded clutch hub (Item 7). Item Part Number Description...

  • Page 1159: Shaft Seal Reservoir And Shaft End Flanges

    SHAFT SEAL RESERVOIR AND SHAFT END FLANGES 11 12 11 12 Item Part Number Description 05GA503-724 Access Valve, Coreless, 7/16-20, With O-Ring 17-44771-00 Reservoir, Shaft Seal 05GA503-734 Washer, Internal Tooth, 3/8 Inch, Plated AA06GS228 Cap Screw, Hex Head, 3/8-16 X 0.75 Inch Long, Grade 8 Gasket, End Flange, Ultra Style or Full Ring Flange (Used With Items 6 17-44119-00 and 7)
  • Page 1160 UNLOADERS Pressure Electric Valve Valve Valve Plug 9,10 COILS 62--11053...
  • Page 1161 UNLOADERS (Continued) Item Part Number Description 17-55018-01 Valve Assembly (Pressure) - Includes: Power Assembly, Unloader (Suction Pressure Activated) Body Assembly, Valve 17-40409-00 Piston, Unloader - Includes: 17-55010-00 Ring, Piston 17-40104-07 Gasket, Unloader Valve 17-40111-00 Screw, Socket Head, 1/4-28 x 3/4 Inch Long 17-40104-20 Gasket, Socket Head Screw, 1/4 Inch 17-55028-00...

  • Page 1162: Valve Plate Assembly

    VALVE PLATE ASSEMBLY CAUTION: The above valve plate can only be used on the Twin Port 05G compressor. It will not function in the previous design (3 port) 05G compressor. Item Part Number Description Valve Plate Assembly, Center or Side Bank With No Unloader - 17-44742-00 Includes: 17-44113-00...

  • Page 1163: Unloader Valve Plate Assembly

    UNLOADER VALVE PLATE ASSEMBLY CAUTION: The above valve plate can only be used on the Twin Port 05G compressor. It will not function in the previous design (3 port) 05G compressor. Item Part Number Description 17-44744-00 Valve Plate Assembly, Side Bank With Unloader - Includes: 17-44113-00 Capscrew, HexHead, 1/4-28 x 3/8 Inch Long 17-10715-00...

  • Page 1164: Cylinder Head (Side)

    CYLINDER HEAD (SIDE) STANDARD SHAVED CYLINDER HEAD UNLOADER CYLINDER HEAD Item Part Number Description 17-44743-00 Cylinder Head, Unloader - Side Banks 17-40108-00 Strainer 17-10224-05 Capscrew, Hex Head, 3/8 -16 x 3-1/4 Inches Long - SAE Grade 8 17-44017-00 Stud, Cylinder Head (Unloader or Center), 3/8 -16 x 4-1/4 Inches Long 17-44753-00 Cylinder Head - Side Banks, Shaved (Standard, No Unloader) 17-44117-00...

  • Page 1165: Gasket Set

    GASKET SET Item Part Number Description 17-44775-00 Gasket Set, Metal - Includes: 17-44141-00 Gasket, Suction Service Valve - 4 Bolt 17-44004-06 Gasket, Shaft Seal 17-44746-00 Gasket, Valve Plate 17-44118-00 Gasket, End Flange 17-44119-00 Gasket, End Flange 17-44129-00 Gasket, Bottom Plate 17-44747-00 Gasket, Cylinder Head, Center or Side Banks 17-44022-00...
  • Page 1166 CLUTCH ASSEMBLY - HOUSING MOUNTED (WARNER - GRAY IN COLOR) COMPRESSOR 12,13,14 Item Part Number Description 76-50013-00 Kit, Conversion Shaft to Housing Mounted Clutch 34-00613-07 Capscrew, Hex Head, 3/8-24 x 7/8 Inch Long - SAE Grade 8 --AU--11AR-241 Washer, Lock, Spring, 3/8 Inch 34-00616-00 Washer, 13/32 ID x 1-1/2 OD x 3/16 Inch Thick 34-01161-00...
  • Page 1167 CLUTCH ASSEMBLY - HOUSING MOUNTED (WARNER - GRAY IN COLOR) - Continued Item Part Number Description 50-01122-07 Clutch, Assembly, 24 VDC, 2-B Grooves, 9 Inch Diameter - Includes: 50-01122-50 Coil, 24 VDC 50-01122-90 Rotor/Armature, 2-B Grooves, 9 Inch Diameter - Includes: 34-01186-00 Ring, Snap 04-00130-00...
  • Page 1168 CLUTCH ASSEMBLY - HOUSING MOUNTED (LINNIG - GOLD IN COLOR) Note: Multiple groove rotor/armature designation describes groove location(s) starting at the compressor side and working out. Example: 3 Grooves 2B/1A shown below. 11,12,13 Item Part Number Description 76-50013-00 Kit, Conversion Shaft to Housing Mounted Clutch 34-50035-00 Ring, Snap 34-50034-00...
  • Page 1169 CLUTCH ASSEMBLY - HOUSING MOUNTED (LINNIG - GOLD IN COLOR) - continued Item Part Number Description 50-00226-19 Clutch Assembly, 24 VDC, 4 Grooves (2B/2A), 10.35 Inch Dia. - Includes: 50-00226-50 Coil, 24 VDC 50-50040-11 Rotor/Armature, 4 Grooves (2B/2A), 10.35 Inch Diameter - Includes: 50-50040-05 Ring, Snap 50-50040-04...

  • Page 1170: Clutch Assembly - Shaft Mounted

    CLUTCH ASSEMBLY - SHAFT MOUNTED COMPRESSOR 5,7,8, Item Part Number Description 34-00613-07 Capscrew, Hex Head, 3/8 UNF x 7/8 Inch Long - SAE Grade 8 --AU--11AR-241 Washer, Lock, Spring, 3/8 Inch 34-00616-00 Washer, 13/32 ID x 1-1/2 OD x 3/16 Inch Thick 17-40037-05 Capscrew, Hex Head, 3/8-16 x 1 Inch Long 62--11053...
  • Page 1171 CLUTCH ASSEMBLY - SHAFT MOUNTED Item Part Number Description 50-01108-00 Clutch, 24 VDC, 2-C Grooves, 9 Inch Diameter 50-01110-00 Clutch, 24 VDC, 3-3V Grooves, 8.48 Inch Diameter 50-01110-01 Clutch, 12 VDC, 3-3V Grooves, 8.48 Inch Diameter 50-01114-00 Clutch, 12 VDC, 2-B Grooves, 8.64 Inch Diameter 50-50011-00 Coil, 24 VDC 50-50014-00...

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