MCi Crusader II 1989 Maintenance Manual page 321

Date
1-1-89
Page ___
9_-1_3 _ _
MC-9 MAINTENANCE MANUAL
If the air cylinder does not function as specified or leakage is
excessive, it is recommended that it be replaced with a new or
remanufactured unit or repaired with OEM parts. (A mainte-
nance kit which contains all necessary parts is available.)
To test the solenoids, a source of power (battery) will be
needed. Check to make certain that the battery voltage is 24
volts.
Connect a 60 psi (414 kPa) air source to the supply port and
install a gauge in the delivery port.
1. With 60 psi (414 kPa) applied to the supply port, apply a
soap solution to the exhaust port. Leakage should not exceed a
1-inch qubble in less than five seconds.
2. Simultaneously, apply positive(+) power to pins 3 and 4,
and negative (-) power to terminals or sockets 1 and 2 (figure
9-18). With power applied note that60 psi (414 kPa) is regis-
tered on the gauge installed in the delivery port.
3. Continue'to apply power (Step 2) and apply a soap solu-
tion to the exhaust port, the exterior of the body and around
solenoid coils. Leakage should not exceed a 1-inch bubble in
less than five seconds at the exhaust port. No leakage is permit-
ted elsewhere.
4. Remove the electrical power from the solenoid sockets, or
pins.
5. Refer to figure 9-18) connect an ohmmeter to:
(a) socket 1 and pin 4 or terminals 1 and 4. Resistance
should be 90-110 ohms.
· (b) Socket 2 and pin 3 or terminal 2 and 3. (Resistance
. should be same as in Step a.)
If the solenoid assembly does not test or function as needed,
or leakage is excessive, it must be replaced.
Perform the following procedure to remove the air cylinder:
1. Park and secure the vehicle by means other than air
brakes on a level surface.
2. Vent air pressure from all reservoirs.
3. Disconnectthe throttle cable assembly atthe engine throt-
tle lever.
SOCKET 2 SOCKET 1
~:: ;a,(
PIN3 PIN4
Figure 9-18. Solenoid Assembly Harness Connector.
4. Unscrew the throttle cable coupling nut on the end of the
air cylinder throttle cylinder body (8 in figure 9-16).
5. Unscrew the cable nut at the end of the piston and rod
assembly (1 ).
6. Disconnect the air inlet line.
7. Disconnect the electrical connector for the potentiometer
assembly (7).
8. Remove the two mounting screws and remove the air
cylinder from the vehicle.
NOTE: A maintenar,ce kit (4G-22-141) con-
taining all parts necessary for minor rebuild
is available.
To disassemble the CC-5 air cylinder, proceed as follows:
1. Remove and discard retaining ring (5).
2. Remove and retain the potentiometer assembly (7).
CAUTION: Do not apply force to end of
potentiometer plunger and spring assembly.
3. Remove and discard O-ring (6) from potentiometer
assembly (7).
4.
Push the piston and rod assembly (1) out of the body (8).
5. Remove and discard O-ring (3) and
wear
ring
(4)
from the
piston assembly (1).
6. Remove and discard O-ring (2) from the air cylinder body
(8). This is an internal O-ring and will require an O-ring removal
tool.
Prior to assembly of the air cylinder, the piston and rod
assembly and the body should be cleaned with mineral spirits.
Make certain the vent holes (9) in the body (8) are open. Using
lubricant 4G-22-140 (Dow Corning 55M furnished in mainte-
nance kit), lubricate all O-rings, O-ring grooves. the piston bore
in the body and the rod of the piston assembly. Then follow this
procedure:
1. Install O-ring (2) in body (8). Be sure O-ring (2) and the
body are
well
lubricated before installing. Bend the O-ring in
half and insert it into the body. Using the "dulled" point of a
wooden pencil, push part of the 0-ring into the groove in the
body (use care notto damage the O-ring). Using the eraser end
of the pencil, push the balance of the O-ring into the body
groove. The O-ring should slide into the groove.
2. Install O-ring i3) and wear ring (4) on piston and rod
assembly (1).
3. Install piston and rod assembly (1) in body (8), taking care
not to damage O-rings {2 and 3).
4.
Install O-ring (6) on potentiometer assembly (7).
5. Install potentiometer assembly (7) in body (8) and install
retaining ring (5). Make sure that retaining ring (5) is completely
seated in its groove in the body (8).
6. Perform operating and leakage tests prior to reinstalling
the air cylinder assembly.
.,