Download Print this page

freightliner Custom Chassis MC Workshop Manual

Recreational vehicle chassis

Table Of Contents

Table of Contents

Advertisement

Quick Links

Download this manual

RECREATIONAL VEHICLE CHASSIS WORKSHOP

MANUAL

Models: MC

MCL

XC

XCF

XCL

XCM

XCP

XCR

XCS

VCL

STI-354, S21 (10/10P)

Daimler Trucks North America LLC

4747 N. Channel Ave.

Portland, OR 97217

Printed in U.S.A.

Published by

Table of Contents

Advertisement

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the Custom Chassis MC and is the answer not in the manual?

Questions and answers

Summary of Contents for freightliner Custom Chassis MC

Page 1 RECREATIONAL VEHICLE CHASSIS WORKSHOP MANUAL Models: MC STI-354, S21 (10/10P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
Page 2: Environmental Concerns And Recommendations
Instructions and procedures are those recommended by Freightliner Custom Chassis Corpora- tion (FCCC) or the component manufacturer. Maintenance schedules and additional service information are included in the Recreational Vehicle Chassis Maintenance Manual .
Page 3 EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and ﬂoating pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro.
Page 4 Introduction Descriptions of Service Publications Warranty-related service information available on the AccessFreightliner.com website includes the following documentation. Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety.
Page 5: Page Description
Introduction Page Description For an example of a Recreational Vehicle Chassis Workshop Manual page, see Fig. 33.01 Front Axle Wheel Hubs and Wheel Bearings General Information General Information 03/10/98 f020074 A. Section Title D. Manual Title B. Section Number (made up of the Group Number— E.
Page 6: Table Of Contents
Introduction Workshop Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .
Page 7: List Of Abbreviations
List of Abbreviations List of Abbreviations The following is a list of deﬁnitions for abbreviations and symbols used in Freightliner publications. A ..amperes BBC ..bumper-to-back-of-cab CUM .
Page 8 HDU ..hybrid drive unit lbf·in ..pounds force inches FAS ..Freightliner air suspension HEPA ..high-efficiency particulate air (ﬁlter)
Page 9 00.01 List of Abbreviations List of Abbreviations LPG ..liquid propane gas NO ..normally open (terminal or POE ..polyol ester switch) LPI .
Page 10 00.01 List of Abbreviations List of Abbreviations SAE ..Society of Automotive TIG ..tungsten inert gas °C ..degrees Celsius (centigrade) Engineers TIR .
Page 11: General Information
00.02 Metric/U.S. Customary Conversion Chart General Information U.S. Customary to Metric Metric to U.S. Customary Multiply Multiply When You Know To Get When You Know To Get Length inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft)
Page 12 Table 1 for the character po- 16 characters. These weighted values are processed sitions of a typical Freightliner Custom Chassis through a series of equations designed to check va- Corporation (FCCC) VIN, 4UZ33FAD3VC345678. lidity of the VIN and to detect VIN alteration.
Page 13 VIN for Vehicles Built through April 30, 2000 VIN Position 4 (Chassis, Front Axle Position, Brakes) VIN Position 5 (Vehicle Model Series, Cab) Front Axle Code Freightliner Custom Chassis Corporation Code Chassis Brakes Position FS65 Chassis (School Bus, front engine)
Page 14 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built through April 30, 2000 VIN Positions 6 and 7 (Engine Manufacturer, Model, Horsepower Range) Code Engine Manufacturer Engine Model HP Range Cummins M11 / ISM 276–335 Cummins M11 / ISM 336–407 Cummins 4B 3.9–130 hp (diesel) 126–152...
Page 15 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built through April 30, 2000 VIN Position 11 (Plant of Manufacture) Code Plant of Manufacture Mercedes-Benz, Mexico, Santiago Mercedes-Benz, Mexico, Monterrey Table 8, VIN Position 11 (Plant of Manufacture) 050/4 Recreational Vehicle Chassis Workshop Manual, Supplement 5, July 2000...
Page 16 VIN de- 6 for a FCCC vehicle indicates an MB45 chassis. ﬁnes the manufacturer, model, and major characteris- Code AB in the same position for a Freightliner ve- tics of the vehicle. See Table 1...
Page 17 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built from May 1, 2000 VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model Class (GVWR) MB45 Chassis None Class 4 † MB45 Chassis None Class 5 ‡ MB55 Chassis None Class 6 §...
Page 18 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built from May 1, 2000 VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model Class (GVWR) ER Rear-Engine Bus Chassis None Class 6 ER Rear-Engine Bus Chassis None Class 7 ER Rear-Engine Bus Chassis None Class 8 XC Chassis...
Page 19 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built from May 1, 2000 VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model Class (GVWR) XCF Formed-Rail Rear-Engine Motor Home Chassis None Class 8 XCM Modular-Rail Rear-Engine Motor Home Chassis None Class 8 XCR Raised-Rail Rear-Engine Motor Home Chassis...
Page 20 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built from May 1, 2000 VIN Positions 5 and 6 (Model, Cab, Class/GVWR) Code Model Class (GVWR) MCL Front-Engine Motor Home Chassis None Class 6 MCL Front-Engine Motor Home Chassis None Class 7 MCL Front-Engine Motor Home Chassis None Class 5...
Page 21 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built from May 1, 2000 VIN Positions 7 and 8 (Engine, Brakes) Displacement: Code Engine Fuel Conﬁguration Brakes Liter Caterpillar 3126/CFE Diesel I–6 Caterpillar 3126/CFE Diesel I–6 Hydraulic Caterpillar 3126/CFE Diesel I–6 Air/Hydraulic Caterpillar C10 Diesel...
Page 22 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built from May 1, 2000 VIN Positions 7 and 8 (Engine, Brakes) Displacement: Code Engine Fuel Conﬁguration Brakes Liter Cummins B8.3 Natural Gas I–6 Cummins B8.3 Natural Gas I–6 Hydraulic Cummins B8.3 Natural Gas I–6 Air/Hydraulic...
Page 23 00.03 Vehicle Identiﬁcation Numbering System VIN for Vehicles Built from May 1, 2000 VIN Positions 7 and 8 (Engine, Brakes) Displacement: Code Engine Fuel Conﬁguration Brakes Liter Cummins ISB Diesel I–6 Cummins ISB Diesel I–6 Hydraulic GM 307 HP Gasoline V–8 Hydraulic Enova 120 KW...
Page 24: Threaded Fasteners
00.04 Threaded Fasteners General Information Threaded Fastener Types The majority of threaded fasteners used throughout the vehicle have U.S. customary threads (diameter and pitch are measured in inches). See Fig. 1. How- ever, the engine may use metric fasteners (diameter and pitch are measured in millimeters).
Page 25: Tightening Fasteners
NOTE: Grade 2 bolts have no grade marking; grade 2 threaded hole, or a nut is tightened to its torque bolts are rarely used by Freightliner.These grade mark- value on a bolt, the shank of the capscrew or bolt is ings are used on plain hex-type and ﬂanged bolts...
Page 26 To ensure they are needed to overcome the friction between the under- always torqued accurately, Freightliner recommends side of the capscrew head or nut and the washer. that all fasteners be lubricated with oil (unless spe- Another 30 to 40 percent is needed to overcome the ciﬁcally instructed to install them dry), then torqued to...
Page 27 00.04 Threaded Fasteners General Information ers. When locking compound or anti-seize compound is recommended for a fastener, the compound acts as a lubricant, and oil is not needed. 050/4 Recreational Vehicle Chassis Workshop Manual, Supplement 22, April 2011...
Page 28: Fastener Replacement
Use stainless steel fasteners against chrome plating, strength, and ﬁnish as originally speciﬁed. See the unpainted aluminum, or stainless steel. Freightliner Service Parts Catalog for fastener speci- ﬁcations. Fastener Tightening When replacing graded (or metric class) bolts and...
Page 29: General Instructions
00.04 Threaded Fasteners General Instructions NOTE: Follow the safety precautions given on the locking compound container. 1. Clean the male and female threads of the fasten- ers, removing all dirt, oil, and other foreign mate- rial. If parts are contaminated, use Stoddard sol- vent for cleaning;...
Page 30: Specifications
652 (884) — — Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed, Geomet 321XL coated, or waxed).
Page 31 1–12 524 (710) 1–14 537 (728) Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. Table 2, Torque Values for Grade 8 Regular Hex Zinc-Yellow Plated Capscrews and Cadmium- and Wax-Coated Prevailing Torque Locknuts 400/2...
Page 32 Male and female threads (bolt and nut) must both be unlubricated and unplated; if either is plated or lubricated, use Table 1 Table 2. Freightliner recom- mends that all plated and unplated fasteners be coated with oil before installation. Table 3, Torque Values for U.S. Customary Thread Fasteners with Dry (unlubricated) Plain (unplated) Threads...
Page 33 M30 x 2 792 (1074) 1096 (1486) Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed, Geomet 321XL coated, or waxed).
Page 34 01.00 Cummins B Series Engine Pulley and Drive Belt Inspection Inspection Check for tensile breaks (breaks in the cord body). Cuts in a belt are usually caused by large foreign objects in the pul- 1. See Fig. 1. Inspect all used drive belts (including ley, or by prying or forcing the belt during those that are being replaced) for the following installation or removal.
Page 35 01.00 Cummins B Series Engine Pulley and Drive Belt Inspection cleaning solvent to remove oils. Use a wire brush to remove rust, and a ﬁle to remove burrs. 4. Inspect the pulleys for wear on the inner walls. Hold a small straightedge against the inside of the pulley walls, or use your little ﬁnger or ﬁnger- nail to ﬁnd grooves in the inner walls.
Page 36: Drive Belt Replacement
01.00 Cummins B Series Engine Drive Belt Replacement Refrigerant Compressor Belt Replacement 1. Loosen the bolt holding the belt tensioner, then swing it down to release the belt tension. 2. Remove the drive belt from the compressor pul- ley and the engine pulley. 3.
Page 37 01.00 Cummins B Series Engine Rear Engine Removal and Installation Removal 20. Disconnect the fuel supply and return lines. 21. Disconnect the throttle cable from the injection 1. Park the vehicle, set the parking brakes, then pump lever. See Fig. chock the tires.
Page 38 01.00 Cummins B Series Engine Rear Engine Removal and Installation 38. Remove the fan from the engine. 39. Remove the engine mount brackets from each side of the bell housing. 40. Lower the engine, then remove it from under- neath the vehicle. 41.
Page 39 01.00 Cummins B Series Engine Rear Engine Removal and Installation 8. Attach the front engine mount to the crossmem- 30. Fill the radiator with coolant. See the chassis ber. maintenance manual for speciﬁcations. Install the two bolts that do not hold the 31.
Page 40 01.01 Jacobs Exhaust Brake Exhaust Brake Removal and Installation Removal 1. Park the vehicle, set the parking brakes, then chock the rear tires. 2. Drain the air tanks. For Instructions, see Group 3. From underneath the vehicle, locate and discon- nect the air line supplying the exhaust brake cyl- inder from the solenoid valve on the crossmem- ber.
Page 41 01.01 Jacobs Exhaust Brake Exhaust Brake Removal and Installation 01/20/98 f011142 1. Exhaust Brake 6. Exhaust Pipe from Turbocharger 11. Safety Clip 2. V-Clamp 7. Washer 12. Capscrew 3. U-Clamp 8. Nut 13. Gasket 4. Exhaust Pipe to Muffler 9. Air Cylinder 14.
Page 42 01.01 Jacobs Exhaust Brake Air Cylinder Replacement Replacement NOTE: The air cylinder is the only replaceable part of the exhaust brake. If there is a problem with any other part, replace the entire exhaust brake assembly. 1. Remove the exhaust brake. See Subject 100 instructions.
Page 43 01.01 Jacobs Exhaust Brake Air Cylinder Replacement 01/20/98 f011142 1. Exhaust Brake 6. Exhaust Pipe From Turbocharger 11. Safety Clip 2. V-Clamp 7. Washer 12. Capscrew 3. U-Clamp 8. Nut 13. Gasket 4. Exhaust Pipe to Muffler 9. Air Cylinder 14.
Page 44 01.02 Caterpillar CFE Engine Engine Removal and Installation, Caterpillar CFE Removal 10. At the fuel/water separator, disconnect the fuel delivery line that runs to the engine. NOTE: For engine wiring diagrams, refer to the 11. Disconnect the transmission shift cable. For in- applicable section in Group 54.
Page 45 01.02 Caterpillar CFE Engine Engine Removal and Installation, Caterpillar CFE 04/14/95 f010929 A. To Cab Studs H. To Back Up Switch Wiring Harness B. To Mag Switch To Neutral Start Switch C. To Fan Clutch Solenoid J. Jumper Assembly D. To Coolant Temperature Switch K.
Page 46 01.02 Caterpillar CFE Engine Engine Removal and Installation, Caterpillar CFE 16.1 With the engine securely supported by the Connect the wiring to the speedometer jack, disconnect the rear engine legs from sensor at the transmission output. the engine mounts on the frame rails. Connect the wiring harness connectors to On each engine leg, remove the nut from the back-up alarm switch and the neutral...
Page 47 01.02 Caterpillar CFE Engine Engine Removal and Installation, Caterpillar CFE 13. Connect the parking brake and shift cables. 14. Fill the radiator. 15. Connect the batteries. 16. From inside the vehicle, close the engine access hatch, then lower the bed. 17.
Page 48: Air Cleaner
09.00 Air Cleaner General Information General Information The air cleaner is horizontally mounted on the out- side of the left frame rail, at the rear of the vehicle. Air enters through the air intake screen and is di- verted into the air cleaner where it passes from the outside to the inside of a replaceable, moisture- resistant, ﬁne-mesh paper air cleaner.
Page 49 09.00 Air Cleaner Air Cleaner Replacement Replacement NOTE: Replace the air cleaner only when it reaches the maximum restriction level allowed by the engine manufacturer. See Fig. 1. See Subject 110. NOTICE Do not operate the engine with the air cleaner or 01/02/98 f090191 any air intake component removed—damage to...
Page 50 09.00 Air Cleaner Air Cleaner Restriction Checking Air Cleaner Restriction Checking H 2 O VACUUM H 2 O VACUUM The restriction of air ﬂowing through the air cleaner is measured at the ﬁtting in the air intake tube between the 90-degree reducing elbow and the 90-degree elbow at the engine turbocharger.
Page 51 09.00 Air Cleaner Farr ECO Air Cleaner Replacement Farr ECO SE Replacement 9. Slide the metal elbow into the molded urethane outlet until the bead is positioned into the groove. (front-mounted) Do not tighten the T-bolt clamp yet. IMPORTANT: If the beaded tube or elbow is not IMPORTANT: If the air cleaner assembly has positioned correctly into the molded urethane been dented or damaged, immediately check all...
Page 52 09.00 Air Cleaner Farr ECO Air Cleaner Replacement 03/05/2008 f090458 1. Air Outlet Clamp 2. Mounting Bracket Clamps 3. Air Inlet Clamp Fig. 2, Farr ECO BC Air Cleaner (rear-mounted) 9. Insert the side outlet tube of the ECO BC in the air outlet rubber connector, being sure the tube is inserted 1-1/4 inch.
Page 53 09.01 Air Intake Ducting General Information General Information An average diesel engine needs over 10,000 gallons (38 000 liters) of clean air for each gallon (3.8 liters) of fuel burned. So that complete combustion occurs in each engine cylinder, more clean air than is needed is present in each cylinder.
Page 54 09.01 Air Intake Ducting Air Intake Ducting, Removal and Installation, Cummins B Series Engine General Information Loosen the hose clamp that attaches the air intake tube to the 90-degree reducing elbow, and remove the air intake tube. WARNING Remove the ﬁtting and hose from the air intake tube.
Page 55 09.01 Air Intake Ducting Air Intake Ducting, Removal and Installation, Cummins B Series Engine f490161 01/14/98 1. Air Intake Ducting 5. Air Intake Tube 8. Fitting 2. Hose Clamp 6. Metal Band 9. Hose 3. Inlet Cap 7. 90-Degree Reducing Elbow 10.
Page 56 09.01 Air Intake Ducting Air Intake Ducting, Removal and Installation, Cummins M11 Series Engine Loosen the hose clamp that secures the WARNING air intake tube to the turbo elbow and re- move the air intake tube. Do not operate the engine with any component of Loosen the hose clamp that secures the the air intake system removed;...
Page 57 09.01 Air Intake Ducting Air Intake Ducting, Removal and Installation, Cummins M11 Series Engine 06/27/2000 f090321 1. Intake Hose Attaches Here 2. Air Cleaner 3. Air Cleaner Outlet Elbow 4. Air Intake Tube 5. Twist Bracket/Cushion Clamp 6. Turbo Elbow 7.
Page 58: Charge Air Cooler
09.02 Charge Air Cooler General Information General Information The charge air cooler (CAC) is attached to the radia- tor, and is similar to the radiator. Outside ambient air passing through the CAC core cools the engine’s intake air charge. Air leaving the turbocharger is compressed, which heats it to about 275°...
Page 59 09.02 Charge Air Cooler Charge Air Cooler, Removal and Installation Removal (Rear-Mounted CAC) to secure the cooler in position when the mount- ing nuts are tightened. 1. Park the vehicle, apply the parking brakes, and 5. Disconnect the upper and lower oil line clamps chock the tires.
Page 60 09.02 Charge Air Cooler Charge Air Cooler, Removal and Installation f090308 12/17/1999 1. Charge Air Cooler (CAC) 4. CAC Mounting Bracket Bolt 2. CAC Mounting Tab 5. Radiator 3. CAC Mounting Bracket Fig. 1, Charge Air Cooler (CAC) Mounting 5. Remove the tie straps temporarily holding the 9.
Page 61 09.02 Charge Air Cooler Charge Air Cooler, Removal and Installation 14. Remove the chocks from the front tires. 100/3 Recreational Vehicle Chassis Workshop Manual, Supplement 5, July 2000...
Page 62: Engine
09.02 Charge Air Cooler Charge Air Cooler Inspection and Leakage Test Inspection 3. Connect the test equipment to the CAC core. Fig. 1. Park the vehicle, apply the parking brakes, and Remove the inlet and outlet air piping from chock the tires. the convoluted hoses that attach them to the CAC air inlet and air outlet.
Page 63: Air Intake
09.02 Charge Air Cooler Charge Air Cooler Inspection and Leakage Test 02/25/98 f090147 1. Safety Chain 5. Thumbscrew 9. CAC Air Outlet 2. Test Plug 6. Safety Ring 10. Test Plug With Adaptor 3. Constant-Torque Hose Clamp 7. CAC Air Inlet 11.
Page 64 09.02 Charge Air Cooler Charge Air Cooler Inspection and Leakage Test 8. Close the access panel, and remove the chocks from the tires. 110/3 Recreational Vehicle Chassis Workshop Manual, Supplement 6, October 2000...
Page 65 09.02 Charge Air Cooler Charge Air Cooler Flushing Charge Air Cooler Flushing If the charge air cooler is suspected of being con- taminated, ﬂush the charge air cooler. 1. Turn off the engine, apply the brakes, and chock the tires. 2.
Page 66 09.02 Charge Air Cooler Charge Air Cooler Restriction Test Restriction Test After ﬂushing the charge air cooler because of turbo- charger or engine damage, test the pressure drop across the charge air cooler and air piping, as fol- lows: 1. Remove the pipe plug from the tapped hole in the turbocharger air outlet elbow.
Page 67: Specifications
09.02 Charge Air Cooler Speciﬁcations Torque Values Torque Torque Description lbf·in (N·cm) lbf·ft (N·m) Charge Air Cooler to Radiator Mounting Bolt 55 (75) Charge Air Cooler Constant-Torque Hose Clamp 72 (813) Hose Clamp 45 (500) Table 1, Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 68: General Description
13.00 Air Compressor, Midland SS191 General Information General Description Cummins B Series engines use the Midland SS191B air-cooled air compressor, an engine-driven, single- piston compressor which supplies compressed air to the vehicle air system. The compressor draws turbo- charged, aftercooled air from the engine manifold. It compresses the air further, and delivers it to the air system supply reservoir.
Page 69: Air Compressor
13.00 Air Compressor, Midland SS191 Air Compressor Removal and Installation Removal Disconnect the air inlet line at the rear of the compressor head. 1. Park the vehicle, apply the parking brakes, and Disconnect the air outlet line from the side chock the tires.
Page 70 13.00 Air Compressor, Midland SS191 Air Compressor Removal and Installation Disconnect the air signal line between the 5. Start the engine, and check for leaks in the com- compressor and the air governor. pressor mounting. Repair any leaks as neces- sary.
Page 71 13.00 Air Compressor, Midland SS191 Speciﬁcations Fastener Torques Description Grade Size Torque lbf·ft (N·m) Air Governor Bracket Bolts 5/16–18 15 (20) Air Compressor Mounting Bolts M12 x 1.75 54 (73) Power Steering Pump Mounting Bolts 3/8–16 28 (38) Table 1, Fastener Torques 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 72: General Information
15.00 Starters, Delco Remy General Information General Information IMPORTANT: On vehicles with automatic trans- missions, be sure the transmission is in NEU- TRAL before attempting to start the engine. The Delco Remy 28–MT starter mounts on the right side of the engine at the forward face of the ﬂywheel To prevent overrun and damage to the drive and ar- bell housing on Cummins B Series engines.
Page 73 15.00 Starters, Delco Remy General Information 06/30/94 f150376a 1. Starter Drive Gear 3. Solenoid Plunger 5. Motor (M) Terminal 2. Shift Lever 4. Battery (B) Terminal 6. Cranking Motor Fig. 2, Starter Components 050/2 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 74 15.00 Starters, Delco Remy Delco Remy Starter Removal and Installation IMPORTANT: Since the engine is located in the rear of the vehicle with the fan pointing back- wards, references to the front of the engine or starter refer to aft on the vehicle. Likewise, ref- erences to the rear of the engine, or back of the starter, refer to forward on the vehicle.
Page 75 15.00 Starters, Delco Remy Delco Remy Starter Removal and Installation 09/05/96 f150601 1. See insert for detail of mounting bolt installation. Fig. 3, Starter Installation Connect the positive battery cable to the Protectant Material Approved Brands batteries. MMM 1602 IVI–Spray Sealer, Connect the battery ground cable to the Spray-On Application Red Electric Grade;...
Page 76: Troubleshooting Table
15.00 Starters, Delco Remy Troubleshooting Troubleshooting Table Problem—Starter Cranks Slowly Or Not At All Problem—Starter Cranks Slowly Or Not At All Possible Cause Remedy The alternator drive belt is loose. Check the drive belt. See the drive belt subject in the appropriate engine section in Group 01 for instructions.
Page 77 15.00 Starters, Delco Remy Troubleshooting Connect voltmeter More than 6.0 V from solenoid "S" 6.0 V or less terminal to ground. Engage start switch. Symptoms continue Remove starter. Check & repair Visually check pinion. magnetic switch Milled pinion circuit. Repair or replace starter. (Do not install) Repair verified.
Page 78 15.00 Starters, Delco Remy Troubleshooting If any cable or connection feels warm to the touch, check and replace the intercon- necting cables as required. 3. If the starter still does not crank, go to "Ring and Pinion Gear Test." Starter Solenoid Circuit Test The starter solenoid circuit includes the starter sole- noid, cranking motor, starter relay, and ignition key- switch.
Page 79 15.00 Starters, Delco Remy Troubleshooting 3. Set a digital voltmeter on the high (20V) scale If any voltage shows, reconnect to the other and connect the positive lead to the starter "B" large terminal. (battery) terminal. Connect the negative lead to the starter relay lead to which the carbon pile is already connected.
Page 80 15.00 Starters, Delco Remy Troubleshooting Ring and Pinion Gear Test 1. This test requires two persons. While the ﬁrst person bars the engine over, the second person visually checks the entire ﬂywheel ring gear and starter pinion gear visually (check all the teeth in both gears).
Page 81 15.00 Starters, Delco Remy Speciﬁcations Fastener Torque Values Description Grade Size Torque: lbf·ft (N·m) Torque: lbf·in (N·cm) Starter Mounting Capscrews 10.9 M10 x 1.5 38 (52) — Battery (B) Terminal Nut Brass 13 (18) — Solenoid (S) Terminal Nut Brass —...
Page 82 15.01 Alternators, Delco Remy General Information General Information Since the vehicle’s system is negative ground, the output terminal connects to the starter’s positive ter- minal. The Delco Remy 21–SI series alternator features a solid-state regulator that is mounted inside the end frame.
Page 83 15.01 Alternators, Delco Remy General Information 07/20/94 f150350a 1. Rotor 4. Regulator 2. Roller Bearings 5. Field Windings 3. Brushes 6. Ball Bearings Fig. 2, Delco Remy 21-SI Alternator (cutaway view) 050/2 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 84 15.01 Alternators, Delco Remy Delco Remy Alternator Removal and Installation, Cummins B IMPORTANT: Since the engine is located in the rear of the vehicle with the fan pointing back- wards, references to the front of the engine or alternator refer to aft on the vehicle. Likewise, references to the rear of the engine, or back of the alternator, refer to forward on the vehicle.
Page 85 15.01 Alternators, Delco Remy Delco Remy Alternator Removal and Installation, Cummins B 08/13/96 f150590 08/27/96 f011105 Rotate the belt tensioner down and off the belt. 1. Output Terminal 2. Ground Terminal 1. Delco Remy Alternator 2. Pivot Capscrew Fig. 4, Electrical Connectors 3.
Page 86 15.01 Alternators, Delco Remy Delco Remy Alternator Removal and Installation, Cummins B see "Alternator Voltage Output Test" in Trouble- shooting, 300. 08/09/96 f150592 1. Pivot Capscrew 2. Mounting Lug 3. Pivot Bracket 4. Washer 5. Pivot Nut 6. Alternator Link Fastener 7.
Page 87 15.01 Alternators, Delco Remy Troubleshooting Troubleshooting moved before proceeding with the alterna- tor test. To remove the surface charge, do the following: Many alternators have been replaced that later inves- tigation reveals were working properly. This may be A. Turn on the headlights and blower mo- due to incorrectly diagnosing the problem.
Page 88 15.01 Alternators, Delco Remy Troubleshooting 09/10/99 f150983 1. Red Alligator Clip 2. Black Alligator Clip 3. Hand-Held Alternator Analyzer Fig. 1, Delco Remy Intelli-Check Alternator Analyzer tem using the instructions in "Alternator/ 8. If the LOW BATTERY VOLTAGE (blue) LED illu- Charging System Testing."...
Page 89 15.01 Alternators, Delco Remy Troubleshooting If the OCV is less than 12.4 volts, charge the Start the engine and run it at 1500 rpm for batteries properly. For instructions, see 3 to 5 minutes to stabilize the system be- Group fore proceeding to the next step.
Page 90 15.01 Alternators, Delco Remy Troubleshooting 4. Perform an alternator amperage output test. If the reading at the batteries is more than 0.5 volts lower than the reading at the al- Connect a carbon pile tester across the ternator, do the next step. vehicle batteries as shown in Fig.
Page 91 15.01 Alternators, Delco Remy Speciﬁcations Mounting Fastener Torques, Cummins Engines Description Grade Size Torque: lbf·ft (N·m) Cummins B Series Engine M8 x Alternator Mounting Capscrew 10.9PO 16 (21) 1.25 M10 x Pivot Nut 10.9PO 40 (54) Table 1, Mounting Fastener Torques, Cummins Engines Terminal Fastener Torques, All Engines Description Grade...
Page 92 15.02 Alternators, Leece-Neville General Information General Information psi (138 kPa) low-pressure compressed air, to blow away loose debris. Leece-Neville alternators are equipped with a built-in WARNING cooling fan. The purpose of the cooling fan is to cir- culate air from the rear of the alternator. Air ﬂows Compressed air can dislodge harmful materials through the alternator, and cools the internal compo- or debris and cause eye injury.
Page 93: Removal And Installation
15.02 Alternators, Leece-Neville Removal and Installation Removal 5. Disconnect the cables at the alternator. Note the wire positions on the terminals, for correct instal- lation; see Fig. 1. Park the vehicle on a level surface, apply the parking brake, shut down the engine, and chock the tires.
Page 94 15.02 Alternators, Leece-Neville Removal and Installation 5. Spray any exposed terminal connectors with di- electric red enamel. See Table Protectant Material Approved Brands MMM 1602 IVI–Spray Sealer, Spray-On Application Red Electric Grade; order from the PDC Glyptal 1201EW– Low VOC, Brush-On Application Red;...
Page 95 15.03 Starter, Nippondenso General Information General Information The Nippondenso starter mounts on the left-hand side of the engine directly into the transmission, through a hole in the torque converter access cover. The starter motor incorporates a planetary gear sys- tem between the electric motor and pinion gear. This feature allows the armature to rotate at a higher speed and delivers increased torque to the drive plate ring gear or ﬂywheel.
Page 96 15.03 Starter, Nippondenso Nippondenso Starter Removal and Installation Removal 1. Park the vehicle on a level surface and apply the parking brake. Shut down the engine. Chock the rear tires. 2. Disconnect the batteries. WARNING Never work under or around a vehicle that is sup- ported only by jacks.
Page 97: Starter Relay Removal And Installation
15.03 Starter, Nippondenso Starter Relay Removal and Installation Removal Protectant Material Approved Brands Glyptal 1201EW– Low VOC, 1. Disconnect the batteries. Brush-On Application Red; order at www.glyptal.com or 1-800-GLP-1201 2. Remove the electrical connectors from the four Table 1, Approved Dielectric Red Enamel terminals on the starter relay.
Page 98 15.03 Starter, Nippondenso Troubleshooting Troubleshooting Table Problem—Starter Does Not Crank or Cranks Slowly Problem—Starter Does Not Crank or Cranks Slowly Possible Cause Remedy The batteries are undercharged. Do a load test on the batteries. See Section 54.02 for instructions. Charge or replace batteries as needed.
Page 99 15.03 Starter, Nippondenso Troubleshooting Interconnecting Cable Test 1. This test requires two people. While the ﬁrst per- son cranks the engine, the second person uses a voltmeter to measure the voltage across the starter "B" (battery) and "G" (ground) terminals. 2.
Page 100 15.03 Starter, Nippondenso Troubleshooting Brieﬂy touch the other end to the "S" terminal of the starter. See Fig. If the starter relay does operate, replace the starter. If the starter relay still does not operate, replace the starter relay. f150606 01/29/97 1.
Page 101 15.03 Starter, Nippondenso Troubleshooting studs on the starter relay. Then touch the other end of the jumper to the other large stud. 3. If the starter engages, remove the jumper cable and do the "Starter Operation Test." Repair/ replace the wire connections, terminals, and/or starter relay as necessary.
Page 102 15.03 Starter, Nippondenso Speciﬁcations For fastener torque values, see Table For a charging circuit wiring diagram, see Fig. Fastener Torque Values Description Grade Size Torque: lbf·ft (N·m) Torque: lbf·in (N·cm) Starter Mounting Capscrews 10.9 M10 x 1.5 38 (52) — Battery (B) Terminal Nut Brass 13 (18)
Page 103: Troubleshooting Tables
20.00 Cooling System Troubleshooting Troubleshooting Troubleshooting Tables other sections of this manual or to the engine and component manufacturer’s service publications. Possible causes of abnormally high or low coolant temperatures are listed below. For repairs, refer to Problem—Coolant Temperature Above Normal Problem—Coolant Temperature Above Normal Possible Cause Remedy...
Page 104 20.00 Cooling System Troubleshooting Troubleshooting Problem—Coolant Temperature Above Normal Possible Cause Remedy The radiator core is internally plugged or To check for blockages, warm the engine to normal operating temperature. damaged. Turn off the engine, and run your hand over the ﬁnned surface of the radiator. If there is a blockage in the radiator, it should cause an obvious temperature difference from one area of the core to another.
Page 105: Radiator Assembly
20.01 Radiator Assembly Radiator Removal and Installation, Rear Engine Move the air dam down and out of the NOTICE way so the radiator can be removed. If the radiator is being replaced due to a failure of 7. Disconnect the engine oil ﬁll tube and dipstick the transmission cooler, cleaning contamination tube from the bracket on top of the right side of from the transmission is necessary.
Page 106 20.01 Radiator Assembly Radiator Removal and Installation, Rear Engine 3. Put the radiator and CAC assembly into the en- 7. Connect the lower transmission oil cooler hose to gine compartment, making sure the lower mount- the right side of the radiator. ing studs line up with the holes in the crossmem- 8.
Page 107 20.01 Radiator Assembly Radiator Removal and Installation, Rear Engine 18. Connect the charge air cooler hoses. See Table 1 for proper torque values. 19. Using a suitable riveting tool, install the metal air dam to the top and bottom edges of the bumper. 20.
Page 108 20.01 Radiator Assembly Radiator Removal and Installation, Rear Engine 23.1 Close the heater inlet valve at the rear of 24.5 Open the heater inlet valve (on the engine the engine cylinder head. cylinder head). 23.2 Open the drain petcock at the heater out- 24.6 Close the drain petcock on the heater out- let valve (at the inside rear of the left...
Page 109 20.01 Radiator Assembly Radiator Removal and Installation, Rear Engine 8. Remove the hose clamp, disconnect the lower WARNING (outlet) hose, and allow the radiator to drain completely. Drain the coolant only when the coolant and the engine are cool. Draining it when these are hot 9.
Page 110 20.01 Radiator Assembly Radiator Removal and Installation, Rear Engine the upper radiator mounting brackets and the 5. Attach the upper (inlet) radiator hose to the inlet pipe and the radiator. Install the two hose clamps rubber bushings in the upper radiator mounts. and tighten them securely.
Page 111 20.01 Radiator Assembly Radiator Removal and Installation, Rear Engine tial property damage, severe injury, and death could result. 13. Jack up the rear of the vehicle. Remove the jack- stands and lower the vehicle. 14. Remove the chocks from the front tires. 100/7 Recreational Vehicle Chassis Workshop Manual, Supplement 27, October 2013...
Page 112 20.01 Radiator Assembly Pressure Testing the Radiator Pressure Testing 1. Remove the radiator. For instructions, see Sub- ject 100. 2. Pressure test the radiator as follows: Leaving the coolant inlet port open, plug the outlet and all other ports on the radia- tor.
Page 113 Diesel Antifreeze No. (Canada) 6038 Freightliner-approved antifreeze must meet one of the following condi- tions: A. Ethylene glycol solution that meets GM 6038–M Engineering Stan- dards. B. Ethylene glycol solution that has less than 0.1% anhydrous so- dium metasilicate, and meets either GM 1825–M or GM 1899–M Engineering Standards.
Page 114: General Information
20.02 Horton Fan Clutch General Information General Information ® The Horton VMaster Direct Sensing Viscous Fan Drive is managed by the engine’s electronic control module (ECM) for precision fan control, improved fuel economy, and less noise. The fan drive is oper- ated in an on/off control conﬁguration, providing a low fan speed under most operating conditions and full fan speed when requested by the ECM.
Page 115 20.02 Horton Fan Clutch Horton VMaster ® Direct Sensing Viscous Fan Drive Removal and Installation Removal 1. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the tires. 2. Remove the fan from the fan drive. Place it out of the way of the fan drive mounting bolts.
Page 116 20.02 Horton Fan Clutch Horton VMaster ® Air Sensing Viscous Fan Drive (front-engine diesel chassis) Removal and Installation Removal 1. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the tires. NOTE: Depending on the vehicle design, it may be necessary to remove the radiator and shroud in order to install the fan drive.
Page 117 20.03 Engine Block Heater, Phillips General Information General Information To turn on the heater, connect the heater cord to a power source. The element has no thermostat. Heat dissipating from the engine block prevents coolant An engine block heater keeps the engine coolant overheating.
Page 118 20.03 Engine Block Heater, Phillips Block Heater Element Removal and Installation Removal Installation 1. Park the vehicle, apply the parking brakes, and 1. Position the heater element in the engine block. chock the tires. Coat the threads of the element with a small 2.
Page 119: Wiring Problems
20.03 Engine Block Heater, Phillips Troubleshooting Troubleshooting Procedures WARNING Use the following procedures to check for the most Drain the coolant only when the coolant and en- common engine block heater problems. gine are cool. Draining it when these are hot could cause severe personal injury due to scald- Wiring Problems ing.
Page 120 20.03 Engine Block Heater, Phillips Speciﬁcations Approved Sealants • Loctite 567 • Henkel 790 Pipegrip • Perma-Loc LH-150 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 14, April 2007...
Page 121 26.00 Automatic Transmission, Allison Automatic Transmission Removal and Installation, MD Models IMPORTANT: Since the engine is located in the 4. Disconnect the driveline from the transmission. rear of the vehicle with the fan pointing back- Remove the transmission yoke U-joint end wards, references to the front of the engine or caps or lock straps.
Page 122: Transmission
26.00 Automatic Transmission, Allison Automatic Transmission Removal and Installation, MD Models 8. Remove the piping from the exhaust brake to the 13. Disconnect the ﬂexplate from the transmission. muffler. 13.1 Remove the capscrews holding the ring 9. Remove the turbocharger outlet piping. gear access cover.
Page 123 26.00 Automatic Transmission, Allison Automatic Transmission Removal and Installation, MD Models 08/04/94 f260109a 1. Support Bracket 3. ATF Fill/Dipstick Tube 2. U-Bolt 4. Metal Strap Fig. 4, Removing the Fill/Dipstick Tube 08/04/94 f260111a Fig. 5, Ring Gear Access Cover 08/04/94 f260112a Fig.
Page 124 26.00 Automatic Transmission, Allison Automatic Transmission Removal and Installation, MD Models 10. Install the ATF ﬁll/dipstick tube. 10.1 Install the ﬁll/dipstick tube support bracket. Tighten the two capscrews 80 lbf·ft (108 N·m). 10.2 Inspect the ﬁll/dipstick tube seal. Replace it if damaged. 10.3 Install the ﬁll/dipstick tube and metal strap.
Page 125 26.00 Automatic Transmission, Allison Automatic Transmission Removal and Installation, MD Models 20. Start the engine, and check for any leaks. Repair leaks as needed. 21. Check the ATF level. Add ﬂuid as needed. 22. Remove the chocks from the tires. 23.
Page 126 26.00 Automatic Transmission, Allison Transmission Shift Controller Removal and Installation Removal 1. Apply the parking brake, chock the tires, and dis- connect the batteries. 2. From underneath the shift controller panel, re- MODE move the locknut attaching each of the two brackets to the shift controller remote (control box).
Page 127 26.00 Automatic Transmission, Allison Speciﬁcations Torque Values, Automatic Transmission, MD Models Description Torque: lbf·ft (N·m) ATF Cooler Hoses 45 (61) Drain Plug 18–24 (25–32) Fill/Dipstick Tube Clamp Capscrews 12 (16) Fill/Dipstick Tube Support Bracket Capscrews 80 (108) Fill/Dipstick Tube Support Bracket U-Bolt Nuts 8 (11) Flexplate Adapter Capscrews 48 (65)
Page 128 26.01 Arens Shift-by-Wire (SBW) System General Information General Information and the neutral start-backup (NSBU) switch. The ac- tuator control communicates with the Arens actuator and the integrated position sensor (IPS). The Arens Shift-by-Wire (SBW) system is an elec- tronic shift control device used with Allison 1000/ The actuator is mounted on the Allison transmission.
Page 129: Actuator Adjustment
26.01 Arens Shift-by-Wire (SBW) System Actuator Adjustment Adjustment NOTE: The following procedure is for adjusting or calibrating a shift-by-wire (SBW) actuator al- ready installed on a vehicle. This procedure does not pertain to the ﬁrst-time installation of an SBW actuator. 1.
Page 130 26.01 Arens Shift-by-Wire (SBW) System Actuator Adjustment There is an alternate method (different from that described in the steps below) to determine if the transmission is in Neutral (N). Momentarily en- gage the starter. If the transmission is not in Neutral (N) the starter won’t engage (except on vehicles with a Park [P] position).
Page 131 26.01 Arens Shift-by-Wire (SBW) System Actuator Adjustment NOTE: When rotating counter-clockwise, you will engage two detents. The second detent will be Neutral (N). IMPORTANT: The transmission must be in Neu- tral (N) to calibrate it properly. Rotate the adap- tor slowly so that you don’t go beyond the Neu- tral (N) position.
Page 132: Troubleshooting Tables
26.01 Arens Shift-by-Wire (SBW) System Troubleshooting Troubleshooting Tables SBW System Troubleshooting Problem—Display Doesn’t Illuminate With Ignition Switch ON Problem—Display Doesn’t Illuminate With Ignition Switch ON Possible Cause Remedy Electrical Problem See "Electrical Troubleshooting" Problem—Display Doesn’t Indicate P or NN With Ignition Switch ON Problem—Display Doesn’t Indicate P or NN With Ignition Switch ON Possible Cause Remedy...
Page 133: Electrical Troubleshooting
26.01 Arens Shift-by-Wire (SBW) System Troubleshooting Problem—Display Indicates DD After Pressing D on Selector Problem—Display Indicates DD After Pressing D on Selector Possible Cause Remedy J1939 CAN not Working or Poor Contact Ensure a Good Contact at the CAN Connector at Connector The CAN (controller area network) connector is located behind the instrument panel, to the left of the steering column.
Page 134 26.01 Arens Shift-by-Wire (SBW) System Troubleshooting Problem—Display Illuminates but Transmission Doesn’t Shift Problem—Display Illuminates but Transmission Doesn’t Shift Possible Cause Remedy Actuator Assembly Connectors Damaged Repair Connectors and Ensure Good Connections (Pushed-out Pins) or Poorly Connected † Wheel Chair Lift (if so equipped) not Ensure That the Wheel Chair Lift is Properly Stowed Properly Stowed Open Circuit or too Much Resistance...
Page 135 26.01 Arens Shift-by-Wire (SBW) System Speciﬁcations Table 1 for SBW wiring information and Fig. 1 for an SBW wiring diagram. Shift-by-Wire (SBW) Wire Harness Connectors Selector High- Selector Signal Position Sensor Motor Connector Wire Power Connector Connector (1) Connector (3) VBATT 1 —...
Page 136 26.01 Arens Shift-by-Wire (SBW) System Speciﬁcations Shift-by-Wire (SBW) Wire Harness Connectors Selector High- Selector Signal Position Sensor Motor Connector Wire Power Connector Connector (1) Connector (3) RESERVED — — — Table 1, Shift-by-Wire (SBW) Wire Harness Connectors 06/10/2003 f544324 1. Shift Selector Connector (24 pin) 3.
Page 137: Throttle Control
30.00 Mechanical Throttle Control General Information General Description The Cummins B Series engines in the recreational vehicles use a manual throttle pedal, and a throttle cable that connects the throttle pedal to the throttle lever on the engine. The cable runs from the pedal, through the ﬂoorboard, and directly to the engine throttle lever.
Page 138: Operation Checking
30.00 Mechanical Throttle Control Non-Adjustable Throttle Control Cable Operation Checking Operation Checking 1. Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the tires. 2. Gain access to the throttle lever and linkage. 3.
Page 139 30.00 Mechanical Throttle Control Non-Adjustable Throttle Control Cable Operation Checking 06/23/2000 f300219 A. Breakover Range 1. Throttle Cable 2. Throttle Lever Fig. 3, Breakover Range 100/2 Recreational Vehicle Chassis Workshop Manual, Supplement 6, October 2000...
Page 140: Throttle Cable Removal And Installation
30.00 Mechanical Throttle Control Throttle Cable Removal and Installation Removal 3. Place the throttle cable on the throttle cable bracket. Turn the tab to secure the cable to the bracket. 1. Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the 4.
Page 141 30.00 Mechanical Throttle Control Throttle Pedal Removal and Installation Removal 3. Install the carpet around the pedal mounting. 4. Remove the chocks from the tires. 1. Park the vehicle on a level surface, shut down 5. Test drive the vehicle and ensure that the throttle the engine, set the parking brake, and chock the system operates properly.
Page 142: Throttle Cable Lubrication
30.00 Mechanical Throttle Control Throttle Cable Lubrication Lubrication 1. Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the tires. 2. From under the front of the vehicle, lubricate the throttle cable with silicone spray. See Fig.
Page 143: General Information
30.01 Electronic Throttle Control, Williams General Information General Information The Williams electronic suspended throttle pedal as- sembly is used with Cummins ISB Series engines. The throttle pedal assembly mounts to the inside of the driver’s compartment frontwall and communicates with the engine through a wiring harness. As the driver presses the pedal, the drive lever is forced downward, rotating the pinion gear which meshes with the pedal sensor (sometimes called the...
Page 144 30.01 Electronic Throttle Control, Williams General Information 06/27/2000 f300385 1. Pedal Assembly Mounting Bolt Hole 2. Throttle Sensor 3. Throttle Sensor Mounting Screws 4. Wiring Harness Connector 5. Throttle Pedal Fig. 3, Throttle Pedal Assembly (with an electronic automatic transmission) 050/2 Recreational Vehicle Chassis Workshop Manual, Supplement 6, October 2000...
Page 145 30.01 Electronic Throttle Control, Williams Throttle Pedal Removal and Installation Removal 06/27/2000 f300384 A. Idle Position Fig. 1, Electronic Throttle Pedal (side view) 1. Park the vehicle on a level surface, shut down Position the carpet around the pedal the engine, set the parking brake, and chock the mounting.
Page 146 30.01 Electronic Throttle Control, Williams Throttle Pedal Removal and Installation 06/27/2000 f300383 1. Screw, #10–32 UNF-2A x 1.25" 7. Mounting Plate 13. Pedal Pin 2. Screw, Hex 1/4–20 x 0.75" 8. Throttle Base 14. Pedal 3. Sensor 9. Spacer Washer 15.
Page 147 30.01 Electronic Throttle Control, Williams Throttle Sensor Replacement Replacement 1. Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the tires. 2. Disconnect the negative battery cable. 3. On vehicles with a non-electronic automatic transmission, remove the cotter pin and discon- nect the transmission kick-down modulator cable adjusting pivot from the pedal bracket.
Page 148 30.01 Electronic Throttle Control, Williams Throttle Sensor Replacement 06/27/2000 f300385 1. Pedal Assembly Mounting Bolt Hole 2. Throttle Sensor 3. Throttle Sensor Mounting Screws 4. Wiring Harness Connector 5. Throttle Pedal Fig. 3, Throttle Pedal Assembly (with an electronic automatic transmission) 110/2 Recreational Vehicle Chassis Workshop Manual, Supplement 6, October 2000...
Page 149 30.02 Electronic Throttle Control, Felsted General Information General Information The Felsted electronic throttle pedal is mounted on a throttle pedal base which is mounted to the driver’s compartment ﬂoor. It communicates with the engine through a wiring harness. As the driver presses the pedal, the drive lever is forced downward, rotating the pinion gear which meshes with the pedal sensor (sometimes called the "potentiometer").
Page 150 30.02 Electronic Throttle Control, Felsted Throttle Pedal Removal and Installation Removal the engine, set the parking brake, and chock the tires. 2. Disconnect the batteries. 3. Remove the throttle pedal. See Fig. 1 Fig. NOTE: None of the individual parts of the pedal assembly are serviceable.
Page 151 30.03 Throttle Kick-Down Cable Throttle Kick-Down Cable Removal And Installation Removal 1. Park the vehicle on a level surface, shut down the engine, set the parking brake, and chock the tires. 2. Gain access to the throttle kick-down cable ad- justing pivot, at the top of the throttle pedal as- sembly.
Page 152 30.03 Throttle Kick-Down Cable Throttle Kick-Down Cable Removal And Installation Installation 13. Test drive the vehicle and ensure that the throttle kick-down cable assembly operates properly. NOTE: The bulkhead seal washer must be on the forward side of the operator’s station and the internally toothed lock washer must be on the driver’s side.
Page 153 30.03 Throttle Kick-Down Cable Throttle Kick-Down Cable Adjustment Adjustment and measure the clearance between the cable end and the threaded end of the cable. 1. Park the vehicle on a level surface, shut down IMPORTANT: Clearance between the cable end the engine, set the parking brake, and chock the and the threaded end of the cable must be 0.02 tires.
Page 154: Frame Assembly
31.00 Frame Assembly General Information General Description There is no identifying mark for station zero; it is lo- cated about 1.6 inches (40 mm) forward of the for- ward end of the frame rail, and about 11.4 inches IMPORTANT: This service manual does not (290 mm) forward of the centerline of the front sus- cover the procedures and calculations neces- pension’s forward spring pin.
Page 155: General Handling
31.00 Frame Assembly General Handling General Handling Whenever the frame rails are lifted or moved, take care to avoid anything that may scratch, cut, or dam- age the exposed frame assembly. Cushion all chain hoists or cable slings with a section of heavy hose. If the frame rail is raised with a jack, place a block of wood between the jack and the frame rail.
Page 156 31.00 Frame Assembly Frame Rail Repair Repairing Cracks IMPORTANT: In most cases, cracked or dam- aged frame rails should be replaced. In some cases it may be necessary to repair minor dam- age; before attempting any repairs, contact your regional service representative for approval. CAUTION Before performing any electric welding on a ve- hicle, disconnect the battery power and ground...
Page 157 31.00 Frame Assembly Frame Rail Repair 08/15/95 f310016a 08/14/95 f310014a A. Frame Rail Thickness A. Frame Rail Thickness B. Grind the weld ﬂush with the frame rail. 1. V-groove (full depth) 1. Crack Fig. 3, Full Depth Groove Fig. 5, Weld Ground Flush 08/15/95 f310017a f310015a...
Page 158: Drilling Holes
31.00 Frame Assembly Frame Rail Repair 3. Tighten the fasteners to the applicable torque value. For proper frame fastening instructions, refer elsewhere in this group. Drilling Holes During vehicle manufacture, holes are drilled or punched in the frame rail only as speciﬁed on the vehicle frame drilling chart.
Page 159 31.00 Frame Assembly Frame Fasteners Frame Fasteners Never hammer or screw bolts into place. Align the holes of the frame and the part being attached to it, so that the nut and bolt surfaces are ﬂush against ® Either Huckbolts or grade 8 hexhead bolts and the frame and the part.
Page 160 31.00 Frame Assembly Frame Fasteners 02/22/93 f310007 A. Grade 8.2 Flanged Bolt B. Grade G Prevailing Torque Locknut Fig. 3, Flanged Hexhead Fasteners 10/19/93 f310006 A. Grade 8 Hexbolt B. Grade 8 Low-Proﬁle Hexbolt C. Grade C Prevailing Torque Locknut Fig.
Page 161 31.00 Frame Assembly Frame Fasteners 04/28/93 f230019 04/28/93 f230022 Fig. 5, Positioning the Collar Fig. 8, Installed Huckbolt Fastener breakneck; the pintail should break ﬂush with the top of the collar. No more than two grooves should be visible on the collar after installation. Fig.
Page 162 31.00 Frame Assembly Frame Fasteners Maintenance Schedule in Group 00 and the frame section in Group 31 of the vehicle maintenance manual for intervals. When tightening the fasteners, tighten the nut, not the bolt head. This will give a true torque reading by eliminating bolt body friction.
Page 163: Installation
31.00 Frame Assembly Crossmember Replacement, Model XC Replacement Remove the tie straps that secure the trailer electrical hook up harness along the underside of the hitch assembly. The placement of crossmembers affects the overall stability of the frame. If a crossmember is being Remove the fasteners that hold the hitch eliminated, added, or relocated, dealers must contact assembly to the frame rails, and move the...
Page 164 31.00 Frame Assembly Crossmember Replacement, Model XC 2. Install the eight 1/2-inch, grade 8 fasteners, and 3. Leave the hoses and wiring routed through the torque them 95 lbf·ft (129 N·m). crossmember intact, and cut out the existing crossmember. See Fig.
Page 165 31.00 Frame Assembly Frame Rail Alignment Alignment Determine how far forward that the upper (or lower) ﬂanges of both frame rails are clear. Frame rail alignment is checked by measuring the distances from two sets of points on the upper (or Find a matched set of bolt holes on the lower) ﬂanges of the frame rails.
Page 166 31.00 Frame Assembly Frame Rail Alignment IMPORTANT: To align the frame rails, the frame must have all of the crossmembers in place, but the attachment fasteners should not be tight- ened. 9. Using a large hammer and a large wooden block, place the block against the rear end of the frame rail that had its rear point the greater dis- tance from its opposite rail’s front point.
Page 167: General Information
31.01 Chassis Layout Diagrams General Information General Information The chassis layout diagrams below are not speciﬁc to a particular RV body builder or model. They repre- sent the general locations of the air plumbing compo- nents and of the electrical connectors and compo- nents on a generic RV chassis.
Page 168 31.01 Chassis Layout Diagrams General Information 04/22/2003 f310947 1. Customer Air Manifold (2 10. Park Brake Warning Sensor 17. WABCO ABS Combo Valve possible locations) 11. Rear Height Control Valves 18. Front Quick-Release Valve 2. Stop Light Switch 12. Rear R-14 Relay Valve 19.
Page 169 31.01 Chassis Layout Diagrams General Information 3p 26 48/38P 38/30p 2w 20 2p 17 4x8p 2p 12 2p 11 7p 10 12/20/2004 f310948 1. Electric Horn (2-pin) 14. ECU-S Connector (black, 32-pin) 2. Body Builder Interface Connector (LH-side lights, 3/5- 15.
Page 170: Component Locations
31.01 Chassis Layout Diagrams Air Plumbing and Electrical Component Locations Component Locations The following chassis layout diagrams are not spe- ciﬁc to a particular RV body builder or model. They represent the general locations of the air plumbing components and of the electrical connectors and components on a generic RV chassis.
Page 171 31.01 Chassis Layout Diagrams Air Plumbing and Electrical Component Locations 04/22/2003 f310947 1. Customer Air Manifold (2 possible locations) 13. Air Dryer 2. Stop Light Switch 14. Air Compressor/Governor 3. Park Brake Control Valve 15. VDC (located by body builder at rear of coach) 4.
Page 172 31.01 Chassis Layout Diagrams Air Plumbing and Electrical Component Locations 3p 26 48/38P 38/30p 2w 20 2p 17 4x8p 2p 12 2p 11 7p 10 12/20/2004 f310948 NOTE: Connectors 13 through 16 and the batteries (#18) are located by the body builder. 1.
Page 173 31.01 Chassis Layout Diagrams MMDC Air Plumbing and Electrical Component Locations Component Locations NOTE: The following chassis layout diagrams are not speciﬁc to a particular RV body builder or model. They represent the general locations of the air plumbing components and of the electrical connec- tors and components on a generic RV chassis with the Multiple Module Data Computer (MMDC) instru- ment system.
Page 174 31.01 Chassis Layout Diagrams MMDC Air Plumbing and Electrical Component Locations 02/20/2006 f311010 1. Customer Air Manifold (2 possible locations) 13. Air Dryer 2. MMDC (located by body builder at front of coach) 14. Air Compressor/Governor 3. Stop Light Switch 15.
Page 175 31.01 Chassis Layout Diagrams MMDC Air Plumbing and Electrical Component Locations 30/38p 2p 15 2x8p 2x2p 13 2p 12 2p 11 8p 10 03/02/2006 f311011 NOTE: Connectors 7, 13, 14, 17 and the batteries (#16) are located by the body builder. 1.
Page 176: General Description
32.00 Front Suspension, Neway AS–120 General Information General Description The air (bag) springs are mounted on a leaf spring, which is attached to the front axle. The leaf spring is equipped with rubber bushings. If an air spring is damaged or is leaking, it should be replaced.
Page 177: Installation
32.00 Front Suspension, Neway AS–120 Air Spring Removal and Installation Removal 8. Remove the leaf spring and the air spring as- semblies. 1. Park the vehicle on a level surface. Shut down 9. Inspect, remove, and replace the front spring the engine.
Page 178 32.00 Front Suspension, Neway AS–120 Sway Bar Replacement Replacement 11. Position the sway bar assembly on the axle seat. Position the shim in place and raise the axle into position. 1. Park the vehicle on a level surface. Shut down the engine.
Page 179: Shock Absorber Replacement
32.00 Front Suspension, Neway AS–120 Shock Absorber Replacement Replacement 1. Park the vehicle on a level surface. Shut down the engine. Set the parking brake, and chock the front and rear tires. 2. Remove the prevailing torque nut and steel washer at the upper end of the shock absorber.
Page 180: Bushing Replacement
32.00 Front Suspension, Neway AS–120 Bushing Replacement Leaf Spring Bushing Replacement 1. Park the vehicle on a level surface. Shut down the engine. Set the parking brake and chock the front and rear tires. Raise the vehicle frame until the weight is off the front suspension with the wheels still touching the ﬂoor.
Page 181: Troubleshooting Tables
32.00 Front Suspension, Neway AS–120 Troubleshooting Troubleshooting Tables Problem—Vehicle Leans to One Side Problem—Vehicle Leans to One Side Possible Cause Remedy A leaf spring or an air spring is broken. Replace the leaf spring or the air spring. The leaf spring/air spring assembly is Replace the leaf spring/air spring assembly.
Page 182: Specifications
32.00 Front Suspension, Neway AS–120 Speciﬁcations Front Suspension Fastener Torque Values Torque Description lbf·ft (N·m) Rear U-Bolts 150 (203) Front U-Bolts 150 (203) Spring Center Bolt 30 (41) Front Shock Absorbers 100 (136) Rear Drag Link to Front Axle Control Arm 80 (108) Drag Link Castle Nut 80 (108)
Page 183 32.01 Rear Suspension, Neway AD–200 General Information General Description The Neway Air Ride suspension is a single-axle sus- pension that uses air springs. See Fig. 1. The top of each air spring is bolted to a frame-rail bracket, and the bottom of each spring is attached to a suspen- sion crossmember.
Page 184 32.01 Rear Suspension, Neway AD–200 General Information 25 24 07/31/96 f320512a 1. Bolt, 3/4-16 x 7 inch (Grade 5) 11. Control Rod Axle Bracket 22. Lockwasher 2. Adaptor Bushing 12. Torque Rod Axle Bracket 23. Air Spring Hexnut 3. Frame Bracket 13.
Page 185: Suspension
32.01 Rear Suspension, Neway AD–200 Height Control Valve Adjustment Adjustment the height control valve. See Table 1 for model- speciﬁc measurement information. 1. Park the vehicle on a level surface. Run the en- On IFS114 and ADTB280 suspensions, measure gine until the air brake system is fully charged. the distance from the lower shock mount bolt Chock the tires.
Page 186 32.01 Rear Suspension, Neway AD–200 Height Control Valve Adjustment 8. To adjust the Neway valve, loosen the adjust- ment locknut on the height control valve lever arm. See Fig. 1. Move the control lever arm (slightly relative to the nylon block). Tighten the locknut when the required height measurement is reached.
Page 187 32.01 Rear Suspension, Neway AD–200 Air Spring Replacement Replacement 1. Chock the front tires to prevent vehicle move- ment. Open the stopcocks on the air tanks to drain the air system. 2. Raise the rear of the vehicle to remove all weight from the rear axles, and place safety stands un- der the frame rails to secure the vehicle in its raised position.
Page 188 32.01 Rear Suspension, Neway AD–200 Air Spring Replacement 25 24 07/31/96 f320512a 1. Bolt, 3/4-16 x 7 inch (Grade 5) 11. Control Rod Axle Bracket 22. Lockwasher 2. Adaptor Bushing 12. Torque Rod Axle Bracket 23. Air Spring Hexnut 3. Frame Bracket 13.
Page 189 32.01 Rear Suspension, Neway AD–200 Shock Absorber Replacement Replacement 1. Remove the locknuts from the shock absorber upper and lower mounting brackets. See Fig. 2. If the shock absorber is fully extended, chock the vehicle wheels and jack up the axle to relieve tension from the shock.
Page 190 32.01 Rear Suspension, Neway AD–200 Shock Absorber Replacement 25 24 07/31/96 f320512a 1. Bolt, 3/4-16 x 7 inch (Grade 5) 11. Control Rod Axle Bracket 22. Lockwasher 2. Adaptor Bushing 12. Torque Rod Axle Bracket 23. Air Spring Hexnut 3. Frame Bracket 13.
Page 191: Installation
32.01 Rear Suspension, Neway AD–200 Equalizing Beam Removal and Installation Removal Installation 1. Chock the front tires. 1. Make sure the adaptor bushings are installed in the frame bracket. 2. Raise the rear of the vehicle to remove all weight from the rear suspension, and place safety 2.
Page 192 32.01 Rear Suspension, Neway AD–200 Equalizing Beam Removal and Installation 25 24 07/31/96 f320512a 1. Bolt, 3/4-16 x 7 inch (Grade 5) 11. Control Rod Axle Bracket 22. Lockwasher 2. Adaptor Bushing 12. Torque Rod Axle Bracket 23. Air Spring Hexnut 3.
Page 193 32.01 Rear Suspension, Neway AD–200 Equalizing Beam Removal and Installation 10. Apply SAE-20 oil to the threads of the capscrews that secure the air springs to the air spring lower mounting plates. Position the air springs on the plates and install the capscrews and lockwash- ers.
Page 194 32.01 Rear Suspension, Neway AD–200 Equalizing Beam Bushing Replacement Replacement 1. Remove the equalizing beam. Refer to Sub- ject 130. WARNING Do not use a torch to cut the bushing sleeve out of the equalizing beam. To do so could weaken the casting, possibly resulting in loss of vehicle control and personal injury.
Page 195 32.01 Rear Suspension, Neway AD–200 Equalizing Beam Bushing Replacement 25 24 07/31/96 f320512a 1. Bolt, 3/4-16 x 7 inch (Grade 5) 11. Control Rod Axle Bracket 22. Lockwasher 2. Adaptor Bushing 12. Torque Rod Axle Bracket 23. Air Spring Hexnut 3.
Page 196 32.01 Rear Suspension, Neway AD–200 Control Rod Removal, Inspection, and Installation Removal 1. Apply the parking brakes. 2. Remove the locknuts and ﬂatwashers from the bolts that secure the control rod frame bracket to the frame rail. See Fig. 1. To ease reassembly, note the order of the axle alignment shims be- tween the control rod frame bracket and the backing plate.
Page 197 32.01 Rear Suspension, Neway AD–200 Torque Rod Removal, Inspection, and Installation Removal 3. Remove the torque rod crossmember bracket bolts. Swing the torque rod clear of the torque rod crossmember bracket, and remove the axle 1. Apply the parking brakes. plane shims together with the torque rod cross- member bracket.
Page 198 Fig. 2. Press the bushing into the tool kit P-097-009. This tool kit can be pur- torque rod eye. chased from Freightliner, or it can be machined, using the dimensions given in Speciﬁca- tions, 400. 1. Remove the snap ring and washer from each side of the bushing to be removed.
Page 199 32.01 Rear Suspension, Neway AD–200 Torque Rod Bushing Replacement 8. Place a pressing sleeve over the end of the torque rod pin, then seat the snap ring. See Fig. 9. After assembly, press the torque rod pin slightly to center it in the torque rod eye. There should be no slack on either side of the polyurethane bushing, and the bushing should be compressed by about half the thickness of the...
Page 200 32.01 Rear Suspension, Neway AD–200 Rear Axle Lateral Alignment Lateral Alignment engine oil; tighten the locknuts to the torque under Speciﬁcations 400. 1. Park the vehicle on a level surface; then position 9. Perform the previous three steps on the other the front tires straight ahead and chock them.
Page 201 32.01 Rear Suspension, Neway AD–200 Rear Axle Lateral Alignment 25 24 07/31/96 f320512a 1. Bolt, 3/4-16 x 7 inch (Grade 5) 11. Control Rod Axle Bracket 22. Lockwasher 2. Adaptor Bushing 12. Torque Rod Axle Bracket 23. Air Spring Hexnut 3.
Page 202 32.01 Rear Suspension, Neway AD–200 Rear Axle Parallel Alignment Parallel Alignment Position the alignment bushings in the frame bracket; then raise the equalizing beam until the front eye is aligned with the 1. Check and, if needed, adjust the lateral align- frame bracket.
Page 203 32.01 Rear Suspension, Neway AD–200 Rear Axle Parallel Alignment 02/12/98 f320079a A. Without Frame Rail Spacer, With B. With Frame Rail Spacer, With C. With Frame Rail Spacer, Without Alignment Bushings Alignment Bushings Alignment Bushings 1. Alignment Bushings 4. Delrin Spacer 2.
Page 204: Troubleshooting Tables
32.01 Rear Suspension, Neway AD–200 Troubleshooting Troubleshooting Tables Problem—Air Springs Are Flat Problem—Air Springs Are Flat Possible Cause Remedy Low air pressure in the vehicle brake Check the air pressure gauge on the instrument panel. If the air pressure is system.
Page 205 32.01 Rear Suspension, Neway AD–200 Troubleshooting Problem—Air Springs Deﬂate Rapidly When the Vehicle Is Parked Problem—Air Springs Deﬂate Rapidly When the Vehicle Is Parked Possible Cause Remedy Air leakage from the suspension air Listen for leakage due to loose ﬁttings or damaged air lines, air springs, or system.
Page 206 32.01 Rear Suspension, Neway AD–200 Troubleshooting Problem—Air Spring Doesn’t Fully Deﬂate When All Weight Is Removed from the Suspension Problem—Air Spring Doesn’t Fully Deﬂate When All Weight Is Removed from the Suspension Possible Cause Remedy Restricted air line between the height Disconnect the height control valve linkage, and push the control lever down.
Page 207: Specifications
32.01 Rear Suspension, Neway AD–200 Speciﬁcations Suspension Torque Speciﬁcations (lubricated threads) Description Torque: lbf·ft (N·m) Axle U-Bolts 150 (203) Axle Front U-Bolts 150 (203) Rear Spring Eye Bolts 200 (271) Spring Shackle Eye Bolts 240 (325) Rear Shock Upper Bracket 120 (163) Rear Shock Mounting Bolts 55 (75)
Page 208 32.01 Rear Suspension, Neway AD–200 Speciﬁcations 1.50 7.25 0.12 0.50 1.75 1.25 2.00 3.50 2.42 0.25 60° 2.88 1.12 2.11 0.12 0.12 2.22 1.81 3.12 3.00 02/23/96 f320080a A. Detail B. Radius C. Minimum Radius 1. Plunger 3. Insertion Sleeve 5.
Page 209: General Information
32.02 Front Suspension, Neway IFS–114 General Information IMPORTANT: Do not tow the vehicle by the in- dependent front suspension assembly, if so equipped. Components of the suspension can be damaged. General Description The Neway IFS–114 is an independent, front-steer air suspension system designed for RV use. The system consists of long and short double wishbone control arms, wide-mount air springs, ABS-ready wheel ends, shock absorbers set outside the frame...
Page 210 32.02 Front Suspension, Neway IFS–114 Suspension Assembly Removal and Installation Removal 9. Disconnect the air suspension height control valve control rod from its mounting tab (not shown) on the rear of the lower control arm. See WARNING Fig. 10. Remove the lower and upper shock absorber Before beginning work on the vehicle, ensure mounting bolts and remove the shock absorber.
Page 211 32.02 Front Suspension, Neway IFS–114 Suspension Assembly Removal and Installation 03/16/99 f320793 1. Subframe 5. Upper Control Arm/Subframe 10. Post 2. Lower Control Arm/Subframe Bolt 11. Upper Control Arm/Post Bolt Bolt 6. Upper Control Arm 12. Air Spring 3. Lower Control Arm 7.
Page 212: Installation
32.02 Front Suspension, Neway IFS–114 Suspension Assembly Removal and Installation 03/16/99 f320791 1. Air Spring 2. Upper Control Arm/Post Bolt 3. Post 02/04/2000 f320792 4. Lower Control Arm/Post Bolt 1. Subframe/Frame Rail Mounting Bolt Holes 5. Shock Absorber 2. Subframe 6.
Page 213 32.02 Front Suspension, Neway IFS–114 Suspension Assembly Removal and Installation NOTE: The height control valve line brackets mount to the lower rear subframe bolts on each side. Install the brackets later in the procedure. 2. Install the 12 bolts (facing out) on each side of the subframe and the 12 nuts.
Page 214 32.02 Front Suspension, Neway IFS–114 Suspension Assembly Removal and Installation tween the two arms, to facilitate the positioning 22. Position the bottom of the height control valve control rod against the tab (not shown) on the of the post in the control arm tabs. See Fig.
Page 215 32.02 Front Suspension, Neway IFS–114 Speciﬁcations Fastener Torques Torque Description lbf·ft (N·m) Crossmember Adjustment Bolts 49-63 (66-85 Subframe to Frame Rail Bolts 98-125 (133-170) Tie Rod End Nut (pitman arm) 100-125 (135-170) Lower Control Arm to Subframe Bolts 130-170 (176-230) Control Arm to Post Bolts (upper and lower) 630-770 (855-1045) Upper Control Arm to Subframe Bolts...
Page 216 32.03 Rear Suspension, Neway ADTB–280 General Information General Description The Neway ADTB–280 is a drive axle air suspension system designed for RV use. This is a single-axle suspension that uses air springs. The top of each air spring is bolted to an outrigger, and the bottom of each air spring is attached to a suspension beam assembly crossmember.
Page 217 32.03 Rear Suspension, Neway ADTB–280 Suspension Assembly Removal and Installation Removal WARNING Before beginning work on the vehicle, ensure that the front tires are securely chocked and that the vehicle is secure on jackstands. If the vehicle is not properly supported, with the wheels re- moved and as the suspension is being removed, it could fall, which could cause severe injury, death, and substantial property damage.
Page 218 32.03 Rear Suspension, Neway ADTB–280 Suspension Assembly Removal and Installation 15. Repeat the above three steps on the opposite side and remove the torque rod on that side. 16. On both sides of the vehicle, mark and then dis- connect the brake chamber air lines from the brake chambers (not shown).
Page 219 32.03 Rear Suspension, Neway ADTB–280 Suspension Assembly Removal and Installation out from underneath the vehicle, raise the rear Installation of the vehicle at the rear crossmember and re- position the jackstands higher. 26. Using a fork lift truck, withdraw the pallet or dolly out from underneath the vehicle on whichever side offers better access.
Page 220 32.03 Rear Suspension, Neway ADTB–280 Suspension Assembly Removal and Installation IMPORTANT: Place any alignment shims or WARNING washers back in their original positions when installing the torque rods. Before jacking on the vehicle, ensure that the front tires are securely chocked. Exercise caution 4.
Page 221 32.03 Rear Suspension, Neway ADTB–280 Suspension Assembly Removal and Installation 22. Install the inner wheels and then install the outer wheel fasteners over the inner fasteners. See Group 40 for instructions. 23. Install the outer wheels and the lug nuts. WARNING Before jacking on the vehicle, ensure that the front tires are securely chocked.
Page 222 32.03 Rear Suspension, Neway ADTB–280 Speciﬁcations Fastener Torques Torque Description lbf·ft (N·m) Lower Torque Rod to Forward Mounting Bracket Bolts 170 (230) Lower Torque Rod Nuts (rear) 400 (542) Upper Longitudinal Torque Rod to Differential Bolts 170 (230) Upper Longitudinal Torque Rod to Crossmember Bolts 170 (230) Upper Transverse Torque Rod to Differential Nut 400 (542)
Page 223 32.04 Rear Suspension, Neway ADL General Information General Information ® ® The Holland Neway suspension uses air drawn from the vehicle air system to pressurize the air springs. The height control valve regulates the air pressure required for varying loads and maintains the design ride height.
Page 224: Ride Height Adjustment
32.04 Rear Suspension, Neway ADL Ride Height Checking and Adjustment Ride Height Checking 3. Exhaust all air from the air springs by pushing the control lever down to the vertical position. 1. Park the vehicle on a level surface, shut down 4.
Page 225 32.04 Rear Suspension, Neway ADL Axle Alignment Adjustment Follow the instructions in the rear axle alignment checking section of Group 35 to see if rear axle alignment adjustment is needed. If it is needed, pro- ceed as follows: Axle Alignment Adjustment ®...
Page 226 32.04 Rear Suspension, Neway ADL Axle Alignment Adjustment 08/17/2004 f321005 A. Weld Both Sides as Shown (One Continuous Weld; Start forward of the centerline. End forward of the bolt center line). 1. Weld Start 2. Weld End 3. Equalizing Beam Plate Fig.
Page 227 32.04 Rear Suspension, Neway ADL Pinion Angle Adjustment Follow the instructions in the rear axle alignment checking section of Group 41 to see if rear axle pin- ion angle adjustment is needed. If it is needed, pro- ceed as follows: Pinion Angle Adjustment 1.
Page 228 32.04 Rear Suspension, Neway ADL Suspension Air Spring Replacement Replacement 1. Park the vehicle on a level surface, shut down the engine, apply the parking brake, and chock the tires. 2. Support the frame with jack stands. WARNING Always use jack stands of sufficient strength. Failure to do so may cause the vehicle to fall, re- sulting in personal injury and/or vehicle damage.
Page 229 32.04 Rear Suspension, Neway ADL Suspension Air Spring Replacement 11. Both air springs should inﬂate the suspension to the proper ride height. Check the ride height us- ing the instructions in Subject 100, and follow the instructions there, if an adjustment is needed. 12.
Page 230 32.04 Rear Suspension, Neway ADL Axle Adapter Bushing Replacement Replacement NOTE: If the air spring has a leak and is de- ﬂated, this step must still be completed. NOTE: Because the axle adapter is welded to 7. Disconnect the shock absorbers and the air the axle, a Holland ®...
Page 231 32.04 Rear Suspension, Neway ADL Axle Adapter Bushing Replacement 9. Using a ﬂoor jack, support the equalizing beam 16. Connect the air springs, shock absorbers, and and slowly lower the assembly to provide access height control valve link. to the axle adapter bushings. 16.1 Tighten the air spring nuts 30 to 35 lbf·ft NOTE: If the equalizing beam plates are too...
Page 232 32.04 Rear Suspension, Neway ADL Frame Bracket Pivot Bushing Replacement Replacement ® ® NOTE: A Holland Neway bushing service tool (p/n 505 44 012) is available to ease removal and replacement of bushings. The bushing ser- vice tool can be used on all ADL bushings, in- cluding pivot connections and equalizing beam connections.
Page 233 32.04 Rear Suspension, Neway ADL Frame Bracket Pivot Bushing Replacement connection to avoid bushing windup. The axle bowl can be supported with a ﬂoor jack. Do not raise the rear of the vehicle. 17. Connect the air springs, shock absorbers, and height control valve link.
Page 234 32.04 Rear Suspension, Neway ADL Equalizing Beam Bushing Replacement Replacement ® ® NOTE: A Holland Neway bushing service tool (p/n 505 44 012) is available to ease removal and replacement of bushings. The bushing ser- vice tool can be used on all ADL bushings, in- cluding pivot connections and equalizing beam connections.
Page 235 32.04 Rear Suspension, Neway ADL Equalizing Beam Bushing Replacement 8. Using the ﬂoor jack, support and lower the equal- 17. Install the tires. Remove the jack stands, lower izing beam, to provide access to the equalizing the vehicle, and remove the ﬂoor jack supporting beam bushings.
Page 236 32.04 Rear Suspension, Neway ADL Shock Absorber Replacement Replacement 1. Park the vehicle on a level surface, shut down the engine, apply the parking brake, and chock the tires. 2. Support the frame with jack stands. WARNING Always use jack stands of sufficient strength. Failure to do so may cause the vehicle to fall, re- sulting in personal injury and/or vehicle damage.
Page 237 32.04 Rear Suspension, Neway ADL Torque Rod Bushing Replacement Replacement 7. With the ﬂoor jack supporting the axle bowl, lower the suspension and axle to gain access to the torque rod. 1. Park the vehicle on a level surface, shut down the engine, apply the parking brake, and chock 8.
Page 238 32.04 Rear Suspension, Neway ADL Torque Rod Bushing Replacement 08/17/2004 f580383 Fig. 4, Bushing Service Tool 13. Center the bushings in the frame bracket recep- tacle. Using the bushing service tool, press in the torque rod bushings. 08/18/2004 f321014 14. Attach the torque rod using new hardware, and 1.
Page 239 32.04 Rear Suspension, Neway ADL Torque Rod Bushing Replacement spring pressure must not be set above 100 psi (690 kPa) or the rubber air spring can tear or fracture. 18. Remove the chocks from the tires. 180/3 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 240: Track Bar Replacement
32.04 Rear Suspension, Neway ADL Track Bar Replacement Replacement 7. Using the ﬂoor jack that supports the axle bowl, lower the axle and suspension to gain access to the frame bracket pivot bushings. 1. Park the vehicle on a level surface, shut down the engine, apply the parking brake, and chock 8.
Page 241 32.04 Rear Suspension, Neway ADL Track Bar Replacement CAUTION While the vehicle air system pressure capabilities may be in excess of 120 psi (827 kPa), the air spring pressure must not be set above 100 psi (690 kPa) or the rubber air spring can tear or fracture.
Page 242: Troubleshooting
32.04 Rear Suspension, Neway ADL Troubleshooting Problem—All Air Springs Are Flat Problem—All Air Springs Are Flat Possible Cause Remedy There is insufficient air pressure in the Check the air pressure gauge on the instrument panel. If air pressure is low, vehicle air system.
Page 243 32.04 Rear Suspension, Neway ADL Troubleshooting Problem—The Air Spring(s) Fail to Fully Deﬂate When All Weight Is Removed from the Suspension Problem—The Air Spring(s) Fail to Fully Deﬂate When All Weight Is Removed from the Suspension Possible Cause Remedy There are restricted air line(s) between the Disconnect the height control valve linkage and rotate the actuating lever to height control valve and the air spring(s).
Page 244 32.04 Rear Suspension, Neway ADL Troubleshooting Problem—Constant Noise from the Suspension Possible Cause Remedy There is debris wedged between the axle Remove the debris shield and remove all debris. Install the the debris shield. adapter and the transverse beam. Problem—Driveline Vibration Problem—Driveline Vibration Possible Cause Remedy...
Page 245: Front Axle
33.00 Front Axle Alignment General Information General Description Caster angle is the tilt of the knuckle pin (or kingpin) as viewed from the side. See Fig. 3. Caster angle is measured in degrees and it is adjustable. A positive Correct front axle wheel alignment is needed to en- caster angle is the tilt of the top of the knuckle pin sure long tire life, ease of handling, and steering sta- toward the rear of the vehicle.
Page 246 33.00 Front Axle Alignment General Information f330082a 08/29/94 NOTE: B minus A equals toe-in. Fig. 4, Wheel Toe-In (overhead view) 08/29/94 f400094a A. Feathered Edges Fig. 5, Tire Damage Due to Excessive Toe-In or Incorrect Drive Axle Alignment 12/20/94 f400096a 1.
Page 247: Preliminary Checks
33.00 Front Axle Alignment Preliminary Checks Preliminary Checks bent or twisted over 1/2 degree, replace it before aligning the front axle wheels. 1. Steering axle wheel assemblies should be bal- 7. Check for damaged, worn, or bent steering gear anced, especially for vehicles that travel at sus- or linkage parts.
Page 248: Checking And Adjusting
0.75 inch (19 mm) from any moving object. months by a qualiﬁed technician from the equip- ment manufacturer. Freightliner dealers must If necessary, loosen the stopscrew locknut; ad- have proof of this calibration history. just the stopscrew to contact the axle when the maximum turning angle of the wheels is deter- 1.
Page 249 33.00 Front Axle Alignment Steering Angle Checking and Adjusting 5. Repeat the step above with the steering wheel turned counterclockwise. Adjust the axle stop, as needed. 6. Adjust the power steering gear so that pressure is released ahead of the axle stop. This will pre- vent possible damage to the steering or axle components.
Page 250 Freightliner dealers must 7. Remove the chocks from the tires. have proof of this calibration history. 1. Apply the parking brakes, and chock the rear tires.
Page 251 Caster Angle Checking and Adjusting Checking and Adjusting equipment must be calibrated every three months by a qualiﬁed technician from the equip- ment manufacturer. Freightliner dealers must NOTE: See Fig. 1 for this procedure. have proof of this calibration history.
Page 252 33.00 Front Axle Alignment Caster Angle Checking and Adjusting CAUTION Failure to periodically retighten the U-bolt nuts could result in spring breakage and abnormal tire wear. 7. Using the steps above, replace the shim on the other side of the axle. 8.
Page 253 NOTE: B minus A equals toe-in. months by a qualiﬁed technician from the equip- Fig. ment manufacturer. Freightliner dealers must 1, Wheel Toe-In (overhead view) have proof of this calibration history. 7. Place the trammel bar at the front of the tires as shown in Fig.
Page 254 33.00 Front Axle Alignment Wheel Toe-In Checking and Adjusting 08/30/94 f330014a Fig. 2, Trammel Bar Positioning 08/30/94 f400100a Fig. 3, Calculating Wheel Toe-In 140/2 Recreational Vehicle Chassis Workshop Manual, Supplement 9, May 2004...
Page 255: Specifications
33.00 Front Axle Alignment Speciﬁcations NOTE: The speciﬁcations in Table 1 are for un- loaded vehicles. The speciﬁcations will vary as weight is added to the vehicle and transferred to the front axle. IMPORTANT: Caster settings for the left and right sides must be within 1/2 degree of each other.
Page 256: Wheel Hub
33.01 Front Axle Wheel Hubs and Wheel Bearings General Information General Information The front axle full-ﬂoating wheel hub assembly is made up of four major components: tapered wheel bearings, the wheel hub, wheel studs, and the brake drum or rotor. See Fig.
Page 257 33.01 Front Axle Wheel Hubs and Wheel Bearings General Information 4 5 6 7 12/05/97 f330151 1. Hub Cap Capscrew and Washer 7. Wheel Bearing Adjusting Nut 13. Wheel Stud 2. Hub Cap 8. Outer Wheel Bearing 14. Inner Wheel Bearing Cup 3.
Page 258 33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels Removal 4 5 6 7 12/05/97 f330151 1. Hub Cap Capscrew and Washer 7. Wheel Bearing Adjusting Nut 13. Wheel Stud 2. Hub Cap 8. Outer Wheel Bearing 14.
Page 259: Installation
33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels IMPORTANT: Use extreme care in cleaning the wheel hub cavity and axle spindle. Dirt, metal ﬁlings, or other debris can scratch the bearing roller surfaces, and cause premature wear of the bearing assembly.
Page 260 33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels the axle spindle, to prevent rust from forming be- hind the inner wheel bearing. 5. Install the new oil or grease seals. Seat the small outer edge of the seal in the recess of the tool adaptor.
Page 261 33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels 09/27/2005 f330023a NOTE: Typical application. Fig. 6, Insert the Tool seal back and forth. A slight movement indicates a damage-free installation. 09/27/2005 f330024a 6. Carefully mount the hub and inner wheel bearing assembly on the axle spindle.
Page 262 33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels hub’s drum pilot, then adjust the brake or have someone apply the brakes to hold the drum securely while you secure the drum using the stud at the 12 o’clock posi- tion, then the studs at about the 4 o’clock and 8 o’clock positions.
Page 263 33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels 11. Rotate the wheel in both directions. It should turn freely with no dragging or binding. 12. If the axle is equipped with grease-packed bear- ings, pack the hub between the bearing cups with lithium-based wheel bearing grease to the level of the smallest diameter of the cups.
Page 264 33.01 Front Axle Wheel Hubs and Wheel Bearings Axle Components Cleaning and Inspection Wheel Hub Assembly Inspection 1. Inspect the wheel hub mounting ﬂange. A loose wheel assembly will cause the ﬂange to be worn, jagged, or warped. See Fig. 1.
Page 265 33.01 Front Axle Wheel Hubs and Wheel Bearings Axle Components Cleaning and Inspection 04/14/94 f230017a Fig. 4, Damaged Wheel Stud Nut 5. Inspect the wheel studs or rim studs. Replace studs that are stripped, broken, bent, or other- wise damaged. See Subject 130 Sub- 04/14/94...
Page 266 33.01 Front Axle Wheel Hubs and Wheel Bearings Axle Components Cleaning and Inspection 04/14/94 f330004a Fig. 8, Rubbing Marks on Bearing Cage 05/12/94 f330085a 1. New Bearing 2. Worn Bearing Rollers Fig. 6, Wheel Bearing Roller Wear 04/14/94 f330086a Fig. 9, Etching (Pitting) on Bearing Surfaces 04/14/94 f330087a Fig.
Page 267 33.01 Front Axle Wheel Hubs and Wheel Bearings Wheel Bearing Cup Removal and Installation, Ferrous Hubs Removal Wheel bearing cups in ferrous hubs are removed by driving them out; there is no need to ﬁrst heat the hubs. 1. Using a solvent, completely remove all grease, oil, and other debris from the outer and inner surfaces of the wheel hub assembly.
Page 268 33.01 Front Axle Wheel Hubs and Wheel Bearings Wheel Stud Replacement, Disc Wheels Replacement needed to ensure the least amount of metal re- moval from the wheel stud bore. Concentrated heat will damage the hub. If the hub is damaged WARNING during wheel stud removal or installation, replace If a wheel stud breaks, the remaining studs are...
Page 269 33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Runout Measurements If either the lateral or radial runout of the hub is be- yond acceptable limits, replace the hub. For instruc- tions, see Subject 100 in this section. Measurements 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake.
Page 270 33.01 Front Axle Wheel Hubs and Wheel Bearings Hub Runout Measurements 04/01/2014 f330284 1. Hub 2. Dial Indicator (with roller point) Fig. 2, Setup to Measure Radial Runout 140/2 Recreational Vehicle Chassis Workshop Manual, Supplement 29, October 2014...
Page 271: Troubleshooting Tables
33.01 Front Axle Wheel Hubs and Wheel Bearings Troubleshooting Troubleshooting Tables Problem—Noisy Bearings or Excessive Bearing Replacement Intervals Problem—Noisy Bearings or Excessive Bearing Replacement Intervals Possible Cause Remedy Not enough oil was used on the bearings, Clean then inspect the bearings for wear. Replace worn seals. Coat the or the wrong type of oil was used.
Page 272 33.01 Front Axle Wheel Hubs and Wheel Bearings Troubleshooting Problem—Vehicle Doesn’t Slow Down Quickly Enough When the Brakes Are Applied Problem—Vehicle Doesn’t Slow Down Quickly Enough When the Brakes Are Applied Possible Cause Remedy The brake drums are worn, heat-checked, Install new brake drums.
Page 273: Specifications
Bearings Approved Lubricants for Freightliner Axles with Oil-Filled Hubs Recommended Lubricant Type Lubricant SAE Viscosity Grade Hypoid Gear Oil 80W–90 Table 3, Approved Lubricants for Freightliner Axles with Oil-Filled Hubs 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 10, April 2005...
Page 274: General Information
33.02 ™ Detroit Front Axles General Information General Information ™ Detroit front axles have a unique steering knuckle design that reduces vibration and wear. Low-friction, high-strength needle bearings roll on a large- diameter kingpin, replacing the conventional bush- ings. They are compatible with industry-standard brakes, hubs, and wheel bearings.
Page 275: Removal And Installation
33.02 ™ Detroit Front Axles Removal and Installation Removal Installation 1. Park the vehicle on a level surface, shut down 1. With the axle on a suitable jack, position it under the engine, set the parking brake, and chock the the vehicle.
Page 276 33.02 ™ Detroit Front Axles Steering Knuckle Disassembly and Assembly Disassembly 6. Remove the steering knuckle and spindle assem- bly from the axle beam. See Fig. NOTE: The following procedures can be done Remove the upper and lower snap rings with the axle installed on the vehicle or with the that hold the cover plates in place.
Page 277 33.02 ™ Detroit Front Axles Steering Knuckle Disassembly and Assembly 06/08/2011 f330211a NOTE: The number of upper and lower needle bearing sets may vary, depending on the axle model. 1. Tie-Rod Ball Joint 9. Lower Draw Key Nut 18. Shim 2.
Page 278 33.02 ™ Detroit Front Axles Steering Knuckle Disassembly and Assembly Assembly Align the steering knuckle with the axle beam, then check the clearance between the axle beam bore and the upper steer- IMPORTANT: If replacing the kingpin, use a ing knuckle bore. Clearance is to be a complete rebuild kit with all new components.
Page 279 33.02 ™ Detroit Front Axles Steering Knuckle Disassembly and Assembly 11. Attach the tie-rod arm to the tie rod. Tighten the castle nut 120 to 170 lbf·ft (163 to 230 N·m) plus a maximum of one-sixth of a turn to align a slot in the castle nut with the cotter pin hole in the tie rod stud.
Page 280 33.03 Front Axle Oil Seals General Information General Information Wheel oil seals (also called "oil bath seals" or "hub seals") work as a dam to keep oil in the hub cavity so that it constantly "bathes" the wheel bearings. Seals also protect the wheel bearings by keeping dirt, dust, and water out of the hub.
Page 281 33.03 Front Axle Oil Seals General Information 01/25/2008 f350488 A. Oil and Bearing Side B. Air Side Fig. 3, Scotseal Plus XL Oil Seal 050/2 Recreational Vehicle Chassis Workshop Manual, Supplement 29, October 2014...
Page 282 33.03 Front Axle Oil Seals Seal Replacement, Chicago Rawhide Scotseal Plus XL IMPORTANT: Make sure the required tools are 9. Apply a thin layer of lubricant to the inside and outside diameters of the seal using the same available before beginning the service proce- lube used in the hub.
Page 283 33.03 Front Axle Oil Seals Seal Replacement, Chicago Rawhide Scotseal Plus XL 07/09/2008 f580457 1. Handle 3. Plug Bushing 5. Washer 2. Driver Plate 4. Centering Tool 6. Nut Fig. 1, Installation Tool f330096a 08/08/94 f330021a 11/30/94 Fig. 3, Cleaning the Spindle NOTE: Rear hub shown.
Page 284 33.03 Front Axle Oil Seals Seal Replacement, Chicago Rawhide Scotseal Plus XL 09/27/2005 f330024a NOTE: Rear hub shown. Fig. 4, Striking the Tool 100/3 Recreational Vehicle Chassis Workshop Manual, Supplement 29, October 2014...
Page 285 33.03 Front Axle Oil Seals Speciﬁcations Scotseal Plus XL Tool and Seal Numbers Cone, Inner Bearing Seal Stock Number Centering Tool Driver Plate HM212049 35058 The seal stock number is listed on the air-side ﬂange of the seal. Table 1, Scotseal Plus XL Tool and Seal Numbers 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 29, October 2014...
Page 286 35.00 Rear Axle Alignment General Information General Information Rear axle alignment should be checked whenever rear axle or suspension components are replaced. It should also be checked when there is excessive front or rear tire wear, or hard or erratic steering. Manufacturers of axle alignment equipment offer a variety of systems to precisely measure and correct rear axle alignment.
Page 287 35.00 Rear Axle Alignment Preliminary Checks The following preliminary checks should be com- Group 32 in this manual or the suspension pleted before checking any alignment measurements. manufacturer’s service literature. Sagging, fa- tigued, or broken suspension springs create a lopsided vehicle appearance and an unbalanced Preliminary Checks weight distribution.
Page 288 35.00 Rear Axle Alignment Alignment Checking, Single Axle Checking Using Computerized 4. Make sure that all three marks are aligned and of equal distance from the outside edge of the Alignment Systems frame rail. Using a center point or trammel bar, place one pointer on the forwardmost point, and IMPORTANT: For vehicle alignment to be accu- make an arc with a pencil or soapstone on the...
Page 289 35.00 Rear Axle Alignment Alignment Checking, Single Axle f350110b 03/25/94 For items A and D, see Speciﬁcations 400. A. Distance from Rear Axle to Target (using Bee Line Alignment Tools) B. Maximum Allowable Difference if Aligned Manually = ±3/8 inch (9 mm) C.
Page 290: Materials Required
35.00 Rear Axle Alignment Center Point Bar Construction Materials Required NOTE: To obtain metric conversions (millime- ters), multiply the number of inches by 25.4. The following materials are required: • 62" of square steel tube (1" x 1", measured outside) •...
Page 291: Troubleshooting
35.00 Rear Axle Alignment Troubleshooting Chassis Vibration Diagnosis NOTE: Caterpillar engines have a D-shaped washer. and Repair 7. Check the clearance between the exhaust sys- tem and other components. Check for signs of 1. Test drive the vehicle and determine the nature contact between the exhaust and other compo- of the vibration.
Page 292 35.00 Rear Axle Alignment Troubleshooting Rear Axle Pinion Angle Pinion Angle: Engine Transmission Axle Seat Part Number Production Date degrees 16-15233-000 Cummins ISB MD 3060 — (Neway p/n 90501374) Cummins ISB MT 643 GAF P115527 — Cummins ISB 2000 MH NEW 90501414 —...
Page 293 The turn plates for the front wheels must rotate freely without friction, and the alignment equipment must be calibrated every three months by a qualiﬁed technician from the equip- ment manufacturer. Freightliner dealers must have proof of this calibration history. Maximum Tolerance from Perpendicular, Manual Method Maximum Tolerance ±...
Page 294 35.01 Rear Axle Wheel Hubs and Wheel Bearings General Information General Information The rear axle full-ﬂoating wheel hub assembly is made up of ﬁve major components: inner and outer tapered wheel bearings, the drive axle spindle as- sembly, the wheel hub, the brake drum, and the wheel studs.
Page 295 35.01 Rear Axle Wheel Hubs and Wheel Bearings General Information DRIVE AXLE SPINDLE erations, the replacement part may not be cor- rectly aligned on the spindle. This can cause ASSEMBLY damage to the spindle nut. The drive axle spindle assembly is made up of a WHEEL HUB drive axle ﬂange and shaft, drive axle studs and stud nuts, a ﬂange gasket, an axle spindle, an oil seal,...
Page 296 35.01 Rear Axle Wheel Hubs and Wheel Bearings General Information 02/22/94 f350055a 1. Serrations 2. Clipped Head Fig. 5, Typical Headed Wheel Studs installed on the driver’s side of the vehicle. Studs stamped with an "R" are right-hand threaded and are installed on the passenger’s side of the vehicle.
Page 297 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels Removal CAUTION 1. Chock the front tires to prevent vehicle move- When tapping the drive axle ﬂange, avoid striking ment. Release the parking brakes. the drive axle studs. If struck, the studs may bend or break, or the stud threads can be dam- 2.
Page 298 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels 12/10/97 f350164 1. Inner Wheel Bearing Cup 7. Gasket 12. Brake Drum 2. Inner Wheel Bearing 8. Jam Nut 13. Outer Wheel Bearing 3. Oil Seal 9.
Page 299: Installation
35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels 18. Remove the inner wheel bearing from the hub. If the bearings aren’t easily removed, place a pro- tective cushion where it will catch them. Then, use a hardwood drift and a light hammer to gen- tly tap the bearings (and seal, if needed) out of the cup.
Page 300 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels are corrosives) and could cause damage to both wheel bearing assemblies and the wheel hub. Seat the small outer diameter of the seal in the recess of the tool adaptor. See Fig.
Page 301 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels 08/30/2001 f350412 1. Axle Spindle 2. Adjusting Nut 3. Dowel 4. Lockring 5. Nut-Lock 6. Retaining Washer (may be used in place of nut- lock) 7.
Page 302 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels Jam Nut Torques Torque: lbf·ft (N·m) Locking Device 1-1/8 to 2-1/2 Inch Jam Nuts 2-5/8 Inch or Larger Jam Nuts Tanged Nut-Lock and Lockring 200 to 300 (271 to 407) 250 to 400 (339 to 542) Lockwasher and Lockring Table 1, Jam Nut Torques...
Page 303 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels for one minute on each side, to allow oil to run into the wheel end. 06/07/94 f330111 Fig. 10, Axle Shaft Flange Nut-Tightening Sequence 08/08/94 f330058a WARNING Fig.
Page 304 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Assembly Removal and Installation, Disc Wheels 06/07/94 f350061a A. Correct: Lube level at the bottom of the ﬁll hole. B. Incorrect: Lube level is below the ﬁll hole. Fig. 13, Checking Lubricant Level prevents stagnation, and minimizes the mainte- nance required on bearings and hub assem- blies.
Page 305 35.01 Rear Axle Wheel Hubs and Wheel Bearings Axle Components Cleaning and Inspection Wheel Hub Assembly and tions. Damaged nuts, usually caused by inad- equate tightening, must be replaced with new Drive Axle Inspection ones. See Fig. Inspect the wheel studs or rim studs. Replace 1.
Page 306 35.01 Rear Axle Wheel Hubs and Wheel Bearings Axle Components Cleaning and Inspection 06/30/93 f230016a 04/14/94 f330006a 1. Cup Fig. 5, Damaged Wheel Studs (shouldered type) 2. Cone meet. See Fig. 7. Replace the drive axle assem- Fig. 3, Spalling (Flaking) of Wheel Bearing Assembly bly if damaged.
Page 307 35.01 Rear Axle Wheel Hubs and Wheel Bearings Axle Components Cleaning and Inspection Wheel bearings should be very closely inspected at the time of disassembly. The best inspection condi- tions are possible only after the bearings have been thoroughly cleaned using kerosene or diesel fuel oil, and a stiff brush.
Page 308 35.01 Rear Axle Wheel Hubs and Wheel Bearings Axle Components Cleaning and Inspection 04/14/94 f330004a Fig. 11, Rubbing Marks on Bearing Cage 05/12/94 f330085a 1. New Bearing 2. Worn Bearing Rollers Fig. 9, Signs of Wear 04/14/94 f330086a Fig. 12, Etching (Pitting) on Bearing Surfaces 04/14/94 f330087a Fig.
Page 309 35.01 Rear Axle Wheel Hubs and Wheel Bearings Wheel Bearing Cup Removaland Installation, Ferrous Hubs Removal Wheel bearing cups are removed from ferrous hubs by driving them out; there is no need to ﬁrst heat the hubs. 1. Using a solvent, completely remove all grease, oil, and other debris from the outer and inner surfaces of the wheel hub assembly.
Page 310 35.01 Rear Axle Wheel Hubs and Wheel Bearings Wheel Stud Replacement, Disc Wheels Replacement 4. Apply a coat of clean axle grease to the entire shaft on headed studs. 5. With the hub on a suitable press, make sure the WARNING hub ﬂange is evenly supported around and next to the stud being installed.
Page 311 35.01 Rear Axle Wheel Hubs and Wheel Bearings Wheel Stud Replacement, Disc Wheels 06/30/93 f350014a Fig. 2, Wheel Nuts 130/2 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 312 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Runout Measurements If either the lateral or radial runout of the hub is be- yond acceptable limits, replace the hub. For instruc- tions, see Subject 100 in this section. Measurements 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake.
Page 313 35.01 Rear Axle Wheel Hubs and Wheel Bearings Hub Runout Measurements 04/01/2014 f350590 1. Hub 2. Dial Indicator (with roller point) Fig. 2, Setup to Measure Radial Runout 140/2 Recreational Vehicle Chassis Workshop Manual, Supplement 29, October 2014...
Page 314: Troubleshooting
35.01 Rear Axle Wheel Hubs and Wheel Bearings Troubleshooting Problem—Noisy Bearings or Excessive Bearing Replacement Intervals Problem—Noisy Bearings or Excessive Bearing Replacement Intervals Possible Cause Remedy Not enough oil was used on the bearings, Clean then inspect the bearings for wear. Replace worn seals. Coat the or the wrong type of oil was used.
Page 315: Specifications
35.01 Rear Axle Wheel Hubs and Wheel Bearings Speciﬁcations Torque Values Fastener Description Size (grade 8) Torque lbf·ft (N·m) Wheel Brake Drum Nuts 3/4–10 240 (325) Hub Cap Capscrews 5/16–18 15 (20) Drive Axle Stud Nuts (with or without 5/8–18 150-170 (203-230) dowels) 1/2–13...
Page 316: General Information
Fig. 1, Rear Axle ID Tag NOTE: Detroit axles are a proprietary product, though in some applications they may be re- ferred to as "Freightliner" or "Axle Alliance" axles or "MB components." 050/1 Recreational Vehicle Chassis Workshop Manual, Supplement 25, October 2012...
Page 317 35.02 ™ Detroit Rear Axles Single Axle Removal and Installation Removal 15. Remove the brake shoes. For instructions, see the applicable service brake section in Group For rear axle components, see Fig. 16. If applicable, disconnect the leveling valve rod(s) 1.
Page 318 35.02 ™ Detroit Rear Axles Single Axle Removal and Installation 05/23/2005 f350459 1. Differential Carrier 4. Carrier Yoke 6. Rear Axle Housing 2. Radial Shaft Seal 5. Carrier Capscrew 7. Axle Shaft 3. Yoke Nut Fig. 1, Single Axle Components On vehicles with air suspensions, in addi- 5.
Page 319 35.02 ™ Detroit Rear Axles Single Axle Removal and Installation 10. Using new gaskets, install the axle shafts. For instructions, see Subject 120. 11. Install the brake drums on the hubs. 12. Install the tire and wheel assemblies. For instruc- tions, see Group 13.
Page 320 35.02 ™ Detroit Rear Axles Single Axle Differential Carrier Removal and Installation Removal 3. With the differential carrier securely supported, remove it from the axle housing. NOTE: The differential carrier can be removed Installation either with the rear axle installed on the vehicle or with the rear axle removed from the vehicle.
Page 321 35.02 ™ Detroit Rear Axles Single Axle Differential Carrier Removal and Installation 05/23/2005 f350459 1. Differential Carrier 4. Carrier Yoke 6. Rear Axle Housing 2. Radial Shaft Seal 5. Carrier Capscrew 7. Axle Shaft 3. Yoke Nut Fig. 1, Single Axle Components IMPORTANT: The end caps ﬁt tightly into the axle housing.
Page 322 35.02 ™ Detroit Rear Axles Single Axle Differential Carrier Removal and Installation 8. Connect the driveshaft to the carrier input yoke. For instructions, see Section 41.00, Sub- ject 110. 9. Using new gaskets, install the axle shafts. For instructions, see Subject 120.
Page 323 35.02 ™ Detroit Rear Axles Axle Shaft Removal and Installation Removal Carefully raise the axle with the ﬂoor jack, and support the axle with jack stands. Slide the axle shaft into the axle. 1. Chock the front tires. Apply light pressure with the hand or knee 2.
Page 324: Special Tools
35.02 ™ Detroit Rear Axles Single Axle Yoke and Seal Replacement, Model 4 Axles Special Tools ing. Do not allow dirt or grease to contaminate the seal bore or shaft bearings. See Fig. Special tools are required for this procedure. See 5.
Page 325 35.02 ™ Detroit Rear Axles Single Axle Yoke and Seal Replacement, Model 4 Axles NOTE: It is not necessary to replace the yoke when replacing the seal. 7. Install a new M45 x 1.5 yoke nut on the carrier yoke and tighten 627 lbf·ft (850 N·m). 8.
Page 326 35.02 ™ Detroit Rear Axles Speciﬁcations Torque Values Application Size Torque: lbf·ft (N·m) Detroit Axles (all models) 115 (156) Carrier Capscrews 200 (270) 1/2–20 75–115 (102–156) Drive Axle Stud Nuts 5/8–18 150–170 (203–230) Pinion Nut (model 2 axles) M40 x 1.5 370 (502) Pinion Nut (model 4 axles) M45 x 1.5...
Page 327 35.02 ™ Detroit Rear Axles Speciﬁcations Special Tools for Axle Yoke and Seal Replacement, Model 4 Axles Tool Description Manufacturer Part Number Output Seal Installer Kent-Moore J-47368 f580408 † Yoke Nut Socket Daimler MBA 742589020700 f580450 To order Kent-Moore tools call 1-800-328-6657. †...
Page 328: Wheels And Tires
40.00 Wheels and Tires General Information General Information Wheels and Tires The tires support the weight of the vehicle, and are integral parts of the drivetrain and braking systems. The wheels serve as load carrying members be- tween the tires and the axle. The disc wheels consist of a rim and disc.
Page 329 40.00 Wheels and Tires General Information certiﬁcation label. See the vehicle chassis operator’s manual for the location of these labels. Tire and rim labels certify the minimum tire and rim combinations that can be installed on the vehicle for the given GAWRs. Each GAWR is determined by considering each component of the axle system, in- cluding suspension, axle, wheels, and tires.
Page 330 40.00 Wheels and Tires General Information • If both radial and bias ply tires are used, better handling is usually obtained by using the bias ply tires on the front axle. CAUTION Mixing radial and bias ply tires should be done as an emergency measure only.
Page 331 40.00 Wheels and Tires 8-Hole Disc Wheel With Two-Piece Flange Nuts Removal and Installation Removal CAUTION 1. Park the vehicle on a level surface and apply the The wheel center hole and hub pilot have close parking brakes. Shut down the engine. Chock all tolerances.
Page 332 40.00 Wheels and Tires 8-Hole Disc Wheel With Two-Piece Flange Nuts Removal and Installation 7. Check that the wheel is correctly seated against 10. After operating the vehicle for 50 to 100 miles the hub and on the hub-pilot pads. (80 to 160 km), retighten the wheel nuts 450 to 500 lbf·ft (610 to 678 N·m).
Page 333 40.00 Wheels and Tires 10-Hole Disc Wheel With Two-Piece Flange Nuts Removal and Installation Removal 2. Apply a few drops of light engine oil to the wheel studs and the area between the body and the ﬂange of each two-piece ﬂange nut. Wipe off any 1.
Page 334 40.00 Wheels and Tires 10-Hole Disc Wheel With Two-Piece Flange Nuts Removal and Installation 6. Install and hand-tighten the remaining two-piece 10. After operating the vehicle for 50 to 100 miles ﬂange nuts. Tighten the nuts 50 lbf·ft (68 N·m) (80 to 160 km), retighten the wheel nut 450 to following the sequence in Fig.
Page 335 40.00 Wheels and Tires 10-Hole Disc Wheel With Inner and Outer Nuts Removal and Installation Removal the same side of the assembly as the brake drum balance weight(s). See Fig. 1. Park the vehicle on a level surface and apply the If, on ﬁve-handhole or aluminum wheels, the parking brakes.
Page 336 40.00 Wheels and Tires 10-Hole Disc Wheel With Inner and Outer Nuts Removal and Installation 07/14/93 f400035a 1. Brake Drum Balance Weight(s) 5. Outer Wheel Balance Weight(s) 2. Inner and Outer Wheel Balance Weight(s) 6. Inner Wheel Balance Weight(s) 3. Hub 7.
Page 337 40.00 Wheels and Tires 10-Hole Disc Wheel With Inner and Outer Nuts Removal and Installation 08/23/93 f400081a Fig. 4, 10-Stud Disc Wheel Tightening Sequence CAUTION Locknuts seat during vehicle operation. It is nec- essary to periodically tighten the wheel nuts to the speciﬁed torque.
Page 338: Tire Inflation
40.00 Wheels and Tires Tire Inﬂation • Metal rings, which use a blast of compressed Tire Inﬂation air to seat the beads. • Rubber rings, which seal between the tire bead WARNING and rim, allowing the bead to move out and seat correctly.
Page 339: Safety Precautions
40.00 Wheels and Tires Tire Demounting and Mounting Service Precautions • Handle the wheels and rims on a wooden ﬂoor Safety Precautions or rubber mat to prevent nicking or gouging the wheel or rim. IMPORTANT: Don’t mount or demount tires •...
Page 340 40.00 Wheels and Tires Demounting and Mounting Tubeless Tires on One-Piece Drop Center Wheels or Rims Fifteen Degree Tapered Drop Center WARNING Read the information under Subject 140. Failure to follow the precautions, before and during tire demounting and mounting, could cause tire or rim damage while servicing or in use.
Page 341 40.00 Wheels and Tires Demounting and Mounting Tubeless Tires on One-Piece Drop Center Wheels or Rims 05/13/94 f400005a 05/13/94 f400006a Fig. 3, Prying the Rim Out of the Tire Fig. 4, Valve Stem Installation lubricant to enable correct bead seating, and to make mounting easier.
Page 342 40.00 Wheels and Tires Demounting and Mounting Tubeless Tires on One-Piece Drop Center Wheels or Rims 05/13/94 f400008a Fig. 6, Working the Upper Bead into the Rim 150/3 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 343 40.00 Wheels and Tires Wheel and Components Inspection Inspection Remove all foreign matter, such as grease and dirt, from the wheel mounting surface. Smooth any pro- jections on the mounting surface to ensure even WARNING pressure when tightening the wheel nuts. Failure to inspect the tires and wheels and cor- rect any problems, could cause tire or rim dam- age while servicing or while in use.
Page 344 40.00 Wheels and Tires Tire and Components Inspection Inspection WARNING Failure to inspect the tires and wheels and cor- rect any problems, could cause tire or rim dam- age while servicing or while in use. An incor- rectly mounted tire can burst causing equipment damage and personal injury.
Page 345: General Information
40.00 Wheels and Tires Wheel and Tire Runout Measurements General Information Runout is side-to-side (lateral) or up-and-down (ra- dial) movement when the tire/wheel assembly is ro- tated. Runout can be measured with a dial indicator, a tire runout gauge, or another instrument capable of measuring small movements of the tire/wheel assem- bly.
Page 346 40.00 Wheels and Tires Wheel and Tire Runout Measurements • hub radial runout measured near the hub Wheel Runout Speciﬁcations pilots—0.015 inch (0.38 cm) Lateral Runout: Radial Runout: Wheel Type If hub and brake drum runouts are within speciﬁca- inches (cm) inches (cm) tion, then the wheel runout will need to be checked.
Page 347 40.00 Wheels and Tires Wheel and Tire Runout Measurements 02/04/2013 f400374 A. Tubeless Aluminum Disc Wheel B. Tubeless Steel Disc Wheel 1. Lateral Runout 2. Radial Runout Fig. 4, Runout Check for Wheels 180/3 Recreational Vehicle Chassis Workshop Manual, Supplement 27, October 2013...
Page 348: Troubleshooting Tables
40.00 Wheels and Tires Troubleshooting Troubleshooting Tables Problem—Abnormal Tire Wear Problem—Abnormal Tire Wear Possible Cause Remedy Tires are not inﬂated to the correct Operate the tires at the recommended inﬂation pressure and use the proper pressure. size tires, wheels, and rims for the load to be carried. Refer to the applicable tables in Speciﬁcations 400 for speciﬁcations.
Page 349 40.00 Wheels and Tires Troubleshooting Problem—Excessive On-the-Road Tire Failures Possible Cause Remedy Water or foreign material is inside the Clean and dry the tires prior to mounting. Make sure excess lubricant does not casing. ﬂow down into the tire. Store unmounted tires indoors, or under cover, to prevent moisture from collecting inside.
Page 350 40.00 Wheels and Tires Speciﬁcations IMPORTANT: Do not reduce the pressure of a proved for a higher load or inﬂation. Some rims hot tire if it exceeds the speciﬁed pressure. In and wheels are stamped with a maximum load normal driving, tire temperature and inﬂation and maximum cold inﬂation rating.
Page 351 40.00 Wheels and Tires Speciﬁcations 01/21/93 f230015a 1. Head-Type Wheel Stud (1-1/8–16) 2. Wheel Nut Fig. 1, Head-Type Wheel Stud 400/2 Recreational Vehicle Chassis Workshop Manual, Supplement 13, October 2006...
Page 352: Tire Pressure Monitoring System
40.01 Tire Pressure Monitoring System General Information General Information IMPORTANT: See the SmarTire Tire Pressure Monitoring System (TPMS) Owner’s Manual in- cluded with this vehicle for additional informa- tion, including operation, TPMS warnings, and proper tire removal/installation. The Tire Pressure Monitoring System (TPMS) con- stantly monitors the pressure and temperature of each tire on the vehicle, and provides tire status in- formation to warn the driver about a tire-related prob-...
Page 353 40.01 Tire Pressure Monitoring System Tire Pressure Monitoring System (TPMS) Component Replacement Replacement Receiver The existing receiver is externally mounted near the IMPORTANT: If any TPMS component(s) should front of the vehicle and is in a position as close to ever need to be replaced, it should be done so the vehicle’s centerline as possible.
Page 354 40.01 Tire Pressure Monitoring System Tire Pressure Monitoring System (TPMS) Component Replacement 01/14/2008 f400282 1. Wiring 2. Receiver Fig. 2, TPMS Wiring to the Receiver 5. Make sure all wiring harness connections are correctly locked and secured. 100/2 Recreational Vehicle Chassis Workshop Manual, Supplement 17, October 2008...
Page 355 40.01 Tire Pressure Monitoring System Tire or Tire Sensor Replacement Replacement cess metal strap must be removed or it could break off and damage the tire. IMPORTANT: Tire sensors can be broken when 8. Slide the sensor in place. mounting and demounting a tire if the speciﬁc IMPORTANT: The sensor must always be in- instructions listed here are not followed.
Page 356 40.01 Tire Pressure Monitoring System Tire or Tire Sensor Replacement 09/18/2007 f400272 Fig. 1, Sensor Location Decal 6. Repeat the last two steps to remove the bottom bead. 7. Cut the metal strap that holds the tire sensor in place and remove the sensor. 8.
Page 357 40.01 Tire Pressure Monitoring System Tire or Tire Sensor Replacement 09/18/2007 f400273 A. Beads are pushed under the rim ﬂange opposite the sensor. B. The beads are worked over the ﬂange toward the sensor. C. The bead slips over the rim ﬂange at the sensor without contacting it. Fig.
Page 358 40.01 Tire Pressure Monitoring System Tire or Tire Sensor Replacement 09/19/2007 f400276 1. Mounting Hook Fig. 6, Mounting Hook Placement 110/4 Recreational Vehicle Chassis Workshop Manual, Supplement 17, October 2008...
Page 359: System Programming
40.01 Tire Pressure Monitoring System System Programming System Programming axles by clicking them on the screen. Once the axle is removed, it will no longer be highlighted. Dual wheel axle can also be selected on the If a tire sensor is damaged, it will have to be re- screen if it is present on the vehicle.
Page 360 40.01 Tire Pressure Monitoring System System Programming on the laptop. Next, push "initiate" on the LF Initiator. Each tire will ap- pear in red on the laptop screen. Once each tire has been veriﬁed, it will appear in white on the laptop screen.
Page 361 Cycle ignition power for the vehicle one more time to restart the display black or shows black lines but no SmarTire logo. and clear the screen. If the screen remains black, contact Freightliner Custom Chassis Corporation. The gauge only displays dashes for the tire Depending on the type of tire sensor purchased, the vehicle may need information;...
Page 362 40.01 Tire Pressure Monitoring System Troubleshooting Tire Pressure System Troubleshooting Problem Solution A tire continues to show a deviation value/ Check the CIP value in the gauge to make sure it matches that of the warning although it has the correct amount of intended inﬂation value for the tire in question.
Page 363 40.01 Tire Pressure Monitoring System Speciﬁcations Figure 1 shows a wiring schematic for the Tire Pres- sure Monitoring System (TPMS). See Figure 2 low range cold inﬂation pressure (CIP) and Figure 04/15/2008 f400286 Fig. 1, TPMS Wiring Schematic Pressure / Temperature Correlation Chart: Pressure / Temperature Correlation Chart: Low Pressure Range High Pressure Range...
Page 364: Driveline Components
41.00 Driveline Components General Information General Information SLIP-JOINTS, U-JOINTS, AND YOKES The simplest driveline consists of a transmission output-shaft end-yoke, an axle input-shaft end-yoke, The basic function of the driveline is to send torque and a single slip-jointed driveshaft connecting the from the transmission to the axle in a smooth and two end-yokes.
Page 365 ﬂange-yokes by capscrews inserted through semicir- NOTE: Components shown are typical of all U-joints cular bearing straps that hold the bearing cups in installed on Freightliner chassis with half-round end- place under tabs in the yoke cross-holes. See Fig. yokes.
Page 366 41.00 Driveline Components General Information 05/02/95 f410006b A. In Phase B. Out of Phase Fig. 6, U-Joint Phasing After manufacture, each driveline yoke is statically balanced. After assembly, each driveshaft and cou- pling shaft is checked for out-of-roundness, straight- ened as necessary, then dynamically balanced. AVOIDING DRIVELINE 05/02/95 f410072b...
Page 367 41.00 Driveline Components General Information movement of a driveshaft will cause driveline imbal- ance: loose end-yoke nuts, loose U-joint bearing cup retaining capscrews, worn U-joint trunnions and bear- ings, and worn slip-joint splines. Among the most common causes of U-joint and slip- joint damage is lack of lubrication.
Page 368 41.00 Driveline Components U-Joint Uncoupling and Coupling NOTE: It is easier to check driveline parts, and Check the torque on the end-yoke nut; see the applicable table in Speciﬁca- to replace a U-joint or midship bearing assembly tions, 400. if the driveshaft is removed from the vehicle. If a driveshaft requires straightening or balancing, it Check the end-yoke (or ﬂange-yoke) must be removed, and installed on a lathe or a...
Page 369 41.00 Driveline Components U-Joint Uncoupling and Coupling 02/26/98 f410387 NOTE: Not all fasteners are shown. A. End-yoke cross-hole centerline is horizontal. B. Install a half-round bearing-cup retaining wire (or safety wire) before removing the bearing straps. 1. Transmission 4. Retaining-Wire Groove 2.
Page 370 41.00 Driveline Components U-Joint Uncoupling and Coupling 6. If they were removed, install the fasteners that attach each midship bearing to its bracket; tighten the ﬂanged locknuts 91 lbf·ft (123 N·m). 7. Lubricate the U-joint, following the procedure in Group 41 of the chassis maintenance manual. 8.
Page 371: Driveshaft Installation
41.00 Driveline Components Driveshaft Removal and Installation NOTE: Many service operations do not require driveshaft removal from the vehicle: end-yoke or companion-ﬂange nut tightening; drive compo- nent shaft seal, end-yoke, or ﬂange-yoke re- placement; changing U-joint phasing at the slip- yoke;...
Page 372 41.00 Driveline Components Driveshaft Removal and Installation 02/19/98 f410386 NOTE: Not all fasteners are shown. A. Uncouple this end ﬁrst; couple this end last. B. Uncouple this end last; couple this end ﬁrst. 1. Transmission Output-Shaft Half-Round End-Yoke 3. Single Axle or Forward-Rear Axle Input-Shaft Half- 2.
Page 373 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly U-Joint Removal 1. Remove the driveshaft from the vehicle; see Subject 110. 2. Clamp the driveshaft in a soft-jawed vise; do not distort the tube with excessive grip. 3.
Page 374 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly IMPORTANT: Misaligned driveshaft yokes will the remaining bearing assembly moves straight out of the cross-hole. cause the U-joints to be out of phase, which will cause vibration in the driveline. IMPORTANT: If the cross or bearing assem- bly is cocked, the bearing assembly will 2.
Page 375 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly 05/10/95 f410092b Fig. 7, Axle End-Yoke Locknut 05/08/95 f410147 A. Axle End-Yoke B. Coupling Shaft End-Yoke 1. Yoke Puller 2. Full-Round End-Yoke Fig. 9, Removing a Full-Round End-Yoke Driveshaft Tube, Slip-Joint, Sleeve-Yoke, and Tube-Yoke Cleaning and Inspection...
Page 376 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly splined shaft if the slip-joint is damaged; see the torque value given in Speciﬁcations, 400. If "Slip-Joint Replacement or Assembly" and the end-yoke is still loose after tightening the "Driveshaft Tube, Stub Shaft (Slip-Joint), and yoke nut, install a new yoke and yoke nut.
Page 377 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly 11/28/94 f410106a Fig. 14, Forcing Out Old Lubricant From a U-Joint Cross dry with compressed air. Check for minute par- ticles of dirt or grit, and clean again if necessary. 4.
Page 378 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly To replace a driveshaft tube, a tube-yoke, or a stub shaft, the driveshaft must be chucked in a lathe, so the welds can be removed. See Fig. 17.
Page 379 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly Slip-Joint Replacement or 2. Make sure the alignment marks on the slip-joint assembly are aligned, to keep the U-joints in Assembly phase. See Fig. 4 Fig. IMPORTANT: Misaligned driveshaft yokes will IMPORTANT: Parts for different series drivelines cause the U-joints to be out of phase, which will must not be intermixed.
Page 380 41.00 Driveline Components Driveline Component Removal/Disassembly, Cleaning and Inspection, and Replacement or Installation/Assembly 1. Apply Loctite 242 to the input- or output-shaft threads where the end-yoke locknut will be in- stalled. See Fig. 2. By hand, install the end-yoke on the input or out- put shaft as far as it will go.
Page 381 Driveline Angularity and Balance Driveline angularity is dependant on the type of axle and suspension the vehicle has. Contact customer support at Freightliner Custom Chassis Corporation for speciﬁcations and procedures covering driveline angularity and driveline balance. 130/1 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 382: Troubleshooting Procedure
41.00 Driveline Components Troubleshooting Troubleshooting Procedure it is ﬁrmly against a ﬂat side of the tightened cap- screw head. Noise or vibration associated with the driveline can CAUTION be caused by non-driveline parts. To ﬁnd the cause of noise or vibration, ﬁrst road test the loaded ve- Do not overtighten the bearing-cup-plate or hicle.
Page 383 41.00 Driveline Components Troubleshooting NOTE: To disassemble the slip-joint, un- If damaged, jack up the rear axle, support it on jackstands, place the transmission in neutral, and couple the U-joint at one end of the drive- turn the driveshaft by hand to check runout. shaft, unscrew the slip-joint seal from the sleeve-yoke, then pull the sleeve-yoke and The driveshaft must be straight within 0.015 in...
Page 384: Specifications
41.00 Driveline Components Speciﬁcations Fastener Torques Description Size Torque: lbf·ft (N·m) End-Yoke Nut Transmission Output Shaft Allison MD Series 2–16 600–800 (815–1085) RS-15-120, RS- 15-210, RS-17- M32 x 1.5 740–920 (1000–1250) 140, RS-17-220 Single Axle Input Shaft Meritor RS-23-160 M45 x 1.5 1000–1230 (1355–1670) RS-23-240 M39 x 1.5...
Page 385 41.00 Driveline Components Speciﬁcations U-Joint Removal Tool Kit (For removing Spicer 1610, 1710, 1760 and 1810 U-joints and Meritor 17N, 17T, 176T and 18T U-joints from full-round yokes) To order Owatonna Tool Kit No. 7057, contact: Owatonna Tool Company Owatonna, Minnesota 55060 End-Yoke/Flange-Yoke Puller (For removing end-yokes from transmission output shafts, coupling shafts, and rear-axle input and out-...
Page 386 42.00 Air Brake Plumbing, Chassis Diagrams XC Model Air Plumbing Diagram, Chassis Built From July 1997 Fig. 1 for a full view of the chassis plumbing diagram. See Fig. 2 Fig. 3 for a partial view. Fig. 2 Fig. 3 Ref.
Page 387 42.00 Air Brake Plumbing, Chassis Diagrams XC Model Air Plumbing Diagram, Chassis Built From July 1997 Fig. 3 Ref. Diag. D12−16290 03/03/98 f542430 Fig. 2, Air Plumbing Diagram, Chassis Built From July 1997 (partial view) 100/2 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 388 42.00 Air Brake Plumbing, Chassis Diagrams XC Model Air Plumbing Diagram, Chassis Built From July 1997 Fig. 2 03/03/98 f542431 Fig. 3, Air Plumbing Diagram, Chassis Built From July 1997 (partial view) 100/3 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 389: General Information
42.01 Air Brake System Troubleshooting General Information General Information This troubleshooting guide is designed to help locate causes of problems originating in the air brake sys- tem. The corrective measures given are not intended to replace the detailed service information found in other sections of this manual or in the component manufacturer’s service manuals.
Page 390: Safety Precautions
42.01 Air Brake System Troubleshooting Safety Precautions Safety Precautions WARNING Follow the manufacturer’s procedures while working on any air device so as to avoid injury or damage from parts which, when released, are subject to mechanical (spring) or pneumatic pro- pulsion.
Page 391: Troubleshooting Tables
42.01 Air Brake System Troubleshooting Troubleshooting Troubleshooting Tables Problem—Vehicle Does Not Slow Down Quickly Enough When Brakes Are Applied Problem—Vehicle Does Not Slow Down Quickly Enough When Brakes Are Applied Possible Cause Remedy The vehicle is overloaded. Observe the recommended maximum load limits. There is low air pressure in the brake The drain cock on the air reservoir was left open;...
Page 392 42.01 Air Brake System Troubleshooting Troubleshooting Problem—Service Brakes Release Too Slowly Problem—Service Brakes Release Too Slowly Possible Cause Remedy The brake shoe anchor pins are frozen. Inspect the anchor pins. If damaged, replace them; if not damaged, lubricate them. Lubrication of the brake system Lubricate those components requiring periodic lubrication.
Page 393 42.01 Air Brake System Troubleshooting Troubleshooting Problem—Service Brakes Apply When the Parking Brakes Are Released With Air Pressure Possible Cause Remedy There is a leaking push rod seal between Replace the push rod seal. the parking brake and the service brake. The braking mechanism is binding.
Page 394 42.01 Air Brake System Troubleshooting Troubleshooting Problem—Service Brakes Grab or Pull Possible Cause Remedy Grease has saturated the brake linings or Install a matched set of linings on both sets of brake shoes on that axle. the linings are glazed. Clean, replace, or turn both brake drums.
Page 395 42.01 Air Brake System Troubleshooting Troubleshooting Problem—Dragging Service Brake Problem—Dragging Service Brake Possible Cause Remedy The service brake return spring is broken. Replace the service brake return spring. The service-application air is not Test the air system valves for leakage and operation. exhausting or not exhausting fast enough, due to blockage in the control valve, the quick-release valve, or the limiting and...
Page 396 42.01 Air Brake System Troubleshooting Troubleshooting Problem—Air Pressure Will Not Rise to Normal Problem—Air Pressure Will Not Rise to Normal Possible Cause Remedy The air pressure gauge(s) on the dash is Check the dash gauge with an accurate test gauge. Replace the dash (are) registering inaccurately.
Page 397 42.01 Air Brake System Troubleshooting Troubleshooting Problem—Air Pressure Drops Quickly With the Engine Stopped and the Brakes Released Possible Cause Remedy The air compressor discharge valve is Repair or replace the discharge valve. If disassembly is not recommended by leaking. the compressor manufacturer, replace the air compressor with a factory-rebuilt or a new unit.
Page 398 42.01 Air Brake System Troubleshooting Troubleshooting Problem—Safety Valve Activates Possible Cause Remedy The air reservoirs need to be drained Drain the air reservoirs daily. more often. Problem—Oil or Water in the Brake System Problem—Oil or Water in the Brake System Possible Cause Remedy Excessive oil is passing through the air...
Page 399 42.02 Air Lines and Fittings Safety Precautions • To avoid injury, keep clear of the air chamber Safety Precautions pushrod when brakes are applied or when air is exhausted from the system. Before attempting to work on the air brake system, observe the following precautions: •...
Page 400 42.02 Air Lines and Fittings Air Lines Replacement Pull the air line out of the ﬁtting. WARNING 4. Use pliers to remove the stainless steel insert from the ﬁtting. Discard the insert. Make sure the air system has been reduced to 0 psi before attempting to remove an air line.
Page 401 42.02 Air Lines and Fittings Air Lines Replacement 04/24/2000 f420003a A. Air line end must bottom before tightening the nut. Fig. 3, Installing Nylon Air Line into Compression 02/14/2002 f422349 Fitting 1. Push-to-Connect Fitting 13. Pressurize the air system. Check the air system 2.
Page 402 42.02 Air Lines and Fittings Air Lines Replacement 4. Make sure the wire braid air line assembly is free of grease and dirt. Replace the assembly if the air line or ﬁtting is crimped or otherwise dam- aged. 5. Install the air line and ﬁnger-tighten the nut. 6.
Page 403 42.02 Air Lines and Fittings Fittings Replacement WARNING Make sure the air system has been reduced to 0 psi before attempting to remove an air line. Do not disconnect pressurized air lines as they may whip as air escapes. Failure to take all necessary precautions could result in personal injury.
Page 404: Quick-Connect Fittings
42.02 Air Lines and Fittings Fittings Replacement 7. Pressurize the air system. Check the air system for leaks. 8. Remove the chocks from the tires. Copper Fittings 1. Park the vehicle on a level surface and apply the parking brakes. Shut down the engine. Chock the tires.
Page 405 42.02 Air Lines and Fittings Fittings Replacement 12. Pressurize the air system. Check the air system for leaks. 13. Remove the chocks from the tires. 120/3 Recreational Vehicle Chassis Workshop Manual, Supplement 8, January 2002...
Page 406: Specifications
42.02 Air Lines and Fittings Speciﬁcations Nylon Air Lines 213 Wire Braid Air Lines Inside Outside Minimum Bend Inside Outside Minimum Bend Number Diameter Diameter Radius Number Diameter Diameter Radius Inch Inch inches (mm) Inch Inch inches (mm) 0.170 1.00 (25) 3/16 0.49 0.75 (20)
Page 407 42.02 Air Lines and Fittings Speciﬁcations Brass or Steel Pipe Fittings on Plastic Components Torque Port Size Description Inch lbf·in (N·cm) lbf·ft (N·m) 60–90 (680–1020) — Midland Quick Release Valve — 13–17 (18–23) Bendix MV-2/MV-3 Valve — 10 (14) Tighten to the lower torque value. If needed, turn the ﬁttings to allow for the proper routing of the air lines. Table 5, Brass or Steel Pipe Fittings on Plastic Components Copper Fittings Additional Turns from Hand-...
Page 408: Air Reservoir
42.03 Air Reservoir General Information General Information Each reservoir and/or reservoir compartment is iden- tiﬁed as one of three types: supply, primary, and sec- ondary. the supply air and primary air compartments are located within the same reservoir. There may be up to three compartments in the secondary reservoir encompassing the secondary air and the air require- ments of the front suspension.
Page 409 42.03 Air Reservoir Safety Precautions Safety Precautions When working on or around air reservoirs and com- ponents, the following precautions should be ob- served: 1. Never connect or disconnect a hose or line con- taining air pressure. It may whip as air escapes. Never remove a component or pipe plug unless you are certain all system pressure has been released.
Page 410: Leakage Tests
42.03 Air Reservoir Leakage Tests Tests IMPORTANT: Before working on or around air reservoirs and components, review Safety Pre- cautions, 100. NOTE: If equipped with an automatic drain valve, see Section 42.08 for leak testing. Be sure the air system is fully charged. Using a soap solution or leak detector, check for leaks on the out- side surfaces of the reservoirs and drain valves.
Page 411 42.03 Air Reservoir Drain Valve Replacement and Leak Elimination Drain Valve Replacement and Leak Elimination IMPORTANT: Before working on or around air reservoirs and components, review Safety Pre- cautions, 100. NOTE: If equipped with an automatic drain valve, see Section 42.08.
Page 412 42.03 Air Reservoir Air Reservoir Replacement Replacement 4. Mark all reservoir air lines, couplers, and valves for later assembly. Carefully disconnect the parts. Cap the exposed ports tightly to keep out con- IMPORTANT: Before working on or around air taminants. If access is limited, remove air lines reservoirs and components, review Safety Pre- after loosening the reservoir in the straps.
Page 413 42.03 Air Reservoir Air Reservoir Replacement 5. Remove the transverse link bracket. Use at least one person to hold the bracket in place while performing the following substeps. On the drivers-side, remove the two re- taining bolts that fasten the transverse link bracket to the frame rail.
Page 414: Brake Drums
42.04 Brake Drums General Information General Description The front and rear axle full-ﬂoating wheel hub as- sembly is made up of four major components: ta- pered wheel bearings, the wheel hub, wheel studs, and the brake drum. See Fig. 1 Fig.
Page 415: Installation
42.04 Brake Drums Outboard-Mounted Drum Removal and Installation 4. Remove wheel and tire assemblies. For instruc- WARNING tions, see Group When replacing brake pads, shoes, rotors, or 5. Remove the brake drum. See Fig. 1 Fig. drums, always replace components as an axle To minimize the possibility of creating airborne set.
Page 416 42.04 Brake Drums Outboard-Mounted Drum Removal and Installation 4 5 6 7 12/05/97 f330151 1. Hub Cap Capscrew and Washer 7. Wheel Bearing Adjusting Nut 13. Wheel Stud 2. Hub Cap 8. Outer Wheel Bearing 14. Inner Wheel Bearing Cup 3.
Page 417 42.04 Brake Drums Outboard-Mounted Drum Removal and Installation 05/03/94 f350125 NOTE: Pilot pad at 12 o’clock position. 1. Drum Pilot 2. Wheel Pilot Fig. 3, Front Axle Drum and Wheel Pilots (rear axle similar) 100/3 Recreational Vehicle Chassis Workshop Manual, Supplement 20, April 2010...
Page 418 42.04 Brake Drums Inspection Inspection 1. Inspect the inner friction surface. If a veneered (highly glossed) or glazed surface exists, renew the drum by using 80-grit emery cloth or by turn- New brake drums are purposely undersized to allow ing the drums. See Fig.
Page 419 42.04 Brake Drums Inspection NOTE: If there is normal heat checking as de- differential in the drum wall between a relatively cool exterior and a hot friction surface. Heat scribed above, inspect the drums at least every checking is normal on all drums and may not 12,000 miles (19 300 km) thereafter.
Page 420 42.04 Brake Drums Inspection 07/30/93 f420940 Fig. 7, Blue Drums 07/29/93 f420938 Fig. 5, Oversized Drums 07/30/93 f420939 Fig. 6, Heat Spotted Drums 110/3 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 421 42.04 Brake Drums Speciﬁcations Fastener Torque Values Grade Size Torque Description Inch lbf·ft (mm) (N·m) Brake Drum Bolt 240 (325) (20) Table 1, Fastener Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 422: Principles Of Operation
42.05 Service Brake Chamber, Midland General Information General Description rod. Piston rod force is determined by multiplying the delivered air pressure by the effective diaphragm area. For example, if 60 psi (415 kPa) is admitted to Brake chambers convert the energy of compressed a type 16 brake chamber, the force on the end of the air into the mechanical force and motion needed to piston rod is about 960 lb (436 kg).
Page 423: Operating Test
42.05 Service Brake Chamber, Midland Brake Chamber Operating and Leakage Tests NOTE: For both of these tests, the air system must be pressurized to at least 80 psi (550 kPa). Operating Test 1. Chock the tires. 2. Apply the brakes. Check that each piston rod moves out promptly, without binding.
Page 424 42.05 Service Brake Chamber, Midland Brake Chamber Diaphragm Replacement NOTE: This procedure is for service of a leaking brake chamber diaphragm only . If there are any other problems, refer to the applicable subjects elsewhere in this section. Replacement 1. Chock the tires. WARNING Wear safety goggles when draining the air sys- tem or loosening an air line because dirt or...
Page 425 42.05 Service Brake Chamber, Midland Brake Chamber Diaphragm Replacement 8. Adjust the brakes at the slack adjuster. For in- structions, see Section 42.07. 9. Remove the chocks from the tires. 110/2 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 426 42.05 Service Brake Chamber, Midland Brake Chamber Removal and Installation Removal escapes. Failure to take all necessary precau- tions could result in personal injury. Follow the manufacturer’s recommendations when working on any airdevice so as to avoid injury or damage from parts which, when re- leased, are subject to mechanical (spring) or compressed-air propulsion.
Page 427 42.05 Service Brake Chamber, Midland Brake Chamber Removal and Installation Mounting-Stud Locknut Torque Values Description Chamber Size (in Torque lbf·ft (N·m) 38–43 (52–58) 16 (7/16–14 stud) 38–43 (52–58) 16 (1/2–13 stud) 60–65 (81–88) Brake Chamber Mounting-Stud Locknuts 16 (1/2–20 stud) 65–70 (88–95) 120–130 (162–176) 120–130 (162–176)
Page 428: Inspection And Cleaning
42.05 Service Brake Chamber, Midland Brake Chamber Disassembly, Inspection and Cleaning, and Assembly Disassembly 10/11/94 f420433a A. Reference Line Fig. 2, Mark a Reference Line on the Chamber 07/07/98 f420051a piston rod assembly and body until the 1. Clamp Ring 6.
Page 429 42.05 Service Brake Chamber, Midland Brake Chamber Disassembly, Inspection and Cleaning, and Assembly Place the return spring on the piston rod. Place the body on the piston rod assem- bly, and press the body down, working against the tension of the spring, until the body bottoms out on the ﬂat surface.
Page 430 42.05 Service Brake Chamber, Midland Speciﬁcations Mounting-Stud Locknut Torque Values Chamber Size Description Torque lbf·ft (N·m) 38–43 (52–58) 16 (7/16–14 38–43 (52–58) stud) Brake Chamber 16 (1/2–13 stud) 60–65 (52–58) Mounting-Stud Locknuts 16 (1/2–20 stud) 65–70 (88–95) 120–130 (162–176) 120–130 (162–176) Table 1, Mounting-Stud Locknut Torque Values Clamp Ring Torque Values Chamber Size...
Page 431: General Information
42.06 Service Brake Chamber, MGM General Information General Information a type 16 brake chamber, the force on the end of the piston rod is about 960 lb (4270 N). Brake chambers convert the energy of compressed When the brake pedal is depressed, air pressure air into the mechanical force and motion needed to from the brake valve passes through the port in the apply the brakes.
Page 432 42.06 Service Brake Chamber, MGM Service Brake Chamber Operating and Leakage Tests NOTE: For both of these tests, the air system must be pressurized to at least 80 psi (550 kPa). Operating Test 1. Chock the tires. 2. Apply the brakes. Check that each piston rod moves out promptly, without binding.
Page 433 42.06 Service Brake Chamber, MGM Service Brake Chamber Diaphragm Replacement NOTE: This procedure is for service of a leaking brake chamber diaphragm only . If there are any other problems, refer to the applicable subjects elsewhere in this section. Replacement 1.
Page 434 42.06 Service Brake Chamber, MGM Service Brake Chamber Removal and Installation Removal 4. Remove the brake chamber. Remove the cotter pin(s) from the clevis pin(s). NOTE: Gunite and Meritor automatic slack adjusters have two clevis pins, one large and one small, each locked by a cotter pin. Remove the clevis pin(s) from the slack adjuster.
Page 435 42.06 Service Brake Chamber, MGM Service Brake Chamber Removal and Installation 4. Connect the air line to the brake chamber. Check that the hoses are properly sup- ported and, if needed, clamped to provide good clearance. Before connecting the air line, make sure the ﬁttings are clean and free of debris.
Page 436 42.06 Service Brake Chamber, MGM Service Brake Chamber Disassembly, Inspection and Cleaning, and Assembly Disassembly 02/28/95 f421327 A. Reference Line 02/28/95 f421326 Fig. 2, Mark a Reference Line Along the Chamber 1. Clamp Ring 6. Piston Rod Assembly 2. Pressure Cap 7.
Page 437 42.06 Service Brake Chamber, MGM Service Brake Chamber Disassembly, Inspection and Cleaning, and Assembly age. Insert the piston rod assembly through the chamber and clamp the rod (if the chamber wasn’t removed from the ve- hicle). Place the diaphragm in the chamber. CAUTION Don’t overtighten the clamp ring.
Page 438 42.06 Service Brake Chamber, MGM Speciﬁcations Mounting Stud Locknut Torque Values Description Chamber Torque: lbf·ft (N·m) Size (in 35–40 (47–54) Brake Chamber Mounting-Stud 100–115 (136–156) Locknuts 100–115 (136–156) Table 1, Mounting Stud Locknut Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 439: General Description
42.07 Automatic Slack Adjuster, Meritor (Rockwell) General Information General Description the worm to turn, advancing the gear and the cam- shaft to automatically adjust the brake. The Meritor automatic slack adjuster has two main functions: • As a lever, it converts the straight-line force of the brake chamber push rod to torque on the brake camshaft.
Page 440 42.07 Automatic Slack Adjuster, Meritor (Rockwell) General Information 01/23/98 f421722 1. Brake Air Chamber 10. Actuator Rod 18. Pawl Spring 2. Brake Chamber Push Rod 11. Boot 19. Worm 3. Clevis Jam Nut 12. Piston Retaining Ring 20. Worm Retaining Snap Ring 4.
Page 441 42.07 Automatic Slack Adjuster, Meritor (Rockwell) Slack Adjuster Removal and Installation Removal CAUTION 1. Park the vehicle on a level surface, and chock Before turning the adjusting nut, remove the the tires. If the rear slack adjusters will be re- pressure relief capscrew, spring, and pull assem- moved, release the parking brakes, then cage bly.
Page 442 42.07 Automatic Slack Adjuster, Meritor (Rockwell) Slack Adjuster Removal and Installation 01/23/98 f421722 1. Brake Air Chamber 10. Actuator Rod 18. Pawl Spring 2. Brake Chamber Push Rod 11. Boot 19. Worm 3. Clevis Jam Nut 12. Piston Retaining Ring 20.
Page 443 42.07 Automatic Slack Adjuster, Meritor (Rockwell) Slack Adjuster Removal and Installation 09/26/94 f420178a 09/27/94 f420693a A. Measure slack adjuster arm length. A. Insert screwdriver here. B. Camshaft Center Fig. 3, Pull-Pawl Assembly (sectional view) Fig. 5, Measure the New Slack Adjuster Attn: Literature Distribution Meritor Interna- tional 2135 W.
Page 444 42.07 Automatic Slack Adjuster, Meritor (Rockwell) Slack Adjuster Removal and Installation Install the spacing washers and the snap With the brakes fully released, place the ring that attach the slack adjuster to the applicable installation template over the camshaft. Add enough washers to limit the clevis and camshaft end.
Page 445 42.07 Automatic Slack Adjuster, Meritor (Rockwell) Slack Adjuster Removal and Installation through the clevis more than 1/8 inch (3.2 The difference between the two measure- ments is the initial free-stroke, and sets mm). See Fig. 9. If needed, either cut the the clearance between the linings and the push rod, install a new push rod, or install a drum.
Page 446 42.07 Automatic Slack Adjuster, Meritor (Rockwell) Slack Adjuster Removal and Installation 6. Install the pawl assembly, spring, and the pres- sure relief capscrew. Tighten the capscrew 15 to 20 lbf·ft (20 to 27 N·m). Or, remove the screw- driver from the pull-pawl assembly (if equipped). 7.
Page 447 42.07 Automatic Slack Adjuster, Meritor (Rockwell) Speciﬁcations Lubricant Speciﬁcations Brake Chamber Strokes Lubricant Type Temperature Maximum Chamber Stroke for Cam Chamber Size Brake Amoco Super Permalube No. 2 Less than 2 inches (51 mm) Aralub 3837 Long stroke. Citco Premium Lithium EP No. 2 Table 3, Brake Chamber Strokes Exxon Ronex MP No.
Page 448 42.08 Automatic Drain Valve, Bendix DV–2 General Information General Description The length of time the exhaust valve remains open and the amount of moisture and contaminants ejected depends upon the sump pressure and the The DV–2 automatic reservoir drain valve automati- wet tank pressure drop that occurs each time air is cally removes contaminants and water from the wet- used from the system.
Page 449 42.08 Automatic Drain Valve, Bendix DV–2 General Information 05/25/2005 f421887 Fig. 4, System Pressure Rising 05/25/2005 f421888 Fig. 5, Exhaust Cycle 050/2 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 450: Safety Precautions
42.08 Automatic Drain Valve, Bendix DV–2 Safety Precautions Safety Precautions When working on or around air brake systems and components, the following precautions should be ob- served. 1. Always chock the vehicle’s wheels and stop the engine when working under a vehicle. Keep hands away from brake chamber push rods and slack adjusters;...
Page 451 42.08 Automatic Drain Valve, Bendix DV–2 Operating and Leakage Tests Operating Test IMPORTANT: Before working on or around air brake systems and components, see Safety Precautions, 100. Do the following test after repairing or replacing the DV–2 valve to ensure that the valve is functioning correctly.
Page 452 42.08 Automatic Drain Valve, Bendix DV–2 Drain Valve Removal and Installation Removal IMPORTANT: Before working on or around air brake systems and components, see Safety Precautions, 100. 1. Chock the tires, and drain the reservoirs. 2. Remove the drain valve assembly from the end of the wet tank reservoir.
Page 453: Inspection, And Assembly
42.08 Automatic Drain Valve, Bendix DV–2 Drain Valve Disassembly, Cleaning and Inspection, and Assembly Disassembly the disassembled moisture ejection valve with compressed air. IMPORTANT: Before working on or around air 2. Wipe all rubber parts clean with a clean cloth. brake systems and components, see Examine all rubber parts.
Page 454 42.08 Automatic Drain Valve, Bendix DV–2 Speciﬁcations Torque Values Description Torque: lbf·in (N·cm) Valve Cover Capscrews 72–96 (820–1080) Hexhead Nipple (to valve body) 48–72 (540–820) Table 1, Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 455 42.09 Relay Valve, Bendix R–12 and R–14 General Information General Information Principles of Operation APPLICATION The R–12 and R–14 relay valves are control relay stations in the air brake system to speed the applica- tion and release of the brakes. See Fig.
Page 456 42.09 Relay Valve, Bendix R–12 and R–14 General Information 03/16/98 f421789 1. Exhaust Seat 5. Supply Port 2. Service Port 6. Exhaust Port 3. Relay Piston 7. Retaining Ring 4. Inlet/Exhaust Assembly Fig. 3, R-12 Relay Valve (sectional view) quick release portion of the R–14 is removed and a line is installed, which is connected to the delivery of the service brake valve or relay valve.
Page 457 42.09 Relay Valve, Bendix R–12 and R–14 General Information 05/15/98 f420648a 1. Exhaust Seat 4. Service Port 7. Inlet/Exhaust Valve 2. Balance/Quick Exhaust (Anti- 5. Diaphragm 8. Exhaust Port Compound) 6. Relay Piston 9. Retaining Ring 3. Exhaust Cover Fig. 4, R-14 Relay Valve (sectional view) 050/3 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 458 42.09 Relay Valve, Bendix R–12 and R–14 Safety Precautions Safety Precautions When working on or around air brake systems and components, observe the following precautions: A. Chock the tires and stop the engine before work- ing under the vehicle. Releasing air from the sys- tem may cause the vehicle to roll.
Page 459: Operation Test
42.09 Relay Valve, Bendix R–12 and R–14 Relay Valve Operation and Leakage Tests Operation Test IMPORTANT: If the valves do not function as described in the above test, or if leakage is ex- cessive, replace it. For instructions, see Sub- IMPORTANT: Before working on or around air ject 120.
Page 460 42.09 Relay Valve, Bendix R–12 and R–14 Relay Valve Removal and Installation Removal IMPORTANT: Before working on or around air brake systems and components, see Safety Precautions, 100. 1. Chock the tires, and drain the air system. 2. Remove all air hoses from the valve. Cap the hoses and mark them for reassembly.
Page 461 42.09 Relay Valve, Bendix R–12 and R–14 Relay Valve Disassembly, Cleaning and Inspection, and Assembly Disassembly Cleaning and Inspection IMPORTANT: Before working on or around air WARNING brake systems and components, refer to Safety Precautions, 100. Wear goggles when using compressed air to clean or dry parts, as permanent harm to eyes 1.
Page 462 42.09 Relay Valve, Bendix R–12 and R–14 Relay Valve Disassembly, Cleaning and Inspection, and Assembly 09/27/94 f420645a 1. Body 8. Retainer Ring 15. Lockwasher (4 qty) 2. Inlet/Exhaust Valve 9. Diaphragm 16. Capscrew (4 qty) 3. Valve Retainer 10. Rivet 17.
Page 463 42.09 Relay Valve, Bendix R–12 and R–14 Relay Valve Disassembly, Cleaning and Inspection, and Assembly ring, making sure the retaining ring is completely seated in the groove. On R–14 valves, place the diaphragm in the service port making sure it is posi- tioned between the guide ribs.
Page 464 42.09 Relay Valve, Bendix R–12 and R–14 Speciﬁcations Torque Values Description Torque: lbf·in (N·cm) Valve Cover Capscrews 80–120 (900–1360) Valve Mounting Capscrews 132–180 (1500–2040) Service Port Cap nut 150 (1700) Phillips Screw, no. 10–24 25 (280) Table 1, Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 465: General Information
42.10 Service Brakes, Meritor Cam-Master "Q" Series General Information General Information Edge Codes Vendor Code Design. Meritor (formally Rockwell) "Q" and "Q" Plus Series 931–162 R301 brakes are actuated by an S-type cam head, which is forged integrally with the camshaft and supported R201 Abex with nylon bushings.
Page 466 42.10 Service Brakes, Meritor Cam-Master "Q" Series General Information BRAKES R201 LINING: REPLACE SR2014515Q WITH: The Meritor brake warranty does not cover the cost of any repairs to a covered product that might result from the use of non−genuine Meritor parts. See Pub. SP−9260. 01/27/98 f421034 Fig.
Page 467: General Safety Precautions
42.10 Service Brakes, Meritor Cam-Master "Q" Series Safety Precautions General Safety Precautions the correct tools and observe all precautions pertaining to use of those tools. • Replacement hardware, tubing, hose, ﬁttings, WARNING etc. should be the equivalent size, type, length, and strength of the original equipment.
Page 468 42.10 Service Brakes, Meritor Cam-Master "Q" Series Safety Precautions and ﬁlter must be approved by MSHA or NIOSH, and worn during all procedures. OSHA recommends that enclosed cylinders equipped with vacuums and high-efficiency particulate air (HEPA) ﬁlters be used during brake repairs. Under this system, the entire brake assembly is placed within the cylinder and the mechanic works on the brake through sleeves attached to the cylinder.
Page 469 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Shoe Removal and Installation WARNING Before starting the procedure below, read the in- formation in Safety Precautions, 100. Failure to be aware of the dangers of brake lining dust ex- posure could result in serious and permanent health damage.
Page 470 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Shoe Removal and Installation Installation shoe on the bottom anchor pin and attach two new brake shoe retaining springs. See Fig. IMPORTANT: For best brake performance, don’t mix "Q" and "Q" Plus Series brakes. Use the Turn the lower brake shoe forward and attach a new brake shoe return spring.
Page 471 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Shoe Removal and Installation retainer together to permit the retainer to ﬁt between the brake shoe webs. See Fig. Push the retainer into the brake shoe until the ears lock in the holes in the shoe webs.
Page 472 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Shoe and Lining Inspection WARNING Before starting the procedure below, read the in- formation in Safety Precautions, 100. Failure to be aware of the dangers of brake lining dust ex- posure could result in serious and permanent health damage.
Page 473 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Shoe and Lining Inspection 4. Check the anchor pin for looseness and cam- shaft roller recesses in the shoe webs for visible wear. Replace the shoe if needed. 5. Check the shoe span. Measure the distances between the centerlines of the anchor pin and the camshaft roller pin recesses in the shoe web.
Page 474 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Adjustment Adjustment If the free-stroke is incorrect, remove the pressure relief capscrew, spring and pawl assembly from the slack adjuster housing. MERITOR AUTOMATIC SLACK Fig. 2. If equipped with a pull-pawl ADJUSTER assembly, carefully insert a screwdriver and raise the relief cap about 1/8 inch (3.2 1.
Page 475 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Adjustment 01/23/98 f421722 1. Brake Air Chamber 10. Actuator Rod 19. Worm 2. Brake Chamber Push Rod 11. Boot 20. Worm Retaining Snap Ring 3. Clevis Jam Nut 12. Piston Retaining Ring 21.
Page 476 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Adjustment HALDEX AUTOMATIC SLACK ADJUSTER 1. Turn the adjusting hexnut clockwise until the brake lining meets the brake drum, then back off counterclockwise 3/4 turn. See Fig. 5. There will be a ratcheting sound. 2.
Page 477 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Adjustment f420699a 10/17/95 1. Adjusting Hexnut Fig. 5, Turn the Adjusting Hexnut Clockwise 10/03/2005 f420015a A. Air Chamber to Clevis Pin Hole (brakes released) B. Air Chamber to Clevis Pin Hole (brakes applied) Fig.
Page 478 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Shoe Lining Replacement WARNING Before starting the procedure below, read the in- formation in Safety Precautions, 100. Failure to be aware of the dangers of brake lining dust ex- posure could result in serious and permanent health damage.
Page 479 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Shoe Lining Replacement 5. Begin riveting at the center of each edge of the shoe and lining, and work toward each end. See Fig. 09/27/94 f420717a Fig. 5, Area of Feeler Gauge Clearance 7.
Page 480: Disassembly And Inspection
42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Components Disassembly and Inspection, Cleaning, and Assembly Disassembly and Inspection IMPORTANT: If any slack adjuster problem is found, repair or replace the unit, depending on the manufacturer’s recommendations. WARNING 6. Remove the camshaft by grasping its head and Before starting the procedure below, read the in- pulling the camshaft outboard.
Page 481 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Components Disassembly and Inspection, Cleaning, and Assembly 17 18 06/23/94 f420691a NOTE: 16–1/2 inch "Q" series and all "Q" Plus series shown. 1. Brake Shoe and Lining Assembly 12. Brake Shoe Roller Retainer 21.
Page 482 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Components Disassembly and Inspection, Cleaning, and Assembly 16.1 Check for cracks at the bolt holes, cam area, and around the anchor pin. Replace if damaged. 16.2 Check the anchor pin. If worn or loose, replace it.
Page 483 42.10 Service Brakes, Meritor Cam-Master "Q" Series Brake Components Disassembly and Inspection, Cleaning, and Assembly tion. Wipe the interior of the drums with a Apply a thin ﬁlm of chassis grease on the greaseless solvent to remove lining dust. inside of the camshaft bushings and jour- nals.
Page 484 42.10 Service Brakes, Meritor Cam-Master "Q" Series Speciﬁcations Torque Values Torque Description Grade Size lbf·in (N·cm) lbf·ft (N·m) — 24–31 (18–23) Brake Shoe Lining Nuts — 80–100 (900–1120) — 25–35 (34–47) Dust Shield Capscrews 3/8–16 — 35–50 (47–68) Spider Mounting Bolts: Customary 1/2–13 60–80 (81–108) Thread Capscrew...
Page 485: General Information
42.11 Air Dryer, Midland Pure Air Plus General Information General Information Principles of Operation DRYING CYCLE The function of the air dryer is to collect and remove air system contaminants in solid, liquid, and vapor form before they enter the brake system. The air dryer consists of a replaceable desiccant car- tridge, coalescent ﬁlter, purge valve, check valve, ™...
Page 486: Purge Cycle
42.11 Air Dryer, Midland Pure Air Plus General Information PURGE CYCLE drying cycle. The moist air is then expelled through the purge valve. 03/07/98 f430082 1. Control Port 3. Outlet Port 2. Purge Valve 4. Inlet Port Fig. 2, Purging Cycle When the reservoir reaches the governor cutout pressure, air pressure from the governor unloading port enters the air dryer.
Page 487: Safety Precautions
42.11 Air Dryer, Midland Pure Air Plus Safety Precautions Safety Precautions When working on or around air brake systems and components, observe the following precautions. 1. Chock the tires and stop the engine before work- ing under a vehicle. Depleting air system pres- sure may cause the vehicle to roll.
Page 488: Installation
42.11 Air Dryer, Midland Pure Air Plus Air Dryer Removal and Installation Removal Remove the air dryer from the mounting bracket. Installation WARNING Before working on or around air brake systems and components, read Safety Precautions, 100. Failure to do so could result in personal injury. 1.
Page 489 42.11 Air Dryer, Midland Pure Air Plus Air Dryer Disassembly, Inspection and Cleaning, and Assembly Disassembly IMPORTANT: Do not proceed with disassembly until the dryer has completed the purge cycle and the compressor is fully unloaded. 3. Remove the air dryer. See Fig.
Page 490 42.11 Air Dryer, Midland Pure Air Plus Air Dryer Disassembly, Inspection and Cleaning, and Assembly 2. Clean any debris and/or contaminants from the interior of the air dryer. Assembly 1. Install a new pressure relief valve. Tighten the valve 12 to 16 lbf·ft (16 to 22 N·m). If dry sealant is not present on the pipe threads, apply pipe sealant.
Page 491 42.11 Air Dryer, Midland Pure Air Plus Desiccant Cartridge and Coalescent Filter Replacement Replacement 7. Insert the coalescent ﬁlter with the O-ring end going into the air dryer opening ﬁrst. The "X" section of the coalescent ﬁlter will then be facing WARNING out.
Page 492 42.11 Air Dryer, Midland Pure Air Plus Turbo-Saver ™ Valve Replacement Turbo-Saver Valve 13. Thread the desiccant cartridge onto the dryer and hand tighten. Replacement 14. Reconnect the inlet and control air line. 15. Perform the operational checks in Subject 170.
Page 493 42.11 Air Dryer, Midland Pure Air Plus Purge Valve Replacement Replacement WARNING Before working on or around air brake systems and components, read Safety Precautions, 100. Failure to do so could result in personal injury. 1. Shut down the engine, apply the parking brake, and chock the tires.
Page 494 42.11 Air Dryer, Midland Pure Air Plus Outlet Check Valve Replacement Replacement WARNING Before working on or around air brake systems and components, read Safety Precautions, 100. Failure to do so could result in personal injury. 1. Shut down the engine, apply the parking brake, and chock the tires.
Page 495: Operational Check
42.11 Air Dryer, Midland Pure Air Plus Air Dryer Operational Check Operational Check WARNING Before working on or around air brake systems and components, read Safety Precautions, 100. Failure to do so could result in personal injury. 1. Chock the tires, start the engine, and build the air pressure to 100 psi (689 kPa).
Page 496: Troubleshooting Tables
42.11 Air Dryer, Midland Pure Air Plus Troubleshooting Troubleshooting Tables Problem—Long Purge Cycle (More Than 40 Seconds) Problem—Long Purge Cycle (More Than 40 Seconds) Possible Cause Remedy The outlet check valve is damaged. Replace the outlet check valve. See Subject 160.
Page 497 42.11 Air Dryer, Midland Pure Air Plus Troubleshooting Problem—No Purge Cycle Problem—No Purge Cycle Possible Cause Remedy The governor is damaged. Disconnect the air line from the governor. Air should come from the governor line when the compressor unloads. If not, repair/replace the governor. For instructions, see Group The air line between the governor and the...
Page 498: Specifications
42.11 Air Dryer, Midland Pure Air Plus Speciﬁcations Speciﬁcations For an air dryer air plumbing diagram, see Fig. Torque Values Torque Description lbf·in (N·cm) lbf·ft (N·m) 3/8-Inch Mounting Bolt — 20 to 25 (27 to 35) Air Dryer Mounting Strap Locknut 50 (565) —...
Page 499: General Information
42.12 Hydraulic Brake System, Bosch General Information General Information The hydraulic brake components include two com- pletely separate hydraulic systems that use different and incompatible hydraulic ﬂuids, lines, and seals. The major parts of the hydraulic disc brake system The components of each must be kept separate are: from the other.
Page 500 42.12 Hydraulic Brake System, Bosch General Information 04/29/2003 f420369b A. Service Brake System (DOT 3 Brake Fluid) B. Power Brake Booster and Power Steering System (ATF) 1. Power Steering Gear 3. Power Steering Reservoir 5. Brake Master Cylinder 2. Power Steering Pump 4.
Page 501: Master Cylinder
42.12 Hydraulic Brake System, Bosch General Information 02/15/2002 f420375a NOTE: Not all parts are shown. A. Automatic Transmission Fluid (ATF) 1. Flow Switch 5. Rubber Boot 9. Electric Backup Pump 2. Return Port (to steering 6. Brake Pedal Rod 10. End-Cap reservoir) 7.
Page 502 42.12 Hydraulic Brake System, Bosch General Information 04/29/2003 f420370 A. Rear Brake Lines B. Front Brake Lines 1. Master Cylinder Reservoir 3. Master Cylinder (DOT 3 brake 2. Power Brake Booster (ATF only) ﬂuid only) Fig. 4, Dual Supply System Fig.
Page 503 42.12 Hydraulic Brake System, Bosch General Information 05/09/2003 f420376a NOTE: Not all parts are shown. A. DOT 3 Brake Fluid 1. Secondary Compensating Valve 6. Primary Compensating Valve 11. Primary Piston Return Spring (open) (open) 12. Secondary Piston/Actuator 2. Secondary Reservoir Section 7.
Page 504: Applying The Brakes
42.12 Hydraulic Brake System, Bosch General Information If the power brake booster loses pressure from the Monitor Module Terminal Identiﬁcation power steering pump, the ﬂow switch turns on the Terminal Circuit backup pump. This closes the main supply check Function Number Number valve and opens the backup pump check valve.
Page 505 42.12 Hydraulic Brake System, Bosch General Information 23 22 04/05/2004 f420373a NOTE: Not all parts are shown. A. DOT 3 Brake Fluid B. ATF C. Air Space 1. Secondary Compensating Valve (closed) 14. Frontwall 2. Secondary Reservoir Section 15. Power Piston 3.
Page 506 42.12 Hydraulic Brake System, Bosch General Information Input/Output Terminal Activation Terminal Circuit Function Activated if Number Number Ignition Input The ignition is on. Not Used — — Relay Output 388F The ignition is on or brake pedal is depressed. Not Used —...
Page 507: General Safety Precautions
42.12 Hydraulic Brake System, Bosch Safety Precautions General Safety Precautions Special care must be taken when disposing of used brake ﬂuid. Put the ﬂuid in a sealed plastic container and label it "Used Brake Fluid." Then dispose of it in WARNING an approved manner.
Page 508 42.12 Hydraulic Brake System, Bosch Safety Precautions (HEPA) ﬁlters be used during brake repairs. Under this system, the entire brake assembly is placed within the cylinder and the mechanic works on the brake through sleeves attached to the cylinder. Com- pressed air is blown into the cylinder to clean the assembly, and the dirty air is then removed from the cylinder by the vacuum.
Page 509 42.12 Hydraulic Brake System, Bosch Hydraulic System Bleeding Bleeding Pressure Bleeding Pressure bleeding is the preferred method for bleed- WARNING ing the service brake system. It requires the use of a special pressure bleeder kit consisting of a tank, Before working on or around hydraulic brake pressure pump and valve, gauge, tubing, and systems and components, see Safety Precau-...
Page 510: Manual Bleeding
42.12 Hydraulic Brake System, Bosch Hydraulic System Bleeding Using the supplied adapter, connect the needed. Be careful not to let it run low and suck pressure bleeder to either one of the ﬁll air into the system as you bleed the brakes at ports on the master cylinder reservoir.
Page 511 42.12 Hydraulic Brake System, Bosch Hydraulic System Bleeding NOTE: It will not usually be necessary to Using a wrench and holding a rag under it to absorb leaking brake ﬂuid, loosen the bleed the master cylinder unless the brake ﬁtting at the front outlet port on the master ﬂuid reservoir has run dry or master cylinder cylinder.
Page 512 42.12 Hydraulic Brake System, Bosch Hydraulic System Bleeding the ﬂuid in the tube is completely free of air bubbles. Check the brake ﬂuid level in the reser- voir. Add new DOT 3 heavy-duty brake ﬂuid as needed. Repeat the steps for bleeding the left rear caliper, the right front caliper, and the left front caliper.
Page 513 42.12 Hydraulic Brake System, Bosch Hydro-Max ® II Power Brake Booster Bleeding Power Brake Booster Bleeding 3. Place the transmission in neutral and crank the starter several times, but do not start the engine. 4. Check the ATF level in the power steering reser- WARNING voir.
Page 514 42.12 Hydraulic Brake System, Bosch Replacing Hydraulic Lines Replacing Hydraulic Lines 2. Replace all power steering hoses that are leak- ing or showing signs of cracking, softening, or bulging. If a hose is damaged, replace the entire WARNING hose; do not attempt to repair it. Remove all hose clamps and tie straps Before working on or around hydraulic brake used for routing the hose.
Page 515: Service Brake System
42.12 Hydraulic Brake System, Bosch Replacing Hydraulic Lines booster return ﬁtting and the power steer- 5. Remove the plugs installed earlier. Install the ing reservoir. new section of brake line and tighten the connec- tions. Install the hose clamps and replace any 6.
Page 516: Installation
42.12 Hydraulic Brake System, Bosch Master Cylinder Removal and Installation Removal underneath it to catch any ﬂuid leaking as it is disconnected. 3. Disconnect the brake lines from the outlet ports WARNING of the master cylinder. See Fig. 2. Plug the brake lines to prevent contamination and leak- Before working on or around hydraulic brake age.
Page 517 42.12 Hydraulic Brake System, Bosch Master Cylinder Removal and Installation f420604 10/28/94 f420552a Fig. 5, Outlet Ports With Master Cylinder Bleeder Tubes 1. Reservoir 3. Flanged Hexnut The brake bleeder plastic adapters and 2. Master Cylinder 4. Power Brake Booster tubing may be left in place to keep the ﬂuid from dripping.
Page 518 42.12 Hydraulic Brake System, Bosch Master Cylinder Removal and Installation 03/28/2003 f430345 1. DOT 3 Brake Fluid 2. Filler Caps 3. Fill to Bottom Ring of Filler Neck Fig. 6, Master Cylinder Fill Level 140/3 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 519 42.12 Hydraulic Brake System, Bosch Hydro-Max ® II Power Brake Booster Removal and Installation Removal WARNING Before working on or around hydraulic brake systems and components, see Safety Precau- tions 100. Failure to follow those safety precau- tions may result in personal injury. 1.
Page 520 42.12 Hydraulic Brake System, Bosch ® Hydro-Max II Power Brake Booster Removal and Installation 07/26/93 f420704 Fig. 5, Power Brake Booster Removal 3. Install the master cylinder on the power brake booster, following the instructions in Sub- ject 140. 02/12/2002 f420703b 1.
Page 521 42.12 Hydraulic Brake System, Bosch Hydro-Max ® II Power Brake Booster Removal and Installation 02/12/2007 f461917a 1. Power Steering Reservoir 2. Steering Gear Fig. 6, Fluid Level Check 150/3 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 522 42.12 Hydraulic Brake System, Bosch Hydraulic Brake Electronic Monitor Module Removal and Installation NOTE: The monitor module is located on the 3. If it was removed, install the ICU3-M2. For in- structions, see Section 54.06, Subject 100. driver side of the dash behind the instrumenta- tion control unit (ICU3).
Page 523 42.12 Hydraulic Brake System, Bosch Flow Switch Removal, Inspection, and Installation NOTE: Refer to Fig. 1 when performing the following 3. Place a container under the booster to catch any procedures. automatic transmission ﬂuid (ATF) that may drain out while removing the ﬂow switch contact as- The most likely problems requiring service of the ﬂow sembly.
Page 524 42.12 Hydraulic Brake System, Bosch Flow Switch Removal, Inspection, and Installation Installation 1. If a new contact assembly or O-ring is being used, install the O-ring onto the contact assem- bly. 2. Install the spring and metering piston into the ﬂow switch bore.
Page 525: Troubleshooting Index
42.12 Hydraulic Brake System, Bosch Troubleshooting Troubleshooting Index Hydraulic Brake Troubleshooting Index Problem Figure Brake warning lamp and buzzer (related to parking brake) Fig. 1 Brake warning lamp and buzzer (related to service brake) Fig. 2 Backup pump runs continuously Fig.
Page 526: Troubleshooting
42.12 Hydraulic Brake System, Bosch Troubleshooting − Ignition ON − Parking brake applied 1 = No Check the park brake at the axle. Start engine and release Has it released completely? parking brake. 1. Are the light and See Fig. 2. buzzer OFF? 1 &...
Page 527 42.12 Hydraulic Brake System, Bosch Troubleshooting Is master Is the master cylinder Problem is probably with cylinder differential reservoir the brake control module. pressure switch more than Check for malfunction. closed to ground? 1/2 full? Fill master Is there a leak Has someone cylinder in the brake...
Page 528 42.12 Hydraulic Brake System, Bosch Troubleshooting Verify that pump is running continuously. Disconnect the Does the pump run only Is the backup Is the engine running? flow switch with the ignition ON? pump still running? connector. Normal condition Problem is probably Check for proper power with the backup pump steering pump flow by rapidly...
Page 529 42.12 Hydraulic Brake System, Bosch Troubleshooting 11/21/2003 f430359 1. Fluid Level Indicator Switch 6. Brake Pedal 2. Master Cylinder Reservoir 7. Brake Warning Lamp Switch 3. Flow Switch 8. Backup Pump 4. Power Booster 9. Master Cylinder 5. Brake Pedal Linkage 10.
Page 530 42.12 Hydraulic Brake System, Bosch Troubleshooting Disconnect flow switch connector. Check continuity Verify that the backup in circuit 388G from the relay to the flow switch pump does not run with the connector and check continuity through the flow switch. key on, engine off, and park brake applied.
Page 531 42.12 Hydraulic Brake System, Bosch Troubleshooting Verify that a pedal problem does exist. Determine which of the four pedal conditions exist. The brake pedal drops about The brake pedal continues The brake pedal feels spongy, The brake pedal 1/2−inch (12mm) when the to fall with steady foot force.
Page 532 42.12 Hydraulic Brake System, Bosch Troubleshooting 08/16/2002 f430324 A. Reservoir cap and diaphragm from uncontaminated system. B. Reservoir cap and diaphragm from a system contaminated with power steering ﬂuid, motor oil, or ATF. Fig. 7, Undamaged and Damaged Master Cylinder Fluid Reservoir Caps and Diaphragms Start the vehicle and With engine OFF,...
Page 533 42.12 Hydraulic Brake System, Bosch Troubleshooting Verify that fluid is leaking. Is the leak at the Is leak at the tube Caliper Is leak at the bleed ABS valve, calipers, fitting? screw? booster, master Booster or Master Brake cylinder, or lines Cylinder Lines/Fittings and fittings?
Page 534 42.12 Hydraulic Brake System, Bosch Troubleshooting (continued from Fig. 9) Examine the booster & master Booster Is leakage at booster cylinder assembly. Is the leak or at master cylinder? at the booster to master cylinder interface? See Fig. 12. Master cylinder Tighten tube nuts to Brake...
Page 535 42.12 Hydraulic Brake System, Bosch Troubleshooting 09/30/2002 f430323 1. Flow Switch and Power Brake Booster Interface 2. Inlet Port 3. Booster, Adapter, and Pump Interface 4. Power Brake Booster and Master Cylinder Interface Fig. 12, Potential Hydraulic Fluid Leak Points 1.
Page 536 42.12 Hydraulic Brake System, Bosch Troubleshooting (continued from Fig. 13) Apply & release the brakes, Tighten secondary tube Tighten tube nut. Does fluid flow out Does fluid flow out loosen the primary tube nut nut. See Subject 400, Apply & release under pressure? under pressure? at the master cylinder...
Page 537: Pressure Testing
42.12 Hydraulic Brake System, Bosch Pressure Testing Brake System Pressure Tests If the residual pressure on one or both gauges is more than 2 psi (14 kPa), check the linkage be- tween the brake pedal and the booster. Repair NOTE: On most vehicles in the ﬁeld, the pri- the linkage if needed.
Page 538 42.12 Hydraulic Brake System, Bosch Pressure Testing 6. If the pressure reading on both gauges is within power steering pump. Bleed the system following 10 percent but the gauges show less than 1770 the instructions in Subject 110. psi (12 204 kPa), turn off the engine but leave If either gauge does not show constant pressure the ignition on.
Page 539: Specifications
42.12 Hydraulic Brake System, Bosch Speciﬁcations Fig. 1 Fig. 2 for views of the hydraulic brake system wiring. NOTE: Technicians can refer to wiring diagrams in PartsPro, Module 877, in addition to those shown here. Ref. Dia. G06−48302 03/04/2004 f544426 Fig.
Page 540 42.12 Hydraulic Brake System, Bosch Speciﬁcations Ref. Dia. G06−48302 03/04/2004 f544427 Fig. 2, Hydraulic Brake Dash Wiring Fastener Torque Values Description Torque: lbf·in (N·cm) Torque: lbf·ft (N·m) Power Brake Booster Mounting Bolts — 16–24 (22–32) Master Cylinder Tube Nuts — 16 (22) Master Cylinder Mounting Nuts —...
Page 541 42.12 Hydraulic Brake System, Bosch Speciﬁcations Approved Fluid for Power Brake Booster Fluid Type Recommended Fluid Automatic Transmission Fluid Dexron ® (ATF) Table 2, Approved Fluid for Power Brake Booster Approved Brake Fluid for Brake System Fluid Type Recommended Fluid Wagner-Premium Plus Super HD DOT 3 Brake Fluid...
Page 542: General Information
42.13 Bosch Pin Slide Brakes General Information General Information chor plate. The anchor plate is mounted on the steer- ing knuckle ﬂange on front axles or on the axle ﬂange on rear axles. Two sizes of calipers are used: ® Bosch hydraulic pin slide disc brakes are two-piston 66 mm Twin (2 piston) and 73 mm Twin (2 piston).
Page 543 42.13 Bosch Pin Slide Brakes General Information 05/24/2001 f430246 A. 73 mm slider disc brakes incorporate a tie bar between the anchor plate abutment arms. 1. Caliper Assembly 2. Brake Pads 3. Anchor Plate Assembly Fig. 2, Bosch Pin Slide Brakes Major Components word FORWARD for proper installation.
Page 544 42.13 Bosch Pin Slide Brakes General Information 06/05/2001 f430247 A. Front (66 mm shown) B. Rear (73 mm shown) 1. Hydraulic Pistons with Seals and Boots 4. Upper Slipper 2. Sealed Pins 5. Brake Pads 3. Anchor Plate 6. Lower Slipper Fig.
Page 545 42.13 Bosch Pin Slide Brakes General Information 05/29/2001 f430248 A. Front B. Rear 1. Pad Abutment 4. Antilock Braking System Sensor Mounting 2. Anchor Plate 5. Splash Shield 3. Floating Guide Pin 6. Tie Bar (73 mm brakes only) Fig. 4, Anchor Plate and Splash Shield 050/4 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 546: General Safety Precautions
42.13 Bosch Pin Slide Brakes Safety Precautions General Safety Precautions Special care must be taken when disposing of used brake ﬂuid. Put the ﬂuid in a sealed plastic container and label it "Used Brake Fluid." Then dispose of it in WARNING an approved manner.
Page 547 42.13 Bosch Pin Slide Brakes Safety Precautions (HEPA) ﬁlters be used during brake repairs. Under this system, the entire brake assembly is placed within the cylinder and the mechanic works on the brake through sleeves attached to the cylinder. Com- pressed air is blown into the cylinder to clean the assembly, and the dirty air is then removed from the cylinder by the vacuum.
Page 548 42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation 3. Chock the front or rear tires, depending on which WARNING axle is being worked on. Jack up the axle and support it with jackstands. Before starting the procedures below, read the information in Safety Precautions 100.
Page 549: Installation
42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation pin or anchor plate grooves, which could dam- age the guide pin boot. 9. Swing the caliper assembly away from the rotor by carefully rotating the caliper on the lower guide pin and bolt.
Page 550 42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation 05/24/2001 f430244 A. Make sure this clip is detached from the support C. Do not loosen the lower guide pin bolt. bracket. D. Swing the caliper down until it stops. B.
Page 551 42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation 07/30/96 f420383a A. Cracking C. Discoloration E. Normal Finish B. Heat Checking D. Scoring Fig. 5, Rotor Surface Check 110/4 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 552 42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation 05/24/2001 f430245 Fig. 6, Retracting Pistons Into the Caliper 8. Check the ﬂuid level in the master cylinder reser- voir and add the necessary amount of new DOT 3 approved brake ﬂuid. 9.
Page 553 42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation 06/01/2001 f430264 A. Driver Side Rear B. Driver Side Front 1. Wheel Rotation 2. Rotor Face 3. Pad Notch Fig. 7, Replacing Brake Pads on Front and Rear Brakes 110/6 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 554 42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation 05/24/2001 f430243 A. Swing the caliper up into position. 1. Flat on Guide Pin 2. Flat on Caliper Fig. 8, Closing the Caliper Over Brake Pads and Rotor 110/7 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 555 42.13 Bosch Pin Slide Brakes Brake Pad Removal, Inspection, and Installation 06/04/2001 f430266 A. Front Brakes B. Rear Brakes 1. Tighten First 2. Tighten Second Fig. 9, Tightening Sequence for Caliper Mounting Bolts 110/8 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 556 42.13 Bosch Pin Slide Brakes Brake Caliper Removal and Installation 7. Remove the upper (top) guide pin bolt. See WARNING Fig. Before starting the procedures below, read the CAUTION information in Safety Precautions 100. Failure to do so could result in serious and permanent Do not pull on the guide pins.
Page 557 42.13 Bosch Pin Slide Brakes Brake Caliper Removal and Installation IMPORTANT: Always tighten caliper guide pin bolts in the proper sequence. Do not overtighten caliper guide pin bolts. Increased brake drag may result from incorrect tightening. See Fig. 6 Fig. 7 before tightening either the upper or lower bolt.
Page 558 42.13 Bosch Pin Slide Brakes Brake Caliper Removal and Installation 05/24/2001 f430244 A. Make sure this clip is detached from the support D. Swing the caliper down until it stops. bracket. E. Caliper in the lowered position. B. Upper guide pin bolt has been removed. C.
Page 559 42.13 Bosch Pin Slide Brakes Brake Caliper Removal and Installation 05/29/2001 f430249 1. Brake Line 3. Machined Face 5. Piston Boots 2. Lower Guide Pin Bolt 4. Pistons Fig. 4, Removing the Caliper from the Anchor Plate 120/4 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 560 42.13 Bosch Pin Slide Brakes Brake Caliper Removal and Installation 05/24/2001 f430243 A. Swing the caliper up into position. 1. Flat on Guide Pin 2. Flat on Caliper Fig. 5, Closing the Caliper Over the Brake Pads and Rotor 01/06/2006 f422432 01/06/2006 f422431...
Page 561 42.13 Bosch Pin Slide Brakes Brake Rotor Removal and Installation Installation WARNING Before starting the procedures below, read the 1. Inspect the rotors for scoring, warping, cracks, information in Safety Precautions 100. Failure to bluing or heat spots, or other damage. See do so could result in serious and permanent Fig.
Page 562 42.13 Bosch Pin Slide Brakes Brake Rotor Removal and Installation 07/30/96 f420383a A. Cracking C. Discoloration E. Normal Finish B. Heat Checking D. Scoring Fig. 2, Rotor Surface Check 130/2 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 563 42.13 Bosch Pin Slide Brakes Brake Rotor Removal and Installation 10/28/94 f420485a 1. Rotor 2. Wheel Hub Fig. 3, Rotor-to-Hub Position f420500 Fig. 4, Tightening Pattern 130/3 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 564: Runout Check
42.13 Bosch Pin Slide Brakes Brake Rotor Runout and Parallelism Check Runout Check Brake rotor runout refers to the amount of lateral wobble the rotor has when it is turning, with the wheel bearings correctly adjusted. See Fig. 1. Check the rotor runout whenever you replace the brake pads.
Page 565 42.13 Bosch Pin Slide Brakes Brake Rotor Runout and Parallelism Check crease the overall thickness of the rotor to 1.32 inches (33.5 mm) or less, replace the rotor. 140/2 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 566: Cleaning And Inspection
42.13 Bosch Pin Slide Brakes Anchor Plate Disassembly, Cleaning and Inspection, and Assembly WARNING Before starting the procedures below, read the information in Safety Precautions 100. Failure to do so could result in serious and permanent health damage. Disassembly 1. Park the vehicle on a level surface. Chock the rear or front tires, as required.
Page 567 42.13 Bosch Pin Slide Brakes Anchor Plate Disassembly, Cleaning and Inspection, and Assembly 05/31/2001 f430259 A. Driver Side Front Backing Plate Assembly (66 mm brakes) B. Driver Side Front Backing Plate Assembly (73 mm brakes) C. Driver Side Rear Backing Plate Assembly (typical) 1.
Page 568 42.13 Bosch Pin Slide Brakes Anchor Plate Disassembly, Cleaning and Inspection, and Assembly 2. Apply a thin coat of Aeroshell Grade 5 grease to the inside opening at each end of the boot. 3. Slide the guide pin into the guide pin boot. 4.
Page 569 42.13 Bosch Pin Slide Brakes Anchor Plate Disassembly, Cleaning and Inspection, and Assembly On 73 mm brakes, install the anchor plate tie bar using the four tie bar bolts to the anchor plate face. Tighten the bolts 40 to 50 lbf·ft (54 to 68 N·m).
Page 570: System Bleeding
42.13 Bosch Pin Slide Brakes System Bleeding Bleeding WARNING Before starting the procedures below, read the information in Safety Precautions 100. Failure to do so could result in serious and permanent health damage. Whenever any hydraulic system ﬁtting is loosened or disconnected, the entire system must be bled to re- move any air that may have entered it.
Page 571 42.13 Bosch Pin Slide Brakes System Bleeding 10. Remove the chocks from the rear tires. Manual Bleeding NOTE: If you do not have pressure bleeding equipment, you can use the manual bleeding procedure. WARNING Read over the information in Subject 100 before starting the procedure below.
Page 572 42.13 Bosch Pin Slide Brakes System Bleeding Check the brake ﬂuid level in the front compartment of the reservoir. Add new DOT 3 approved brake ﬂuid if needed. 4. Bleed the hydraulic connections at the wheel calipers, starting at the right rear wheel caliper, as follows.
Page 573: Troubleshooting Tables
42.13 Bosch Pin Slide Brakes Troubleshooting Troubleshooting Tables IMPORTANT: See Section 42.12 for detailed hydraulic brake system troubleshooting proce- dures. Problem—Noise and Chatter Problem—Noise and Chatter Possible Cause Remedy Bent, damaged, or incorrect pads. Replace with the correct pads in axle sets. Worn out lining plates (plates rubbing Resurface or replace the rotor.
Page 574 42.13 Bosch Pin Slide Brakes Troubleshooting Problem—Springy or Spongy Pedal Problem—Springy or Spongy Pedal Possible Cause Remedy Excessive rotor runout. Check the bearing adjustment. See Subject 140. Poor quality brake ﬂuid (low boiling point). Drain and clean the system. Reﬁll with the approved brake ﬂuid. Weak brake hoses that expand under Replace the hoses.
Page 575: Specifications
42.13 Bosch Pin Slide Brakes Speciﬁcations Kent-Moore Tools Kent-Moore Part Number Tool ZTSE4417 Seating Tool for 66 mm Caliper Pistons ZTSE4418 Seating Tool for 73 mm Caliper Pistons Table 1, Kent-Moore Tools Fastener Torque Values Description Size Grade Torque: lbf·ft (N·m) Caliper Pin Mounting Bolts M12 x 1.25 —...
Page 576: General Information
42.14 Bendix Air Disc Brakes General Information General Information guide pins, away from the inner side of the rotor, which pulls the outer brake pad into the rotor. The clamping action of the brake pads on the rotor ap- ® Bendix Air Disc Brakes use a ﬂoating caliper design plies braking force to the wheel.
Page 577 42.14 Bendix Air Disc Brakes Safety Precautions General Safety Precautions the correct tools and observe all precautions pertaining to use of those tools. • Replacement hardware, tubing, hose, ﬁttings, WARNING etc., should be the equivalent size, type, length, and strength of the original equipment. When replacing brake pads, shoes, rotors, or •...
Page 578 42.14 Bendix Air Disc Brakes Safety Precautions OSHA recommends that enclosed cylinders equipped with vacuums and high-efficiency particulate air (HEPA) ﬁlters be used during brake repairs. Under this system, the entire brake assembly is placed within the cylinder and the mechanic works on the brake through sleeves attached to the cylinder.
Page 579 42.14 Bendix Air Disc Brakes Brake Pad Removal, Inspection, and Installation Removal 1. Shut down the engine. Chock the tires on the axle that is not being repaired. WARNING Before jacking on the vehicle, ensure that the rear tires are securely chocked. Exercise caution when jacking and do not rely on jacks alone to support the vehicle.
Page 580 42.14 Bendix Air Disc Brakes Brake Pad Removal, Inspection, and Installation 8. Slide the caliper to the inboard position. remove the inner pad. Inspection Brake Pads 1. Measure the thickness of the friction material on the brake pad. If the thickness of the friction material is less than 0.079 in (2 mm) the pads must be replaced.
Page 581: Installation
42.14 Bendix Air Disc Brakes Brake Pad Removal, Inspection, and Installation 3. Install a new in-pad wear indicator. See Sub- ject 120. 4. Using a box-end wrench or socket, turn the shear adapter clockwise until the pads come into contact with the rotor. Then turn the shear adapter counterclockwise two clicks, to set the initial running clearance.
Page 582 42.14 Bendix Air Disc Brakes Electronic Wear Indicator Replacement General Information 5. Insert the longer branch of the wear indicator cable into the pre-cut slot in the outboard pad. The wear indicator will snap into place. New wear indicators are normally installed whenever brake pads are replaced.
Page 583 42.14 Bendix Air Disc Brakes Tappet and Boot Assemblies Removal and Installation Removal 1. Remove the brake pads. See Subject 110 instructions. IMPORTANT: Never turn the adjuster without the shear adapter installed. The shear adapter is a safety feautre and is designed to prevent applying excess torque to the adjuster.
Page 584 42.14 Bendix Air Disc Brakes Tappet and Boot Assemblies Removal and Installation 06/10/2008 f422488 1. Tappet Assembly 2. Press-In Tool Fig. 3, On-Vehicle Installation of Tappet 5. Remove the safety stands and lower the vehicle. With Caliper Off Vehicle 1. Using the long press-in extension tool, install the boots.
Page 585 42.14 Bendix Air Disc Brakes Caliper/Carrier Assembly Replacement Replacement IMPORTANT: Do not attempt to use the pad re- tainer to attach any lifting device to the brake. The pad retainer is not suitable for this purpose. 1. Chock the front and rear tires. Shut down the Damage to the brake and/or unsafe conditions engine.
Page 586 42.14 Bendix Air Disc Brakes Service Brake Chamber Replacement Replacement brake chamber mounting nuts. Remove the ser- vice (spring) brake chamber. WARNING Drain the air system before disconnecting the air hoses. Do not disconnect pressurized hoses be- cause they will whip as air escapes from the line, which could result in personal injury.
Page 587 42.14 Bendix Air Disc Brakes Service Brake Chamber Replacement 7. Using white grease, lubricate the spherical cup. Fig. 3. The seal and pushrod area must be clean and dry. See Fig. 07/01/2008 f422479 A. Pushrod Area B. Do Not Use if Thickness is Less than 0.12 in (3 1.
Page 588: Troubleshooting Flowchart
42.14 Bendix Air Disc Brakes Troubleshooting Troubleshooting Flowchart Fig. 1 for a troubleshooting procedure ﬂowchart. 01/23/2009 f422501 Fig. 1, Bendix Air Disc Brakes Troubleshooting Flowchart 300/1 Recreational Vehicle Chassis Workshop Manual, Supplement 18, April 2009...
Page 589: General Description
42.15 Meritor WABCO Pneumatic Antilock Braking System General Information General Description the braking force applied to each wheel by sending control signals to the individual wheel modulator valves. Pneumatic-brake-equipped Recreational Vehicle chassis use the Meritor WABCO E-Version Antilock Major components of the ABS are: Braking System (ABS) with a frame-mounted elec- •...
Page 590 42.15 Meritor WABCO Pneumatic Antilock Braking System General Information 01/21/2004 f430361 1. Tone Ring and Sensor 3. Electronic Control Unit (ECU) 2. Front Modulator Valve Assembly 4. Rear Modulator Valve Assembly Fig. 1, ABS Component Location (4-channel, 4S/4M system) activates the engine and exhaust brakes when there the dash illuminates for about 3 seconds.
Page 591 42.15 Meritor WABCO Pneumatic Antilock Braking System General Information in the diagonal in which the fault occurred. However, normal braking is still functional in both diagonals. Fault codes can be retrieved using Meritor TOOL- BOX software (the recommended software), Service- Link, or the ICU if it is equipped with a mode/reset switch.
Page 592 42.15 Meritor WABCO Pneumatic Antilock Braking System General Information STOP CHECK 05/05/2009 f610840a 1. ABS Warning Lamp Fig. 4, ABS Lamp (Lightbar Control Unit [LBCU] instrument panel shown) The supply diaphragm control chamber of the inlet valve is open to the atmosphere. Air pressure enter- ing the supply port unseats the supply diaphragm.
Page 593: Abs Warning Lamp
42.15 Meritor WABCO Pneumatic Antilock Braking System General Information haust port, which releases air pressure from the brake chamber. 02/27/2004 f422055 1. Exhaust Solenoid 2. Supply Solenoid 02/17/2004 f422056 3. Supply Port A. Air From Brake Chamber 4. Supply Diaphragm Control Chamber 5.
Page 594 42.15 Meritor WABCO Pneumatic Antilock Braking System General Information lamp may come on. Do not continue driving with the ABS lamp illuminated. Call Meritor WABCO at 1-800-535-5560 for a consul- tation if you plan a tire-size difference greater than 14 percent. Calculate the percentage difference of the tire sizes with the following equation: Percentage Difference = {(steer-axle tire RPM ÷...
Page 595: Safety Precautions
42.15 Meritor WABCO Pneumatic Antilock Braking System Safety Precautions Safety Precautions WARNING Follow the manufacturer’s procedures while working on any air device. Some parts are sub- ject to mechanical (spring) or pneumatic propul- sion and may cause personal injury or property damage when released.
Page 596: Front Axle
42.15 Meritor WABCO Pneumatic Antilock Braking System Wheel Speed Sensor Replacement Replacement 9. Press the sensor spring clip into the sensor bracket at the brake spider hole until it stops. Make sure the spring clip tabs are on the inboard NOTE: Wire repairs may require the use of spe- side of the vehicle.
Page 597 42.15 Meritor WABCO Pneumatic Antilock Braking System Wheel Speed Sensor Adjustment, Rear Axle Adjustment NOTE: The following adjustment procedure re- quires the use of special tool T11-17556-000. Use of this tool, available through the Parts Dis- tribution Centers (PDCs), eliminates the time- consuming task of removing the wheel and tire assembly, and the brake drum.
Page 598: Installation Checkout
42.15 Meritor WABCO Pneumatic Antilock Braking System Modulator Valve Removal and Installation Removal 4. Mark the air lines for ease of installation. Discon- nect the air lines. NOTE: Wire repairs may require the use of spe- 5. Remove the fasteners that attach the front modu- lator valve or rear modulator valve assembly to cial tools for certain connectors and terminals.
Page 599 42.15 Meritor WABCO Pneumatic Antilock Braking System Modulator Valve Disassembly and Assembly Disassembly 2. Install the modulator valve assembly on the bracket on the crossmember. For instructions, Subject 130. 1. Remove the modulator valve assembly from the crossmember. See Subject 130 for instructions.
Page 600 42.15 Meritor WABCO Pneumatic Antilock Braking System ABS Tone Ring Installation on Service Hubs Tone Ring Installation 2. Using pliers, remove the tone ring from the boil- ing water or oven and center it on the machined area of the hub bore. See Fig.
Page 601 42.15 Meritor WABCO Pneumatic Antilock Braking System ABS Tone Ring Installation on Service Hubs 02/27/98 f421666 1. Hub 3. Dial Indicator 2. Tone Ring Fig. 3, Positioning the Dial Indicator 02/27/98 f421667 A. Rotate the hub. 1. Tone Ring 3. Axle 2.
Page 602: Troubleshooting Tables
42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting General Information J1587 Fault Code Cross-Reference Troubleshooting MID-SID Description This subject contains information for diagnosing Table problems in the WABCO E-Version pneumatic ABS Wheel Sensor system under the following headings: 136-001 Left Front Table 2...
Page 603 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Left Front Wheel Sensor Troubleshooting (SID 001) Problem Test Test Result Action Sensor shorted to 2. Measure the voltage Measurable If the short is in the vehicle power across pin 7 of the X2 voltage at any pin.
Page 604 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Left Front Wheel Sensor Troubleshooting (SID 001) Problem Test Test Result Action Wire mismatch 6. Check for mixed sensor Correct wiring connections, as connections. While using needed. Meritor TOOLBOX software, spin each wheel individually.
Page 605 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Right Front Wheel Sensor Troubleshooting (SID 002) Problem Test Test Result Action Short to ground 3. Measure the resistance Resistance If the short is in the vehicle between pin 5 of the X2 between either pin harness, repair the wiring.
Page 606 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Right Front Wheel Sensor Troubleshooting (SID 002) Problem Test Test Result Action Intermittent signal 7. Adjust the sensor. Using Signal output OK. Adjustment solved the problem. the wheel sensor output Make sure brake chatter is not screen in Meritor causing the problem.
Page 607 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Left Rear Wheel Sensor Troubleshooting (SID 003) Problem Test Test Result Action Open circuit 4. Measure the resistance Resistance is 900– Repeat the test and check for between pins 1 and 2 of 2000 ohms.
Page 608 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Right Rear Wheel Sensor Troubleshooting (SID 004) Problem Test Test Result Action Incorrect sensor 1. Adjust the sensor. Voltage is 0.2 VAC Sensor adjustment solved the air gap Check the AC voltage or greater.
Page 609 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Right Rear Wheel Sensor Troubleshooting (SID 004) Problem Test Test Result Action Damaged tone Inspect the tone ring for damage ring and missing teeth. Make sure the correct tone ring is installed (100- tooth is normal application).
Page 610 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Left Front Modulator Valve Troubleshooting (SID 007) Problem Test Test Result Action Open circuit 2. Measure the modulator Resistance in both Check harness wiring circuits valve inlet and outlet circuits is within 4 378LFI, 378LFO, or 378LF–...
Page 611 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Left Rear Modulator Valve Troubleshooting (SID 009) Problem Test Test Result Action Short to power 1. Measure the voltage No voltage at any Repeat test. Check circuits between pin 10, 11, and pin.
Page 612 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Right Rear Modulator Valve Troubleshooting (SID 010) Problem Test Test Result Action Short to ground 3. Measure the modulator Resistance in both Check harness wiring circuits valve inlet and outlet circuits is within 4 378RRO and 378RRI for short to Inlet or outlet...
Page 613 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Auxiliary Output Troubleshooting (Not ﬁtted, but possible to encounter error code) (SID 019) Problem Action Short to power This fault should not appear. Re-conﬁgure the ECU. If fault continues to appear, check the wiring in the X2 (black) ABS ECU connector.
Page 614 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting J1939 Datalink Troubleshooting (SID 231) Problem Test Action J1939 time out Check engine and Check J1939 datalink, engine ECU, transmission ECU, transmission ECUs and and wiring. Repair as necessary. NOTE: Fault wires.
Page 615 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Miscellaneous Faults Troubleshooting (SID 254) Problem Action Modulator valve actuated too long. Modulator valve was activated too long (more than 75% of 5 minutes). After a delay, function will return to normal.
Page 616 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting 01/21/2004 f430361 1. Tone Rings and Wheel Sensors 3. ABS ECU (Inside Frame Rail) 2. Front Modulator Valves 4. Rear Modulator Valve Assembly Fig. 1, ABS Main Component Locations 300/15 Recreational Vehicle Chassis Workshop Manual, Supplement 19, October 2009...
Page 617 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting WABCO E-Version Circuit Pin and Wire Numbers Wire Connector Circuit Description Number Number 376A ECU Battery Supply (+12 volt) 376C ECU Ignition Supply (+12 volt) 1587+ J1587+ — — 1939–...
Page 618 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting Wheel Speed Sensor Voltage 3. When the ABS warning light comes on, listen for the modulator valves to cycle one by one. The NOTE: Meritor TOOLBOX software can be used 4-Channel valve cycle is: 1, 2, 3, 4.
Page 619 42.15 Meritor WABCO Pneumatic Antilock Braking System WABCO E-Version ABS Troubleshooting 4. The resistance in both cases must be 4 to 9 ous test, "Modulator Valve and Circuit Re- ohms. sistance" was not, repair or replace the chassis harness. • If the resistance in both cases is 4 to 9 •...
Page 620: General Description
42.16 Service Brake Chambers, Haldex General Information General Description Principles of Operation Brake chambers convert the energy of compressed The greater the air pressure admitted to the brake air into the mechanical force and motion needed to chamber, the greater the force applied by the piston apply the brakes.
Page 621 42.16 Service Brake Chambers, Haldex Operating and Leakage Tests NOTE: For both of these tests, the air system must be pressurized to at least 80 psi (550 kPa). Operating Test 1. Chock the tires. 2. Apply the brakes. Check that each piston rod moves out promptly, without binding.
Page 622: Diaphragm Replacement
42.16 Service Brake Chambers, Haldex Diaphragm Replacement Replacement 8. Release the clamp on the piston rod. 9. Do both of the tests in Subject 100. NOTE: This procedure is for service of a leaking 10. Adjust the brakes at the slack adjuster. For in- brake chamber diaphragm only .
Page 623 42.16 Service Brake Chambers, Haldex Diaphragm Replacement 10/11/94 f420433a A. Reference Line Fig. 2, Marking a Reference Line 110/2 Recreational Vehicle Chassis Workshop Manual, Supplement 19, October 2009...
Page 624: Installation
42.16 Service Brake Chambers, Haldex Brake Chamber Removal and Installation Removal 1. Chock the tires. WARNING Wear safety goggles when draining the air sys- tem or loosening an air line because dirt or sludge could ﬂy out at high speeds. Do not direct the airstreams at other people.
Page 625 42.16 Service Brake Chambers, Haldex Brake Chamber Removal and Installation be restricted, resulting in loss of control of the vehicle and personal injury or property damage. 2. Attach the brake chamber to the mounting bracket using a hardened ﬂatwasher and prevail- ing torque locknut.
Page 626 42.16 Service Brake Chambers, Haldex Brake Chamber Disassembly, Inspection and Cleaning, and Assembly Refer to Fig. 1 during chamber disassembly and as- sembly. 10/11/94 f420433a A. Reference Line Fig. 2, Marking a Reference Line rod, being careful to contain the piston rod as- 07/07/98 f420051a sembly and body until the return spring is re-...
Page 627 42.16 Service Brake Chambers, Haldex Brake Chamber Disassembly, Inspection and Cleaning, and Assembly making sure to protect the rod from damage. In- sert the piston rod assembly through the body and clamp the rod (if the body wasn’t removed from the vehicle). 4.
Page 628: Specifications
42.16 Service Brake Chambers, Haldex Speciﬁcations Fastener Torque Speciﬁcations Fastener Description Chamber Size: in Torque: lbf·ft (N·m) 30 (41) 16 (5/8-inch stud) 100 (136) Brake Chamber Mounting-Stud Locknuts 100 (136) 100 (136) 17–21 (22–28) 17–21 (22–28) Clamp Ring Flange Nuts 9–19 (12–26) 13–19 (17–26) 20–30 (27–41)
Page 629: General Information
42.17 Automatic Slack Adjusters, Meritor General Information General Information The Meritor automatic slack adjuster has two main functions: • As a lever, it converts the straight-line force of the brake chamber pushrod to torque on the brake camshaft. Rotation of the camshaft forces the brake shoes against the brake drum.
Page 630 42.17 Automatic Slack Adjusters, Meritor General Information 06/14/2000 f422134 1. Brake Air Chamber 11. Boot 20. Worm Retaining Snap Ring 2. Brake Chamber Pushrod 12. Piston Retaining Ring 21. Worm Seal 3. Clevis Jam Nut 13. Boot Retaining Clamp 22. Manual (Worm) Adjusting Nut 4.
Page 631 42.17 Automatic Slack Adjusters, Meritor General Information 07/20/2000 f430163 1. Straight Clevis 3. Threads 2. Offset Clevis Fig. 2, One-Piece Threaded Clevis Conﬁgurations 050/3 Recreational Vehicle Chassis Workshop Manual, Supplement 19, October 2009...
Page 632: Safety Precautions
42.17 Automatic Slack Adjusters, Meritor Safety Precautions Safety Precautions When working on or around a vehicle, observe the following precautions: • Park the vehicle on a level surface, apply the parking brake, shut down the engine, and chock the tires. •...
Page 633 42.17 Automatic Slack Adjusters, Meritor Slack Adjuster Removal and Installation Removal Installation 1. With the vehicle parked on a level surface, set NOTE: For brake chambers that have pushrods the parking brake, shut down the engine, and with threaded clevises, measure the pushrod chock the tires.
Page 634 42.17 Automatic Slack Adjusters, Meritor Slack Adjuster Removal and Installation 06/14/2000 f422134 1. Brake Air Chamber 11. Boot 20. Worm Retaining Snap Ring 2. Brake Chamber Pushrod 12. Piston Retaining Ring 21. Worm Seal 3. Clevis Jam Nut 13. Boot Retaining Clamp 22.
Page 635 42.17 Automatic Slack Adjusters, Meritor Slack Adjuster Removal and Installation Using a screwdriver or an equivalent tool, pry the pawl button out at least 1/32 inch (0.8 mm). See Fig. 2. Wedge the tool in place. IMPORTANT: Never pull the pushrod out to meet the slack adjuster or push the slack adjuster into position.
Page 636 42.17 Automatic Slack Adjusters, Meritor Slack Adjuster Removal and Installation IMPORTANT: Never pull the pushrod out to meet the slack adjuster or push the slack adjuster into position. Always turn the adjust- ing nut for positioning. Using a wrench, turn the manual adjusting nut counterclockwise to align the hole in the slack adjuster housing with the large hole in the clevis.
Page 637: Brake Adjustment
42.17 Automatic Slack Adjusters, Meritor Slack Adjuster Removal and Installation • For 1/2–20 threads, tighten the clevis jam IMPORTANT: The pushrod must be installed nut 20 to 30 lbf·ft (27 to 41 N·m). in the clevis at least 1/2 inch (13 mm) and not extend beyond it more than 1/8-inch (3- •...
Page 638 42.17 Automatic Slack Adjusters, Meritor Slack Adjuster Removal and Installation 4. Using the manual adjusting nut on the slack ad- juster, adjust the brake chamber stroke (coarse adjustment), as follows. See Fig. Turn the adjusting nut counterclockwise until the brake linings touch the brake drum.
Page 639 42.17 Automatic Slack Adjusters, Meritor Slack Adjuster Removal and Installation The applied chamber stroke must not ex- ability, which could cause personal injury or ceed the maximum value speciﬁed in death, and property damage. Table 8. In a safe area, check for proper brake operation before you put the vehicle in service, as follows.
Page 640 42.17 Automatic Slack Adjusters, Meritor Speciﬁcations Speciﬁed Lubricant Chamber Pushrod Thread Size Lubricant Type Temperature Chamber Size Pushrod Thread Size Amoco Super Permalube No. 2 9, 12, 16 1/2–20 Aralub 3837 20, 24, 30, 36 5/8–18 Citco Premium Lithium EP No. 2 Table 4, Chamber Pushrod Thread Size Exxon Ronex MP No.
Page 641: General Description
42.18 Automatic Slack Adjuster, Bendix General Information General Description is not repairing. Before adjusting an automatic slack adjuster, troubleshoot the foundation brake system and inspect it for worn or damaged com- ® ® The Bendix ASA-5 automatic slack adjuster is de- ponents.
Page 642: Brake Release
42.18 Automatic Slack Adjuster, Bendix General Information away from the drum. As the ASA-5 slack adjuster rotates back to the release position, the yoke again pivots, causing the link to be pushed downward into the slack adjuster body. The free-play between the link teeth and pinion is taken up during the initial part of the release.
Page 643 42.18 Automatic Slack Adjuster, Bendix General Information 07/13/2010 f430513 A. 1-5/16" B. 3/8" Out 1. Mounting Stud 4. Adaptor 2. Pushrod 5. Yoke 3. Jam Nut Fig. 3, Easy-On Yoke Assembly 06/22/2010 f430514 A. 1" 1. Mounting Stud 5. Flush 2.
Page 644 42.18 Automatic Slack Adjuster, Bendix Safety Precautions Safety Precautions When working on or around a vehicle, observe the following precautions: • Park the vehicle on a level surface, apply the parking brake, shut down the engine, and chock the tires. •...
Page 645 42.18 Automatic Slack Adjuster, Bendix Slack Adjuster Removal and Installation Removal NOTE: Refer to Fig. 1 for an example of the ASA-5 slack adjuster when completing this pro- cedure. 07/13/2010 f430513 A. 1-5/16" B. 3/8" Out 1. Mounting Stud 4. Adaptor 2.
Page 646: Installation
42.18 Automatic Slack Adjuster, Bendix Slack Adjuster Removal and Installation 06/22/2010 f430514 06/22/2010 f430515 A. 1" A. Distance 1. Mounting Stud 5. Flush 1. Mounting Stud 3. Square 2. Pushrod 6. Retaining Ring 2. Brake Actuator 3. Jam Nut 7. Yoke Pushrod 4.
Page 647 42.18 Automatic Slack Adjuster, Bendix Slack Adjuster Removal and Installation Brake Actuator Pushrod Measurement Slack Adjuster Standard Easy-On or Quick- Extended Easy-On Adaptor Arm Length Connect Adaptor (inches) (inches) (inches) 1-15/16 to 3-1/32 2-7/16–3-17/32 5-1/2 1-15/16 to 3-3/16 2-7/16–3-11/16 1-3/16 to 3-3/16 1-11/16–3-11/16 Table 1, Brake Actuator Pushrod Measurement 3.
Page 648: Brake Inspection
42.18 Automatic Slack Adjuster, Bendix Slack Adjuster Removal and Installation recommendation. If they are not available, the Brake Stroke * following procedure can be used. 16.5 x 7 15 x 4 16.5 x 7 5. Manually adjust the brakes. Area Length Tractor, Front Trailer...
Page 649 42.18 Automatic Slack Adjuster, Bendix Troubleshooting Troubleshooting Tables Problem—Brake Actuator Stroke is Too Long Problem—Brake Actuator Stroke is Too Long Possible Cause Remedy Loose actuator pushrod jam nut. Reposition components and tighten to speciﬁcation. Excessive clearance between the adaptor/ Replace damaged or worn parts. adaptor bushing and yoke due to wear.
Page 650 42.18 Automatic Slack Adjuster, Bendix Troubleshooting Problem—Brakes Dragging–Over-Adjustment of Brakes Possible Cause Remedy Vehicle brake torque imbalance (more Check all brakes to make sure they are working. Check the air pressure work is being done by some brakes than balance and threshold pressure (refer to Bendix publication BW-1555). Check others;...
Page 651 42.18 Automatic Slack Adjuster, Bendix Speciﬁcations Bendix Extended Adaptors Extended Adaptor Bendix Part Number 5/8–18 297700 1/2–20 297701 Table 1, Bendix Extended Adaptors Brake Actuator Pushrod Measurement Slack Adjuster Standard Easy-On or Quick- Extended Easy-On Adaptor Arm Length Connect Adaptor (inches) (inches) (inches) 1-15/16 to 3-1/32...
Page 652: General Information
42.19 ® PURest Air Dryer General Information General Information ® The Haldex PURest air dryer is designed to pro- mote efficiency and extend the life of the air brake system. Using the combination of the integrated multi-treatment cartridge and a large purge volume, the PURest air dryer removes up to 99% of the con- taminates in the air system and eliminates the need for a separate purge tank.
Page 653 42.19 ® PURest Air Dryer Safety Precautions Safety Precautions When working on or around air brake systems and components, observe the following precautions. • Chock the tires and shut down the engine be- fore working under a vehicle. Depleting air sys- tem pressure may cause the vehicle to roll.
Page 654: Removal And Installation
42.19 ® PURest Air Dryer Removal and Installation Removal 5. Test the air dryer following the instructions in Subject 120. WARNING Before working on or around air brake systems and components, see Safety Precautions 100. Failure to do so may result in personal injury. 1.
Page 655 42.19 ® PURest Air Dryer Operating and Leakage Tests Operating and Leakage Tests Once the PURest air dryer has been installed, per- form the following tests before putting the vehicle back in service. 1. Chock the tires. 2. Close all of the reservoir drain cocks. 3.
Page 656 42.19 ® PURest Air Dryer Troubleshooting Problem—Water in the Air Dryer System Problem—Water in the Air Dryer System Possible Cause Remedy There are contaminants in the desiccant. Change the desiccant cartridge. Check the compressor for excessive oil passage. The are leaks in the air system. Tighten the air connections.
Page 657 42.19 ® PURest Air Dryer Troubleshooting Problem—Poor Drying Efficiency Problem—Poor Drying Efficiency Possible Cause Remedy Air at the dryer inlet exceeds 175°F Extend the length of the compressor discharge line by 12 to 15 feet (4 to 5 (79°C). 300/2 Recreational Vehicle Chassis Workshop Manual, Supplement 22, April 2011...
Page 658: Principles Of Operation
42.20 Air Dryer, Bendix AD-IP General Information General Information To ease servicing, the desiccant cartridge and dis- charge check valve assembly are screw-in types. The purge valve housing assembly, which includes The function of the AD-IP Integral Purge Air Dryer, the heater and thermostat assembly, and the dis- shown in Fig.
Page 659 42.20 Air Dryer, Bendix AD-IP General Information 11/06/2001 f430287 1. Compressor 6. Oil Separator 11. Purge Valve 2. Governor 7. Desiccant Bed 12. Exhaust 3. Purge Control Line 8. Purge Volume 13. Turbo Cutoff Valve 4. Control Port 9. Delivery Check Valve 14.
Page 660 42.20 Air Dryer, Bendix AD-IP General Information 11/06/2001 f430286 1. Compressor 6. Oil Separator 11. Purge Valve 2. Governor 7. Desiccant Bed 12. Exhaust 3. Purge Control Line 8. Purge Volume 13. Turbo Cutoff Valve 4. Control Port 9. Delivery Check Valve 14.
Page 661 42.20 Air Dryer, Bendix AD-IP General Information through the purge oriﬁce in the desiccant cartridge bolt, then through the center of the bolt and into the desiccant bed. Pressurized air from the purge vol- ume expands after passing through the purge oriﬁce; its pressure is lowered and its volume increased.
Page 662 42.20 Air Dryer, Bendix AD-IP Safety Precautions Safety Precautions When working on or around air brake systems and components, observe the following precautions. • Chock the tires and shut down the engine be- fore working under a vehicle. Depleting air sys- tem pressure may cause the vehicle to roll.
Page 663 42.20 Air Dryer, Bendix AD-IP Removal and Installation 6. Mark the relationship of the saddle bracket to the WARNING end cover assembly. Remove the 5/16-inch bolt, washer, and nut that secures the upper mounting Before working on or around air brake systems strap to the saddle bracket.
Page 664: Cleaning And Inspection
42.20 Air Dryer, Bendix AD-IP Air Dryer Disassembly, Cleaning and Inspection, and Assembly 6. Remove the O-rings from the purge valve hous- WARNING ing. Before working on or around air brake systems 7. Remove the purge piston and the return spring. and components, see Safety Precautions 100.
Page 665 42.20 Air Dryer, Bendix AD-IP Air Dryer Disassembly, Cleaning and Inspection, and Assembly 06/07/2004 f430283 1. 5/16-Inch Bolt 12. O-Ring 23. O-Ring 2. 5/16-Inch Lockwasher 13. O-Ring 24. O-Ring 3. 5/16-Inch Locknut 14. Retaining Ring 25. Retaining Ring 4. Upper Bracket Strap 15.
Page 666 42.20 Air Dryer, Bendix AD-IP Air Dryer Disassembly, Cleaning and Inspection, and Assembly Assembly using the retaining ring. Make certain the retain- ing ring is fully seated in its groove in the end cover. 1. Before assembly, coat all O-rings, O-ring grooves, and bores with a generous amount of 8.
Page 667 42.20 Air Dryer, Bendix AD-IP Air Dryer Thermostat Testing Testing During cold-weather operation, check the operation of the end cover heater and thermostat assembly. 1. With the ignition on, check for voltage to the hea- ter and thermostat assembly. Unplug the electri- cal connector at the air dryer, and place the test leads on each of the pins of the male connector.
Page 668 42.20 Air Dryer, Bendix AD-IP Troubleshooting Problem—Air Dryer Is Constantly Cycling or Purging Problem—Air Dryer Is Constantly Cycling or Purging Possible Cause Remedy Excessive system leakage. Test for excessive leakage. Eliminate leaks, as needed. Allowable leakage is 1 psi/min (7 kPa/min) per service reservoir There is excessive leakage in the ﬁttings, Using a soap solution, test for leakage at the ﬁttings, drain valve, and safety hoses, and tubing connected to the...
Page 669 42.20 Air Dryer, Bendix AD-IP Troubleshooting Problem—Water in the Vehicle Reservoirs Possible Cause Remedy Purge (air exhaust) time is signiﬁcantly Replace the desiccant cartridge/end cover O-ring. Make sure the desiccant less than the minimum allowable. cartridge assembly is properly installed. Replace the desiccant cartridge assembly.
Page 670 42.20 Air Dryer, Bendix AD-IP Troubleshooting Problem—Air Dryer Does Not Purge or Exhaust Air Problem—Air Dryer Does Not Purge or Exhaust Air Possible Cause Remedy Purge control line is broken, kinked, See if air ﬂows through the purge control line when the compressor is frozen, plugged, or disconnected.
Page 671 42.20 Air Dryer, Bendix AD-IP Troubleshooting Problem—Pinging Noise Is Excessive During Compressor Loaded Cycle Problem—Pinging Noise Is Excessive During Compressor Loaded Cycle Possible Cause Remedy Pinging noise is due to a single cylinder A slight pinging sound may be heard during system build-up when a single compressor with high pulse cycles.
Page 672: General Information
42.21 Air Dryer, Bendix AD-9 General Information General Information To ease servicing, the desiccant cartridge and dis- charge check valve assembly are screw-in types. The purge valve housing assembly, which includes The function of the Bendix AD-9 air dryer is to collect the heater and thermostat assembly, and the dis- and remove air system contaminants in solid, liquid, charge check valve assembly, can be serviced with-...
Page 673: Principles Of Operation
42.21 Air Dryer, Bendix AD-9 General Information The standard air dryer uses a metal seat turbo cutoff After exiting the end cover, air ﬂows into the desic- valve. See Fig. 2. The function of the metal seat is to cant cartridge. Once in the cartridge, air ﬁrst ﬂows prevent turbocharger boost pressure loss through the through an oil separator, which removes water, oil, oil air dryer during the purge (compressor unloaded)
Page 674 42.21 Air Dryer, Bendix AD-9 General Information 05/26/95 f420541a 1. Desiccant Cartridge 7. Sump 13. Reservoir 2. Check Valve 8. Heater Element 14. Governor 3. Oriﬁce 9. Exhaust 15. Compressor 4. Purge Volume 10. Purge Valve 16. Control Port 5. Check Valve Assembly 11.
Page 675 42.21 Air Dryer, Bendix AD-9 General Information 05/09/95 f420542a 1. Desiccant Cartridge 8. Heater Element 14. Reservoir 2. Check Valve 9. Exhaust 15. Governor 3. Oriﬁce 10. Purge Valve 16. Compressor 4. Purge Volume 11. Turbocharger Cutoff Piston 17. Control Port 5.
Page 676 42.21 Air Dryer, Bendix AD-9 General Information The purge valve will remain open after the purge At the beginning of the purge cycle, the downward cycle is complete, and will not close until air brake travel of the purge piston is stopped when the turbo system pressure is reduced and the governor signals cutoff valve (tapered portion of the purge piston) con- the compressor to charge.
Page 677: Safety Precautions
42.21 Air Dryer, Bendix AD-9 Safety Precautions Safety Precautions When working on or around air brake systems and components, observe the following precautions. • Chock the tires and shut down the engine be- fore working under a vehicle. Depleting air sys- tem pressure may cause the vehicle to roll.
Page 678: Installation
42.21 Air Dryer, Bendix AD-9 Air Dryer Removal and Installation Removal 2. Using the remaining two bolts, four special washers, and two locknuts, secure the air dryer to the lower bracket. Tighten the two remaining WARNING bolts 23 to 32 lbf·ft (31 to 43 N·m). 3.
Page 679 42.21 Air Dryer, Bendix AD-9 Air Dryer Removal and Installation 08/09/95 f421383 1. 5/16-Inch x 4-1/2-Inch Upper 9. Desiccant Cartridge 18. Purge Valve Bracket Bolt 10. O-Ring 19. 1/4-Inch Tapping Screw 2. Upper Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3.
Page 680 42.21 Air Dryer, Bendix AD-9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly NOTE: As a convenience when rebuilding the purge valve housing. Then, slide the heater element out, to the right and up. air dryer, several replacement parts and mainte- Discard the assembly.
Page 681 42.21 Air Dryer, Bendix AD-9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly 08/09/95 f421383 1. 5/16-Inch x 4-1/2 Inch Upper Bracket Bolt 14. Check Valve Assembly 2. Upper Bracket Strap 15. Purge Valve Assembly 3. 5/16-Inch Lockwasher 16. Purge Valve Bolt 4.
Page 682: Cleaning And Inspection
42.21 Air Dryer, Bendix AD-9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly Cleaning and Inspection 2. Install the heater and thermostat assembly, as follows. Insert the heater element into the slot in WARNING the purge valve housing until the connec- tor contacts the housing.
Page 683 42.21 Air Dryer, Bendix AD-9 Air Dryer Disassembly, Cleaning and Inspection, and Assembly Start all three screws by hand, then torque them 85 to 125 lbf·in (960 to 1412 N·cm). 4. Install an O-ring on the check-valve assembly, then install the assembly in the end cover using a socket.
Page 684 42.21 Air Dryer, Bendix AD-9 Air Dryer Thermostat Testing Testing During cold-weather operation, check the operation of the end cover heater and thermostat assembly. 1. With the ignition on, check for voltage to the heater and thermostat assembly. Unplug the electrical connector at the air dryer, and place the test leads on each of the pins of the male connector.
Page 685: Troubleshooting
42.21 Air Dryer, Bendix AD-9 Troubleshooting Troubleshooting Tables Problem—Air Dryer Is Constantly Cycling or Purging Problem—Air Dryer Is Constantly Cycling or Purging Possible Cause Remedy Excessive system leakage. Test for excessive leakage. Eliminate leaks, as needed. Allowable leakage is 1 psi/min (7 kPa/min) per service reservoir There is excessive leakage in the ﬁttings, Using a soap solution, test for leakage at the ﬁttings, drain valve, and safety...
Page 686 42.21 Air Dryer, Bendix AD-9 Troubleshooting Problem—Water in the Vehicle Reservoirs Possible Cause Remedy Air bypasses the desiccant cartridge Replace the desiccant cartridge/end cover O-ring. Make sure the desiccant assembly. cartridge assembly is properly installed. Purge (air exhaust) time is signiﬁcantly Replace the desiccant cartridge/end cover O-ring.
Page 687 42.21 Air Dryer, Bendix AD-9 Troubleshooting Problem—Constant Exhaust of Air at the Air Dryer Purge Valve Exhaust; Unable to Build System Pressure Possible Cause Remedy Purge valve stays open; supply air leaks Replace the purge valve assembly O-rings. to control side. Problem—Air Dryer Does Not Purge or Exhaust Air Problem—Air Dryer Does Not Purge or Exhaust Air Possible Cause...
Page 688 42.21 Air Dryer, Bendix AD-9 Troubleshooting Problem—Pinging Noise Is Excessive During Compressor Loaded Cycle Problem—Pinging Noise Is Excessive During Compressor Loaded Cycle Possible Cause Remedy Pinging noise is due to a single cylinder A slight pinging sound may be heard during system build-up when a single compressor with high pulse cycles.
Page 689: General Information
46.00 Steering Driveline, Spicer General Information General Description the relative positions of the frame rails and body change during vehicle operation. The steering driveline connects the steering column The upper end yoke is internally serrated to match and jacket assembly to the steering gear by means the external serrations at the end of the steering col- of a telescoping shaft with integral yokes, an upper umn shaft;...
Page 691: Installation
46.00 Steering Driveline, Spicer Steering Driveline Removal and Installation Steering Driveline Removal Remove the yoke from the steering gear input shaft. Don’t turn the steering gear input shaft when removing the lower end NOTE: It is not necessary to loosen the steering yoke.
Page 692 46.00 Steering Driveline, Spicer Steering Driveline Removal and Installation 10. Leave the parking brakes applied and the chocks at the rear tires. 11. Raise the front of the vehicle, so that the front tires are off the ground, then place safety stands under the frame.
Page 693 46.00 Steering Driveline, Spicer Steering Driveline Disassembly and Assembly Disassembly cup, and place the expansion plug against the opposite needle bearing cup. 1. Remove the steering driveline from the vehicle. Tighten the pressure screw to press one Refer to Subject 100 for instructions.
Page 694 46.00 Steering Driveline, Spicer Steering Driveline Disassembly and Assembly NOTE: The U-joint cross lube ﬁtting should bearing cup, and place it on the pressure screw. Place a bearing driver on the oppo- face away from the base of the upper end site end of the tool.
Page 695 46.00 Steering Driveline, Spicer Steering Driveline Disassembly and Assembly 03/10/94 f460562a A. Align arrows. 1. Lower End Yoke 2. Driveline Tube and Yoke Assembly Fig. 2, Driveline Alignment 5. Install the steering driveline in the vehicle. Refer Subject 100 for instructions. 110/3 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 696: Specifications
46.00 Steering Driveline, Spicer Speciﬁcations Torque Values Torque: Description Grade Size lbf·ft (N·m) Lower End Yoke Pinch-Bolt Nut 7/16–20 UNF 45 to 55 (61 to 75) Upper End Yoke Pinch-Bolt Nut 3/8–24 UNF 30 to 40 (40 to 54) Table 1, Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 18, April 2009...
Page 698 46.01 Drag Link General Information General Description The socket ball studs, one located at each end of each drag link, rotate to allow for changing angles between the pitman arm and steering arm as the ve- The Model XC uses two drag links to connect the hicle is steered and the suspension articulates.
Page 699 46.01 Drag Link Drag Link Removal and Installation Removal 14, 15 12/18/97 f461268 1. Cotter Pin, 2-Inch 11. Bearing, 1.75-Inch Diameter 18. Screw, 1/4–20, Grade 8 2. Capscrew, 1/2–13, Grade 8 12. Idler Arm Shaft 19. Idler Arm Bracket Assembly 3.
Page 700 46.01 Drag Link Drag Link Removal and Installation 3. Remove the nut that holds the idler arm, and re- move the arm from the shaft. See Fig. 4. Remove the cotter pin and castle nut from the forward end of the rear drag link. 5.
Page 701 46.01 Drag Link Ball Stud Testing, On Vehicle Testing Check for wear of the drag link ball stud end, and nut tightness as follows: Have someone gently turn the steering wheel back and forth; check for looseness between the ball stud end, and both the pitman arm and steering arm.
Page 702 46.01 Drag Link Speciﬁcations Torque Values Torque Nut Size lbf·ft (N·m) 3/4–16 90–170 (122–230) 7/8–14 160–300 (217–407) Table 1, Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 703 Steering Column Assembly, Douglas Autotech 46.02 Tilt/Telescoping General Information General Description If the vehicle is equipped with a telescoping steering column, push the lever down and extend or retract the steering column as desired. To change the position of the steering wheel, pull the lever upward and move the steering wheel to the de- sired position.
Page 704 Steering Column Assembly, Douglas Autotech 46.02 Tilt/Telescoping General Information 04/10/97 f461176 1. Tilt/Telescope Lever Fig. 2, Tilt/Telescoping Steering Column 050/2 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 705: Steering Wheel Removal And Installation
Steering Column Assembly, Douglas Autotech 46.02 Tilt/Telescoping Steering Wheel Removal and Installation Removal Installation 1. Make sure the front tires are pointed straight ahead and the steering gear is centered. 2. Put the steering wheel on the steering column so that the spokes are within 10 degrees of the 3 o’clock and 9 o’clock positions.
Page 706: Steering Column Removal And Installation
Steering Column Assembly, Douglas Autotech 46.02 Tilt/Telescoping Steering Column Removal and Installation Removal 1. Position the front wheels in the straight ahead position. If possible, drive the vehicle in a straight line for a short distance, stopping at the place where the work will be done.
Page 707 Steering Column Assembly, Douglas Autotech 46.02 Tilt/Telescoping Speciﬁcations Torque Values Torque Description lbf·ft (N·m) Steering Column Mounting Capscrews 146 (198 ) Steering Wheel Nut 60 (81) Steering Driveline Pinch Bolt 37 (50) Table 1, Torque Values 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 708: Principles Of Operation
46.03 Ross TAS55/65/85 Steering Gear General Information General Description shaft, and the inside end is fastened to the worm- shaft; thus, the force of the driver turning the steering wheel travels from the input shaft to the worm shaft The Ross TAS55, TAS65 and TAS85 integral power through the torsion bar.
Page 709 46.03 Ross TAS55/65/85 Steering Gear General Information 12/17/97 f461267 1. Capscrew, 1/2–13, Grade 8 6. Steering Gear Mounting Plate 10. Pitman Arm 2. Washer, 1/2 x 1.06 7. Straight Fitting 11. Capscrew, 7/8–14, Grade 8 3. Hexnut, 1/2–13 8. Steering Gear 12.
Page 710 46.03 Ross TAS55/65/85 Steering Gear General Information f460581a 10/31/96 1. Lower Cylinder Cavity 7. Input Shaft 12. Upper Cylinder Cavity 2. Poppet Fixed Stopscrew 8. Torsion Bar 13. Ball (recirculating) 3. Poppet Assembly 9. Control Valve 14. Rack Piston 4. Poppet Spring 10.
Page 711 46.03 Ross TAS55/65/85 Steering Gear In-Vehicle Adjustments Sector (Output) Shaft Adjustment 1. Position the sector shaft at its center of travel by turning the steering wheel until the alignment mark on the sector shaft is at a right angle to the input shaft centerline, and in line with the timing mark on the end of the housing trunnion.
Page 712 46.03 Ross TAS55/65/85 Steering Gear In-Vehicle Adjustments through the use of a special service poppet adjusting screw and sealing jam nut kit, unless they were reset for automatic adjustment while the steering gear was disassembled. Use the following procedure for manually resetting the poppet valves: 1.
Page 713 46.03 Ross TAS55/65/85 Steering Gear In-Vehicle Adjustments This pushes out the left-hand turn poppet With the steering wheel held in place, to prepare it for setting. See Fig. loosen the sealing nut one turn, and while holding the sealing nut, turn the adjusting screw using an allen wrench.
Page 714 46.03 Ross TAS55/65/85 Steering Gear In-Vehicle Adjustments the adjustment procedure must be repeated if steering travel is either increased or de- creased in the future. 100/4 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 715 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Removal and Installation Removal when removing, lifting, and carrying the steering gear, to avoid injury. IMPORTANT: Before removing the steering 8. Remove the fasteners that attach the steering gear, see Section 46.06, Subject 300 to iden- gear to the frame rail.
Page 716 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Removal and Installation 12/17/97 f461267 1. Capscrew, 1/2–13, Grade 8 6. Steering Gear Mounting Plate 10. Pitman Arm 2. Washer, 1/2 x 1.06 7. Straight Fitting 11. Capscrew, 7/8–14, Grade 8 3. Hexnut, 1/2–13 8.
Page 717 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Removal and Installation wrench to tighten the nut until there is ﬁrm resistance. Tighten one-sixth turn more. 6. Fill and bleed the steering system. IMPORTANT: Do not turn the steering wheel until instructed. Doing so can cause air to enter the system, which can make it more difficult and time-consuming to bleed air from the system.
Page 719 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments Disassembly Using a small screwdriver, remove and discard the water seal from the housing trunnion. See Fig. 3. Remove any dirt, WARNING paint, or corrosion from the sector shaft with a piece of ﬁne emery cloth.
Page 720 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 54 51 31 30 12 11 03/15/94 f460320a NOTE: The side cover for TAS55 and TAS65 steering gears contains a bushing. The side cover for the TAS85 contains a bearing and is secured with eight special bolts.
Page 721 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/10/94 f460322a 03/09/94 f460325a A. Timing Marks Fig. 5, Tape the Splines Fig. 2, Line Up the Timing Marks 03/09/94 f460323a 03/09/94 f460326a Fig. 3, Remove the Water Seal Fig.
Page 722 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments Make sure the bolt is in far enough so that it will support a rolling head (lady-foot) type pry bar. See Fig. 03/09/94 f230001a 1. Ring 2. Washer Fig.
Page 723 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/09/94 f460332a 03/09/94 f460336a Fig. 12, Unstake the Adjusting-Screw Retainer Fig. 14, Remove the Valve Housing Bolts 03/09/94 f460335a 03/09/94 f460337a Fig. 13, Clean the Input Shaft Fig.
Page 724 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments ton by turning the worm shaft until all of them are out. See Fig. 19. Don’t lose any of these balls, or you will have to replace the entire set.
Page 725 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 11. Cut and remove the Teﬂon seal ring and the O-ring from the rack piston. See Fig. 03/09/94 f460432a Fig. 22, Slide the Special Tool Over the Poppet Adjuster Seat 03/09/94 f460344a...
Page 726 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/09/94 f460348a 12/16/94 f460346a Fig. 26, Unscrew the Adjuster Locknut and Bearing 1. Poppet 4. Poppet Spring Adjuster 2. Adjuster Seat and 5. Nylon Spacer Rod Sleeve Assembly (inside poppet 3.
Page 727 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/09/94 f460350a 03/09/94 f460354a Fig. 28, Remove the Thin Washer, Thrust Bearing, Input Shaft, Rotary Valve, and Worm Shaft Assembly Fig. 30, Remove and Discard the Seal Rings and O-Rings from the Valve Housing f460355a 03/09/94...
Page 728 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/09/94 f460358a 03/09/94 f460356a Fig. 34, Remove the Retaining Ring Fig. 32, Tap Out the Seal from the Valve Housing 03/09/94 f460357a 1. Poppet Fixed Capscrew f460359a 03/09/94 2.
Page 729 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments the housing, from the side of the bore Inspection where the side cover was attached. See Fig. All sealing surfaces and seal cavities must be free of nicks and corrosion.
Page 730 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments scoring is the cause of internal leakage greater than 1 gpm (3.8 Lpm). For test procedure, see Section 46.06, Subject 300. 03/09/94 f460364a Fig. 40, Inspect the Rack Piston Internal Ball-Track Grooves 03/09/94 f460367a...
Page 731 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 6. Inspect the housing roller bearing Fig. 45 brinelling or spalling. If either condition exists, replace the housing bearing. Inspect the side cover bushing. If the clearance between the bushing and the sector shaft is more than 0.008 inch (0.20 mm), replace the side cover and bushing assembly.
Page 732 All seals, seal rings, and gaskets must be replaced with new ones each time the gear is disassembled. Individual seals, seal rings, and gaskets, as well as complete seal kits, are available from Freightliner parts distributors. See Fig. 1. If required, install a new sector shaft roller bear- ing;...
Page 733 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/09/94 f460379a 03/09/94 f460377a Fig. 54, Install the Second Retaining Ring Fig. 52, Put the New Seal on Special Tool Turn the gear housing over so that the trunnion end of the bore is up;...
Page 734 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/09/94 f460383a 03/09/94 f460381a Fig. 58, Install the Roller Thrust Bearing and the Thick Thrustwasher Fig. 56, Lubricate and Install a New O-Ring Lubricate a new large diameter O-ring and a new seal ring, then install them in the valve housing.
Page 735 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/09/94 f460386a 03/09/94 f460388a Fig. 60, Lubricate, then Install a Second Thrust Bearing Fig. 62, Install the Bearing Adjuster over the Worm and Thin Washer Shaft 03/09/94 f460387a 03/01/94 f460389a...
Page 736 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments NOTE: The torque needed to turn the input shaft must not be more than 22 lbf·in (240 N·cm). 3.19 Oil the new seal rings, and install them in the valve housing.
Page 737 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/10/94 f460393a 03/10/94 f460396a Fig. 67, Screw the Poppet Adjuster Seat and Sleeve Assembly into the Rack Piston Fig. 70, Install a new Backup O-Ring and new Teﬂon Seal Ring 6.
Page 738 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/10/94 f460399a Fig. 73, Install the Poppet Assembly Parts 03/10/94 f460397a Fig. 71, Apply Locquic Primer T 03/10/94 f460400a Fig. 74, Tighten both Poppet Adjuster Seat and Sleeve Assemblies Put the rack piston on a clean, cloth- covered bench, with the worm end of the...
Page 739 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments CAUTION If you are installing a new rack piston or a new input-shaft/valve/worm assembly, do not install the existing steel balls. Use a new set of steel balls or damage to the steering gear may result.
Page 740 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments balls, remove all of the balls, and the input-shaft/valve/worm assembly from the rack piston. Repeat the previous steps beginning with inserting the worm shaft and input shaft assembly into the worm end of the rack piston.
Page 741 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments from the bottom of the jam nut. See not to damage the seal ring on the rack Fig. 1, Ref. 38 and Ref. 39 and Fig. piston. Don’t let the poppet adjuster sleeve assemblies bottom out inside the gear housing.
Page 742 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 13. If the sector shaft adjusting screw is being re- placed, do the following; otherwise go to the next step and install the sector shaft/side cover com- ponents.
Page 743 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 14.1 For a TAS55/65 steering gear, lightly oil For a TAS85 steering gear, heavily grease the side-cover "DU" bushing. Don’t grease the short bearing end of the sector shaft. it.
Page 744 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 14.5 Press a new rubber plug into the hole pro- vided in the side cover, until the plug is ﬂush. See Fig. 03/10/94 f460418a Fig. 92, Install the Side Cover Gasket 03/10/94 f460417a Fig.
Page 745 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments CAUTION If the splines on the sector shaft are not taped correctly, the spline will damage the housing seal during assembly, causing the seal to leak. 15.4 Install the sector shaft and side cover, as an assembly, in the gear housing.
Page 746 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments 03/10/94 f460424a 03/10/94 f460688a 1. Retaining Ring Fig. 99, Install a New Trunnion Dirt Seal Fig. 101, Install a New Retaining Ring over the input shaft. Using special tool J37073 and a mallet, tap the seal installer tions of the input shaft, and against the tool until the tool shoulder is square...
Page 747: Final Adjustments
46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments install the special poppet adjusting screw kit 021407-X1. 03/10/94 f460428a Fig. 103, Install a New Grease Fitting 03/10/94 f460322a A. Timing Marks Final Adjustments Fig. 104, Check the Timing Marks Before installing the steering gear on the vehicle, NOTE: If new or reset poppets are in the make these adjustments:...
Page 748 46.03 TRW TAS55/65/85 Steering Gear Steering Gear Disassembly, Inspection, Assembly, and Final Adjustments Back out the sector shaft adjusting screw one-half turn. Note the torque needed to turn the input shaft through 180 degrees each side of center. Tighten the sector shaft adjusting screw so that the torque noted in the above sub- step is increased by 6 to 8 lbf·in (60 to 100 N·cm).
Page 749 46.03 Ross TAS55/65/85 Steering Gear Input Shaft Seal Removal and Installation Removal 1. Disconnect the return line from the steering gear and plug the line. See Fig. 1. Also cap the return port of the gear with a high pressure ﬁtting. 03/10/94 f460574a 1.
Page 750: Installation
46.03 Ross TAS55/65/85 Steering Gear Input Shaft Seal Removal and Installation 03/10/94 f460576a 03/10/94 f460578a 1. Pinch-Bolt 1. Input Shaft Seal 2. Pinch-Bolt Nut Fig. 6, Install the Input Shaft Seal Fig. 4, Install the Pinch Bolt against the valve housing. Remove any seal ma- terial that may have sheared off in the seal bore or retaining ring groove.
Page 751 46.03 Ross TAS55/65/85 Steering Gear Input Shaft Seal Removal and Installation Repeat this procedure three times, each time checking and ﬁlling the reservoir. Start the engine and let it idle for two min- utes. Shut down the engine, and check the ﬂuid level in the reservoir.
Page 752 46.03 TRW TAS55/65/85 Steering Gear Post-Service Checks Post-Service Checks the steering wheel spokes are not within ±10 de- grees of the 3 o’clock and 9 o’clock positions, remove the steering wheel and reposition it. After power steering components have been worked on, and before the vehicle is placed into service, the following items must be checked.
Page 753: Specifications
46.03 TRW TAS55/65/85 Steering Gear Speciﬁcations Refer to Fig. 1 for a plumbing diagram of the steer- ing system with hydraulic brakes. Refer to Fig. 2 a plumbing diagram of the steering system with air brakes. Kent-Moore Tools Kent-Moore Part Number Tool TAS55/65 TAS85...
Page 754 46.03 TRW TAS55/65/85 Steering Gear Speciﬁcations Steering Gear Torque Values Bolt or Nut Torque: Description Grade Size lbf·ft (N·m) 5/8–18 120–140 (163–190) Pitman Arm Pinch-Bolt Nut 3/4–16 215–245 (292–332) Steering Gear Mounting 7/8–14 377–477 (511–647) Hexbolt Nut Torque values are for a plain capscrew with a phosphate and oil coated locknut with a hardened washer. Table 2, Steering Gear Torque Values WARNING Fill only with approved clean automatic transmis-...
Page 755 46.03 TRW TAS55/65/85 Steering Gear Speciﬁcations 10/27/94 f460613a 1. Steering Pump 3. Steering Gear 5. Reservoir 2. Pressure Line 4. Return Line 6. Supply Line Fig. 2, Steering System With Air Brakes 400/3 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 756: General Description
46.04 Power Steering Pump, VT10 Series General Information General Description The Vickers VT10 power steering pump supplies ﬂuid for the operation of the power steering gear and the hydraulically-assisted service brakes. The pump is mounted on the passenger’s side of the engine, at the rear of the air compressor, and is pow- ered by the same drive gear in the engine that pow- ers the air compressor.
Page 757 46.04 Power Steering Pump, VT10 Series Steering Pump Removal and Installation Removal washers and mounting bolts. Tighten the bolts 35 lbf·ft (47 N·m). 1. Apply the parking brakes, chock the tires. 3. Connect the hoses to the pump inlet and outlet ports.
Page 758 46.04 Power Steering Pump, VT10 Series Speciﬁcations CAUTION Fill only with approved clean automatic transmis- sion ﬂuid. Any mixture or any unapproved ﬂuid could lead to seal deterioration and leaks. Any ﬂuid leak could eventually cause loss of power steering assist. Steering System Hydraulic Fluid Recommended Fluid Type...
Page 760: General Information
46.05 SmartWheel Steering Wheel General Information General Information The SmartWheel Steering Wheel Control System of- fers control of the horn, headlamp and marker lamp interrupt, cruise control, and wiper functions from switches mounted in the steering wheel. The system consists of two components: the PC209 and PC210 steering wheel, or PC217 steering wheel and the SM209 master control.
Page 761: Troubleshooting
46.05 SmartWheel Steering Wheel Troubleshooting Troubleshooting +12Vdc power is not present, check the supply fuses or breakers and wiring. 4. Measure the DC voltage at J1.1 (multiplex SIG) CAUTION on the master control. It should measure in the range of 7 to 10 volts. If it doesn’t, check the Clock springs can be damaged if they are not continuity between J1.2 and chassis ground.
Page 762 46.05 SmartWheel Steering Wheel Troubleshooting BACKLIGHT PWR BACKLIGHT GND MPX GND VIP MASTER CONTROLLER P/N SM210 MPX SIG STEERING COLUMN BACKLIGHT FUSE (3A) MPX COMMUNICATIONS BACKLIGHT PWR BACKLIGHT GND MPX GND CONTROL BLOCK MPX GND MPX SIG MPX SIG P21 P22 4 PIN KK−156 MPX SIG (YEL) +12V BAT.
Page 763 46.05 SmartWheel Steering Wheel Troubleshooting IPX MASTER RV MODULAR WIPER CONTROLLER by VEHICLE IMPROVEMENT PRODUCTS CONNECTOR AREA HORN RELAY CRUISE SET N.O. HEADLAMP SRC WPR PWR WASH PUMP PWR GROUND CRUISE SET N.C. HEADLAMP PWR WPR GND PWR GROUND CRUISE RES N.O. MRKRLAMP PWR PARK IGNITION...
Page 764 46.05 SmartWheel Steering Wheel Troubleshooting IMPORTANT: For the cruise and wiper tests be- does not exist, the cruise "RESUME" circuitry on the master control is damaged and must be replaced. low, the ignition switch on the vehicle should be With the cruise "RESUME" switch on the steering turned to the "ACCESSORY"...
Page 765: Steering Wheel
46.05 SmartWheel Steering Wheel Troubleshooting present on any of these output pins, the wiper "OFF" circuitry on the master control is damaged. Replace the master control. In order to check the dynamic braking circuitry after the wiper "OFF" switch is pressed, check for continuity between J9.2 and J9.4 and also between J10.2 and J10.4.
Page 766: Troubleshooting Procedures
46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures General Information Inspections and Maintenance chapter in the ve- hicle driver’s/operator’s manual. A Checklist for Troubleshooting Power Steering Prob- Steps 1 through 4 may have been performed by the lems , form STI-492, has been developed to accom- customer.
Page 767 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures Check that the rear tires are inﬂated to the wheel and check for looseness or binding. correct pressure, and the tire pressure is Make sure all components are free to equal on both sides. Correct the pressure move, but are not excessively loose.
Page 768 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures Inspect all suspension fasteners and com- NOTICE ponents for wear or looseness. 5. Check the steering system for leaks and restric- Do not turn the steering wheel or allow system tions, and test the system back pressure. pressure to exceed the rating of the gauge during the following test.
Page 769 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures 05/19/2011 f462203 A. Vehicles With Air Brakes B. Vehicles With Hydraulic Brakes 1. Steering Pump 3. Reservoir 2. Steering Gear 4. Brake Booster Fig. 1, Plumbing Diagrams gear input and output lines to the done with the steering gear and gear and continue with this substep.
Page 770 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures 05/19/2011 f462204 1. Steering Pump 3. Low Pressure Gauge 2. Steering Gear 4. Reservoir Fig. 2, Testing Steering Gear Restriction Install the PSSA between the steering pump and Check the pump relief pressure. the gear for the following substeps.
Page 771 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures Minimum Measured Pump Flow and Relief Pressure at Engine Idle Flow at 1500 Flow at 1000 Flow at 1800 psi Typical Relief Power Steering Gear rpm, No Load: psi (6900 kPa): (12 400 kPa): Pressure: gpm (L/min) gpm (L/min)
Page 772 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures tion three times. The ﬂow rate be limited to prevent excessive pressure from should return to the ﬂow rate ﬁrst damaging the gear, and the internal PRV pas- noted with the load valve open. sage must be blocked to direct oil ﬂow through the gear.
Page 773 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures loss of assist, as the steering wheel ap- Have someone turn the steering wheel, applying enough force to completely close proaches either full-left or full-right turn. the rotary valve. Check the steering system for stop bolt Complete closure of the rotary valve re- adjustment.
Page 774 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures • Run the engine at governed speed. Check for normal hissing sound at full turn. • Observe the power steering ﬂuid tempera- ture until it stabilizes. NOTE: Noise from the power steering sys- tem does not necessarily mean there is a •...
Page 775 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures Power Steering System Internal Leakage Test Setup, Analyzer Setup TRW Steering Gears With an Internal PRV The hydraulic power steering system is tested with a Power Steering System Analyzer (PSSA), and with Select TRW steering gears are equipped with an in- the hydraulic ﬂuid at operating temperature.
Page 776 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures gauge on the PSSA reaches 2,000 psi (13 790 NOTICE kPa), then fully open the shutoff valve on the PSSA. Do not leave the PSSA shutoff valve fully closed for longer than ﬁve seconds. Doing so could 10.
Page 777 46.06 Power Steering System Troubleshooting Procedures Troubleshooting Procedures 12/03/2009 f462182 A. High-Pressure Input Port B. Low-Pressure Output Port 1. Power Steering Fluid Reservoir 9. Connector, Male NPT to Beaded Hose Barb 2. Existing Power Steering Fluid Lines (Qty 3) 10. Pipe Coupling 3.
Page 778 46.07 Power Steering Pump, TRW PS Series General Information General Information ﬂow returns to normal, ﬂowing from the inlet port to the outlet port and then into the power steering sys- tem. The TRW PS Series power steering pump supplies ﬂuid for the operation of the power steering gear.
Page 779: Installation
46.07 Power Steering Pump, TRW PS Series Steering Pump Removal and Installation Removal 2. Install the new gasket on the pump mounting ﬂange, then place the pump on the engines ac- cessory drive mounting ﬂange. 1. Apply the parking brake, chock the tires. 3.
Page 780 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 11. Remove the locating pins. See Fig. 12. Make CAUTION marks on the outside of the cover (not on the sealing surface) to note from which holes the Be careful when working on the pump housing;...
Page 781 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 25 24 04/18/95 f460977 1. Pump Housing 12. Spring 23. Locating Pin 2. Boost Tube 13. O-Ring 24. Small O-Ring 3. Oriﬁce 14. Plug 25. Large O-Ring 4.
Page 782 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 03/13/95 f460978 03/20/95 f460980 Fig. 2, Removing the End Plug Fig. 4, Removing the Control Valve Assembly 03/13/95 f460979 03/13/95 f460981 Fig. 3, Removing the Spring Fig. 5, Marking the Housing and the Cover side of the needle bearing is facing toward 6.
Page 783 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 03/10/95 f460984 Fig. 8, Marking the Top Plate and the Bottom Plate 03/13/95 f460982 Fig. 6, Removing the Screws and Washers 03/13/95 f460985 Fig. 9, Removing the Top Plate Applying pressure to the engine drive end of the input shaft, press the input shaft from the ball bearing.
Page 784 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 03/13/95 f460986 03/13/95 f460988 1. Dots Fig. 12, Removing the Locating Pins Fig. 10, Checking Whether the Dots are Up or Down. 03/13/95 f460989 03/13/95 f460987 Fig. 13, Removing the Bottom Plate Fig.
Page 785 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 03/13/95 f460990 Fig. 14, Removing the Large Retaining Ring 03/10/95 f460992 Fig. 16, Removing the Spacer 03/13/95 f460991 Fig. 15, Pressing out the Input Shaft and Ball Bearing 03/13/95 f460993 Assembly...
Page 786 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly f460996 04/06/95 03/13/95 f461016 A. Sealing Areas Fig. 20, Pressing the Needle Bearing out of the Cover 1. Valve Bore Fig. 18, Housing Inspection Areas 03/13/95 f461017 03/13/95 f460997 1.
Page 787 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 03/13/95 f460998 03/13/95 f461013 Fig. 22, Checking the Vanes Fig. 24, Removing the Retaining Ring 03/20/95 f461000 A. Splines B. Shaft Seal Area 03/13/95 f461014 Fig. 25, Pressing the Input Shaft Fig.
Page 788 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 03/13/95 f461015 03/13/95 f461003 Fig. 26, Pressing the New Input Shaft Fig. 28, Pressing the Shaft and Bearing into the Cover 03/13/95 f461004 1. Small O-Ring 2. Large O-Ring 03/13/95 f461002 Fig.
Page 789 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 04/06/95 f461005 05/18/95 f461007 1. Pockets A. Squared edge of vane pointing toward the center of 2. Bar the rotor. Fig. 30, Installing the Bottom Plate Fig. 32, Installing the Rotor and the Vanes 03/13/95 f461006 05/18/95...
Page 790 46.07 Power Steering Pump, TRW PS Series Steering Pump Disassembly, Inspection, and Assembly 04/10/95 f461009 03/13/95 f461011 Fig. 34, Greasing the O-Rings Fig. 36, Installing the Housing 04/10/95 f461010 03/13/95 f461012 Fig. 35, Greasing the Sealing Areas Fig. 37, Installing the Valve Spool Assembly 20.
Page 791: Troubleshooting
46.07 Power Steering Pump, TRW PS Series Troubleshooting Problem—The Power Steering Pump Doesn’t Deliver Fluid Problem—The Power Steering Pump Doesn’t Deliver Fluid Possible Cause Remedy The pump input shaft is broken, or not Remove the pump. Repair or replace parts as needed. engaging.
Page 793: Specifications
46.07 Power Steering Pump, TRW PS Series Speciﬁcations Fastener Torques Torque: Description lbf·ft (N·m) Pump Mounting Hexbolts 35 (47) Pump Housing-to-Cover Assembly 30 (41) Bolts Pump End-Plug 30 (41) Pump Inlet Connection 26 (35) Table 1, Fastener Torques Approved Steering System Hydraulic Fluid Lubricant Type Recommended Lubricant Automatic Transmission...
Page 795: General Information
46.08 Steering Column Assembly, TRW Tilt/Telescoping General Information General Information The steering wheel has four-spokes and a cushioned rim, with a button for the electric horn mounted in the center of the wheel hub. NOTE: The TRW tilt/telescoping steering column A turn signal switch attaches to the steering column was installed on vehicles built after October 7, just below the steering wheel.
Page 796 46.08 Steering Column Assembly, TRW Tilt/Telescoping General Information The TRW tilt/telescoping steering column is equipped with a tilt/telescopic foot pedal control. To tilt the steering wheel, depress the foot pedal and move the wheel to the desired angle. To telescope the steering wheel, depress the foot pedal and extend or retract the steering wheel to the desired position.
Page 797: Installation
46.08 Steering Column Assembly, TRW Tilt/Telescoping Steering Wheel Removal and Installation Removal 1. Put the front wheels in the straight ahead posi- tion. If possible, drive the vehicle in a straight line for a short distance, stopping at the place where the work will be done.
Page 798 46.08 Steering Column Assembly, TRW Tilt/Telescoping Steering Wheel Removal and Installation NOTE: The horn wires may be connected to either terminal. 5. Install the horn button in the steering wheel hub so the logo on it is aligned with the steering wheel spokes.
Page 799 46.08 Steering Column Assembly, TRW Tilt/Telescoping Steering Column Assembly Removal and Installation Removal 5. Place the turn signal switch mounting assembly on the steering column. Align the switch so that it is pointed directly to the left. Install and ﬁrmly 1.
Page 800 46.08 Steering Column Assembly, TRW Tilt/Telescoping Steering Column Assembly Removal and Installation 08/12/2005 f462015 1. Tilt/Telescope Foot Pedal Control 4. Lower Steering Column Cover 2. Steering Column 5. Upper Steering Column Cover 3. Mounting Fasteners (Qty. 4) Fig. 1, Tilt/Telescope Steering Column Assembly 110/2 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 801 46.08 Steering Column Assembly, TRW Tilt/Telescoping Steering Column Assembly Removal and Installation 10° 10° 10° 10° 06/28/2007 f462089 1. 9 o’Clock 2. 3 o’Clock Fig. 2, Steering Wheel Centered 110/3 Recreational Vehicle Chassis Workshop Manual, Supplement 16, April 2008...
Page 802: General Description
47.00 Fuel Tanks and Fuel Lines General Information General Description The fuel system delivers fuel from the fuel tank(s) to the engine. It consists of the engine fuel system components, the fuel tank and tank mounting compo- nents, the fuel lines, and (if so equipped) a shutoff valve.
Page 803: Fuel Tank Removal And Installation
47.00 Fuel Tanks and Fuel Lines Fuel Tank Removal and Installation Removal If there is any damage to the fuel tank, replace it. Do not repair fuel tanks. WARNING Damaged fuel tanks must be replaced. A repaired fuel tank will not meet the strength, leakage, and venting standards required by U.S.
Page 804 47.00 Fuel Tanks and Fuel Lines Fuel Tank Removal and Installation aged. Clean a plugged vent line by direct- WARNING ing shop air through the vent line. An un- damaged vent line may be transferred Do not overtighten the fuel tank straps. Torque to from the old tank to the new tank.
Page 805 47.00 Fuel Tanks and Fuel Lines Fuel Tank Strap Replacement Replacement NOTE: This procedure is for vehicles with straight-frame rail chassis. 1. Park the vehicle on a level surface. Shut down the engine. Set the parking brake and chock the front and rear tires.
Page 806: Fuel Line Routing
47.00 Fuel Tanks and Fuel Lines Fuel Line Routing Fuel Line Routing GENERAL GUIDELINES If diesel fuel lines are worn, damaged, or deterio- rated, replace them. Use the following guidelines for installing and routing them. Fuel lines must be free of droops, sharp bends, and kinks in the lines.
Page 807: Fuel System Priming
47.00 Fuel Tanks and Fuel Lines Fuel System Priming Priming IMPORTANT: To prevent fuel loss or entry of air into a fuel line, make sure that all fuel line connections are tight. Before priming the system, make sure there is enough fuel in the tank.
Page 808 47.00 Fuel Tanks and Fuel Lines Inline Fuel Strainer Replacement Replacement NOTE: Vehicles equipped with a Cummins ISB02 engine have an inline fuel strainer lo- cated inside the rail on the right-hand side above the rear axle, above the suspension air bag in the frame.
Page 809: Specifications
47.00 Fuel Tanks and Fuel Lines Speciﬁcations Fuel System Fastener Speciﬁcations Description Speciﬁcation Upper Tank Strap Nut (torque) 100 lbf·ft (136 N·m) 3-5/16 to 3-7/16 Lower Tank Strap Spring (height) inches (84 to 87 mm) Table 1, Fuel System Fastener Speciﬁcations 400 /1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 810 47.01 Fuel/Water Separator, Alliance General Information General Description The fuel/water separator is installed between the en- gine and the fuel tanks. It may be mounted on the side of the transmission, the backwall frame of the engine compartment, or on the right-hand outside wall of the engine compartment, depending on the vehicle design.
Page 811 47.01 Fuel/Water Separator, Alliance General Information 01/29/2013 f470597 1. Drain Plug 7. Mounting Head 2. Sight Bowl 8. Fuel Inlet Port 3. Filter Element 9. Fuel Outlet Port 4. Nut 10. Backwall Frame 5. Washer 11. Bolt 6. Priming Pump Fig.
Page 812 47.01 Fuel/Water Separator, Alliance General Information 02/02/2010 f470178 1. Priming Pump 7. Water Sensor Probe 2. Mounting Head 8. Water Sensor Probe 3. Gasket Wiring Harness 4. Filter Element 9. Heater Wiring 5. O-Ring Harness 6. Sight Bowl 10. Drain Plug Fig.
Page 813 47.01 Fuel/Water Separator, Alliance Removal and Installation Removal 1. Park the vehicle on a level surface, shut down the engine, apply the parking brake. Chock the tires. Open the engine access door. 2. Place a suitable container under the fuel/water separator.
Page 814 47.01 Fuel/Water Separator, Alliance Removal and Installation 01/29/2013 f470597 1. Drain Plug 7. Mounting Head 2. Sight Bowl 8. Fuel Inlet Port 3. Filter Element 9. Fuel Outlet Port 4. Nut 10. Backwall Frame 5. Washer 11. Bolt 6. Priming Pump Fig.
Page 815 47.01 Fuel/Water Separator, Alliance Filter Element Replacement Replacement 1. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tires. 2. Open the engine access door. 3. Place a suitable container under the fuel/water separator.
Page 816: Heater Replacement
47.01 Fuel/Water Separator, Alliance Heater Replacement The heater is an integral part of the sight bowl. If the heater fails, replace the sight bowl. Replacement 1. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tires.
Page 817 47.01 Fuel/Water Separator, Alliance Heater Replacement If not equipped with a priming pump, ﬁll the ﬁlter element and sight bowl with clean fuel and crank the engine until it starts. 16. Start the engine and check for leaks. 17. Shut down the engine and repair any leaks. 120/2 Recreational Vehicle Chassis Workshop Manual, Supplement 26, April 2013...
Page 818 47.01 Fuel/Water Separator, Alliance Water Sensor Probe Replacement Replacement 7. Spin the sight bowl and ﬁlter element off as a unit. 1. Park the vehicle on a level surface, shut down 8. Unscrew the water sensor probe from the base the engine, and apply the parking brakes.
Page 819: Troubleshooting
47.01 Fuel/Water Separator, Alliance Troubleshooting Troubleshooting Problem—Air Leaking into the Fuel System Problem—Air Leaking into the Fuel System Possible Cause Remedy The drain is not closed. Tighten the drain valve. The sight bowl or ﬁlter element is loose. Hand-tighten the sight bowl or ﬁlter element until snug. There are loose, broken, or clogged fuel Tighten, clean, or repair the fuel ﬁttings, valves, or ﬁlters as needed.
Page 820 47.02 Fuel/Water Separators, DAVCO General Information General Description Fuel/water separators are mounted between the fuel tank and the fuel pump, usually on the right frame rail in the engine comaprtment. See Fig. 1 for the typical location. Fuel drawn to the engine travels through the fuel/water separator, which removes water and impurities.
Page 821 47.02 Fuel/Water Separators, DAVCO General Information 02/09/2011 f470568 1. Drain Valve 9. Filter Element 02/08/2011 f470567 2. Lower Housing 10. Check Valve 3. Cover O-Ring Assembly 1. Drain Valve 9. Fuel Outlet Port 4. Vent Cap O-Ring 11. Fuel Inlet Port 2.
Page 822 47.02 Fuel/Water Separators, DAVCO General Information DAVCO fuel/water separators come in a number of different conﬁgurations. There may be an electric heating element installed in the lower housing (Fig. 2, items 11 and 12) or there may be a ﬂuid heat exchanger in the lower housing (Fig.
Page 823 47.02 Fuel/Water Separators, DAVCO Removal and Installation Removal 8. Remove the fuel/water separator mounting fas- teners and remove the fuel/water separator from the frame rail. If the fuel inlet line was not com- WARNING pletely disconnected in the previous step, discon- nect it.
Page 824 47.02 Fuel/Water Separators, DAVCO Removal and Installation 6. Prime the system Ensure that the drain valve is closed. Remove the vent cap from the cover, and ﬁll the housing to the top with clean diesel fuel. Install and hand-tighten the vent cap. Start the engine.
Page 825: Filter Element Replacement
47.02 Fuel/Water Separators, DAVCO Filter and Check Valve Replacement Filter Element Replacement 6. Clean all threads and sealing surfaces very thor- oughly. Even a small amount of dirt will prevent the fuel/water separator from sealing, and an air WARNING leak will result. 7.
Page 826 47.02 Fuel/Water Separators, DAVCO Filter and Check Valve Replacement FOR REMOVAL OF TOP COLLAR ONLY 02/16/2009 f470277 Fig. 2, DAVCO Collar Wrench heat. To do so could cause ﬁre, possibly result- ing in serious personal injury or property dam- age. 1.
Page 827 47.02 Fuel/Water Separators, DAVCO Filter and Check Valve Replacement the fuel/water separator from sealing, and an air 2. Put a clean receptacle under the fuel/water sepa- leak will result. rator and attach a piece of hose to the drain valve, to direct fuel into the receptacle. 7.
Page 828 47.02 Fuel/Water Separators, DAVCO Filter and Check Valve Replacement 1. Park the vehicle on a level surface, shut down Check Valve Assembly Torque Values the engine, and apply the parking brakes. Chock Torque Value: the tire. Fuel/Water Separator lbf·ft (N·m) IMPORTANT: When draining ﬂuid from a fuel/ Fuel Pro 482 45 (61)
Page 829 47.02 Fuel/Water Separators, DAVCO Filter and Check Valve Replacement 11.4 Start the engine. When the lubricating oil reaches its normal operating pressure, increase engine speed to high idle for one to two minutes to purge air from the sys- tem. 11.5 While the engine is running, and after the air is purged from the system, loosen the...
Page 830: Electric Heater
47.02 Fuel/Water Separators, DAVCO Electric Heater, Thermoswitch, and Fluid Heater Tests Any one of several types of heaters and ther- Electric Heater Test Paramaters moswitches may be ﬁtted to DAVCO fuel/water sepa- Resistance rators. They include 12 VDC heaters, 120 VAC heat- Electric Heater Watts Range: Ohms...
Page 831 47.02 Fuel/Water Separators, DAVCO Electric Heater, Thermoswitch, and Fluid Heater Tests Combination Heater Thermoswitch 1. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tire. WARNING Fluid circulated through the fuel/water separator may be diesel fuel returned from the engine, or engine coolant.
Page 832 47.02 Fuel/Water Separators, DAVCO Electric Heater, Thermoswitch, and Fluid Heater Tests Fluid Heat Exchanger 1. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tire. WARNING Fluid circulated through the fuel/water separator may be diesel fuel returned from the engine, or engine coolant.
Page 833 47.02 Fuel/Water Separators, DAVCO Electric Heater, Thermoswitch, and Fluid Heater Tests While looking into the ﬂuid port of the bottom plate (Fig. 4), ﬂow cold water over the thermov- alve for 30 seconds, then run hot water over the thermovalve to determine whether the thermov- alve spool is opening and closing.
Page 834 47.02 Fuel/Water Separators, DAVCO Electric Heater, Thermoswitch, and Fluid Heater Tests Shut down the engine and check for leaks. 120/5 Recreational Vehicle Chassis Workshop Manual, Supplement 26, April 2013...
Page 835 47.02 Fuel/Water Separators, DAVCO Troubleshooting The Daimler Trucks North America Learning Center (accessible through www.AccessFreightliner.com) and DAVCO (www.DavcoTec.com) offer excellent online resources for understanding, testing, and diag- nosing fuel/water separator problems. Identifying Bubble Types Vapor Bubbles Vapor bubbles are harmless and are present in all diesel fuel systems.
Page 836 47.02 Fuel/Water Separators, DAVCO Troubleshooting • a faulty inlet check valve; • faulty O-rings; • leakage elsewhere in the fuel system; • or dirt on threads and sealing surfaces. Air leaks originating between the fuel tank and the fuel/water separator cause air bubbles visible in the clear cover, as shown in Fig.
Page 837 47.02 Fuel/Water Separators, DAVCO Troubleshooting the threads with liquid or paste sealer, and re- Start the engine. When the lubricating oil connect the fuel connections and tighten them reaches its normal operating pressure, securely. increase engine speed to high idle for one to two minutes to purge air from the sys- Air Pressure Testing tem.
Page 838 47.02 Fuel/Water Separators, DAVCO Troubleshooting 8. Apply a soft-set pipe thread sealant to the check WARNING valve body threads. Install the check valve body in the fuel/water separator housing. Do not use Fluid circulated through the fuel/water separator tape to seal the fuel ﬁttings; it will eventually may be diesel fuel returned from the engine, or leak.
Page 839 47.02 Fuel/Water Separators, DAVCO Troubleshooting Conditions Visible Inside DAVCO Clear Filter Covers If You See: What to Do: Comments: Amber-colored fuel below Nothing, the ﬁlter is doing its job Do not change the ﬁlter. the top of the ﬁlter element Amber-colored fuel with Dark patches indicate bacteria or algae may be It may be necessary to use a microbicide,...
Page 840: Specifications
47.02 Fuel/Water Separators, DAVCO Speciﬁcations Fuel Pro Fuel Pro 382 Diesel Pro 243 Diesel Pro 233 Component lbf·in lbf·in lbf·in lbf·ft (N·m) lbf·ft (N·m) lbf·ft (N·m) lbf·ft (N·m) (N·cm) (N·cm) (N·cm) 44–60 12–14 25–40 Inlet Port/Check Valve 45 (61) — —...
Page 841: Exhaust System
49.00 Exhaust System General Information General Information The exhaust system routes hot exhaust gas away from the vehicle, and reduces engine exhaust noise. System components include various conﬁgurations and lengths of piping and clamps, a catalytic con- verter muffler and mounting components, and an ex- haust brake.
Page 842 49.00 Exhaust System General Information 01/28/98 f490156 A. Connects to the Turbocharger 1. Exhaust Brake Outlet Pipe 6. Wide-Band Clamp 11. Hexbolt 2. Saddle Clamp Assembly 7. Flex Pipe 12. Catalytic Converter Muffler 3. Constant-Torque Clamp 8. Muffler Mounting Band 13.
Page 843 49.00 Exhaust System General Information 01/27/94 f490058 1. Baffle 2. Substrate Fig. 2, Typical Catalytic Converter Muffler 050/3 Recreational Vehicle Chassis Workshop Manual, Supplement 9, May 2004...
Page 844: Installation
49.00 Exhaust System Exhaust System Components Removal and Installation Removal Position the exhaust brake inlet pipe to the turbocharger outlet. Install the clamp and tighten it 60 to 108 lbf·in (678 to 1220 NOTE: It is not necessary to remove the muffler N·cm).
Page 845 49.00 Exhaust System Exhaust System Components Removal and Installation 01/28/98 f490156 A. Connects to the Turbocharger 1. Exhaust Brake Outlet Pipe 6. Wide-Band Clamp 11. Hexbolt 2. Saddle Clamp Assembly 7. Flex Pipe 12. Catalytic Converter Muffler 3. Constant-Torque Clamp 8.
Page 846 49.00 Exhaust System Exhaust System Alignment Alignment Perform the following procedure to align the com- plete exhaust system. 1. Loosen the pipe connection clamps and the pipe support bracket clamps. Loosen the inlet pipe-to- exhaust manifold attaching nuts. 2. Work from the front and progressively align the exhaust system components and hangers to eliminate any interferences.
Page 847 49.00 Exhaust System Exhaust System Adjustments Adjustments Inspect inlet pipes, outlet pipes and mufflers for cracked joints, broken welds and corrosion damage that would result in a leaking exhaust system. In- spect the clamps, brackets and insulators for cracks and stripped or badly corroded threads. When pipe clamps are loosened and/or removed to replace a pipe or muffler, replace the clamps if there is a rea- sonable doubt that its service life is limited.
Page 848 49.00 Exhaust System Troubleshooting General Information Exhaust system performance complaints such as ex- cessive back pressure or a malfunctioning exhaust control valve are usually noticeable by their effect on engine performance. However, other malfunctioning components may have similar effects on engine performance and be characterized by the same symptoms or complaints.
Page 849 49.00 Exhaust System Speciﬁcations Fastener Torques Description Size Torque: lbf·ft (N·m) Wide-Band Exhaust — 50–60 (68–81) Clamp Saddle Clamp U-Bolt 3/8–16 24 (33) Mounting Band Fasteners — 10 (14) Table 1, Fastener Torques 400/1 Recreational Vehicle Chassis Workshop Manual, Supplement 0, April 1998...
Page 850 49.01 Aftertreatment System, EPA07 General Information General Information Engine manufacturers use different methods and equipment to reduce emissions from their engines, but an ATD is used on all of them. The ATD is avail- The aftertreatment system (ATS) includes all the pip- able only in chassis-mounted conﬁguration, and can ing and equipment between the engine turbocharger be mounted either vertically or horizontally.
Page 851 49.01 Aftertreatment System, EPA07 General Information remaining particulates are almost completely vapor- is no higher than normal. Under load and at highway ized in the DPF, in a process called regeneration speeds, passive regen may be all that is necessary (regen).
Page 852 49.01 Aftertreatment System, EPA07 Aftertreatment Device (ATD) Removal and Installation Removal 2. Disconnect the connections at the sensor box and the diesel oxidation catalyst (DOC) inlet tem- perature sensor. See Fig. It may be necessary to raise the vehicle or re- 3.
Page 853 49.01 Aftertreatment System, EPA07 Aftertreatment Device (ATD) Removal and Installation 11/2/2006 f490284 A. Inspect this area of the canister for dents. C. DPF Area B. DOC Area 1. Inlet Temperature Sensor 6. Exhaust Outlet to Diffuser 2. Marmon Fitting at Inlet from Turbocharger 7.
Page 854 49.01 Aftertreatment System, EPA07 Aftertreatment Device (ATD) Removal and Installation 9. Run an operational check on the vehicle and check for leaks. 12/11/2007 f490310 1. Mounting Bands 2. Mounting Bracket Fasteners 3. Mounting Brackets 4. V-Band Clamp Fasteners Fig. 2, Aftertreatment Device Mounting Aftertreatment Device Torque Values Fitting Torque: lbf·ft (N·m)
Page 855 To meet the EPA10 requirements, Daimler Trucks speciﬁc information. North America is using technology known as Selec- NOTE: Freightliner documentation deals only tive Catalytic Reduction (SCR) in the exhaust after- with removal and installation of the components treatment system (ATS). The SCR process requires of the ATS.
Page 856 49.02 Aftertreatment System, EPA10 General Information 10/15/2009 f040787 1. Exhaust Gas Recirculation 5. Turbocharger 10. Diesel Exhaust Fluid Tank (EGR) Cooler 6. Hydrocarbon Doser 11. DEF Injector 2. EGR Valve 7. Diesel Oxidation Catalyst (DOC) 12. Mixing Tube (Decomposition 3. Intake Throttle Valve 8.
Page 857 49.02 Aftertreatment System, EPA10 General Information • When conditions permit, the ACM automatically initiates at-speed regeneration. The exact con- ditions for regeneration vary, according to the engine manufacturer’s design. Generally, it can happen only when the vehicle speed is above 7.5 mph (12 km/h), and active regeneration stops when the vehicle slows to 5 mph (8 km/h) or below.
Page 858 49.02 Aftertreatment System, EPA10 Cummins Switchback ATD Removal and Installation Removal 2. Allow the ATS to completely cool before working on it. Refer to Fig. 1 for removal and installation of the Af- NOTICE tertreatment System (ATS) components. Component alignment is critical to proper instal- lation of ATS components.
Page 859 49.02 Aftertreatment System, EPA10 Cummins Switchback ATD Removal and Installation 4. Position the assembly in the mounting straps, then install the clamp bolts and nuts. Do not tighten at this time. NOTICE Make sure that all exhaust outlet piping is in- stalled or the DEF tank will be damaged.
Page 860 49.02 Aftertreatment System, EPA10 Cummins Switchback SCR Catalyst Removal and Installation Removal Refer to Fig. 1 for removal and installation of the SCR catalyst. 1. Shut down the engine and chock the tires. WARNING Aftertreatment Device (ATD) internal tempera- tures can remain hot enough to cause personal injury, or ignite combustible materials, for hours after the engine is shut down.
Page 861 49.02 Aftertreatment System, EPA10 Cummins Switchback SCR Catalyst Removal and Installation 3. Slide the unit under the vehicle and raise it into position. 4. Position the assembly in the mounting straps, and install the clamp bolts and nuts. Do not tighten at this time.
Page 862: Bellows Replacement
49.02 Aftertreatment System, EPA10 Bellows Replacement Replacement NOTE: Always use new exhaust pipe clamps and gaskets when installing exhaust system components. 1. Shut down the engine and chock the tires. WARNING Aftertreatment Device (ATD) internal tempera- tures can remain hot enough to cause personal injury, or ignite combustible materials, for hours after the engine is shut down.
Page 863: General Description
49.03 Diesel Exhaust Fluid System, EPA10 General Information General Description After ﬂowing through the tank, the coolant is redi- rected back to the engine. The Environmental Protection Agency (EPA) man- DEF will degrade over an extended period of time; dated that all engines built after December 31, 2009 shelf life is between twelve and eighteen months in must reduce the level of emissions exhausted by the standard operating conditions and temperatures.
Page 864 49.03 Diesel Exhaust Fluid System, EPA10 General Information 10/15/2009 f040787 1. Exhaust Gas Recirculation 5. Turbocharger 10. DEF Tank (EGR) Cooler 6. Hydrocarbon Doser 11. DEF Injector 2. EGR Valve Diesel Oxidation Catalyst (DOC) 12. Mixing Tube (Decomposition 3. Intake Throttle Valve 8.
Page 865 49.03 Diesel Exhaust Fluid System, EPA10 Tank Removal and Installation NOTE: DEF creeps, causing white crystals to form around the line ﬁttings. The presence of crystals does not mean the system has a leak. Replacing ﬁttings or components is not neces- sary unless there is a system failure or a fault code.
Page 866 49.03 Diesel Exhaust Fluid System, EPA10 Tank Removal and Installation then pull back gently on the coupling to engage the holding clip in the locked position. 7. Connect the DEF supply and return lines to the DEF ports on the back of the tank. 8.
Page 867 49.03 Diesel Exhaust Fluid System, EPA10 Tank Header Unit Replacement The DEF header unit on vehicles with a 13- gallon DEF tank is secured to the top of the tank, and con- tains the engine coolant lines that run through the tank, the coolant valve, the DEF level sensor, and the DEF temperature sensor.
Page 868 49.03 Diesel Exhaust Fluid System, EPA10 Tank Header Unit Replacement 9. Remove the header unit from the tank by pulling 13. Connect the DEF supply and return lines to the the assembly straight up, then tilting it to pull the DEF ports on the tank header unit.
Page 869 49.03 Diesel Exhaust Fluid System, EPA10 Tank Flushing If a contaminant has been introduced into the system and the engine has been started, the following diesel exhaust ﬂuid (DEF) components must be replaced: • Tank • Pump • Header unit •...
Page 870 54.00 Wiring General Information General Information The on-highway environment places severe demands on a vehicles electrical system. The following mate- rial describes the methods for repairing and sealing electrical connections that will provide the durability necessary for the automotive environment. There are four distinct components for making a wire repair that will withstand: •...
Page 871: Parts And Tools
54.00 Wiring Wiring Repair Using Phillips STA-DRY ® Solderless Connectors Parts and Tools 2. Crimp the splice connector onto the wires. Use the type of crimp tool that makes a dimple in the connector. The dimple must be at least 3/16 inch Parts are available through the Parts Distribution wide or there will be too much space inside the Centers (PDCs) in packages of 25 connectors.
Page 872 54.00 Wiring ® Wiring Repair Using Phillips STA-DRY Solderless Connectors Solderless Connector Parts Connector Part Wire Size: gauge (mm) Shrinkable Tubing (Daimler Part Number) Number 20 to 18 (0.5 to 0.8) PHM 1 1863 1/4 inch with internal adhesive coating (48-02461-025) 16 10 14 (1 to 2) PHM 1 1862 1/4 inch with internal adhesive coating (48-02461-025)
Page 873 54.00 Wiring Wiring Repair Using Daimler Trucks North America (DTNA) Kit ESY ES66 404 Parts and Tools 2. Slide a shrinkable solder sleeve from the kit onto one of the wires. Parts are available through the Parts Distribution 3. Place the wires that will be spliced into each end Centers (PDCs) in kits with material for 50 splices.
Page 874 54.00 Wiring Wiring Repair Using Daimler Trucks North America (DTNA) Kit ESY ES66 404 11/04/94 f540392a A. 1/4 inch (6.4 mm) 1. Wire End 3. Solder Sleeve 4. Shrink Tube 2. Barrel Connector Fig. 2, Splice Prepared with Parts in Kit ESY ES66 404 07/30/2010 f545672 1.
Page 875 54.00 Wiring Datalink Repair Parts Twisted-pair datalink wires may be spliced using a mating connector set. See Table 1 for a typical set of datalink connector parts. Datalink Connector Parts Description Part Number Quantity Connector Body Plug 23-13148-204 Terminal Lock 23-13303-015 Terminals 23-13210-020...
Page 876 54.00 Wiring Electrical Connection Protection Use the dielectric protectants and procedures pro- When disconnecting any of these circuits, clean the vided here to protect electrical connections from cor- connection and remove the old dielectric material. rosion. A list of approved dielectric protectants is Completely cover the exposed area after assembly shown in Table...
Page 877 54.00 Wiring Electrical Connection Protection Electrical Component Protection and Procedure Protection Component Procedure Remove the bulb, apply grease to the inside of Tail Lamp Bulb Sockets (non LED) socket. Replace the bulb. Apply grease to battery terminals before Battery Terminals connecting interconnect cables.
Page 878: Specifications
54.00 Wiring Speciﬁcations Standard Wiring Color Coding Color Abbr Typical Usage Black Ground, General Black-White BK-W Ground, Clean or Isolated Blue DK DKBL Backup/Wiper/Trailer Auxiliary Blue LT LTBL HVAC/Circulation Fans/1922+ Blue LT-White LTBL-W Water, Oil Gauge, and Indicator (engine and transmission) Brown Marker, Tail, and Panel Lamps Gray...
Page 879 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number Headlamp, Left 27D 288 304 312 320 659 Headlamp, Right 27D 288 304 312 320 659 Headlamp, Low and High Beam 27D 288 304 312 320 659 Tail Lamps 288 294 296 301 302 304 30A 320 335 Horn, Electric 288 320 321 726 Horn, Air...
Page 880 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number Spot Lamp 316 320 57V Ignition Switch Control Devices 156 285 304 306 320 811 814 860 Starter Mag Switch Power 155 156 157 158 286 320 895 Axle Lock Solenoid 288 320 452 874 878 87A 87B 87F 896 900 Axle Lock 288 320 452 865 866 874 878 87A 87B 87F 896 900...
Page 881 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number Engine Starting Aid, Ether 132 154 286 320 467 Hour Meter, Engine 286 320 812 813 81A 837 852 Fifth Wheel Slide Lock and 173 296 297 303 307 308 309 310 331 334 581 87E Controls Brakesaver, Cat 128 129 286 343 34B 34C 34W 353...
Page 882 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number Electric Fuel Pump 148 150 152 162 164 283 286 320 Predictive Cruise Control 149 283 286 Cab Tilt Indicator 288 320 670 Roof Mounted Emergency Lamp/ 264 271 275 27A 27B 27C 27E 288 31A 31B 31C 31D 31G 320 327 Strobe Advertising/Identiﬁcation Lamp 288 296 302 304 30A 319 320 335...
Page 883 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number Optional Circuit, Cab/Chassis, 160 283 285 286 306 320 321 329 330 343 34B 472 732 736 811 813 Customer Speciﬁed 814 860 Optional Circuit, Cab/Chassis, 329 472 Customer Speciﬁed Engine Start/Stop System, TAS 152 156 162 283 285 286 287 320 321 Emergency Lamp, Alternating, 264 271 275 27A 27B 27C 27E 287 288 318 31A 31B 31C 31D 31G...
Page 884 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number 198 199 283 286 288 320 343 732 810 812 817 830 836 838 83A 840 Fueling Data Recording and 841 842 843 844 845 846 847 852 854 856 858 862 864 865 866 867 Transmitter 868 869 Mirror Dimming Controls...
Page 885 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number Firetruck Pump Controls 148 283 286 372 106 148 152 156 160 162 164 283 285 286 320 330 343 34B 372 732 Engine ECU and Controls 736 811 812 813 814 819 Tire Chains 288 320 452 874 878 87A 87B 87F 896 900 Public Address System...
Page 886 54.00 Wiring Speciﬁcations Circuit Numbers Circuit Description Modules Number Emergency Vehicle Tank Level — Systems Emergency Vehicle Ladder and — Rack Systems Emergency Vehicle Body Lighting — Emergency Vehicle Body Lighting — Emergency Vehicle Body Lighting — Emergency Vehicle Body Lighting —...
Page 887 54.01 Lighting Interior Light Replacement Instrument Cluster Bulb Replacement 1. Disconnect the batteries. 2. Remove the instrument cluster. For instructions, see Section 54.03, Subject 100. 3. On the back of the instrument cluster, remove the ten screws around the outside of the instru- ment cluster housing.
Page 888: Turn Signal Switch Replacement
54.01 Lighting Turn Signal Switch Replacement Replacement 9. Install the steering wheel nut. For more informa- tion, see Section 46.02, Subject 110. The turn signal switch is installed inside the steering 10. Install the horn cover. column. The switch unit also contains circuitry for the headlight dimmer, cruise control, and hazard warning ﬂasher.
Page 889 54.02 Batteries, Maintenance-Free General Information General Information every battery to be certain it is AGM, and never in- stall AGM batteries in the same circuit with other types of batteries. Lead-Acid Batteries AGM batteries are designed for high cranking amps Batteries are electrochemical devices that store and repeated cycle service to accommodate many of chemical energy.
Page 890: Battery Safety Precautions
54.02 Batteries, Maintenance-Free Battery Safety Precautions General Safety Precautions WARNING Do not install any lead-acid battery in a sealed WARNING container or enclosure. Allow hydrogen gas caused by overcharging to escape. Exploding Keep sparks, ﬂames, burning cigarettes, etc. hydrogen gas can cause blindness or other away from batteries.
Page 891 54.02 Batteries, Maintenance-Free Battery Safety Precautions WARNING Do not apply pressure to the end walls of a plastic-case battery. This could cause electrolyte to squirt from the vents, possibly resulting in se- rious injury to skin or eyes. When handling plastic-case batteries, use a battery carrier.
Page 892 54.02 Batteries, Maintenance-Free Emergency (Jump) Starting a Battery Emergency Starting Using 3. Connect the positive (+) jumper cable to the positive terminal or jump start post on the dis- Booster Cables charged battery. See Fig. WARNING Before jump-starting a vehicle, read the instruc- tions in Subject 100.
Page 893 54.02 Batteries, Maintenance-Free Emergency (Jump) Starting a Battery − − − − − − 01/07/2011 f545725 Disconnect jumper cables in the REVERSE order that they were connected. A. Discharged Battery C. Positive Jumper Cable E. Booster Battery B. Negative Ground Stud D.
Page 894 54.02 Batteries, Maintenance-Free Emergency (Jump) Starting a Battery 10. Disconnect the negative jumper cable from the negative cable stud on the jump-started vehicle. 11. Disconnect the negative jumper cable from the booster battery. 12. Disconnect the positive cable from the booster battery.
Page 895: Battery Charging
54.02 Batteries, Maintenance-Free Battery Charging WARNING WARNING Before charging a battery, read the instructions Always turn the charger off before disconnecting Subject 100. Failure to follow the safety pre- it. Touching a charger lead when the circuit is cautions could result in personal injury. live could create a spark and cause an explosion, resulting in personal injury.
Page 896: Battery Removal And Installation
54.02 Batteries, Maintenance-Free Battery Removal and Installation 5. Remove the battery hold-down fasteners; then WARNING remove the batteries from the battery box. See Fig. Before doing any of the following procedures, read the instructions in Subject 100. Failure to follow the safety precautions could result in per- sonal injury.
Page 897: Installation
54.02 Batteries, Maintenance-Free Battery Removal and Installation Installation 8. Start the engine, and check the operation of the charging system. If needed, adjust or repair the charging system to obtain the correct charging 1. Be sure that the batteries to be installed have a output.
Page 898 54.02 Batteries, Maintenance-Free Battery Removal and Installation 5. Remove the battery hold-down fasteners; then WARNING remove the batteries from the battery box. See Fig. Before doing any of the following procedures, read the instructions in Subject 100. Failure to follow the safety precautions could result in per- sonal injury.
Page 899 54.02 Batteries, Maintenance-Free Battery Removal and Installation 4. Position the battery hold-down over the battery, and install the hold-down nut. Tighten the nut until the battery is secure. See Fig. CAUTION Do not overtighten the battery hold-downs. Over- tightening could damage the battery. 5.
Page 900 54.02 Batteries, Maintenance-Free Battery Cleaning and Inspection WARNING Before doing any of the following procedures, read the instructions in Subject 100. Failure to follow the safety precautions could result in per- sonal injury. Cleaning and Inspection 1. Inspect the battery cables for wear, and replace them if necessary.
Page 901: Battery Storage
54.02 Batteries, Maintenance-Free Battery Storage Storage Always store batteries in an upright position. Don’t store batteries on their sides, as electrolyte may es- cape through the vent holes. Maintain inventory levels in balance with demand and always rotate battery stock on a strict ﬁrst-in, ﬁrst-out basis.
Page 902 54.02 Batteries, Maintenance-Free Replacement Battery Selection Selection Long and trouble-free service is assured when the reserve capacity of the battery is equal to or exceeds 160 minutes and the cold cranking amp (CCA) rating of each replacement battery is at least 625 amperes. The CCA rating of the battery is a measure of its ability to supply high cranking power to the cranking motor at 0°F (–18°C).
Page 903 54.02 Batteries, Maintenance-Free Battery Cable Removal and Installation WARNING Before doing any of the following procedures, read the instructions in Subject 100. Failure to follow the safety precautions could result in per- sonal injury. Removal 1. Set the parking brakes; then chock the tires. 2.
Page 904 54.02 Batteries, Maintenance-Free Battery Cable Removal and Installation 4. Tighten all battery connections to the torque speciﬁcations listed on the battery. On Freight- liner batteries, tighten them 10 to 15 lbf·ft (14 to 20 N·m). The correct torque is important for proper electrical system operation.
Page 905: Troubleshooting
54.02 Batteries, Maintenance-Free Troubleshooting Troubleshooting Electrical Drain and Parasitic Load If the batteries pass testing, check for the following causes: Batteries are replenished each time the vehicle is driven with normal vehicle use. In long-term parking 1. Accessories were left on overnight. situations, however, parasitic drains may discharge 2.
Page 906: Battery Troubleshooting
54.02 Batteries, Maintenance-Free Troubleshooting Battery Troubleshooting for a better assessment of the "deep charge" state of the lead plates. 1. Check battery pack voltage to determine state After the surface charge is removed, the batter- of charge. ies need to be at least 80% SoC for further test- ing.
Page 907 54.02 Batteries, Maintenance-Free Troubleshooting hand tool. Lead adapters are available at most tool vendors. Refer to the battery tester instruction manual for complete testing instructions. If the battery tester requires the CCA rating of the battery, it should be on the battery label. See Fig.
Page 908: Specifications
54.02 Batteries, Maintenance-Free Speciﬁcations Table 1 for recharge times. Refer to the com- mercial batteries page at www.dekabatteries.com for more information. Recharge Time Using a Typical Charger (hours) Open Circuit Voltage Charger Maximum Rate State of Charge Flooded 50 Amps 30 Amps 20 Amps 10 Amps...
Page 909: Instrument Cluster
54.03 Instrument Cluster General Information • The engine oil pressure drops below 7 psi (50 General Information kPa); or • The coolant temperature rises above 220°F The instrument cluster is a one-piece unit that con- tains all the gauges and indicators required for safe (105°C).
Page 910 54.03 Instrument Cluster General Information 01/27/98 f610036 NOTE: The warning and indicator light layout shown is typical; arrangement of lights may vary. 1. Left Turn Indicator 2. High Coolant Temperature Warning 3. High Beam Indicator 4. Low Oil Pressure Warning 5.
Page 911 54.03 Instrument Cluster Instrument Cluster Removal and Installation Removal 1. Shut down the engine, apply the parking brake, and chock the tires. 2. Disconnect the batteries. 3. Remove the radio and rear-view TV monitor to gain access to the rear support strap. For de- tailed information, see the body builder’s manual and/or vendor manuals provided by the body builder.
Page 912 54.03 Instrument Cluster Instrument Cluster Removal and Installation 12/16/97 f610040 Remove the fastener indicated by the arrow. NOTE: A typical instrument cluster installation is shown; the procedure is the same for all installations. Fig. 4, Instrument Cluster Hidden Fastener, RH Side 12/17/97 f541859 1.
Page 913 54.03 Instrument Cluster Warning and Indicator Light Replacement Replacement 1. Disconnect the batteries. 2. Remove the instrument cluster. For detailed in- structions, see Subject 100. 3. From the back of the instrument cluster, twist out each bulb that needs replacing. 4.
Page 914 54.03 Instrument Cluster Speedometer Head Calibration Calibration Program Chart, Fractional Part of Divide Number Divide Number 1. Determine the pulses per mile (pul/mi). 0.875 Look on the sidewall of the vehicle’s rear On clusters with microprocessor MPU-100, this setting is 0.333. tires to ﬁnd their size, manufacturer, and †...
Page 915 54.03 Instrument Cluster Speedometer Head Calibration Program Chart, Whole Number Part of Divide Number Divide Number 12/17/97 f541859 1. Tachometer DIP Switches 2. Light Bulbs 3. Low Coolant Harness 4. Transmission Temperature Harness 5. Main Cab Harness 6. Speedometer DIP Switches Fig.
Page 916 54.03 Instrument Cluster Speedometer Head Calibration Write down the correct setting for each switch, either ON or OFF. Using a tool that will not break off, push the pin up to turn it ON; push the pin down to turn it OFF. 7.
Page 917 54.03 Instrument Cluster Tachometer Head Calibration Calibration 1. Remove the instrument cluster from the dash. For detailed instructions, see Subject 100. 2. Locate the tachometer DIP switches on the back of the instrument cluster, to the right of the driver information center light panel.
Page 918 54.04 Air Restriction Indicator General Information General Information A spring-loaded air restriction indicator indicates how much air ﬁlter capacity has been used and how much remains. It registers the actual maximum re- striction of the ﬁlter element when the engine is oper- ating at full load.
Page 919 54.04 Air Restriction Indicator Air Restriction Indicator Replacement Replacement MOUNTED ABOVE THE RADIATOR 1. Chock the tires, then open the rear engine com- partment door. 2. Remove the mounting screw attaching the indi- cator body to the bracket on the railing above the radiator.
Page 920: Troubleshooting
54.04 Air Restriction Indicator Troubleshooting Problem—No Restriction Reading Problem—No Restriction Reading Possible Cause Remedy The indicator leaks. Remove the air restriction indicator. Apply a vacuum to the indicator until the yellow index marker reaches the red line. With your thumb on the mounting ﬁtting, close the end of the indicator airtight.
Page 921 54.05 Electrical Power Center General Information General Information The wiring is protected by fuses (or optional blade- type push-to-reset circuit breakers) mounted on a fuse panel in the electrical power center. The hazard warning ﬂasher is also installed on the fuse panel. Fig.
Page 922 54.05 Electrical Power Center Fuse and Relay Replacement Replacement To remove blade-type fuses, pull outward on the fuse body and release the two prongs. When installing blade-type fuses, insert one prong in each cavity, and press in. Be careful not to bend back the prongs. The cavities are color-coded to make installation easier.
Page 923: Circuit Breaker Replacement
54.05 Electrical Power Center Circuit Breaker Replacement Replacement MODEL VB–3 CIRCUIT BREAKER 1. Slide the old circuit breaker out of the fuse panel. Fig. 2. Snap the new circuit breaker into place. Take care not to damage the two blades while insert- ing them into the panel.
Page 924 54.05 Electrical Power Center Troubleshooting Troubleshooting To troubleshoot malfunctioning fuses, circuit breakers (C/Bs), and relays, do the following: 1. Check the location on the applicable ﬁgure. 2. For fuses or circuit breakers, check the amper- age in the callouts on Fig.
Page 925 54.06 Instrumentation Control Unit, ICU3-M2 General Information • Transmission Fluid Temperature (optional) General Description • Primary Air Pressure (optional) The ICU3-M2 is a basic electronic dashboard that • Secondary Air Pressure (optional) accepts input from the fuel level sensor, the trans- The transmission ﬂuid temperature gauge is required mission temperature sensor (if installed), the J1587 on vehicles with automatic transmissions.
Page 926: Mode/Reset Switch
54.06 Instrumentation Control Unit, ICU3-M2 General Information • Press the mode/reset switch once to display The following items are replaceable: the trip odometer. • air pressure gauges • Press the mode/reset switch again to display • mode/reset button trip engine hours. •...
Page 927 54.06 Instrumentation Control Unit, ICU3-M2 General Information • Fasten Seat Belt Warning (red) • Low Battery Voltage Indicator (red) • Parking Brake On Warning (red) • Tractor ABS Indicator (amber) STOP CHECK • Left Turn Signal (green) BRAKE • Right Turn Signal (green) •...
Page 928 54.06 Instrumentation Control Unit, ICU3-M2 General Information POWER ON HEADLIGHTS ON IGNITION ON 888888.8 ICU INITIALIZES ODOMETER ELECTRONIC GAUGE NEEDLES SCREEN SWEEP, WARNING/INDICATOR LIGHTS COME ON, BUZZER SOUNDS IF NO FAULTS IF FAULT DETECTED WERE DETECTED ABS 136 123456.7 FAULT CODE 12.3 VOLTS SCREEN PARK BRAKE...
Page 929 54.06 Instrumentation Control Unit, ICU3-M2 General Information • The J1939 brake failure message is received NOTE: If the ICU3-M2 receives a message from from the ABS. an ECU that has not been pre-programmed into the ICU’s memory, it displays "SYS ###" in- •...
Page 930: Installation
54.06 Instrumentation Control Unit, ICU3-M2 Instrumentation Control Unit (ICU3-M2) Removal and Installation Removal tions or air hoses from the back of the ICU3-M2, or damage the dash. The instrumentation control unit (ICU3-M2) is a self- 5. Remove the four screws that secure the ICU. contained one-piece unit, including housing, gauges, Carefully remove the ICU from the dash.
Page 931 54.06 Instrumentation Control Unit, ICU3-M2 Instrumentation Control Unit (ICU3-M2) Removal and Installation GREEN 05/14/2002 f610610a 1. Secondary Air Pressure Gauge 2. Primary Air Pressure Gauge 3. 32-Pin Electrical Connector 4. 24-Pin Electrical Connector Fig. 3, ICU3-M2, Rear View 3. Place the ICU3-M2 in the dash opening and se- cure it with the Phillips-head screws.
Page 932 54.06 Instrumentation Control Unit, ICU3-M2 Air Pressure Gauge Replacement Replacement gauge module are removed, take care in sepa- rating the module from the ribbon electrical con- nector. NOTE: The mode/reset switch is part of the air gauge module and is replaced when the air 3.
Page 933 54.06 Instrumentation Control Unit, ICU3-M2 Air Pressure Gauge Replacement ﬁrmly at the edges, place the ribbon end into the slot and push it straight in until it stops. 9. Place the air gauge module into its opening in the ICU3-M2. Make sure the rubber alignment pin in the ICU cavity lines up with the matching alignment receptacle in the air gauge module when placing the module in the ICU.
Page 934 54.06 Instrumentation Control Unit, ICU3-M2 Light Bulb/Telltale Replacement Replacement 1. Remove the dash trim piece by removing the Phillips-head screws that secure it. The instrumentation control unit (ICU3-M2) is a self- CAUTION contained one-piece unit, including housing, gauges, and the dash message center. See Fig.
Page 935 54.06 Instrumentation Control Unit, ICU3-M2 Light Bulb/Telltale Replacement 05/20/2002 f610611a NOTE: For clarity, air gauge and electrical connections are shown removed. 1. ICU3-M2 3. Light Bulb 2. Telltale Fig. 3, ICU3-M2, Rear View (exploded) To Replace Telltales 1. Using a pair of needlenose pliers or a similar tool, grab the exposed tab at the top of the tell- tale slot and carefully pull the telltale out from the top of the ICU.
Page 936 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting Table 1 for an ICU symptom chart. ICU Symptom Chart Problem Where to Begin Diagnosis Gauges (except air pressure gauges) are not Table 2 for initial gauge test procedures. working or are inaccurate. Single-datalink-driven gauge is not working or Table 3 to diagnose the single-datalink-driven gauge.
Page 937 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting Initial Test Gauge Procedure Test Test Description Test Result Action Turn the ignition on. Go to test 3. All the gauges, except air pressure gauges, should sweep full scale and back in unison. Do the gauges sweep correctly when the ignition is Go to test 2.
Page 938 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting Diagnosis for Single-Datalink-Driven Gauge not Working or is Inaccurate Test Test Description Test Result Action Connect Servicelink and open the "ICU3-M2 J1587 Gauges" Datalink Monitor template. Go to test 2. Make sure the operating conditions are such that the gauge would be registering (e.g.
Page 939 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting Diagnosis for Multiple Datalink-Driven Gauges Not Working Test Test Description Test Result Action Go to test 4. Check the J1587 datalink to the Does the ICU3-M2 (MID 140) show up in the ICU, repair as necessary. Servicelink J1708 ECU list? If OK, replace the ICU.
Page 940 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting Air Pressure Gauge Diagnosis Test Test Description Test Result Action Connect an accurate pressure gauge to the air The gauge is OK. suspension. Check the air line to gauge for Is the air pressure gauge in the cluster within 3 psi of kinks.
Page 941 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting Transmission Temperature Gauge Diagnosis Test Test Description Test Result Action Reads minimum Go to test 2. scale all the time What best describes the problem with the transmission Reads maximum Go to test 3. oil temperature gauge? scale all the time Reads...
Page 942 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting ICU3-M2 Fault Code (MID 140) Diagnosis MID PID/SID Fault Description Action Check the power and ground circuits to the ICU and repair as p168 "ICU3-M2 low voltage—less than 10.5 volts." necessary. If OK, check vehicle batteries and charging system.
Page 943 54.06 Instrumentation Control Unit, ICU3-M2 Troubleshooting Gauge Backlighting Diagnosis Test Test Description Test Result Action Access the back of the ICU and disconnect the two electrical connectors. Repair the backlighting ground circuit to ICU pin D3 as necessary. Turn the headlights on. Measure voltage in pins A1(+) and a known good ground while increasing and decreasing the dimmer Check circuit 29A between the...
Page 944: Specifications
54.06 Instrumentation Control Unit, ICU3-M2 Speciﬁcations The two ICU3-M2 main cab harness connectors are Table 4 for fuel level sensor resistance. pink and plug into pins located in the center of the Table 5 for transmission oil temperature sensor unit, on the back. Connector #1 has 24 cavities, resistance, standard gauge.
Page 945 54.06 Instrumentation Control Unit, ICU3-M2 Speciﬁcations ICU3-M2 Connector #2 Pin Assignments, Pins C1 Through D16 Description Wire J1939 (–) 1939– Trailer ABS Warning Lamp 376F1 PC Board Ground (–) Battery Power (+) Ignition Power (+) Headlamp Power (+) Table 2, ICU3-M2 Connector #2 Pin Assignments, Pins C1 Through D16 Message Identiﬁers (MIDs) Description Text Message...
Page 946 54.06 Instrumentation Control Unit, ICU3-M2 Speciﬁcations Transmission Oil Temperature Sensor (Hi-Stat) Resistance Standard Gauge (ºF) Gauge Temperature: ºF Sensor Resistance: ohms 3318 1626 Table 5, Transmission Oil Temperature Sensor (Hi-Stat) Resistance Standard Gauge (ºF) Transmission Oil Temperature Sensor (Hi-Stat) Resistance Metric Gauge (ºC) Gauge Temperature: ºC Sensor Resistance: ohms 2490...
Page 947 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions Use the following ﬂow charts to cycle through the Mode/Reset switch functions and screens. Fig. 1 for the start sequence. See Fig. 2 for the trip miles and hours screens, and Fig. 3 for the en- gine miles and service interval setup screens.
Page 948 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions IGNITION OFF HEADLIGHTS ON 123456.7 TURN OFF ODOMETER IGNITION ON HEADLIGHTS ON IGNITION ON TURN OFF ODOMETER Self−test: 888888.8 clockwise sweep TRIP MI KM HOURS 38.8 VOLTS SERVICE ENGINE Screen displayed for three seconds. Self−test: Alternate between each active fault code.
Page 949 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions From Fig. 1 Metric version screen is similar to English version screen. 123456.7 Hold To Reset Trip Miles TRIP 12.3 VOLTS Push 123456.7 TRIP HOURS Hold To Reset Trip Hours 12.3 VOLTS Push PARK BRAKE ON Go to Fig.
Page 950 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions From Fig. 2 SELECt To Toggle Between Units Hold MI <−−> KM From Fig. 1 *Flash Screen Text Push dIAG See Fig. 4 and 5 for Hold HOURS Diagnostic screen functionality SERVICE n = Number of Active Fault Codes Push MI SERVICE= Service miles enabled...
Page 951 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions From Fig. 1 n = Number of *If fault goes inactive, *If fault goes inactive, Active Fault Codes display "noFault n" display "noFault 1" dIAG *FAULt *FAULt Hold Hold Hold Push Push Push AbS 136 ECU 128...
Page 952 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions From Fig. 1 Metric version screens are similar to English version screens. n = Number of *If fault goes inactive, active fault codes display "noFault n" **If Service miles enabled dIAG *−12345 *FAULt **MI **MI...
Page 953 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions English Units −1 qtS Hold Hold *If Oil Level Low ENGINE ENGINE Push Push 1 qtS *If Oil Level High Hold Hold ENGINE ENGINE Push Push −0 qtS *If Oil Level OK Hold Hold ENGINE...
Page 954 54.06 Instrumentation Control Unit, ICU3-M2 Mode/Reset Switch Functions From Fig. 3 Metric version screens are similar to English version screens. SEt UP rESEt Hold will reset all service **MI **HOURS Hold Hold internal counters. SERVICE **no SERVICE **Display active mode Push Push To toggle between...
Page 955 54.07 Vehicle Data Computer Replacement Replacement If the VDC mounting bracket is not welded to the chassis, remove the mounting bracket and VDC as an assembly. Remove the VDC from the NOTE: The vehicle data computer (VDC) is lo- mounting bracket. cated at the rear of the vehicle, in the engine 8.
Page 956 54.07 Vehicle Data Computer Replacement VDC Locations by Body Builder Body Builder VDC Location Winnebago Bed box, under the second cover to gain engine access ‡ Odessa Behind the storage box and rail, on the passenger-side rear of the vehicle, underneath It is necessary to remove the control panel to see the VDC.
Page 957 54.07 Vehicle Data Computer Speciﬁcations Table 1 lists the location of the vehicle data com- puter (VDC) by body builder. VDC Locations by Body Builder Body Builder VDC Location Airstream Near LP (liqueﬁed petroleum) tank, on the passenger-side of the vehicle Damon Right-side compartment, behind the rear wheels Holiday Rambler/Monaco...
Page 958 54.08 Light Bar Control Unit (LBCU) General Information • The amber check engine indicator light General Description (CHECK ENGINE legend) illuminates when certain faults are detected. If a critical engine The lightbar control unit (LBCU) instrument cluster is condition exists (for example, low oil pressure a full-featured, individual-gauge cluster with an intelli- or high coolant temperature), the check engine gent lightbar (ILB).
Page 959 54.08 Light Bar Control Unit (LBCU) General Information CHECK STOP 09/13/2006 f610840 1. Check Engine Indicator 7. Check Transmission Indicator 12. Shift Inhibit Indicator 2. High Exhaust System 8. Engine Brake Engaged Indicator 13. Headlight High-Beam Indicator Temperature (HEST) Lamp 9.
Page 960 When the ignition is turned on, the information center The following options are found in the menu and will illuminate with the Freightliner Custom Chassis sub-menus of the home screen. logo. If there are no alarms detected from the self- •...
Page 961 54.08 Light Bar Control Unit (LBCU) General Information • Driver’s Favorite Categories—There are nine categories that the driver can select from; three can be viewed at one time. Select the category desired by using the up/down toggle switch. Then, click the right arrow of the toggle switch for three seconds to access the sub-menus within each category.
Page 962 54.08 Light Bar Control Unit (LBCU) Lightbar Control Unit (LBCU) Replacement Replacement 1. Remove the dash panel that covers the LBCU. Remove the four Torx screws, then carefully lift the dash panel to gain access to the LBCU. 2. Disconnect the electrical harness connectors from the back of the LBCU.
Page 963 54.08 Light Bar Control Unit (LBCU) Gauge Replacement 3- and 5-Inch Gauges 4. Correctly orient the replacement gauge and in- stall it through the opening at the front. 1. Remove the dash panel that covers the LBCU. 5. Install the mounting bracket on the back of the Remove the four Torx screws, then carefully lift gauge and use the two wing nuts or the thumb the dash panel to gain access to the LBCU.
Page 964 54.08 Light Bar Control Unit (LBCU) Telltale Replacement Replacement The term "telltale" refers to the small plastic lens in the top row of the LBCU faceplate (dash message center) with a warning or indicator message printed on it. See Fig. 1.
Page 965 54.08 Light Bar Control Unit (LBCU) Troubleshooting • Failure Mode Indicator (FMI) – Indicates in J1939 faults consist of the following, in this order: what way the function failed. • Suspect Parameter Number (SPN) – Indicates what function on the ECU has failed. J1939 Diagnostic Trouble Codes Broadcast Error Description...
Page 966 54.08 Light Bar Control Unit (LBCU) Troubleshooting Diagnosis for Multiple Gauges Not Working (datalink-driven gauges) Step Test Procedure Test Result Action In ServiceLink ® , does the engine ECU show up Go to step 7. in the LBCU list (address 0 on J1939)? Check the J1939 datalink to the engine ECU.
Page 967 54.08 Light Bar Control Unit (LBCU) Troubleshooting Air Pressure Gauge Troubleshooting Step Test Procedure Test Result Action Which air pressure gauge is not functioning Primary or Go to step 2. correctly? secondary Application Go to step 3. Suspension Go to step 4. Drain the air tanks and connect an accurate No problem found.
Page 968 54.08 Light Bar Control Unit (LBCU) Troubleshooting Warning Lamp Troubleshooting Step Test Procedure Test Result Action Is there any error message regarding the Repair the datalink as required. datalink? Check the sensor and its wiring to the control module; repair as needed. Table 5, Warning Lamp Troubleshooting Backlighting Troubleshooting Step...
Page 969 54.08 Light Bar Control Unit (LBCU) Troubleshooting Backlighting Troubleshooting Step Test Procedure Test Result Action Are all of the gauges with dead backlighting in Try a good known jumper wire between the sequence with one another in the daisy-chain? gauge with dead backlighting that is closest to the light bar and the next good gauge (one closer to the LBCU).
Page 970 54.08 Light Bar Control Unit (LBCU) Troubleshooting Warning Light Messages in the LBCU Displayed As (Actual Text for Activation Cause Corrective Action Display Messages) Auto Idle The LBCU has entered auto idle Sys Voltage ~~~~V Low battery plus other conditions mode and will attempt to raise battery voltage using cruise control.
Page 971 54.08 Light Bar Control Unit (LBCU) Troubleshooting Warning Light Messages in the LBCU Displayed As (Actual Text for Activation Cause Corrective Action Display Messages) Odometer ~~~~~~ Replace the toggle switch. If this Menu Navigation Menu toggle switch is missing or faulty does not help, replace the LBCU.
Page 972 54.08 Light Bar Control Unit (LBCU) Troubleshooting Other Other ECU’s ECU’s f545352 07/29/2008 1. Fuel Level Sensor 8. LIN Datalink to LIN Gauges 12. Compass 2. Battery Voltage 9. Optional Gauges 13. Outside Temperature Sensor 3. Ignition 10. Fuel Gauge/Tachometer/ 14.
Page 973 54.08 Light Bar Control Unit (LBCU) Troubleshooting 07/29/2008 f545353 A. Vehicle will shut down if the battery voltage is outside 9V to 18V. The high voltage protection is done in the hardware (H/W), and the low voltage shut down is done in the software (S/W). B.
Page 974 54.08 Light Bar Control Unit (LBCU) Troubleshooting Other Other ECU’s ECU’s LIN Bus f545355 07/29/2008 A. If no J1587 messages are received by the LBCU within 20 seconds, the J1587 NO DATA alert is shown. B. If no J1939 messages are received by the LBCU within 1 second, the J1939 NO DATA alert is shown. C.
Page 975 54.08 Light Bar Control Unit (LBCU) Troubleshooting Other Other ECU’s ECU’s 07/30/2008 f545356 A. Use the "Check Gauges" diagnostic menu to try to move the gauge. B. Use ServiceLink ® to check for the diagnostic trouble code SPN 117. 07/28/2008 f545354 C.
Page 976 54.08 Light Bar Control Unit (LBCU) Troubleshooting 3F GAUGE 3E AIR 65 PSI 0x88 07/29/2008 f545357 A. LBCU B. LIN C. Air Gauge 1. Audible Alarm 3. Request Air 5. Gauge 2. Test Menu 4. Sensor Fig. 6, Air Pressure Message on LIN 300/12 Recreational Vehicle Chassis Workshop Manual, Supplement 18, April 2009...
Page 977 54.08 Light Bar Control Unit (LBCU) Troubleshooting Other Other ECU’s ECU’s 07/30/2008 f545358 A. If the compass module is not properly attached or LIN messages are not received, the compass line 07/31/2008 f545359 will not show up in the menu. B.
Page 978 54.08 Lightbar Control Unit (LBCU) Speciﬁcations 24-Pin Light Bar Control Unit Pin Descriptions Description Description (+) Panel Backlight Power (PWM) Optional Indicator #5—ground activated Future CAN (not connected to LBCU) Engine Brake Active Output—12V activated Engine Brake Level Input—ground activated J1708/J1587 datalink (–) Generator Engaged Input—12V activated Engine Brake Level Input—ground activated...
Page 979 54.08 Lightbar Control Unit (LBCU) Speciﬁcations 32-Pin Light Bar Control Unit Pin Descriptions Description Description (+) Headlamp Power Input 12V—used to control Spare Analog Input LCD brightness Table 2, 32-Pin Light Bar Control Unit Pin Descriptions Table 3 Fig. 1 for a description and illustra- tion of the daisy chain/local interconnect network (LIN) line and pin connection priority.
Page 980 54.08 Lightbar Control Unit (LBCU) Speciﬁcations Gauge Overview Gauge Data Source Optional Range/Scale Unit Transmission Oil Temperature SPN 177 from Transmission 125–300 Fahrenheit Primary Air System Pressure Pressure Transducer over LIN 0–150 Secondary Air System Pressure Pressure Transducer over LIN 0–150 Turbo Boost Air Pressure SPN 102 from Engine...
Page 981 54.08 Lightbar Control Unit (LBCU) Speciﬁcations 24-Pin Description, Pins B1 Through B12 Cleaning Designation Description Current Optional Indicator Optional Ground Activated Telltale Indicator 12V Output Engine Brake Active Output; Sourcing Per Section J1708/J1587 Low Side; Tri-State Transceiver Controlled Network (–) Ground Input Engine Brake Level Input TBD CAN 1 (–)
Page 982: General Information
83.00 Refrigerant Compressor, Sanden SD7 Series General Information General Information The main purpose of the refrigerant compressor is to draw refrigerant gas from the evaporator and squeeze it into high-pressure gas. High pressure raises the condensation point of refrigerant gas, which allows the condenser to change it to a liquid so that it can be used for cooling again.
Page 983: Safety Precautions
83.00 Refrigerant Compressor, Sanden SD7 Series Safety Precautions Safety Precautions have a slightly sweet odor that is difficult to detect. Frequent leak checks and air monitoring equipment are recommended to ensure a safe working environ- Whenever repairs are made to any air conditioner ment.
Page 984 83.00 Refrigerant Compressor, Sanden SD7 Series Pre-Service Checks Pre-Service Checks 2. Check the wiring and connections to the com- pressor clutch. Replace damaged wiring and tighten loose connections. WARNING 3. Check for road debris build-up on the condenser coil ﬁns. Using air pressure and a whiskbroom or Before doing any work, read the information un- a solution of soap and water, carefully clean the Safety Precautions 100.
Page 985: Installation
83.00 Refrigerant Compressor, Sanden SD7 Series Compressor Removal and Installation Removal 7. Remove the compressor. Installation 1. Apply the brakes and chock the tires. Open the access panel at the front of the vehicle. IMPORTANT: A new compressor is ﬁlled with 2.
Page 986 83.00 Refrigerant Compressor, Sanden SD7 Series Compressor Removal and Installation 10. Evacuate, charge, and leak test the refrigerant system. For instructions, refer to Sec- tion 83.01, Subject 120. 11. Close the access panel and remove the chocks. 120/2 Recreational Vehicle Chassis Workshop Manual, Supplement 11, October 2005...
Page 987 83.00 Refrigerant Compressor, Sanden SD7 Series Oil Check and Adding Oil to the Compressor General Information C. Condenser— when the condenser is replaced, about 2.0 ﬂ oz (59 mL) must be added to the com- pressor (in addition to the 10 ﬂ oz [296 mL] that the IMPORTANT: Add the same amount of oil that is compressor requires).
Page 988 83.00 Refrigerant Compressor, Sanden SD7 Series Oil Check and Adding Oil to the Compressor 1. Run the compressor for 10 minutes with the en- gine at idle. Shut down the engine. 2. Recover all of the refrigerant from the system. 3.
Page 989 83.00 Refrigerant Compressor, Sanden SD7 Series Clutch Assembly Removal, Inspection, and Installation Removal 13 14 20 21 08/24/94 f830632 1. Shaft Key 10. Cylinder Head Bolt 18. Drive Plate 2. Felt Ring 11. Pressure Relief Valve 19. Clutch Shims 3. Shaft Seal Snap Ring 12.
Page 990 83.00 Refrigerant Compressor, Sanden SD7 Series Clutch Assembly Removal, Inspection, and Installation 08/25/94 f830635 Fig. 4, Remove the Shaft Key 08/25/94 f830633 1. Socket Wrench 2. Drive Plate Spanner Fig. 2, Remove the Retaining Nut 08/22/94 f830636 08/26/94 f830634 1. Pulley Puller 1.
Page 991 83.00 Refrigerant Compressor, Sanden SD7 Series Clutch Assembly Removal, Inspection, and Installation Position the pulley over the boss of the front housing. Place the pulley installer ring into the bearing bore. Make sure that the edge rests only on the inner race of the bearing, not on the seal, pulley, or outer race of the bearing.
Page 992 83.00 Refrigerant Compressor, Sanden SD7 Series Clutch Assembly Removal, Inspection, and Installation Using pliers, install the shaft key. See 4. Using a feeler gauge, check that the clutch clear- Fig. ance is 0.02 to 0.03 inch (0.4 to 0.8 mm). See Fig.
Page 993: Shaft Seal Replacement
83.00 Refrigerant Compressor, Sanden SD7 Series Shaft Seal Replacement Replacement 1. Remove the drive plate and pulley assemblies. For instructions, refer to Subject 140. 2. Using snap ring pliers, remove the felt ring re- tainer. See Fig. 1. Then remove the felt ring. 08/22/94 f830643 1.
Page 994 83.00 Refrigerant Compressor, Sanden SD7 Series Shaft Seal Replacement 08/23/94 f830645 08/23/94 f830646 Fig. 4, Place the Shaft Seal Assembly into Clean Fig. 5, Tap the New Felt Ring in Place Refrigerant Oil removal and installation tool to remove it from the seal.
Page 995 83.00 Refrigerant Compressor, Sanden SD7 Series Head and Valve Plate Removal and Installation Removal tween the valve plate and the cylinder block) be replaced any time the cylinder head is removed. NOTE: Before doing any work on the head and 3.
Page 996 83.00 Refrigerant Compressor, Sanden SD7 Series Head and Valve Plate Removal and Installation 08/11/94 f830649 Fig. 3, Tightening Sequence 08/25/94 f830648 Fig. 2, Separate the Cylinder Head from the Valve Plate 3. Remove all residual oil from each bolt hole on the cylinder block.
Page 997 83.00 Refrigerant Compressor, Sanden SD7 Series Speciﬁcations Special tools can be purchased from the following Mastercool USA Inc. independent suppliers: 216 Route 10, Bldg. 3 Randolph, NJ 07869 Classic Tool Design (201) 366-1101 31 Walnut St. New Windsor, NY 12550 (914) 562-8700 Torque Values Torque...
Page 999: Air Conditioning System
83.01 Air Conditioning System General Information General Information The components of the air conditioning system that may be supplied by the chassis manufacturer, de- pending on the vehicle conﬁguration, are the con- denser, the condenser fan, and the refrigerant lines. For information on the air conditioning components that are not supplied by the chassis manufacturer, see the body manufacturer’s service manual.
Page 1000 83.01 Air Conditioning System Safety Precautions Safety Precautions have a slightly sweet odor that is difficult to detect. Frequent leak checks and air monitoring equipment are recommended to ensure a safe working environ- Whenever repairs are made to any air conditioner ment.
Page 1001 83.01 Air Conditioning System Receiver-Drier Replacement Replacement drier from the bracket. Remove and discard the receiver-drier. 5. Place a new receiver-drier in the bracket. 6. Place the receiver-drier bracket on the ﬁrewall, and install and tighten the bolts. 7. Attach the inlet and outlet lines to the receiver- drier.
Page 1002 83.01 Air Conditioning System Refrigerant Service Operations Recovery Evacuating (recycling) General Information WARNING Moisture in a Refrigerant System Before doing any of the work below, read the in- formation under Safety Precautions 100. Failure Water forms ice crystals at the thermostatic expan- to read the safety precautions and to be aware of sion valve.
Page 1003 83.01 Air Conditioning System Refrigerant Service Operations Vacuum Pump Selection Water Boiling Temperatures at Converted Pressures Boiling The purpose of a high-vacuum pump is to reduce Absolute Temperature Vacuum and hold a vacuum in the air conditioner system so Pressure of Water inHg (mmHg) moisture can be boiled at ambient temperature.
Page 1004: Evacuation Procedure
83.01 Air Conditioning System Refrigerant Service Operations The second stage pumps at a lower pressure and An electronic thermistor vacuum gauge is designed therefore pulls a higher vacuum on the system than for use with high vacuum pumps and can accurately the ﬁrst pump can by itself.
Page 1005 83.01 Air Conditioning System Refrigerant Service Operations 2. Wearing protective goggles and nonleather receiver-drier, expansion valve(s), and inspect the gloves, attach the recovery/recycling station compressor. hoses to the valves. Do not ﬂush the receiver-drier or the compressor. IMPORTANT: Push down ﬁrmly on the hose Flush the system in segments to lessen the chance connectors until a clicking sound is heard.
Page 1006 83.01 Air Conditioning System Refrigerant Service Operations 2. Disconnect both ends of the line or part(s) being This prevents overcharging, which could damage ﬂushed. Tightly cap the lines to the rest of the the compressor. system. 2. Charge the refrigerant system. NOTE: You must remove the expansion de- NOTE: If equipped with a recovery, recy- vice(s), receiver-drier, and compressor(s) when...
Page 1007 A/C system. dye leak detection and electronic leak detection. Place a label under the hood, preferably Freightliner recommends using the UV dye leak de- next to the charge label, that indicates dye tection method whenever possible, even though has been added to the A/C system.

This manual is also suitable for:

Custom chassis mcl Custom chassis xc Custom chassis xcf Custom chassis xcl Custom chassis xcm Custom chassis xcp ... Show all