PREVOST LE MIRAGE XLII, Maintenance Manual

Page 1: ...COACH MANUFACTURER MAINTENANCE MANUAL LE MIRAGE XLII BUS SHELLS PA1553 ...

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Page 3: ...n Number VIN 6 5 FASTENER STRENGTH IDENTIFICATION 8 5 1 SELF LOCKING FASTENERS 9 5 2 RECOMMENDATIONS FOR REUSE 9 5 3 SIX LOBED SOCKET HEAD 9 ILLUSTRATIONS FIGURE 1 DETROIT DIESEL SERIES 60 5 FIGURE 2 ALLISON TRANSMISSION 5 FIGURE 3 TYPICAL SERIAL MODEL NUMBERS 5 FIGURE 4 ISS TYPICAL SERIAL MODEL NUMBERS 5 FIGURE 5 POWER STEERING PUMP NAMEPLATE 5 FIGURE 6 DOT CERTIFICATION PLATE 6 FIGURE 7 ENGINE C...

Page 4: ...nges at any time without notice NOTE Typical illustrations may be used therefore minor illustration difference may exist when compared to actual parts or other publications Prévost Car occasionally sends Maintenance Information Warranty Bulletins Safety Recalls or other literature to update users with the latest service procedures They are issued when required to supplement or supersede informatio...

Page 5: ...ess o Welding rod conforms to A5 1 of AWS American Welding Society specifications E 7018 type welding rod with 1 8 diameter 3 2 mm o Current 100 amperes to 150 amperes optimum at 120 amps It is important to grind weld bead starts and stops and also to grind arc strikes from surfaces STEEL STAINLESS STEEL OR STAINLESS STEEL STAINLESS STEEL WELDING CAUTION Before welding disconnect electronic module...

Page 6: ...on outlined by the wording and symbols DANGER Directs the operator s attention to unsafe practices which could result in serious personal injury or death WARNING Directs the operator s attention to unsafe practices which could result in serious personal injury or severe damage to the vehicle CAUTION Directs the operator s attention to unsafe practices where personal injury is not likely but damage...

Page 7: ...ocated on a tag on the pump Fig 5 The pump is mounted on the engine beside the crankshaft pulley FIGURE 5 POWER STEERING PUMP NAMEPLATE 00035 4 1 6 Coach Final Record The Coach Final Record is a record of all data pertaining to the assembly of the coach This record is included in the technical publication package supplied with the coach Retain this record in the company records office for referenc...

Page 8: ...lations Fig 7 It gives the operating conditions under which certification was made FIGURE 7 ENGINE COMPARTMENT 00173 4 1 10 Fuel Tank Label The fuel tank label is molded on the side of the fuel tank To read this label unscrew the fuel tank access panel nuts located at the left in the condenser compartment 4 1 11 Vehicle Identification Number VIN The seventeen digit vehicle identification number VI...

Page 9: ...Section 00 GENERAL INFORMATION PA1553 7 FIGURE 9 VEHICLE IDENTIFICATION NUMBER 00050 YEAR CODE YEAR CODE 2000 Y 2006 6 2001 1 2007 7 2002 2 2008 8 2003 3 2009 9 2004 4 2010 A 2005 5 2011 B ...

Page 10: ...the same or greater strength than the original fasteners the same number marking or higher It is also important to select replacement fasteners of the correct size Correct replacement fasteners are available through the parts division Some metric fasteners available in after market parts sources were designed to metric standards of countries other the United States and may be of a lower strength m...

Page 11: ...elops torque per the chart in table two If there is any doubt replace with a new self locking fastener of equal or greater strength e Tighten the fastener to the torque specified in the applicable section of this manual Fasteners which are rusty or damaged should be replaced with new ones of equal or greater strength SELF LOCKING FASTENER TORQUE CHART METRIC 6 6 3 8 10 12 14 16 20 NUTS AND Nm 0 4 ...

Page 12: ...Section 00 GENERAL INFORMATION 10 PA1553 FIGURE 13 METRIC US STANDARD CONVERSION TABLE 00005 ...

Page 13: ...Section 00 GENERAL INFORMATION PA1553 11 FIGURE 14 CONVERSION CHART 00006 ...

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Page 15: ...rules Wear safety goggles Set the battery master switch to the OFF position first Recommendations This procedure should be performed by qualified personnel only Effective Revision 0 Issued with multiplex Revision 1 Modified for Fire Protection System and also for VIP with multiplex Revision 2 Step 5 modified for introduction of VIP with multiplex 0436 Revision 3 Step 1 15 added C397 Addition of SE...

Page 16: ...hes VIP 1 00 Location Main power compartment and dashboard Set the battery master switch to the OFF position Place the ignition switch to the OFF position 1 05 Location Main power compartment Trip circuit breakers CB2 CB4 CB6 Push the red button to open the circuit ...

Page 17: ...the electronic ground terminals from the stud Using electric tape insulate the 2 largest gage wires Make sure the ring terminals do not touch each others and the vehicle body NOTE With disconnection of the electronic ground terminals disconnecting the engine ECM transmission TCM and the dashboard electronic components telltale module HVAC module radio control head is not required ...

Page 18: ...tor C717 Unplug 3 connectors per I O B modules Unplug 3 connectors on the I O A module 1 15 1 20 Location Front electrical compartment VIP COACH Disconnect the I O A I O B ABS master ID CECM and CPC modules Unplug connector C92 VIP Disconnect all keyless module connectors Unplug 3 connectors per I O B modules and 3 connectors per I O A modules Unplug 2 connectors from the ABS module ...

Page 19: ...PROCEDURE NO PR060034 REVISION 3 Page 5 of 15 Unplug 1 connector from the master ID Disconnect CPC connectors Unplug 3 connectors from the CECM Unplug connector C92 ...

Page 20: ...5 Location pneumatic accessory panel inside right console Remove the access panel on the right console R H side of dashboard Disconnect both I O B modules 1 30 Location Evaporator compartment Remove the protective cover and disconnect the I O B module ...

Page 21: ...you can do welding on the vehicle ENSURE THAT THE WELDING GROUND RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE CHASSIS LOCATED NEAR THE WELDING POINT AS MUCH AS POSSIBLE 1 50 When welding is completed reconnect all the modules Make sure that the connectors locking tab are well engaged BE CAREFUL TO MAKE THE PROPER CONNECTIONS IF NOT SOME SYSTEMS...

Page 22: ...ar electrical compartment and dashboard Set the battery master switch to the OFF position Place the ignition switch to the OFF position 2 05 Location Rear electrical compartment Trip circuit breakers CB2 CB4 CB6 located on rear junction panel Push the red button in to open the circuit ...

Page 23: ...rs and the vehicle body NOTE With disconnection of the electronic ground terminals disconnecting the engine ECM transmission TCM and the dashboard electronic components telltale module HVAC module radio control head is not required Location Rear electrical compartment Disconnect the electronic modules 2 15 Disconnect all I O A and I O B modules Disconnect C397 and C717 Disconnect 3 connectors from...

Page 24: ...mpartment Disconnect I O A I O B ABS master ID CECM and CPC modules and also disconnect connector C92 Disconnect the 3 connectors from the I O B and I O A modules Disconnect the 2 connectors from the ABS module 2 20 Disconnect CPC connectors Disconnect connector from master ID ...

Page 25: ...revious steps are done you can do welding on the vehicle ENSURE THAT THE WELDING GROUND RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE CHASSIS LOCATED NEAR THE WELDING POINT AS MUCH AS POSSIBLE 2 40 When welding is completed reconnect all the modules Make sure that the connectors locking tab are well engaged BE CAREFUL TO MAKE THE PROPER CONNECTI...

Page 26: ...ton in to open the circuit 2 10 Location Rear Junction Box Disconnect the electronic ground terminals from this stud Warning The remaining terminals may still be energized Use electric tape make sure that cables do not touch each others and the vehicle body NOTE With disconnection of the electronic ground terminals disconnecting the engine ECM transmission TCM and the dashboard electronic componen...

Page 27: ...transmission module A1 Disconnect 3 connectors from each I O B Disconnect 3 connectors from each I O A Location Front Electrical Compartment Disconnect I O A I O B ABS master ID CECM CPC keyless modules and also disconnect connector C92 Disconnect 3 connectors from the I O B and I O A modules Disconnect connectors from Keyless module 2 20 Disconnect 2 connectors from ABS module ...

Page 28: ...PROCEDURE NO PR060034 REVISION 3 Page 14 of 15 Disconnect connectors from CPC Disconnect connector from master ID Disconnect 3 connectors from CECM Disconnect connector C92 ...

Page 29: ...n the vehicle ENSURE THAT THE WELDING GROUND RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE CHASSIS LOCATED NEAR THE WELDING POINT AS MUCH AS POSSIBLE 2 35 When welding is completed reconnect all the modules Make sure that the connectors locking tab are well engaged BE CAREFUL TO MAKE THE PROPER CONNECTIONS IF NOT SOME SYSTEMS OR COMPONENTS MAY N...

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Page 31: ... ENGINE RELATED COMPONENTS 7 3 1 COOLANT LEVEL SYSTEM CLS 7 3 2 ELECTRONIC FOOT PEDAL ASSEMBLY EFPA THROTTLE POSITION SENSOR 7 3 3 CRUISE CONTROL SWITCHES CCS 7 3 4 DIAGNOSTIC SYSTEM ACCESSORIES DSA 8 3 4 1 Check Engine Telltale Light 8 3 4 2 Stop Engine Telltale Light 8 3 4 3 Stop Engine Override Switch 8 3 4 4 Diagnostic Data Link DDL Connectors 8 4 DDEC V DIAGNOSTIC CODES 9 4 1 READING DIAGNOST...

Page 32: ...TURBO BOOST PRESSURE SENSOR 6 FIGURE 8 FUEL TEMPERATURE SENSOR 6 FIGURE 9 TURBO COMPRESSOR IN TEMPERATURE SENSOR LOCATION 6 FIGURE 10 ENGINE OPS 6 FIGURE 11 ELECTRONIC FOOT PEDAL ASSEMBLY 7 FIGURE 12 ENGINE OIL LEVEL DIPSTICK 20 FIGURE 13 OIL RESERVE TANK 20 FIGURE 14 ENGINE DRAIN PLUG AND OIL FILTERS 20 FIGURE 15 BELT TENSIONER VALVE 22 FIGURE 16 ELECTRIC FAN CLUTCH CONNECTOR 22 FIGURE 17 ENGINE ...

Page 33: ...cted by the electronic unit injectors EUI The system also monitors several engine functions using electrical sensors which send electrical signals to the Electronic Control Module ECM The ECM computes the electrical signals and determines the correct fuel output and timing for optimum power fuel economy and emissions The ECM also has the ability to display warnings or shut down the engine complete...

Page 34: ...o the cruise control and road speed limiter using a diagnostic data reader see paragraph DDEC V Diagnostic Codes in this section FIGURE 2 ELECTRONIC CONTROL MODULE ECM 01145 2 2 N3 ELECTRONIC UNIT INJECTOR The N3 Electronic Unit Injector EUI is a compact device that injects diesel fuel directly into the combustion chamber Fig 3 The amount of fuel injected and injection timing is determined by the ...

Page 35: ...he ECM via a black connector wire The SRS sensor extends through a hole in the gear case It is positioned near the rear of the idler gear A bolt inserted through a hole in the SRS bracket secures the SRS assembly to the gear case The idler gear pin passes by the SRS as piston number one crank pin reaches 45 before Top Dead Center The ECM uses this information to determine engine speed The SRS is n...

Page 36: ...CM uses this information to calculate fuel consumption The FTS is non serviceable and must be replaced as a unit No adjustment is required FIGURE 8 FUEL TEMPERATURE SENSOR 03053B 2 10 AIR TEMPERATURE SENSOR The Air Temperature Sensor Fig 1 7 located on the intake manifold provides input data to vary hot idle speed and injection timing This helps to improve cold starts and reduces white exhaust smo...

Page 37: ...S signal varies in voltage depending on how far the pedal is depressed The system is installed in the space normally occupied by a mechanical foot pedal The EFPA has maximum and minimum stops that are built into the unit during manufacturing Fig 11 The TPS converts the operator s foot pedal input into a signal for the ECM The EFPA is shown in Figure 11 When installed by the equipment manufacturer ...

Page 38: ...t turned on The Stop Engine Light illuminates when the temperature at coolant sensors exceeds 222 F 106 C and the temperature at oil sensors exceeds 239 F 115 C When sensors detect such temperatures DDEC shuts the engine down after a 30 seconds grace period This 30 second delay may be extended another 30 seconds if absolutely necessary by using the STOP ENGINE OVERRIDE switch NOTE Once engine is s...

Page 39: ...ne telltale panel The cycle repeats itself until the operator depresses the stop engine override switch again A code 43 consists of four flashes followed by a short pause then three flashes in quick succession Refer to DDEC Troubleshooting Manual for more information and SAE codes NOTE Active codes are flashed in ascending numerical flash code order Inactive codes are flashed in most recent to lea...

Page 40: ...Temperature Sensor Input Voltage High 27 171 3 Ambient Air Temperature Sensor Input Voltage High 27 172 3 Air Temperature Sensor Input Voltage High 28 105 4 Intake Manifold Temperature Sensor Input Voltage Low 28 171 4 Ambient Air Temperature Sensor Input Voltage Low 28 172 4 Air Temperature Sensor Input Voltage Low 29 351 4 TCI Temperature Circuit Failed Low 29 404 4 Turbo Compressor Temperature ...

Page 41: ...SL Short to Battery 32 238 4 RSL Open Circuit 32 239 3 AWL Short to Battery 32 239 4 AWL Open Circuit 33 102 3 Turbo Boost Pressure Sensor Input Voltage High 34 102 4 Turbo Boost Pressure Sensor Input Voltage Low 35 19 3 High Range Oil Pressure Sensor Input Voltage High 35 100 3 Oil Pressure Sensor Input Voltage High 36 19 4 High Range Oil Pressure Sensor Input Voltage Low 36 100 4 Oil Pressure Se...

Page 42: ... 11 V 12 Low 46 212 4 Injector V slope Voltage Failed Low 46 214 1 RTC Backup Battery Voltage Low Pin E 59 46 221 4 Injector I pull in Voltage Failed Low 46 232 1 Sensor Supply Voltage Low Pin E 12 E 26 47 18 0 High Range Fuel Pressure High 47 94 0 Fuel Pressure High 47 102 0 Turbo Boost Pressure High 47 102 14 Engine Power Derate Due to Turbo Boost Pressure 47 106 0 Air Inlet Pressure High 47 164...

Page 43: ...esponse Time Long 62 26 3 Aux Output 1 Short to Battery Pin V 4 62 26 4 Aux Output 1 Open Circuit Pin V 4 62 26 7 Aux Output 1 Mechanical System Not Responding Properly Pin V 4 62 40 3 Aux Output 2 Short to Battery Pin V 5 62 40 4 Aux Output 2 Open Circuit Pin V 5 62 40 7 Aux Output 2 Mechanical System Not Responding Properly Pin V 5 62 53 3 Aux Output 5 Short to Battery Pin V 6 62 53 4 Aux Output...

Page 44: ... Open Circuit Pin V 53 63 58 0 PWM 2 Above Normal Range Pin V 46 63 58 1 PWM 2 Below Normal Range Pin V 46 63 58 3 PWM 2 Short to Battery Pin V 46 63 58 4 PWM 2 Open Circuit Pin V 46 63 59 0 PWM 3 Above Normal Range Pin E 3 63 59 1 PWM 3 Below Normal Range Pin E 3 63 59 3 PWM 3 Short to Battery Pin E 3 63 59 4 PWM 3 Open Circuit Pin E 3 63 60 0 PWM 4 Above Normal Range Pin E 4 63 60 1 PWM 4 Below ...

Page 45: ...ge High 67 20 4 High Range Coolant Pressure Sensor Input Voltage Low 67 106 3 Air Inlet Pressure Sensor Input Voltage High 67 106 4 Air Inlet Pressure Sensor Input Voltage Low 67 109 3 Coolant Pressure Sensor Input Voltage High 67 109 4 Coolant Pressure Sensor Input Voltage Low 68 230 5 TPS Idle Validation Circuit Fault open circuit 68 230 6 TPS Idle Validation Circuit Fault short to ground 71 xxx...

Page 46: ...73 1 Fire Pump Pressure Low 77 81 0 Exhaust Back Pressure High 77 81 1 Exhaust Back Pressure Low 77 81 3 Exhaust Back Pressure Sensor Voltage High 77 81 4 Exhaust Back Pressure Sensor Voltage Low 77 81 12 Exhaust Back Pressure at Rampdown Threshold 77 95 1 Fuel Filter Differential Pressure Low 77 99 1 Oil Filter Differential Pressure Low 77 100 0 Engine Oil Pressure High 77 102 1 Turbo Boost Press...

Page 47: ...EGR Temperature Network Sensor Not Responding 81 20 3 Timing Actuator Failed High 81 20 4 Timing Actuator Failed Low 81 129 3 Exhaust Port Temperature 1 Sensor Voltage High 81 130 3 Exhaust Port Temperature 2 Sensor Voltage High 81 131 3 Exhaust Port Temperature 3 Sensor Voltage High 81 132 3 Exhaust Port Temperature 4 Sensor Voltage High 81 133 3 Exhaust Port Temperature 5 Sensor Voltage High 81 ...

Page 48: ...re 6 Sensor Voltage Low 82 135 4 Exhaust Port Temperature 7 Sensor Voltage Low 82 136 4 Exhaust Port Temperature 8 Sensor Voltage Low 82 137 4 Exhaust Port Temperature 9 Sensor Voltage Low 82 138 4 Exhaust Port Temperature 10 Sensor Voltage Low 82 139 4 Exhaust Port Temperature 11 Sensor Voltage Low 82 140 4 Exhaust Port Temperature 12 Sensor Voltage Low 82 141 4 Exhaust Port Temperature 13 Sensor...

Page 49: ... 86 73 3 Pump Pressure Sensor Input Voltage High 86 108 3 Barometric Pressure Sensor Input Voltage High 87 73 4 Pump Pressure Sensor Input Voltage Low 87 108 4 Barometric Pressure Sensor Input Voltage Low 88 20 1 High Range Coolant Pressure Low 88 109 1 Coolant Pressure Low 89 95 0 Fuel Restriction High 89 111 12 Maintenance Alert Coolant Level Fault 5 ENGINE OIL LEVEL Check the oil level daily wi...

Page 50: ...e engine is subject to high levels of contamination and or overheating Change intervals may be decreased or gradually increased with experience on specific lubricants until the most practical service condition has been established Always refer to the lubricant manufacturer s recommendations analysis of drained oil can be helpful CAUTION Do not use solvents to dilute the engine oil when draining Di...

Page 51: ...ricant Selection World Wide Oils meeting API CD or CC specifications may be used if they also meet military specification MIL L 2104 D or E Oils which meet European CCMC D4 specifications may also be used Modification of drain interval may be necessary depending on fuel quality Contact Detroit Diesel Corporation for further guidance 8 POWER PLANT ASSEMBLY REMOVAL To access the engine or engine rel...

Page 52: ...e the upper bracket 4 Fig 17 12 If necessary remove the fan drive from the engine compartment by removing the four retaining bolts washers and nuts securing the fan drive to the floor FIGURE 16 ELECTRIC FAN CLUTCH CONNECTOR 010XX 13 Disconnect and remove the air intake duct mounted between the turbocharger outlet and the air cooler inlet 5 Fig 17 14 Disconnect two vent hoses from the thermostat ho...

Page 53: ...n rear side with one close to yoke On right side close to the solenoid valve of the output retarder 34 From under the vehicle disconnect the propeller shaft as detailed in Section 09 under heading Propeller Shaft Removal 35 Inspect the power plant assembly to ensure that nothing will interfere when sliding out the cradle Check for connections or hoses not mentioned in this list as some vehicles ar...

Page 54: ...e 10 1 XLII MOTORHOMES 1 Remove air intake pipe 2 Remove the after CAC Charger Air Cooler air pipe 3 Disconnect ventilation pipe from valve cover 4 Remove trap door located in the middle rear end of vehicle 5 Remove engine cover 6 Adjust Jake brakes if applicable injectors and valves using Detroit Diesel service manual for series 60 engines 7 Verify engine cover gasket and replace if necessary 8 R...

Page 55: ... procedures They are annexed at the end of this section 12 ENGINE MOUNTS The power plant assembly is mounted to the cradle by means of rubber mounts Two rubber mounts are used at the front of the engine while two others are mounted on each side of the flywheel housing Fig 18 It is recommended that new rubber mounts be installed at each major overhaul FIGURE 18 POWER PLANT CRADLE INSTALLATION 01140...

Page 56: ... causes battery cables improperly connected fuse blown faulty battery equalizer activate the DDEC self diagnostic system and contact your Detroit Diesel service center engine does not rotate what is the voltage reading on 24 volt system dashboard indicator is the shift selector to neutral N position higher than 24 volts lower than 24 volts yes no faulty 24 volt system power supply or low battery v...

Page 57: ...nalog voltage indicator on the dashboard or consult the MCD Message Center Display on the telltale panel See the Operator s Manual chap 4 for more details voir note 1 01089 14 SPECIFICATIONS Series 60 Engine Make Detroit Diesel Type Diesel four cycle in line engine Description Turbo Air to air charge cooled No of cylinders 6 Operating range 1200 2100 RPM Maximum RPM 2100 Lubricant Heavy duty engin...

Page 58: ...ntity Oil Pan Capacity Low Limit 26 quarts 25 liters Oil Pan Capacity High Limit 32 quarts 30 liters Total Engine Oil Capacity with Filters 38 quarts 36 liters Lubricating oil filter elements Make AC Rochester Div GMC 25014505 Make A C Filter PF 2100 Type Full Flow Prévost number 510458 Torque specification Engine oil filter Tighten 2 3 of a turn after gasket contact Filters Engine Air Cleaner Fil...

Page 59: ...ce The model part number and serial number are located on the nameplates at the top of each housing See Figure 1 414 1 Identification Plate Figure 1 414 Nameplate Location on Housing NOTICE Only the specific brake model can be used with the engine model it was designed for Also the correct slave piston adjustment specification must be used Failure to follow these instructions may result in serious...

Page 60: ... 0 023 in 6067BK60 1998 12 7L 770 0 660 mm 0 023 in 6067HKXX 1998 Non Line Haul 14L 770 0 660 mm 0 023 in 6067MK28 6067MK45 6067MK57 6067MK60 2000 12 7L Standard 790 0 660 mm 0 026 in 6067BK28 6067BK45 6067BK57 6067BK60 2000 12 7L Premium 790 0 660 mm 0 026 in 6067HK45 6067HK60 2000 14L U S 790A 0 660 mm 0 026 in 6067WK28 6067WK60 2000 11 1L 790B 0 660 mm 0 026 in 6067LK28 6067LK45 6067LK60 2000 1...

Page 61: ...999 Model 790 Jake Brakes are used on all Series 60 engines requiring an engine brake Former Jake Brake production models for the Series 60 engine were the 760A which replaced model 760 760B 765 765A and 770 Detroit Diesel engine model Nos 6067GU28 and 6067GK28 are for bus coach applications Due to interference fits on some coach chassis a two housing Jake Brake kit may be required Contact your De...

Page 62: ...ormal compression stroke releasing the compressed cylinder charge to exhaust See Figure 1 415 1 Exhaust Valve 7 Oil In 2 Slave Piston Assembly 8 Check Valve Model 760 3 Exhaust Valve 9 Solenoid Valve 4 Leveling Screw 10 Control Valve 5 Slave Piston Adjusting Screw 11 Master Piston 6 Accumulator 12 Injector Pin and Roller Figure 1 415 Jake Brake Schematic All information subject to change without n...

Page 63: ...n the control valve traps high pressure oil in the master slave piston system High pressure oil causes the slave piston to move down momentarily opening the exhaust valves while the engine piston is near its top dead center position releasing compressed cylinder air to the exhaust manifold At the bottom of its stroke the slave piston separates from the valve in the slave piston adjusting screw all...

Page 64: ...rake see Figure 1 416 and see Figure 1 416a 1 Ball Check Valve Model 760 Only 5 Power Lash Assembly 2 Control Valve 6 Slave Piston 3 Solenoid Valve 7 Bridge 4 Accumulator Piston 8 Master Piston Figure 1 416 Typical Model 760 765 or 770 Jake Brake Assembly All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 527 ...

Page 65: ...pring 9 Retaining Ring 20 Inner Slave Piston Spring 10 Control Valve 21 Slave Piston Spring Seat 11 Outer Control Valve Spring 22 Shoulder Bolt Figure 1 416a Typical Model 790 Jake Brake Assembly NOTICE This application and adjustment information must be strictly followed Failure to follow these instructions may result in serious engine or engine brake damage All information subject to change with...

Page 66: ... repair is possible or replacement is necessary perform the following procedure See Figure 1 417 Figure 1 417 Jake Brake Repair or Replacement Flowchart All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 529 ...

Page 67: ...ne rocker cover Refer to section 1 6 2 for one piece refer to section 1 6 3 for two piece and refer to section 1 6 5 for three piece NOTE If the engine is equipped with an aluminum two piece valve cover remove only the upper valve cover when installing the engine brake 3 Note the location of the rocker arm shaft the exhaust valve rocker arm the fuel injector rocker arm and the intake valve rocker ...

Page 68: ...Figure 1 418 NOTE Only the Model 760 Jake Brake uses two different length mounting bolts Six bolts 120 mm 4 72 in long are used on the exhaust side of the engine Three bolts 110 mm 4 33 in long are used on the intake side of the engine These bolts must be reinstalled in their correct positions 6 Remove the engine brake assemblies and the spacer bar All information subject to change without notice ...

Page 69: ...nder load from the control valve springs 1 Press down on control valve washer using an appropriate diameter rod to relieve spring pressure See Figure 1 419 1 Jake Brake Assembly 3 Snap Ring Retainer 2 Spring 4 Snap Ring Pliers Figure 1 419 Relieving Spring Pressure All information subject to change without notice 1 532 From Bulletin 16 60 99 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION ...

Page 70: ...e Brake Assembly 5 Washer 2 Control Valve 6 Collar Spring 3 Collar 7 Control Valve Spring 4 Snap Ring Retainer Figure 1 420 Removing Control Valve Springs and Collar 4 Using needle nose pliers reach into the bore and grasp the stem of the control valve Remove control valve All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 ...

Page 71: ...rew locknut 2 Remove adjusting screw from housing See Figure 1 421 1 Jake Brake Assembly 2 Slave Piston Adjusting Screw Figure 1 421 Removing Slave Piston Adjusting Screw All information subject to change without notice 1 534 From Bulletin 16 60 99 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION ...

Page 72: ...enoids or a 3 4 in 6 point socket and extension for current solenoids unscrew solenoid valve 3 Remove and discard the three rubber seal rings See Figure 1 422 1 Seal Rings 3 2 Solenoid Figure 1 422 Removing Rubber Seal Rings 4 If the lower ring stays in the bottom of the housing bore remove with a piece of wire All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIE...

Page 73: ... ring and cover 1 Push down on the accumulator cover using the appropriate diameter rod and remove the retaining ring See Figure 1 423 1 Jake Brake Assembly 3 Retaining Ring Pliers 2 Retaining Ring Figure 1 423 Removing Retaining Ring 2 Relieve pressure on the accumulator cover 3 Remove the cover and spring All information subject to change without notice 1 536 From Bulletin 16 60 99 6SE483 9901 C...

Page 74: ... bore See Figure 1 424 1 Jake Brake Assembly 4 Retaining Ring 2 Piston 5 Washer 3 Spring Figure 1 424 Removing Piston from Accumulator Bore with Magnet All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 537 ...

Page 75: ...s if necessary 1 Washer and Screw Assembly 3 Master Piston 2 Jake Brake Assembly 4 Master Piston Spring Figure 1 425 Removing The Master Piston On Model 760 only remove the ball check valve as follows 1 Remove the plug 2 Remove the ball check valve and spring All information subject to change without notice 1 538 From Bulletin 16 60 99 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION ...

Page 76: ...ring 2 Remove the bridge and the slave piston See Figure 1 426 1 Slave Piston Bridge 4 Return Spring 2 Jake Brake Housing 5 Washer 3 Slave Piston 6 Screw Figure 1 426 Removing Bridge and Slave Piston All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 539 ...

Page 77: ...7 Removing the Leveling Screw from the Bridge The injector rocker arm contains a pin and roller for actuating the engine brake master piston If excessive wear or damage to the roller is present replace the rocker arm assembly Refer to Section 1 6 2 All information subject to change without notice 1 540 From Bulletin 16 60 99 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION ...

Page 78: ...ar adequate eye protection face plate or safety glasses and do not exceed 40 psi 276 kPa air pressure 3 Dry the valve with compressed air and wipe clean with a paper towel 4 Thoroughly clean the control valve bore in the housing using clean paper towels 5 Clean slave piston adjusting screw in an approved cleaning solvent 6 Clean out the solenoid valve bore in the housing NOTICE Use clean paper tow...

Page 79: ...ting screw meets specifications continue with inspection 2 Inspect the accumulator for wear or damage a If worn or damaged replace the accumulator Refer to Section 1 29 4 b If accumulator is not worn or damaged continue with inspection 3 Inspect the master piston bore for wear or damage NOTE Some wear marks are permissible a If worn or damaged replace the master piston Refer to Section 1 29 4 b If...

Page 80: ...d with inspection 1 29 3 3 Inspection of Control Valve Inspect the control valve as follows 1 Dip the control valves in clean lube oil 2 Holding the control valve by the stem let it drop into the bore a If binding occurs or if the ball sticks in the valve replace the control valve Refer to Section 1 29 4 b If no binding occurs and the ball does not stick in the control valve assemble the Jake Brak...

Page 81: ... 7 Control Valve Spring 4 Snap Ring Retainer Figure 1 428 Installing the Control Valve 2 Install the control valve collar and two springs NOTE Ensure the collar is installed with the longer sleeve area facing up If the collar is installed upside down the engine brake cylinder will not operate 3 Press the cover washer into place 4 While holding the cover tightly in place install the retaining ring ...

Page 82: ...lows NOTE As of October 19 1997 former solenoids have been replaced with the current improved solenoids The current solenoids have an increased installation torque and improved durability The current solenoid is interchangeable with the former 1 Coat new solenoid valve seal rings with clean lube oil NOTE Use current upper seals when installing current solenoids New seals are identified with yellow...

Page 83: ...nd extension for current solenoids carefully screw the solenoid valve into the housing without unseating the seals 5 Torque the former solenoid to 12 4 N m 9 lb ft Torque the current solenoid to 20 N m 15 lb ft NOTE Be careful not to twist the seals while installing Install the accumulator as follows 1 Place the piston into the accumulator bore 2 Insert the spring and install the cover 3 Push down...

Page 84: ...y 3 Master Piston 2 Jake Brake Assembly 4 Master Piston Spring Figure 1 431 Inserting Master Piston into Bore 3 Install spring washer and screw NOTE Make sure spring legs are centered around master piston boss 4 Torque screw to 10 N m 7 4 lb ft All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 547 ...

Page 85: ...e and spring See Figure 1 432 1 Ball Check Valve 3 Pipe Plug 2 Spring Figure 1 432 Installation of Ball Check Valve 2 Insert the plug Torque pipe plug to 11 2 N m 8 3 lb ft All information subject to change without notice 1 548 From Bulletin 16 60 99 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION ...

Page 86: ...ll the bridge with the leveling screw toward the center of the housing See Figure 1 433 1 Washer 4 Bridge Assembly 2 Screw 5 Jake Brake Housing 3 Torsion Spring Figure 1 433 Installing Bridge with Leveling Screw Toward Center of Housing All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 549 ...

Page 87: ...ning the screw on the torsion spring push the spring toward the slave piston assembly Failure to do so may result in contact between the intake valve adjusting screw and torsion spring Serious engine damage may result 6 Torque the screw to 20 N m 15 lb ft 7 Torque the slave piston leveling screw locknut to 47 N m 35 lb ft All information subject to change without notice 1 550 From Bulletin 16 60 9...

Page 88: ... to section To prevent possible personal injury when using compressed air wear adequate eye protection face plate or safety glasses and do not exceed 40 psi 276 kPa air pressure 2 Attach the length of tubing to a blow gun nozzle and blow out the oil from the bolt holes 3 Cover the holes with hand towels to minimize oil spray NOTE Removing the oil from the bolt holes prevents the cylinder head from...

Page 89: ...ith the OUT markings adjoining each other and facing the exhaust manifold See Figure 1 435 and see Figure 1 436 Figure 1 435 Spacer Bars with Out Marks Adjoined All information subject to change without notice 1 552 From Bulletin 16 60 99 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION ...

Page 90: ...ake housings over the rocker shafts with the solenoid valves toward the camshaft side of the engine NOTE Be sure housings do not interfere with wiring harness All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 553 ...

Page 91: ...0 mm 4 33 in long and have 12 point heads NOTE In the event of a housing hold down bolt failure on a Jacobs engine brake housing replace all bolts on that particular housing NOTICE Use bolts that have the Jacobs logo circled J Installation of bolts that do not have the circled J may result in damage to the engine engine brake or both a The Jake Brake bolt has the Jacobs logo circled J and the lett...

Page 92: ... 17 0 mm 0 669 in versus 4 mm 0 157 in than the Jake Brake bolt See Figure 1 437 Figure 1 437 Jake Brake and DDC Bolt Identification All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 555 ...

Page 93: ...re to do so will result in engine damage 6 On model 760 install one washer onto each 120 mm 4 75 in bolt and insert into brake housing on the exhaust manifold side two per housing See Figure 1 438 1 Washer 2 Long Bolt Figure 1 438 Installation of Brake Housing Bolts on Exhaust Manifold Side All information subject to change without notice 1 556 From Bulletin 16 60 99 6SE483 9901 Copyright 1999 DET...

Page 94: ...ousing Bolts on Camshaft Side 8 On models 760A 760B 765 and 765A lubricate each hold down bolt with clean engine oil NOTE All the housing mounting bolts for these models are the same length of 110 mm 4 375 in 9 On models 760A 760B 765 and 765A install a washer on each bolt and install into housings three bolts per housing All information subject to change without notice 6SE483 9901 Copyright 1999 ...

Page 95: ...ke mounting bolts using the following sequence a Torque the three bolts on the camshaft side of the engine to 55 N m 40 lb ft b Torque the six bolts on the exhaust manifold side of the engine to 55 N m 40 lb ft c Repeat the tightening sequence and re torque all bolts to 136 N m 100 lb ft d Check the torque to 136 N m 100 lb ft 13 Secure wire harness to spacer bars with plastic ties 14 Connect wiri...

Page 96: ... Brakes For Model 790 Jake Brake slave piston lash setting procedures refer to section 1 29 10 1 NOTE Model 770 Jacobs engine brake requires a special procedure for adjusting the slave piston The procedure is clearly indicated in the following adjustment steps NOTICE Improper slave piston adjustment can result in engine or brake housing damage NOTICE Strictly follow the slave piston adjustment pro...

Page 97: ...e piston assembly 1 Leveling Screw 2 Locknut Figure 1 441 Location of Leveling Screw 3 On models 760 760A 760B 765 and 765A place the correct size feeler gage between the solid side of the slave piston the side without the leveling screw and the exhaust rocker arm adjusting screw Feeler gage sizes are listed in Table 1 9 All information subject to change without notice 1 560 From Bulletin 16 60 99...

Page 98: ...il a slight drag is felt on the feeler gage See Figure 1 442 1 Slave Piston Bridge 3 Feeler Gage 2 Slave Piston Adjusting Screw Figure 1 442 Turn Slave Piston Adjusting Screw Clockwise All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bulletin 16 60 99 1 561 ...

Page 99: ...e NOTE Do not back out the J Lash more than required to obtain a light drag on the feeler gage d Use a screwdriver to hold the J Lash in place and torque the lock nut to 34 N m 25 lb ft NOTE If the J Lash screw is backed out until it no longer compresses the slave piston spring oil will enter the screw and the adjustment will be incorrect If this occurs repeat the J Lash adjustment procedure e Rec...

Page 100: ...linders Refer to step 2 through step 11 NOTE Bar over the engine when necessary to place the exhaust valves in the closed position for slave piston adjustment 13 Install the engine rocker cover Refer to section 1 6 2 for one piece refer to section 1 6 3 for two piece and refer to section 1 6 5 for three piece 14 Install all remaining components that were removed for this procedure 15 Connect start...

Page 101: ...m 1 With the engine at ambient temperature and power to the starting system disconnected Refer to section of the Series 60 Service Manual 6SE483 and remove the engine rocker cover 2 Note the location of the rocker arm shaft the exhaust valve rocker arm the fuel injector rocker arm and the intake valve rocker arm 3 Disconnect the solenoid wiring harness connectors from the Jake Brake solenoids All ...

Page 102: ...igure 1 443a Model 790 Jake Brake Fasteners 5 Remove the three 3 170 mm long mounting bolts and the two 2 nuts that secure the engine brake to the cylinder head 6 Remove the engine brake assembly 7 Repeat steps 1 through step 5 and remove the second Jake Brake assembly from the engine All information subject to change without notice 6SE483 9901 Copyright 1999 DETROIT DIESEL CORPORATION From Bullet...

Page 103: ... 4 Lower Seal 15 Locknut 5 Master Piston 16 Slave Piston 6 Master Piston Pushrod 17 Slave Piston Bridge 7 Master Piston Spring 18 Outer Slave Piston Spring 8 Retaining Ring 19 Inner Slave Piston Spring 9 Control Valve 20 Slave Piston Spring Seat 10 Outer Control Valve Spring 21 Shoulder Bolt 11 Inner Control Valve Spring 22 Shoulder Bolt Figure 1 443b Typical Model 790 Jake Brake Assembly All info...

Page 104: ... for the model 790 Jake Brake assemblies differ slightly from the former engine brakes Two brake housings are used instead of three and spacer bars are not required Install the model 790 Jake Brake assemblies as follows 1 With the engine at ambient temperature install front Jake Brake housing with two solenoids over the front three cylinders Position with solenoids on camshaft side of engine 2 Ins...

Page 105: ...n bolt location number sequence shown See Figure 1 443c 6 Route the wire to the solenoid for cylinder 1 through the front retaining clip on the front housing and connect to the solenoid Torque screw to 1 13 N m 10 lb in 7 Route wire to the solenoid for cylinders 3 and 4 through the rear retaining clip on the front housing and connect to the solenoid Torque screw to 1 13 N m 10 lb in 8 Route wire t...

Page 106: ...knut Then using a 5 16 in Allen wrench turn the J Lash adjusting screw counter clockwise until a 0 660 mm 0 026 in feeler gauge can be inserted between the slave piston and the exhaust rocker adjusting screw Insert the feeler gauge 2 Using the 5 16 in Allen wrench turn the J Lash adjusting screw in clockwise until the slave piston contacts the feeler gauge and the exhaust rocker adjusting screw Wh...

Page 107: ...feeler gage can be moved with a slight resistance See Figure 1 443e Do not back out the J Lash adjusting screw more than required to obtain a light drag on the feeler gage Using the Allen wrench to hold the J Lash adjusting screw in place torque the lock nut to 35 N m 25 lb ft 1 J Lash Adjusting Screw 3 Feeler Gage 2 Locknut Figure 1 443e Adjusting Slave Piston Lash NOTE If the J Lash adjusting sc...

Page 108: ...5 Repeat step 1 through step 3 for the remaining slave piston on the same cylinder 6 Repeat step 1 through step 4 for the remaining cylinders 7 Complete the installation by installing the rocker cover Refer to section 1 6 of the service manual 8 Install all remaining components that were removed for this procedure 9 Connect starting power for the engine 10 Start and drive the vehicle to verify pro...

Page 109: ...mation in this manual was current at time of printing and is subject to change without notice or liability Refer to the Application guide P N 24770 for specific application information Also refer to the Install Manual P N 29901 and the engine manual for specific installation instructions ...

Page 110: ...shTM assembly 790B 0 11 29310 J lashTM assembly 790C 0 11 29908 Solid Screw 3 8 24 795 0 Tune up Kit Contents Model 790 795 Illus No Quantity per kit PartName P N Illus No PartName P N Quantity per kit 12 26142 Slave Piston 0 13 28379 Bridge Slave Piston 0 14 28372 Spring Inner Slave Piston 6 15 28373 Spring Outer Slave Piston 6 16 29295 Bolt Shoulder Slave Piston 6 17 12991 Ring Retainer 6 18 165...

Page 111: ...t could result in personal injury Take care when installing equipment or parts Always wear safety glasses Always use correct tools and follow proper procedures as outlined in this manual Instructions NEVER REMOVE OR ADJUST ANY ENGINE BRAKE OR COMPONENT WITH THE ENGINE RUNNING Access Engine Brake 1 Thoroughly clean engine 2 Remove valve rocker cover and gasket NOTE IF THE ENGINE HAS A TWO PIECE COV...

Page 112: ...OZZLE AND BLOW OUT THE OIL FROM THE HOUSING HOLD DOWN BOLT HOLES COVER THE HOLES WITH HAND TOWELS TO MINIMIZE OIL SPRAY WEAR SAFETY GLASSES WHILE BLOWING THE OIL FROM THE BOLT HOLES 1 Place the engine brake housings on the rocker shafts and spacer tubes with the solenoids on the camshaft side of the engine and the slave pistons over the exhaust valves 2 Lubricate each hold down capscrew with clean...

Page 113: ...ttings If lash setting is incorrect repeat steps 1 through 3 above NOTE ONCE THE ENGINE BRAKE HAS BEEN RUN YOU WILL NOT BE ABLE TO CHECK THE ENGINE BRAKE ADJUSTMENT FOR ENGINES USING J LASH ADJUSTING SCREWS THIS IS BECAUSE OF OIL RETAINED IN THE J LASH ADJUSTING SCREW IF UNSURE OF THE ADJUSTMENT YOU MUST REPEAT STEPS 1 THROUGH 4 ABOVE Engine Brake Operational Check WEAR EYE PROTECTION AND DO NOT E...

Page 114: ...Jacobs Vehicle Systems 22 East Dudley Town Road Bloomfield CT 06002 Visit us on the Internet www jakebrake com P N 29015 Rev A 2000 Jacobs Vehicle Systems Inc Printed in U S A Rev 10 00 ...

Page 115: ...bility Jake Brake is the only engine brake brand installed at Detroit Diesel Backed by Detroit Diesel s worldwide distributor dealer network 2 year unlimited mileage standard warranty Jake Brake Models 790 795 797 Jake Brake Models 790 795 797 for Detroit Diesel Series 60 Engines Year 2000 Production Engines and Beyond 797 Series For engines manufactured 10 01 02 Model 795 For engines manufactured...

Page 116: ...fications Height 4 2 107 mm Length 19 6 498 mm Width 4 102 mm Kit Added Weight 75 lbs 34 kg Housings Per Engine 2 Application Information For the most accurate application information refer to the Detroit Diesel Application Guide Jacobs P N 24770 available from your Detroit Diesel Distributor or online at www jakebrake com How The Jake Brake Works Energizing the engine brake effectively converts a...

Page 117: ...nual was current at time of printing and is subject to change without notice or liability Refer to the Application guide P N 24770 for specific application information Also refer to the Installation Manual P N 29901 and the Engine Manual for specific installation instructions ...

Page 118: ...D 790D 790D 1031226 Front housing Assembly 12 VDC S L 790D 790D 790D 790D 790D 1031227 Rear housing Assembly 12 VDC S L 790D 790D 790D 790D 790D 1031228 Front housing Assembly 24 VDC S L 790D 790D 790D 790D 790D 1031229 Rear housing Assembly 24 VDC S L 795 795 795 795 795 29902 Front housing Assembly 12 VDC S L 795 795 795 795 795 29903 Rear housing Assembly 12 VDC S L 795 795 795 795 795 29904 Fr...

Page 119: ... Piston n a n a Spring Inner Slave Piston n a n a Spring Outer Slave Piston n a n a Shoulder Bolt Slave Piston n a n a 17 Ring Retainer 12991 3 18 Washer 16505 3 19 Spring Inner Control Valve 18179 3 20 Spring Outer Control Valve 10843 3 21 Control Valve Assembly 11930 3 22 Pipe Plug 18485 23 Drive Screw 17303 24 Clip Wire Harness 29127 Notes Bold text deplicts parts that are common to all brake m...

Page 120: ...70 6 26 29132 CapScrew M12X1 75X140 6 27 29118 Spacer Tube 6 17671 Feeler gauge 0 026 IN 0 660 mm 16590 Screw Rocker Adjusting 29013 Tune up kit 790 795 Series 29589 Wire Clip Kit Model 790 30503 Solid Screw Group 12 pack 795 32128 Solid Screw Group 12 pack 797 32146 Tune up kit 797 Series J 45976 Master Piston Assembly Tool 797 29901 InstallationManual SERVICE PARTS 790 795 797 Part Name P N CAB ...

Page 121: ...aging engine conditions such as low oil pressure low coolant or high oil temperature Early Series 60 engines have the DDEC system called DDEC I Later Series 60 engines have the 2nd generation DDEC system called DDEC II See Figure 2 78 The current engines have the third generation DDEC system DDEC III IV Series 60 2004 Exhaust Gas Recirculation EGR engines will use the fifth generation of the DDEC ...

Page 122: ...CTRONIC ENGINE CONTROL Figure 2 78a DDEC V Electronic Control Unit Rev 12 03 All information subject to change without notice 2 151a From Bulletin 21 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 123: ...of engine and vehicle malfunctions The ECU continually monitors the DDEC V system See Figure 2 79a Figure 2 79a DDEC V System Series 60 Diesel Engine All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 22 60 03 2 151b ...

Page 124: ...ow the vehicle to be moved to a safe location during automatic shutdown or rampdown The Detroit Diesel Diagnostic Link DDDL is a sophisticated PC software package that requests and receives engine data and diagnostic codes The Detroit Diesel Diagnostic Link DDDL supports DDEC V and the Series 60 2004 engine See Figure 2 79b The DDDL functions are Read and display current calibration for an ECU Cre...

Page 125: ...60 SERVICE MANUAL Figure 2 79b Detroit Diesel Diagnostic Link DDDL All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 22 60 03 2 151d ...

Page 126: ...J1922 protocol on J1708 hardware Traction control systems Transmission controls SAE J1939 high speed data link Vehicle controls Table 2 6a SAE Standard Communications for DDEC V Inputs Outputs Coolant temperature Single on off fan clutch Oil temperature Dual on off fan clutch Air temperatures Two speed single fan Air conditioning Modulated fan clutch Table 2 6b Fan Controls for DDEC V Engine Brake...

Page 127: ...ensor IMP Mass Air Flow Sensor Supply Fuel Temperature Sensor SFT Sensor Turbo Compressor Temperature Out Sensor Turbo Speed Sensor TSS Table 2 6d Standard Sensors for DDEC V DDEC V Accelerator Pedal Sensor AP Sensor Add Engine Coolant Level Sensor AECL Sensor Air Filter Restriction Sensor AFR Sensor Engine Coolant Level Sensor ECL Fire Truck Pump Pressure Sensor Turbo Compressor In Temperature Se...

Page 128: ...ts two nuts and two studs holding the ECU to the engine remove the ECU from engine See Figure 2 79c 2 16a 3 Installation of the DDEC V Electronic Control Unit Perform the following steps for ECU installation 1 Inspect the ECU isolators for damage and replace if required 2 Mount the ECU to the engine 3 Secure the ECU to the engine with two through bolts two studs and nuts Torque the ECU to engine b...

Page 129: ...to the Detroit Diesel DDEC V Single ECM Troubleshooting Manual 6SE565 1 Nut 5 Electronic Control Unit 2 Stud 6 Bolt 3 Isolater 7 Bolt 4 Isolater 8 Shroud Figure 2 79c DDEC V Electronic Control Unit and Related Parts All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 22 60 03 2 151h ...

Page 130: ...ys start and operate an engine in a well ventilated area If operating an engine in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system or emission control system 6 Start the engine and check for leaks Rev 12 03 All information subject to change without notice 2 151i From Bulletin 22 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION ...

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Page 143: ...The ONLY Motor Coach Power Choice ...

Page 144: ...st Of Operation Reliability Long Life To Overhaul Driver Satisfaction Ease of Service Warranty Satisfaction Ratings Flexibility Electronic Controls Lightweight Residual Value Why Is The Series 60 So Popular Because It Offers Motor Coach Operators The Best Combination Of 7KH ...

Page 145: ...el engines since the 1970s The following chart shows the trend to ever lower emissions Understanding the details of the chart is not of interest to most truckers Even though the emissions standards become increasingly more difficult to meet the diesel engine industry has always been able to continue to improve engine durability reliability performance and fuel economy A quick look at the bottom ri...

Page 146: ...ncoming fresh air and displaces some of the oxy gen Since there is now slightly less oxygen in the air the peak temper atures created in the combustion chamber are reduced and the lev els of NOx are also reduced EGR Is The Best Solution EGR is the technology chosen by all but one major engine maker in North America EGR has been in use on automobile engines since the mid 1970s The challenge faced b...

Page 147: ...he Series 60 Additional Refinements Were Also Made To The Series 60 s Proven Design Improved Liner Valve Seat Guide Materials Compact Gear Train High Performance Turbocharger Stiffer Brackets High Output Water Pump Single Cylinder Air Compressor Large Pin Crankshaft 12 7L ...

Page 148: ...Deck Thickness Intake Manifold Bolt Pattern Intake Port Machining Recessed Exhaust Valves Valves Guides Seals For Long Life Nickel Chrome Intake Valves Pyromet Exhaust Valves Nickel Based Valve Seat Material Powdered Metal Valve Guides Next Generation Gear Train Less Vibration and Noise Decreased Frontal Area for Improved Under Hood Air Flow Improvements in Component Bracketry Higher Water Pump Fl...

Page 149: ...w lower emission diesel engines gave them generally high marks for the way they perform in actual operations Roger Gilroy Transport Topics March 24 2003 Drivers should appreciate the new powerplants as they clearly perform better especially at the bottom end thanks to the changeover to variable geometry turbochargers and improved ECU programs I ve driven all brands with EGR and have been quite imp...

Page 150: ...The Rapid Acceptance Of EGR Q 6KLSSHG 2YHU 6HULHV QJLQHV LWK 5 ULQJLQJ 7KH LHOG 3RSXODWLRQ 2I 6HULHV QG 6HULHV QJLQHV LWK 5 7R Over 40 000 Units ...

Page 151: ...Yourself Main bearings did their job and show no wear Upper no load main bearings show no wear and lower load bearings look as good Bearings show only minor overlay polish Camshaft looks excellent Journals and lobes show only contact path polishing Cam bearings show minor polishing Rod bearings show only minor overlay wear ...

Page 152: ...Connecting rod bushing machining marks are still visible indicating minimal wear Piston bushings only show typical polishing Piston liner shows cross hatch pattern intact More ...

Page 153: ...ets That Ran Their Own SAE Fuel Economy Tests Series 60 w EGR vs ISX w EGR July 24 2003 Fleet A Series 60 5 4 12L 5 9 14L Better August 20 2003 Fleet B Series 60 2 83 Better Series 60 w EGR vs C15 ACERT August 8 2003 Fleet C Series 60 3 9 Better 45 000 GCW Series 60 4 1 Better 75 000 GCW ...

Page 154: ...ead Better Air Flow For Improved Performance Camshaft Overhead Optimized Injector And Valve Events Ceramic Injector Intake And Exhaust Rollers For Better Roller Durability Under Adverse Conditions One Piece Monotherm Piston Reduced Friction For Improved Performance Closed Oil Gallery For Improved Ring Cooling And Longer Life Higher Compression Ratio For Better Cold Weather Starting ...

Page 155: ...Better Efficiency Reduced Weight 2 5 Lbs Stainless Steel Injector Sleeve Replaces Copper Tube Increased Durability Increased Corrosion Resistance Serviced From The Top Of The Engine Electronic Controls DDEC V Increased Capability For Future Needs Increased Microprocessor Power 4 Times More Memory 150 Output Pins vs 81 Current Ability To Add Options MAS Improved Reliability Improved Housing Latest ...

Page 156: ...ne driveability and acceleration Improved performance at high altitudes Better fuel economy Faster turbo response and quicker acceleration 200 150 100 50 0 Idle Speed Maximum Engine Speed Boost Pressure kPa pical urbocharger urbocharger Boost Pressure Bene it ith urbocharger 250 00 50 Boost Pressure Benefit With VGT Turbocharger ...

Page 157: ... and desirability of any coach 425 515 HP The Most Complete Power Range In A Single Engine Package Performance Maximum Fuel Economy 1700 1650 1600 1550 1500 1450 1350 55 60 65 70 75 Max Vehicle Speed MPH Recommended Engine Speed Gearing Recommendations Remain the Same 12 7L Maximum HP RPM Peak Torque RPM 445 HP 1800 RPM 1450 LB FT 1200 RPM 435 HP 1800 RPM 1450 LB FT 1200 RPM 425 HP 1800 RPM 1450 L...

Page 158: ...bolts providing over 1 000 000 pounds of clamp load on the head gasket The cylinder liner is cooled all the way to the top using a patented DDC feature called top liner cooling This reduces ring temperatures by 100ºF another reason Series 60 engines live so long Main and rod bearings are big That s why the Series 60 engine has no requirement to roll out bearings it s just not necessary The Series ...

Page 159: ...ings Three levels of engine braking Engine fan braking Progressive shifting Vehicle speed limiting Vehicle overspeed diagnostics Low gear torque limiting Starter lockout Remote PTO control Communication capability with electronically controlled transmis sions Idle speed adjustment Droop adjustment Idle timer shutdown Air temperature shutdown High or low Warnings for Low voltage Low coolant High oi...

Page 160: ...onics service network ProDriverTM DC ProDriver DC is a dashboard mounted display with data card extraction capabilities It provides real time and summary information on vehicle and engine operation as well as graphic displays of driver performance relative to fleet goals ProDriver DC is a second genera tion display product It delivers all the functionality provided by the original ProDriver displa...

Page 161: ...ters are brought to in range values Optimized Idle provides benefits of Less Fuel Used Extended Battery Life Reduced Idle Time Safety Maintenance Alert System IRIS Infrared Information System Easy to adjust temperature control buttons Optimized Idle display unit Significant fuel economy savings Digital read out appears in F or C Maintenance Alert System The Maintenance Alert System MAS is designed...

Page 162: ...overed by a standard warranty of two years unlimited miles with 100 parts and labor coverage and 5 years or 500 000 mile Want more coverage Custom tailor a support package to fit your needs Extended service coverage is available from 3 years or 300 000 miles or as much as 5 years or 500 000 miles What About Warranty ...

Page 163: ...s 60 the most popular engine with coach operators for the past decade will continue for years to come Maintenance is a substantial savings The Series 60 Engine Will Continue To Provide Coach Operators With The Best Combination Of Performance Fuel Economy Reliability Low Cost Of Operation Proven Durability Driver Satisfaction High Residual Value Proven Electronics DDEC Flexible Power Ratings Excell...

Page 164: ... a common package Easy to change horsepower settings The choice of the top fleets The choice of those who want big power Lightweight Low cost per mile Unaided cold starts to 20º F DDEC controlled automatic Ether Starts to 30º F Maximum revenue ...

Page 165: ...ozens of DDEC features as standard equipment The complete DDEC System ProDriver DC Data Summaries Optimized Idle Fuel Economy Incentive 1 800 445 1980 direct line to support Customized warranties Service throughout North America Diagnostic Link ...

Page 166: ... DDEC and Series 60 are registered trademarks of Detroit Diesel Corporation 6SA0581 0401 As technical advancements continue specifications may change Printed in U S A 13400 Outer Drive West Detroit Michigan 48239 4001 Telephone 313 592 5000 www detroitdiesel com Series 60 24 Hour Hot Line Phone 1 800 445 1980 ...

Page 167: ... Main Fuel Tank 8 5 1 2 Auxiliary Fuel Tank if so equipped 8 5 1 3 Transverse Fuel Tank 8 5 2 TANK INSTALLATION 8 5 3 FUEL TANK VERIFICATION 10 5 4 POLYETHYLENE FUEL TANK REPAIR 10 6 PRIMING FUEL SYSTEM 10 7 FUEL PUMP INSTALLATION 11 8 FUEL OIL SPECIFICATIONS 11 9 AIR CLEANER DRY TYPE 11 9 1 PRE CLEANER SERVICING 11 9 2 AIR CLEANER SERVICING 11 9 3 GENERAL RECOMMENDATIONS 12 9 4 AIR CLEANER RESTRI...

Page 168: ...5 DAVCO FUEL PRO 382 EXPLODED VIEW 7 FIGURE 6 208 US GAL MAIN FUEL TANK 90 US GAL AUXILIARY FUEL TANK OPTIONAL W5 9 FIGURE 7 250 US GALLONS FUEL TANKS MAIN TANK TRANSVERSE FUEL TANK W0 WE 9 FIGURE 8 FUEL TANK REPAIR 10 FIGURE 9 PRIME PUMP SWITCH LOCATION 10 FIGURE 10 FUEL PUMP LOCATION 11 FIGURE 11 RESTRICTION INDICATOR 12 FIGURE 12 FUEL COOLER LOCATION 12 FIGURE 13 ELECTRONIC FOOT PEDAL ASSEMBLY ...

Page 169: ... fuel filter in the system no secondary fuel filter is necessary Leaving the pump under pressure the fuel flows through a secondary fuel filter and a shut off valve then to the cylinder head The fuel reaches the injectors in the cylinder head through passages within the head Excess fuel exits at the rear of the head just above the inlet through a restrictive return fitting which maintains fuel pre...

Page 170: ...de of engine compartment Fig 2 A manual shut off valve is located at the inlet side of the primary fuel filter fuel filter water separator if vehicle is so equipped under the starter Another manual shut off valve is located at the outlet side of the secondary fuel filter under the air compressor 4 FILTERS AND WATER SEPARATOR The fuel system is equipped with primary and secondary fuel filters for a...

Page 171: ...s first The primary fuel filter is equipped with a positive seal drain valve to prevent water infiltration in engine fuel system To drain loosen positive seal drain valve below filter and tighten after water has been flushed out A method of determining when filters are clogged to the extent that they should be changed is based on the fuel pressure at the cylinder head fuel inlet fitting and the in...

Page 172: ...ll as a fuel filter refer to figure 4 When new the fuel level as seen through the clear cover in the 382 filter is very low It rises as dirt collects on the filter from the bottom up Restriction remains consistently low because fuel always flows through clean new media Change filter when fuel level reaches the top of filter element refer to figure 5 Filter renewal 1 Stop engine 2 Drain fuel by ope...

Page 173: ...de of vehicle A pressure relief valve on the fuel tank connection panel relieves high pressure buildup and an overflow tube allows offset air in the tank to escape during filling For 95 of the tank volume 5 of tank inside space is kept filled with air with no exit opening allowing for a fuel expansion safety margin A drain plug accessible from under the vehicle is fitted at the bottom of the tank ...

Page 174: ...e vehicle on the L H side unscrew the 2 bolts 1 in front 1 in back retaining the tank support to the frame 9 Carefully remove tank from under the vehicle 5 1 2 Auxiliary Fuel Tank if so equipped 1 Open the baggage compartment just forward of condenser compartment disconnect the 2 hoses previously joining the tanks 2 From underneath vehicle unscrew the two 2 bolts retaining the tank strap one on ea...

Page 175: ...Section 03 FUEL SYSTEM PA1553 9 FIGURE 6 208 US GAL MAIN FUEL TANK 90 US GAL AUXILIARY FUEL TANK OPTIONAL W5 03028 FIGURE 7 250 US GALLONS FUEL TANKS MAIN TANK TRANSVERSE FUEL TANK W0 WE 03029 ...

Page 176: ... 8 FUEL TANK REPAIR 03014 6 Apply sealant on head plug Prévost 507300 and seal hole with the head plug 6 PRIMING FUEL SYSTEM The problem with restarting a diesel engine that has run out of fuel is that after the fuel is exhausted from the tank it is pumped from the primary fuel filter or the fuel filter water separator if vehicle is so equipped and sometimes partially removed from the secondary fi...

Page 177: ...ne operation is a very important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust emission levels The fuel oil should meet ASTM designation D 975 Grade 1 D is recommended however grade 2 D is acceptable NOTE These fuel grades are very similar to grade DF 1 or DF 2 of Federal Specifications VV F 800 For detailed fuel recommendations refer to publication En...

Page 178: ...he housing must be cleaned with a soft clean cloth 6 Periodically inspect the entire system Dust laden air can pass through an almost invisible crack or opening which may eventually cause damage to an engine 7 Never operate the engine without an element in the air cleaner assembly CAUTION Do not ignore the Warning given by the air restriction indicator This could result in serious engine damage 8 ...

Page 179: ...ntiometer clockwise to increase counts or counterclockwise to decrease When correct output is confirmed tighten retaining screws 11 2 POTENTIOMETER REPLACEMENT 1 Disconnect cable harness connector CAUTION Note the routing and clamping locations of the cable before disassembly Proper cable routing and fastening is critical to the operation of this system Marking the foot pedal assembly to record ca...

Page 180: ...number 531397 O RING Supplier number RK30076 Prévost number 531398 PROBE WATER SENSOR Supplier number RK21069 Prévost number 531391 Primary Fuel Filter Make AC Type Spin on Filter No T 915D Service Part No 25014274 Prévost number 510137 OR Service Part No Type with Water Separator 23512317 Prévost number 531407 Element torque 1 2 turn after gasket contact Secondary Fuel Filter Make AC Type Spin on...

Page 181: ...Part No 7182 8N Supplier number element cartridge 70337N Prévost number element cartridge 530197 Air Cleaner Restriction Indicator Make Donaldson Model RBX00 2220 Indicates at 20 508 mm of water Prévost number 530161 Fuel Cooler Make Berendsen Supplier number DB 1240 Prévost number 950109 ...

Page 182: ......

Page 183: ... TUBE INSTALLATION 4 5 BUS SHELLS HEAT BLANKETS 4 5 1 EXHAUST 4 5 1 1 Installation on W5 Bus Shells 4 5 1 2 Installation on W0 WE Bus Shells 4 ILLUSTRATIONS FIGURE 1 EXHAUST SYSTEM INSTALLATION W0 WE 2 FIGURE 2 EXHAUST SYSTEM INSTALLATION W5 3 FIGURE 3 FLEXIBLE TUBE INSTALLATION 4 FIGURE 4 EXHAUST BLANKET INSTALLATION 4 ...

Page 184: ...uffler In addition to objectionable noise a leaking exhaust system could allow toxic gases to enter the vehicle Inspect the exhaust system as follows At vehicle inspection intervals Whenever a change is noticed in the sound of the exhaust system and Whenever the exhaust system is damaged Replace damaged or corroded exhaust system components without delay When operating the engine in a service gara...

Page 185: ...Section 04 EXHAUST SYSTEM PA1553 3 FIGURE 2 EXHAUST SYSTEM INSTALLATION W5 04013 ...

Page 186: ...LATION The flexible exhaust tube contains an inside rigid pipe To allow appropriate flexibility for assembly make sure that the rigid pipe is concentric to the flexible part To maintain the pipe centered at the time of installation cardboard spacers must be inserted at four places at equal distance around tubing Fig 3 These spacers may be left in place and will deteriorate over time FIGURE 3 FLEXI...

Page 187: ...7 4 7 1 Coolant Not Recommended 8 4 7 2 Additives Not Recommended 8 4 7 3 Vehicles Without Coolant Filters 8 4 7 4 Vehicles With Coolant Filters 8 5 DRAINING COOLING SYSTEM 8 5 1 VEHICLES EQUIPPED WITH CENTRAL HVAC SYSTEM 8 5 2 VEHICLES EQUIPPED WITH SMALL HVAC SYSTEM 9 6 FILLING COOLING SYSTEM 10 7 FLUSHING 10 7 1 COOLING SYSTEM DESCALERS 11 7 2 REVERSE FLUSHING 11 8 SPIN ON COOLANT FILTER 11 9 R...

Page 188: ... W0 WE 8 FIGURE 7 HEATER LINE SHUTOFF VALVES W5 9 FIGURE 8 HEATER LINE SHUTOFF VALVES W0 WE 9 FIGURE 9 ENGINE COOLANT DRAIN COCKS 9 FIGURE 10 WATER PUMP DRAIN PLUG 9 FIGURE 11 COOLANT FILTER 12 FIGURE 12 MECHANICAL LOCKING DEVICE 13 FIGURE 13 SCREWS LOCATION 13 FIGURE 14 THERMOSTAT AND RELATED PARTS 14 FIGURE 15 FAN GEARBOX 14 FIGURE 16 REGULATOR VALVE 15 FIGURE 17 BELT TENSIONER 15 FIGURE 18 ANGL...

Page 189: ... cylinder block the coolant passes up through the cylinder head and when the engine is at normal operating temperature it goes through the thermostat housing and into the upper portion of the radiator The coolant then passes through a series of tubes where its heat is dissipated by air streams created by the revolving fan and the motion of the vehicle Upon starting a cold engine or when the coolan...

Page 190: ...ain flush thoroughly clean and refill the system every two years or every 200 000 miles 320 000 km whichever comes first For vehicle equipped with coolant filters change the precharge element filter or the existing maintenance element filter for a new maintenance element filter If the vehicle is not equipped with filters add the recommended inhibitor concentration to the antifreeze water solution ...

Page 191: ...hat pinch hoses 3 1 CONSTANT TORQUE HOSE CLAMPS All hose clamps of 1 3 8 ID and over used on the heating and cooling systems are of the Constant torque type These clamps are worm driven made of stainless steel and supplied with a series of Belleville spring washers They also feature an extended integral liner that covers the band slots to protect soft silicone hoses from damage and help maintain c...

Page 192: ...cylinder walls and the cylinder head into the coolant Without adequate coolant normal heat transfer cannot take place within the engine and engine temperature rapidly rises Coolant must therefore be carefully selected and properly maintained Select and maintain coolant in order to meet the following basic requirements o Provide for adequate heat transfer o Provide protection from cavitation damage...

Page 193: ...ugh them 4 6 1 Inhibitor Test Procedures Test Kits are commercially available to check engine coolant for nitrite concentration Nitrite concentration is an indication of Supplemental Coolant Additive SCA level Nitrite must be maintained within recommended levels Coolant must be tested at each oil change to insure that inhibitor levels are maintained within the ranges shown hereafter NOTE Above SCA...

Page 194: ...om the heated cooling system can result in severe burns from the expulsion of hot coolant fluid 4 7 3 Vehicles Without Coolant Filters Refer to Nalcool 3000 with Stabil Aid bulletin annexed to the end of this section for preventive maintenance at each oil change and initial treatment instructions each time the cooling system is drained and flushed 4 7 4 Vehicles With Coolant Filters Change the coo...

Page 195: ...of coolant and possible personal injury scalding from the hot liquid 2 Unscrew the surge tank pressure cap counterclockwise turn to let air enter the system and permit the coolant to drain completely from system 3 Unscrew the water pump housing inlet line drain plug Fig 10 4 Open drain cock at bottom of thermostat housing to drain the coolant trapped above the thermostats 1 Fig 9 FIGURE 9 ENGINE C...

Page 196: ...o radiator top tank is required to ensure complete engine fill and proper venting of air in the system 3 Install the filler and pressure caps then start the engine and run it at fast idle until reaching normal operating temperature Check for leaks NOTE If for any reason the coolant level drops below the surge tank level probe the Check Engine light will flash 4 Stop engine and allow cooling 5 Open...

Page 197: ...sed air outlet 5 Turn on the water and when the radiator is full turn on the air in short blasts allowing the radiator to fill between blasts NOTE Apply air gradually Do not exert more than 138 kPa 20 psi air pressure Too great a pressure may rupture a radiator tube 6 Continue flushing until only clean water is expelled from the radiator The cylinder block and cylinder head water passages are reve...

Page 198: ...to coolant system flushing and reverse flushing in this section for maintenance of radiator interior 10 VARIABLE SPEED RADIATOR FAN The radiator fan has two thermostatically controlled speeds The ECM controls the speed by comparing data from engine coolant temperature charge air cooling temperature engine oil temperature A C condenser temperature transmission retarder state manual switch to a set ...

Page 199: ...gine o Check security of fasteners securing fan blade assembly to fan driving mechanism o Check coupling installation between fan blade assembly and gearbox o Visually inspect fan driving mechanism fan blade assembly shroud radiator and surrounding area for evidence of contact between rotating and non rotating parts o Check fan transfer belt for fraying cracking and proper tension o Turn fan throu...

Page 200: ...REPLACEMENT Locate the belt tensioner pressure releasing valve Fig 16 then turn handle counter clockwise in order to release pressure in belt tensioner air bellows thus releasing tension on belts Remove existing belts 3 V belts 1 Poly from fan assembly and replace with new ones Turn the pressure releasing valve clockwise to its initial position to apply tension on the new belts NOTE For proper ope...

Page 201: ...t of the fan clutch is made possible by slots at the base of the fan clutch on some vehicles only or by shimming with additional spacers at anchoring locations Temporarily secure assembly with two nuts P N 500709 74 Fig 18 at both anchoring locations FIGURE 18 ANGLE SUPPORT 05014 CAUTION Tilt fan and check for clearance 3 Using a straight edge align the 3 V pulley on gearbox central shaft pulley w...

Page 202: ...sing a wrench FIGURE 20 PULLEY VERTICAL ANGLE 05063 6 Align multi V pulley with fan pulley Adjust the depth of the pulley on the gearbox shaft 7 Set belt tensioner pressure regulating valve to 50 PSI 345 kPa CAUTION In order for tensioning system to work properly adjust upper tensioning bracket to provide a 7 mm gap between stopper and bracket Otherwise release tension on system and readjust dista...

Page 203: ... 550819 Surge Tank Filler Cap Make Stant Model R3 Prevost number 052355 Pressure Cap Make Stant Pressure setting 14 psi 96 53 kPa Prevost number 550606 Fan Clutch Make Linnig Type 3 speed XLII MTH Prevost number 550839 NOTE The fan clutch is controlled by DDEC not by thermoswitch Fan Gearbox Make Superior Gearbox Ratio 1 1 Prevost number 550789 Lubricating Oil MOBIL SHC 630 Prevost number Oil 6836...

Page 204: ...Fan Belt gearbox motor Make Dayco Type V belt Qty 3 W0 WE MTH Prevost number 506691 W5 MTH Prevost number 509822 Coolant Prevost Number 685125 MAINTENANCE ELEMENT FILTER Prevost number 550630 PRECHARGE ELEMENT FILTER Prevost number 550629 ...

Page 205: ... kpl 7 disc 05 424 07 1125 Riemenscheibe rotor shaft Distanzbuchse 09 702 spacer bush 9 1 Flansch 09 700 flange 10 1 Distanzbuchse 09 703 spacer bush 12 1 Distanzbuchse 11 1 13 1 Kühlrippenring 11 374 cooling ring 35 014 1 cylindrical roller bearing 32 013 grooved ball bearing 14 1 Paßfeder 16 Rillenkugellager 15 1 Zylinderrollenlager O ring 43 027 40 033 17 1 O Ring 42 069 double ball bearing 18 ...

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Page 215: ...e 18 3 5 3 Load Test 18 3 5 4 Testing Battery Cables 18 3 6 BATTERY CHARGING 19 3 6 1 Battery Charging Guide 20 3 6 2 Emergency Jump Starting With Auxiliary Booster Battery 20 3 7 CLEANING AND INSPECTION 21 3 8 COMMON CAUSES OF BATTERY FAILURE 22 3 9 TROUBLESHOOTING 22 3 10 BAT BATTERY VOLTAGE INCORRECT TELLTALE LIGHT 22 3 10 1 Bat Telltale Light Definitions 22 4 TROUBLESHOOTING AND TESTING THE MU...

Page 216: ...tor Winding Check 41 7 3 DIODE REPLACEMENT 41 7 3 1 Diode Replacement in Support 42 7 3 2 Diode Replacement in End Frame 42 7 4 FIELD REMOVAL 42 7 5 FIELD INSTALLATION 42 7 6 STATOR REPLACEMENT 43 7 6 1 Removal 43 7 6 2 Soldering Stator Terminal Leads 43 7 6 3 Installation 43 7 7 DIODE END COVER INSTALLATION 43 7 8 ALTERNATOR REMOVAL DELCO 44 7 8 1 Disassembly of Alternator 44 7 8 2 Alternator Cle...

Page 217: ...3 1 2 Telltale Light Replacement 59 13 1 3 Gauge Light Bulb Replacement 59 13 2 DRIVER S AREA LIGHTS 60 13 2 1 Bulb Removal and Replacement 60 13 2 2 Removal and Replacement of In Station Fluorescent Tubes 60 13 2 3 Removal and Replacement of Reading Lamp Bulb 60 13 3 ENGINE COMPARTMENT LIGHTING 60 14 LIGHT BULB DATA 60 15 SPECIFICATIONS 62 ILLUSTRATIONS FIGURE 1 WIRE IDENTIFICATION 6 FIGURE 2 MUL...

Page 218: ...DERCHARGED BATTERY 48 FIGURE 37 CHECKING TRANSISTOR TR1 49 FIGURE 38 CHECKING TRANSISTOR TR2 50 FIGURE 39 ELECTRIC HEATER PLUG LOCATION 50 FIGURE 40 HEADLIGHT ASSEMBLY 51 FIGURE 41 OPENING HEADLIGHT ASSEMBLY 51 FIGURE 42 HEADLIGHT ASSEMBLY REAR VIEW 52 FIGURE 43 SUPPORT RAIL INSTALLATION 52 FIGURE 44 INSTALLATION OF JIGS 52 FIGURE 45 INSTALLATION OF HOOPY 100 ALIGNER 52 FIGURE 46 ADJUSTING HOOPY 1...

Page 219: ... Circuit breaker code o Connector code o Diode number code o Resistor number code o Fuse code 1 1 1 Using Wiring Diagram Three methods are used to work with electric wiring diagrams Situation You have identified the defective part breaker diode relay etc and you wish to locate its corresponding circuit Problem Circuit breaker CB6 is released open circuit and you don t know which circuit is affecte...

Page 220: ... specific size as designated on the wiring diagram When replacing a wire the correct size must be used Never replace a wire with one of a smaller size The vehicle electrical system is provided with different voltages The insulation on each wire is distinctly colored in order to determine visually the wiring voltage and to assist in making connectors The wires are color coded as follows Yellow Mult...

Page 221: ...rcuit manually to do so simply press down the blue tab on breaker to trip the circuit breaker repair defective circuit and afterwards toggle yellow lever upwards to reset the circuit breaker and close the circuit 1 6 MULTIPLEX FUSES The multiplex outputs are protected in current by an internal soft fuse Each output has programmed specific maximum amperage When an output is shorted the current gets...

Page 222: ... to the OFF position If the vehicle will not be operated for a long period more than 2 weeks it is recommended in order to prevent the batteries from discharging to trip main circuit breakers 1 and 2 located in the rear circuit breakers panel to stop the small current drawn by the radio preset station memory the CECM memory and the instrument cluster clock Note that the radio station presets will ...

Page 223: ...CTOR TOOL Prevost 683766 Using a small flat blade screwdriver open both hinged secondary locks Insert the extractor on the front of the connector over the terminal cavity Remove the terminal by disengaging the flexible lock tab on the terminal Gently remove the terminal from the connector by pulling on the wire SECONDARY LOCK TAB INSERT EXTRACTOR HERE grey 06629 YAZAKI EXTRACTOR TOOL Packard 12094...

Page 224: ...ion 06 ELECTRICAL PA1553 10 2 XLII MOTORHOMES ELECTRICAL COMPARTMENTS AND JUNCTION BOXES FIGURE 3 ELECTRICAL COMPARTMENTS XLII 40 BUS SHELLS 06647 FIGURE 4 ELECTRICAL COMPARTMENTS XLII 45E BUS SHELLS 06648 ...

Page 225: ...ltage Regulator o Vehicle Electrical Center Rear VECR o Relays and Fuses o Transmission ECU o Diagnostic Data Reader DDR Receptacle o Electronic Ground Stud o Rear Junction Box Temperature Sensor Rear Junction Box Multiplex Modules A49 I O A A52 I O B A50 I O B A53 I O B A51 I O B Relays R1 R3 R8 24V IGN 12V IGN Service Brake R30 R31 24V Door llock Unlock 24V Door lock Unlock R11 R17 Not Used 12V ...

Page 226: ...AKERS All manually resettable circuit breakers are located in the engine compartment R H side area An identification decal is affixed on the inside face of the door MTH W0 WE and W5 may be equipped with nine 9 main breakers six 5 of which are standard CB1 CB2 CB3 CB7 CB9 Three 3 are supplied only on vehicles equipped with central A C system CB4 CB5 CB8 and one 1 is supplied only on vehicles equipp...

Page 227: ...12 24V Evaporator fan Diodes D9 Pre heating D19 Baggage compartment 2 D10 Pre heating D20 Baggage compartment 1 D16 Baggage compartment 3 DXX Not used D17 Baggage compartment 5 2 5 FRONT ELECTRICAL SERVICE COMPARTMENT The front electrical service compartment is located on L H side of vehicle under the driver s window It contains the following components Fig 10 o Multiplex Modules o CECM o Vehicle ...

Page 228: ...F23 ABS brake system Diodes D1 Accessories D13 ABS D2 Driver unit liquid solenoid valve D22 Service brake D12 Engine brake D44 ignition 2 6 ENGINE COMPARTMENT REAR START PANEL The rear start panel is located over the engine in the engine compartment Switches to start and stop the engine from inside the engine compartment are mounted on that panel Fig 11 o engine compartment light switch o starter ...

Page 229: ...moke when working near batteries In case of contact with acid flush immediately with water The battery has four 4 major functions 1 Providing a source of current for starting the engine 2 Stabilizing the voltage in the electrical system 3 Supplying current for a limited time when electrical demands of the equipment exceed the power output of the alternator 4 Providing a limited source of power for...

Page 230: ...ary remove battery cables To remove battery cables unscrew terminal nuts and remove cables 4 Remove battery cables from defective batteries NOTE When the battery cables have been removed from the batteries wrap the battery terminals and cable ends with electric tape to prevent accidental grounding The ground cables should always be disconnected first and replaced last 5 Remove defective batteries ...

Page 231: ...performance 3 5 BATTERY TESTING The maintenance free battery has a strong ability to withstand the damaging effects of overcharge The test indicator in the cover is used only to determine if the battery can be tested in case of a cranking problem The test indicator in the battery cover is to be used with accepted diagnostic procedures only It must not be used to determine if the battery is good or...

Page 232: ...he voltmeter indicates 9 6 volts or more the battery is good If the voltmeter reading is less than 9 6 volts replace the battery This voltage is to be used for battery ambient temperatures of 70ºF 21ºC and above For temperatures below 70ºF 21ºC refer to the following Voltage and Temperature Chart Voltage and Temperature Chart Ambient Temperature Minimum Voltage 70ºF 21ºC and above 9 6 60ºF 16ºC 9 ...

Page 233: ... lead pads of the terminal studs Fig 17 after the vehicle cables are detached The alligator clamps should make firm contact with the lead pads DANGER During charging of the batteries an explosive gas mixture forms in each cell Part of this gas escapes through the vent holes and may form an explosive atmosphere around the battery itself if ventilation is poor This explosive gas may remain in or aro...

Page 234: ...ps 1 hours Slow Charging Rate 5 amps 15 hours 10 amps 7 hours The time required for a charge will vary according to the following factors Size of Battery For example a completely discharged large heavy duty battery requires more than twice the recharging time of a completely discharged small passenger car battery Temperature For example a longer time will be needed to charge any battery at 0o F 18...

Page 235: ...the engine compartment R H side area refer to fig 18 4 Connect one end of the remaining negative jumper cable black to the negative terminal of the booster power source and the other end of the black jumper cable to the negative terminal on the structure 5 Make sure the clips from one cable do not inadvertently touch the clips on the other cable Do not lean over the battery when making connections...

Page 236: ...ant drain caused by a shorted circuit such as an exposed wire or water infiltration in junction boxes causing ground fault 9 Extended operation of preheating system with engine not running 10 Failing to close disconnect switches during the night 3 9 TROUBLESHOOTING If a battery is known to be good and then has not performed satisfactorily in service for no apparent reason the following factors may...

Page 237: ...he last 10 Middle faults will be erased If the breakers are tripped the fault history will be erased from the CECM memory NOTE When performing an electrical system diagnostic with the MCD message center display the message No Response ModA41 indicates either module A41 is not responding due to a CAN link problem or module A41 is not powered Similar messages exist for all modules A42 A43 A44 etc Be...

Page 238: ...pears in the telltale panel LCD display 4 3 2 Spare Can A spare CAN network is installed between the front and the rear of the vehicle It has connectors installed at each end to facilitate swapping from the regular CAN network to the spare CAN network Refer to the vehicle wiring diagram and paragraph 4 6 for more information 4 4 TEST MODE FOR SWITCHES AND SENSORS The switch sensor test mode provid...

Page 239: ...est mode is required just set the cabin passenger set point temperature to the minimum 64 F 18 C to shut off the pump 4 5 TEST MODE FOR ELECTRIC MOTORS The test mode allows testing the motors and electric contactors without the need to have the engine running Note that while in test mode the engine cannot be started Prerequisite conditions for the motor test mode A The battery charger must be conn...

Page 240: ...nit hot water pneumatic valve cycles 3 times o Closing of the fresh air dampers This ends the test Activate the dashboard Telltale Light Test switch one time to leave the motor test mode 4 5 2 Test Sequence MTH Equipped With Small HVAC System o Driver s unit fresh air damper opening 20 seconds delay Then 5 beeps can be heard from the back up alarm to indicate to go to the engine compartment In the...

Page 241: ...em Front electrical compartment Evaporator compartment Rear Junction Box Plug Connector 563589 Socket Connector 563590 Plug with integrated Termination Resistor 563593 C5S C13S C5 C1 C1S C3 C3S C100 C100S Spare CAN Termination Resistor plug Termination Resistor plugs Note The termination resistor plug connected to C3S is a spare that can be used when testing the network CAN network Front electrica...

Page 242: ...t the engine ECM is powered and get the ignition signal Check replace fuse F78 and F79 None of the Multiplexed functions are operating including the basic limp home functions door opening flashers wipers in speed 1 Three dashes appear in the telltale panel instead of the outside temperature Note The sunshades are still functioning since these are not multiplexed The program version in the CECM is ...

Page 243: ...Manually control the temperature by playing with the cabin passenger set point Set above 22 C 72 F to heat and below 22 C 72 F to cool Defroster fan not functioning Windshield wipers not functioning in speed 1 or intermittent Module A47 is not powered or is faulty 1 Check the SYSTEM DIAGNOSTIC menu of the message center display MCD Select FAULT DIAGNOSTIC and ELECTRICAL SYSTEM The message No Respo...

Page 244: ...e these symptoms 2 Check reset circuit breaker CB1 3 Check replace fuse F33 and F34 4 Probe gray connector on module to see if it is powered Low beam headlights and flasher on right side not functioning Module A48 is not powered or is faulty 1 Check the SYSTEM DIAGNOSTIC menu of the message center display MCD Select FAULT DIAGNOSTIC and ELECTRICAL SYSTEM The message No Response ModA48 Active indic...

Page 245: ...aker CB4 tripped Module A54 is not powered or is faulty 1 Check reset circuit breaker CB4 2 Check the SYSTEM DIAGNOSTIC menu of the message center display MCD Select FAULT DIAGNOSTIC and ELECTRICAL SYSTEM The message No Response ModA54 Active indicates a power problem on the module A CAN network problem would show the same message but doesn t produce this symptom 3 Check reset circuit breaker CB7 ...

Page 246: ...rns OFF and stays OFF until the soft fuse is reset Turn the ignition key to the OFF position and turn to the ON position again This resets all soft fuses No backlighting in the instrument cluster Circuit breaker CB9 is tripped or fuse F21 blown Check reset circuit breaker CB9 Check replace fuse F21 The radiator fan clutch does not function and the engine is overheating 1 Set the ignition key to th...

Page 247: ...IORITY MODULES FOR BREAKDOWN SERVICE Modules A43 IO A and A44 IO B affect lower priority functions These modules can therefore be used as spare parts for breakdown service while on the road Functions lost if A43 is removed and used as spare part o High beams o Ability to turn on the parking lights only o Driver s area lighting o Tag axle activation o Courtesy blinkers Functions lost if A44 is remo...

Page 248: ...ppears and is displayed alternately with CAN during that sequence will be displayed up to 6 times and the audible alarm will ring Wait until CAN is replaced by that remains for more than 10 seconds At this point the MasterID module has finished loading the program in the CECM o Go to the engine compartment R H side area and trip circuit breaker CB2 once again Wait 1 second and reset it This engage...

Page 249: ...tightening Repeat for the second alternator 3 On the drive shafts of both alternators install key pulley spring washer and nut Tighten to 220 Lbf ft 300 Nm NOTE Final tightening of the pulleys can be performed once the belt is installed This will help keep the pulley from turning when tightening 4 Install the snubber bracket 5 fig 20 using three flanged bolts Do not tighten the adjustment bolts on...

Page 250: ...Section 06 ELECTRICAL PA1553 36 FIGURE 20 TWIN BOSCH ALTERNATORS INSTALLATION FIGURE 21 ALTERNATORS AND ACCESSORIES MOUNTING TORQUES ...

Page 251: ...Section 6 ELECTRICAL PA1553 37 FIGURE 22 50DN DELCO ALTERNATOR SECTIONAL VIEW 06493 FIGURE 23 ALTERNATOR WIRING DIAGRAM DELCO 06067 ...

Page 252: ...nesses and burned open diodes will result Always ensure that the alternator and battery polarities are matched prior to installation THE ALTENATOR WILL NOT REVERSE TO ACCEPT INVERSE POLARITY Also do not ground or short across any of the alternator or regulator terminals CAUTION Since there are no brushes slip rings or rubbing seals the alternator requires no periodic maintenance other than the fol...

Page 253: ...embly without having to remove the rotor drive end frame or bearing If the electrical components are not defective but bearing replacement is necessary this can be done at the drive end without having to disassemble the diode end of the unit The components in the alternator that require electrical checks are the field winding the six diodes and the stator winding 7 2 1 Diode Checks Each diode may ...

Page 254: ... parts D E F The ohmmeter readings may vary considerably when checking diodes for shorts but if the reading is 300 ohms or less the diode is probably defective and should be replaced A diode that reads 300 ohms or less will allow excessive reverse current from the battery Replace defective diodes as explained later in this section To check the diodes mounted in the diode supports for open fields c...

Page 255: ...crews See FIELD REPLACEMENT for a detailed procedure 7 2 3 Stator Winding Check The stator winding may be checked for open and short fields with an ohmmeter as follows Open Fields Connect the ohmmeter leads to two pairs of diode supports as shown in parts A B and C of figure 28 Correct polarity of the leads must be observed The ohmmeter should indicate a low resistance If an infinite or a high res...

Page 256: ...ench on flats of the diode case to unscrew diode from the end frame Thread the new diode into the end frame and tighten to a torque of 160 180 lbf in 18 20 Nm If no other parts are to be replaced refer to DIODE END COVER INSTALLATION in this section 7 4 FIELD REMOVAL 1 Remove three diode and support assemblies from the end frame to provide access to the lower field to end frame bolts 2 2 Remove nu...

Page 257: ...or frame from the end frame and rotor 7 6 2 Soldering Stator Terminal Leads 1 Using a wire brush thoroughly clean the wire and terminal 2 Silver solder the stator lead to the terminal using a torch 3 Thoroughly clean the silver solder connection with a wire brush 4 Using a high grade energized rosin flux coat the silver soldered connection with a 80 20 tin lead solder or pure tin solder to prevent...

Page 258: ...nd lock washers fixing the alternator refer to fig 30 FIGURE 30 ALTERNATOR RETAINING BOLTS AND WASHERS 06350 WARNING Alternator weights approximately 154 lbs 70 kg Another person is required to take the alternator out of the engine compartment 7 8 1 Disassembly of Alternator After diode field and stator winding checks the alternator can be disassembled to repair a faulty component such as field or...

Page 259: ... retainer plate and the inner race is a press fit on to the rotor shaft the bearing will probably be damaged when the shaft is pressed out and need to be replaced with a new part 4 Remove the six screws attaching the bearing retainer plate to the drive end frame Remove the retainer plate the single row bearing and the bearing spacer from the end frame 5 Support the drive end frame in an arbor pres...

Page 260: ...nd diodes If the alternator is to be operated at an output greater than 100 amperes for longer than 15 seconds circulating oil must be provided SAE 30 engine oil must be applied to the connection on the diode end cover at a pressure of 35 psi and at a temperature of 60o F to 220o F 16o C to 104o C This will provide an oil flow of about one gallon per minute To check the alternator on a test bench ...

Page 261: ...t should be replaced The following procedure must be used CAUTION Set the ignition key switch to the OFF position o Open the engine compartment R H side door in order to get access to the voltage regulator o Unscrew the electrical cable connectors o Unscrew the voltage regulator unit o Install a new voltage regulator by reversing the procedure NOTE For information about BOSCH alternator and voltag...

Page 262: ...field Do not allow leads to touch ground 3 Connect a voltmeter and an ammeter in the circuit at the alternator DC terminal 4 Connect a jumper lead from the alternator DC terminal to the alternator field terminal F DC TEST AMMETER VOLTMETER BATTERY REGULATOR ALTERNATOR SWITCH BATTERY JUNCTION BOX GND FLD BAT IGN CARBON PILE JUMPER LEAD LEADS DISCONNECTED FIGURE 36 REGULATOR VOLTAGE TEST UNDERCHARGE...

Page 263: ...test components in the regulator Consult the ohmmeter s manufacturer for specifications concerning the capabilities of the ohmmeter It is important that all of the following checks be made If a defective part is found replace it before proceeding with the remaining checks Be sure to make all the checks since more than one component may be defective A defective regulator can be repaired according t...

Page 264: ...e Service Bulletin A1 M1N 1729EN included at the end of Section 06 shows acceptable levels of wear and illustrates the proper measuring procedure Maximum wear is 0 5mm Ring Gears with more than 0 5mm of wear or damage must be replaced before installing the new starter to prevent engagement and or disengagement problems Failure to do so will render the Warranty null and void CAUTION Do not engage s...

Page 265: ...ass cleaner whenever dirty For maximum illumination headlight connections must be coated with a dielectric grease to prevent oxidation and proper voltage must be maintained Low battery voltage loose or dirty contacts in wiring system and poor ground contribute to a decrease in voltage Check wiring and connections regularly and keep battery properly charged When a headlight burns out a new bulb mus...

Page 266: ... 44 Mark the position for future reference FIGURE 44 INSTALLATION OF JIGS 06499 NOTE The stops will position the support rail between 16 24 inches of vehicle 4 Remove the jigs 5 Install Hoopy 100 Aligner onto support rail Fig 45 6 Using an Allen key on the front wheel level Hoopy 100 aligner until spirit level bubble is centered Fig 46 and 47 7 Install a calibration fixture in the axis of front ax...

Page 267: ...NOTE Make sure that the vehicle is at proper height suspension and that air pressure is above 90 psi 3 Install Hoopy 100 Aligner onto support rail Fig 45 Turn aligner ON CAUTION Vehicle must be parked at the same location each time If location is changed for any reason floor slope alignment and aligner leveling must be redone Refer to Setting aligner according to slope NOTE If aligner indicates LO...

Page 268: ...located on the screen at the left and right limits called for in the specification with reference to centerlines ahead of each headlight assembly 3 The headlight centerlines shall be spaced either side of the fixed centerline on the screen by the lateral distance between the light source centers of the pertinent headlights The horizontal tapes should be located on the screen at the upper and lower...

Page 269: ... 7 6 m 25 ft in front of the vehicle Fig 53 FIGURE 53 AIM INSPECTION LIMITS FOR LOWER BEAM HEADLIGHTS 06506 12 1 4 Sealed Beam Unit Bulb Removal and Replacement 1 Pull the release handle located inside the front service compartment to tilt down the entire bumper assembly 2 Remove the headlight screw fixing the headlight assembly then tilt headlight assembly down Fig 40 and 41 3 Remove connector fr...

Page 270: ...w signal lamp then install signal lamp 6 Fasten back plate fixing screws then tilt headlight assembly up into its housing then secure using fixing screw NOTE Make sure headlight assembly is properly positioned into its housing before securing using fixing screw 12 1 6 Optional Xenon Headlamp The outer lamps of each headlight assembly may be equipped with the optional Xenon lamps These lamps improv...

Page 271: ...here is no immediate danger of electric shock even if the warning is disregarded With this safety concept there is no danger to check the ballast with a new bulb There is a very high probability that the ballast is OK if the ballast can ignite the bulb One simple test to check the ballast would be to measure the Nominal current of 1 58 A after one minute for the 24V ballast 12 2 STOP TAIL DIRECTIO...

Page 272: ...and can be replaced in accordance with the following procedure 1 Unscrew both Phillips light screws and then remove the light assembly 2 Position the new light assembly and then install the Phillips screws FIGURE 55 VARIOUS LIGHTS LOCATION 06544 12 5 DOCKING AND CORNERING LIGHTS MTH vehicles are provided with two halogen sealed beam units that serve as cornering lights They are mounted on the vehi...

Page 273: ...ING The instrument gauges and switches mounted on all control panels are energized whenever the exterior light switch is pushed to the first position A control dimmer located on the dashboard is used to vary the brightness of the panel gauges switches and indicator lights The gauge lights panel lights switch lights and indicator lights have a different bulb arrangement Thus the procedure to change...

Page 274: ...e the screen lens by first inserting one side in the seat then push the other side in and snap it in place by running it in from one corner to the next 13 2 3 Removal and Replacement of Reading Lamp Bulb 1 Engage the tool 830164 over the lamp and turn one quarter turn counterclockwise Then remove the tool slowly 2 Pull the bulb socket off the reading lamp unit 3 Push and turn bulb counterclockwise...

Page 275: ...n red 930334 TL 25420R 12 3 Clearance red 930334 TL 25420R 12 4 Identification amber 930337 TL 25450Y 12 3 Clearance amber 930337 TL 25450Y 12 4 Front directional hazard marker 562135 3057 32 3W 12 2 Rear directional 560589 1156 32 W 12 4 Stop 560589 1156 32 W 12 8 Back up 560589 1156 32 W 12 4 Center stop 930330 HELLA 96208 12 2 Cyclops 930330 HELLA 96208 12 1 Tail 560123 67 4 W 12 4 Exterior com...

Page 276: ...e weight lbs kg 59 26 7 Battery tester cable clamps should be between terminal nuts and lead pads of terminals If not possible load value should be 210 amperes Torque specifications Battery cable to post 10 15 Ft lbs 13 20 Nm Battery cover 45 50 Ft lbs 5 6 Nm Alternator Make Delco Remy Model Number 1117702 Series 50DN Type 600 Field current at 80o F 27o C Amperes 7 2 8 0 Volts 24 Hot output Ampere...

Page 277: ...562752 Battery equalizer Make Vanner Model 60 100D Amperes 100 amps Prévost Number 563334 Starter Make Mitsubishi Electric Corporation MELCO Model Number M009T82479 Type 105P70 Voltage 24 Prévost Number 510752 No load test Volts 23 5 Max current draw 125 amperes Min rpm 3000 rpm Starter solenoid Make Mitsubishi Electric Corporation MELCO Model Number 1115557 Pull In Voltage 16 volts max ...

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Page 279: ... diagram for the 105P70 Ground float type sometimes referred to as Insulated or Isolated Ground The circuit diagram contains a start switch a magnetic switch and a starter solenoid When the start switch is closed the current flows through the magnetic switch windings The magnetic switch contacts are closed enabling the current to flow through the windings in the starter solenoid The clutch is thru...

Page 280: ... measuring the voltage between the S terminal in the starter solenoid and the ground The switch should not be closed for more than 3 seconds If this time is exceeded the starter solenoid may be damaged 2 4 Ring gear and pinion If the battery wiring and magnetic switch are in satisfactory condition it is assumed that a stuck condition may be found this condition is the phenomenon caused when the pi...

Page 281: ...e starter The H coil is assumed to be layer shorted M terminal nut tightening torque 20 to 30 N m Figure 6 TESTING HOLD IN WINDINGS GROUND FLOAT TYPE Below are the resistance values for the P and H coils for reference Coil Resistance reference P coil 0 072ohm at 68 F H coil 1 300 ohm at 68 F 2 5 2 No load test The no load test makes it easy to inspect the starter for functional failure without dis...

Page 282: ...ozen bearings 4 No current draw indicates a Open field coils b Open armature coils c Broken brush springs worn brushes or high insulation resistance between brushes and commutator 5 Extremely low revolution speed and low current draw indicate Poor connection between M terminal and lead wire or between bracket and brush holder screws body ground type only damaged M lead wire damaged brush pig tails...

Page 283: ...tor 0120 689 552 Edition 001 All rights rest with Robert Bosch Corp including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC Repair and Testing Instructions for T1 Alternator 0120 689 552 ...

Page 284: ... All rights rest with Robert Bosch Corp including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC Modifications Edition Date Name Modifications 001 8 28 98 I Serra Original 002 12 4 98 I Serra Update 8 98 Instructions ...

Page 285: ...13 7 3 1 Lubricant Quantities 13 8 EXPLODED VIEW 14 9 ALTERNATOR DISASSEMBLY AND TESTING 15 9 1 REAR COVER REMOVAL 15 9 2 VOLTAGE REGULATOR REMOVAL 15 9 2 1 Brush Replacement 16 9 3 NOISE SUPPRESSION CAPACITOR TESTING AND REMOVAL 16 9 4 PULLEY AND FAN REMOVAL 17 9 5 SEPARATION OF DRIVE SHIELD AND COLLECTOR END SHIELD 17 9 6 RECTIFIER ASSEMBLY TESTING 18 9 7 REMOVAL AND TESTING OF STATOR ASSEMBLY 1...

Page 286: ...7 REGULATOR AND CAPACITOR INSTALLATION 33 11 FUNCTIONAL TESTING 35 11 1 GENERAL INFORMATION 35 11 1 1 Power Output Tests 35 11 1 2 Voltage Trace Evaluation 35 11 2 POWER OUTPUT TESTING 35 11 2 1 Test Bench Mounting 35 11 2 2 Power Output Test 36 11 3 VOLTAGE TRACE EVALUATION 37 11 3 1 Oscilloscope Hook up 37 11 3 2 Normal Pattern 38 11 3 3 Open Exciter Diode 39 11 3 4 Open Positive Rectifier Diode...

Page 287: ...rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 1 General This manual contains repair and testing instructions with corresponding test specifications for the 0 120 689 5 series alternators T1 RL 28V 70 140A Note Alternator 0 120 689 543 was utilized in preparing these instructions ...

Page 288: ...ression the alternator is equipped with capacitors with a long storage time Cleaning of alternator components may cause and electrical discharge when they are immersed in cleaning fluid This discharge may cause combustible liquids to ignite 2 3 Skin Protection To avoid skin irritation when handling oils and greases apply protective gloves or creams before starting work and wash off hands with soap...

Page 289: ...istance 7 5 W 0 10 T1 RL 28V70 140A Power Output Test Alternator Speed RPM Load Current Inductive A Test Duration Min 1500 76 30 T1 RL 28V70 140 A 6000 136 10 Following completion of the output test allow alternator to run at 7000 rpm for one minute Oscilloscope Pattern This image represents a properly functioning alternator The D C voltage produced has a small harmonic wave Small spikes may be su...

Page 290: ...9 in Collector ring diameter Used 31 5 mm 1 240 in minimum New 16 0 mm 0 630 in minimum Carbon Brush Projection Used 7 0 mm 0 275 in minimum 3 3 Tightening Torques Item Number Description Metric Nm SAE 55 Air Intake Stud 3 0 3 4 26 5 30 1 in lbs 66 D Terminal 2 4 3 2 21 2 28 3 in lbs 29 B Terminal B Terminal 10 0 13 0 88 5 115 in lbs 37 W Terminal 4 1 5 5 36 3 48 7 in lbs 15 Voltage Regulator 1 3 ...

Page 291: ...s All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 4 Alternator Schematic Figure 3 Alternator Voltage Regulator Schematic 1 Alternator B Battery Positive B Battery Negative D Dynamo Warning Lamp Output W Tachometer Output 2 Voltage Regulator D Dynamo Alternator Output DF Dynamo Field D Dynamo ...

Page 292: ...12 98 T1ALTFinal DOC 5 Alternator Coding T 1 R 28V 70 140A Rated current in amps measured at 6000 rpm Rated current in amps measured at 1500 rpm Alternator Voltage Direction of Rotation Or R Clockwise Or L Counter Clockwise Or RL Multidirectional 1 Claw Pole Alternator 2 Salient Pole Alternator 3 Windingless Rotor Alternator Outer Diameter of Alternator G 100 109 mm K 120 129 mm N 130 139 mm T 170...

Page 293: ...rnator components may cause and electrical discharge when they are immersed in cleaning fluid This discharge may cause combustible liquids to ignite Alternator components with capacitors should only be cleaned with a non combustible cleaner such as HAKU 1025 6 Caution Compressed Air Only use compressed air regulated to a maximum of 4 Bar 60 PSI and a clean cloth for cleaning of the armature excita...

Page 294: ...9 0 986 619 362 Die Spigot for Arbor Press Used with KDLJ 6011 KDLJ 6012 KDLJ 6015 KDLJ 6010 0 986 618 124 Bearing Remover KDLJ 6009 0 986 618 121 Press Tool for Roller Bearing KDLJ 6021 0 986 618 139 Bearing and Seal Installer KDLJ 6011 0 986 618 125 Collector Ring Installer KDLJ 6012 0 986 618 126 Drive End Shield Support Ring for Rotor Pressing KDLJ 6013 0 986 618 127 Press Tool Spacer Ring Rol...

Page 295: ...Final DOC 7 3 Lubricants and Adhesives Description Manufacturer Number Bosch Number UNIREX N3 5 975 560 125 Ft1 v 34 5 700 009 000 Roller Bearing Grease VS 15164 Ft 5 975 560 000 Molycote Paste Ft 70 v 1 5 700 040 000 Adhesive Dispersant KK57v1 5 703 151 000 Silicon Paste Ft2v4 5 700 083 005 7 3 1 Lubricant Quantities Bottom of Roller Bearing 2 g 0 07 oz Collector End Shield Radial Seal 2 g 0 07 o...

Page 296: ...Ball Bearing 3 Cover Plate 6 Rotor 6 9 Collector Ring 10 Roller Bearing 11 Collector Ring End Shield 12 Rectifier 12 13 Seal 15 Washer Screw Assembly 17 Transistor Regulator 17 3 8 Compression Spring 17 3 801 Carbon Brush Set 17 10 Gasket 18 Stator 19 Spring Lock Washer Item Designation 20 Plain Washer 21 Oval Head Screw 23 Washer Screw Assembly 42 Suppression Capacitor 43 Oval Head Screw 53 Fan 5...

Page 297: ... air intake cover Figure 5 Figure 5 Air Intake Cover Removal 1 Note The voltage regulator must be removed before any further disassembly of the alternator takes place The brushes of the regulator can break if the regulator is not removed before any other disassembly takes place 9 2 Voltage Regulator Removal 1 Remove the three 3 screws that secure the regulator to the collector ring end shield Figu...

Page 298: ... 7 mm 0 276 the brush must be replaced Figure 7 2 To replace the brushes the brush lead must be unsoldered and the brush removed from the regulator 3 Insert the new brush into the regulator and solder the brush lead to the regulator Note Use only rosin core solder to attached the brush lead 4 Check the brushes for freedom of movement after they are soldered 5 Measure the exposed length of the new ...

Page 299: ...or the capacitor lead should be shorted to the capacitor mounting strip to discharge the capacitor Failure to do so may cause the capacitor to discharge while being cleaned 9 4 Pulley and Fan Removal 1 Using a 14 mm hex socket to hold the rotor shaft Loosen and remove pulley retaining nut with a box wrench Figure 9 Note Do not use an air impact gun to remove the nut as the force of the impact may ...

Page 300: ...s to be performed a Using tester WPG 012 00 Bosch Number 0 684 201 200 Figure 11 i Connect the negative black lead of the tester to the collector end shield and the positive red lead to each of the stator connection solder joints ii Connect the positive red lead of the tester to the B Terminal and the negative black lead to each of the stator connection solder joints iii Connect the positive red l...

Page 301: ...he stator connection solder joints No current should pass through the rectifier assembly vi Connect the negative black lead of the tester to the D Terminal and the positive red lead to each of the stator connection solder joints Current should pass through the rectifier assembly If the rectifier assembly fails any test one or more of the diodes are defective and the whole assembly must be replaced...

Page 302: ...xterior of the stator indicates a breakdown of the stator insulation and a short to ground If continuity is present the stator must be replaced 9 8 Rectifier Assembly Removal 1 Loosen and remove the three screws that hold the rectifier to the collector end shield Figure 14 2 Unsolder the W terminal from the rectifier assembly 3 Remove the nuts holding terminals B B and D to the collector end shiel...

Page 303: ...ld read between 3 1 and 3 5 k kilohm If the resistance is above or below this range the W terminal is to be replaced as an assembly Figure 15 2 Loosen the nut retaining terminal W to the collector end shield 3 Remove terminal W 9 10 Removal of Collector End Shield Bearing and Seal 1 Insert extractor KDLJ 6009 Bosch Number 0 986 618 121 into bearing 2 Screw threaded rod KDAW 9995 14 Bosch Number 0 ...

Page 304: ...aded rod KDAW 9995 14 into extractor KDAW 9995 6 f Slide the receiver cup KDAW 9995 0 5 onto threaded rod g Screw on handle and rotate until the bearing race comes out of the collector end shield 9 11 Removal of Sliding Bushing in Collector End Shield 1 Place collector end shield in an arbor press support mounting pivot boss on mandrel KDLJ 6016 Bosch Number 0 986 618 130 Figure 17 2 Place bushing...

Page 305: ... DOC 3 Press out rotor 4 Remove spacer ring from rotor shaft Notes Protect the threads of the rotor from damage prior to pressing Always replace the drive end bearing if the rotor has been pressed out Therefore only remove the rotor if the rotor is to be replaced the excitation winding of the rotor is to be replaced the drive end bearing spacer ring is to be serviced the rotor collector rings are ...

Page 306: ...aring from the drive end shield 9 14 Removal of Collector Ring End Inner Bearing Race from Rotor 1 With a universal bearing puller remove the inner race of the endshield bearing Figure 20 Notes Place jaws of the puller yoke behind the inner bearing race and pull the bearing race only Do not place the yoke behind the spacer ring Pulling both the bearing and the spacer ring at the same time may dama...

Page 307: ... 21 2 Using insulation tester KDAW 9983 or equivalent apply 80 VAC to the rotor claw poles and each of the collector rings If the insulation tester lights there is a short to ground within the rotor Figure 22 Note The insulation tester applies a voltage of 80 VAC to the rotor Voltages of 80V can be fatal When performing this test observe care is used in handling the rotor and any component or surf...

Page 308: ...st be replaced b Each collector ring maximum run out 0 03 mm 0 0012 in If the run out exceeds the maximum the collector rings can be machined down to a minimum of 31 5 mm 1 240 in diameter If the required machining causes the collector ring diameter to drop below the minimum dimension the collector ring s must be replaced 9 16 Collector Ring Replacement 1 Before the collector rings can be removed ...

Page 309: ... lead for the rotor windings does not become damaged while sliding the collector rings over the lead 4 Lining up the slot in tool KDLJ 6012 Bosch Number 0 986 618 126 with the rotor lead press the collector rings onto the rotor as far as possible Figure 25 5 Solder each of the rotor winding leads to one of the collector rings with rosin core solder 6 After soldering touch up surface of collector r...

Page 310: ...mbly 1 Insert sealed ball bearing into the drive end shield 2 Align the holes of the bearing cover plate with the holes in the drive end shield 3 Start the four screws which hold the bearing cover plate and tighten to 4 1 5 5 Nm 36 3 48 7 in lbs Figure 27 4 Insert bearing fan spacer ring into the drive end shield from the fan side of the shield 5 Place drive end shield on to an arbor press with th...

Page 311: ...k the bottom of the collector end housing bearing bore with an additional 2 g 0 07 oz of UNIREX N3 grease 5 Coat the sealing lip of the radial lip seal and pack the seal with 2 g 0 07 oz of UNIREX N3 grease Notes Do not assemble the alternator with a dry radial seal as this will lead to seal failure and contamination of the brushes and collector rings Make sure there is no excess grease on the ext...

Page 312: ...e 30 11 Insert terminal W into collector end shield in location marked W Make sure the locating lug of the terminal assembly indexes the end shield correctly 12 Place insulator and flat washer onto terminal W 13 Install nut and torque to 4 1 to 5 5 Nm 36 3 to 48 7 in lbs 14 Install protective cap onto terminal W Figure 31 Protective Cap 10 4 Rectifier Assembly 1 Place flat washer and insulator a o...

Page 313: ...lating washer flat washer and nut to terminal studs B and D Figure 33 6 Install flat washer and nut onto terminal stud B Figure 33 7 Check that the soldering lug of terminal W is still in the proper location of the rectifier assembly 8 Torque terminal stud nuts B D and B to a Terminal B and B 10 to 13 Nm 88 5 to 115 in lbs b Terminal D 2 4 to 3 2 Nm 21 2 to 28 3 in lbs 9 Install the flat washer an...

Page 314: ...ator leads to the rectifier assembly with rosin core solder 10 6 Rotor and Drive End Shield Installation 1 Place collector end shield and stator assembly on a suitable surface so the rotor and drive end shield assembly can be lowered into place 2 Guide the rotor and drive end shield assembly until the inner bearing race of the collector end bearing enters the roller bearing Once the inner race ent...

Page 315: ...s heard the rotor and drive end shield assembly must be removed the cause determined and repaired before continuing Once the problem has been corrected start at step 1 of this section 11 Remove the alignment pin KDLJ 6014 from the alternator 10 7 Regulator and Capacitor Installation 1 Depress the carbon brush closest to the regulator into the regulator brush holder 2 Insert a straightened paper cl...

Page 316: ...en aligning the mounting holes pay attention to the force used as damage can occur to the brushes 5 Install the three 3 regulator mounting screws and torque to 1 3 to 1 7 Nm 11 5 to 15 in lbs Figure 38 6 Install capacitor on collector end shield and tighten mounting screw to 4 3 to 5 7 Nm 38 0 to 50 4 in lbs Figure 38 7 Connect lead of capacitor to spade terminal 8 Install air intake cover onto al...

Page 317: ...g minimum criteria Characteristic Minimum Specification Variable Speed Control 0 12 000 RPM Drive Motor 4 kW 5 4 hp Load Bank Capability 170 A 28 V for 10 minutes 80 A 28 V for 30 minutes Output Voltage Capability 28 V 11 1 2 Voltage Trace Evaluation The voltage trace evaluation compares the output of the alternator as viewed on an oscilloscope to know oscilloscope patterns The voltage trace evalu...

Page 318: ...to test bench manufacturers operating instructions for correct terminology of test leads Refer to figure 39 for a schematic outline of alternator to test bench connections Compare this schematic to the hook up schematic of your test bench 4 Make sure the test bench is set for the correct voltage and rotation before starting tests 11 2 2 Power Output Test 1 Start test bench and increase speed to 15...

Page 319: ...ternator output and speed during the test period 9 Remove load and operate the alternator at 7000 rpm for one minute to allow the alternator to cool 10 Refer to the test bench operating instructions and allow the load bank to cool the required amount of time before proceeding to the next test 11 Apply a minimum load of 10A to the alternator 12 Measure the regulated voltage of the alternator The co...

Page 320: ...3 2 Normal Pattern This image represents a properly functioning alternator The D C voltage produced has a small harmonic wave Small spikes may be superimposed on the oscilloscope screen if the voltage regulator is regulating Applying a load to the alternator output terminals can turn off the regulator In order to be able to compare oscilloscope images the oscilloscope so the pattern fits between t...

Page 321: ...ghts of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 3 Open Exciter Diode This pattern displays a characteristic dip in the normally smooth wave characteristic of a defective exciter diode This would require disassembly of the alternator and replacement of the rectifier assembly Figure 41 Open Exciter Diode ...

Page 322: ...1ALTFinal DOC 11 3 4 Open Positive Rectifier Diode This pattern identifies an open positive rectifier diode In the case of multiple diodes in parallel all of the diodes on the circuit must be open An example is There are two diodes in the rectifier for each phase of the stator Both diodes must be open for this pattern to appear With this type of defect the rectifier assembly must be replaced Figur...

Page 323: ...1ALTFinal DOC 11 3 5 Open Negative Rectifier Diode This pattern identifies an open negative rectifier diode In the case of multiple diodes in parallel all of the diodes on the circuit must be open An example is There are two diodes in the rectifier for each phase of the stator Both diodes must be open for this pattern to appear With this type of defect the rectifier assembly must be replaced Figur...

Page 324: ...including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 6 Shorted Exciter Diode This pattern identifies a shorted exciter diode This would require disassembly of the alternator and replacement of the rectifier assembly Figure 44 Shorted Exciter Diode ...

Page 325: ...uding patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 7 Shorted Positive Rectifier Diode This pattern identifies a positive rectifier diode that is shorted This defect requires replacement of the rectifier assembly Figure 45 Shorted Positive Rectifier Diode ...

Page 326: ...uding patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 8 Shorted Negative Rectifier Diode This pattern identifies a negative rectifier diode that is shorted This defect requires replacement of the rectifier assembly Figure 46 Shorted Negative Rectifier Diode ...

Page 327: ... Bosch Corp including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 9 Open Phase of Stator This pattern illustrates a stator with an open phase winding This type of defect would require replacement of the stator Figure 47 Open Stator Phase ...

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Page 329: ...ily 4 Family 5 60 10B 60 100C 60 60 65 60 66 60 60 20A 60 100D 60 60M 65 60M 66 80 60 50A 60 100E 60 80 65 80 66 100 60 50E 60 100 65 100 60 50M Table of Contents Introduction 2 Specifications 3 Theory of Operation 4 Typical Applications 5 Installation Instructions 7 Testing and Troubleshooting 9 Warranty 15 12 V 24 V G N D ...

Page 330: ...ttery Equalizer connects to the 24 volt 12 volt and ground terminals of the battery system When the 12 volt loads require power the Battery Equalizer ensures that the current is taken equally from both batteries and that the voltages of the two batteries are kept equal This equalization ensures extended battery life and provides a stable 12 volt supply for operating accessories Parallel Equalizers...

Page 331: ...ounting Location Mount on a flat surface close to the batteries to allow short cable runs Vertical mounting with terminals down is recommended Location should be protected from battery acid and gases 2 3 lbs 5 0 lbs 7 0 lbs 9 5 lbs 6 0 lbs 6 6 lbs 6 6 lbs 6 0 lbs 6 3 lbs 6 3 lbs Weights 7 0 lbs 7 6 lbs 7 6 lbs Unlisted models Model 60 60M and 65 60M have built in EM 70 Electrical System Voltage Mo...

Page 332: ...s the voltage balance and therefore the charge acceptance rate of each battery Family 3 and Family 4 Equalizers hold Battery A and B voltages to within 0 05 volts under light loads and to within 0 1 volts at full rated load Family 1 and Family 2 models hold Battery A and B voltages to within 0 10 volts under light loads and to within 0 50 volts under full rated load When the voltage of Battery A i...

Page 333: ...ing small adjustments to keep the batteries in balance Scenario 2 Both 24 volt and 12 volt loads present alternator is OFF The Battery Equalizer will insure that both batteries will discharge at the same rate even if different loads are present Scenario 3 Both 24 volt and 12 volt loads present alternator is ON The alternator provides 24 volt power to the battery system and to the 24 volt loads The...

Page 334: ...ACH 24V ALT _ 24V VANNER Battery Equalizer 12V GND 12V Battery B 12V Battery A 12V 12 Volt Loads VANNER DC to AC Inverter 120VAC To AC Loads 24 Volt Loads 24V F2 F1 MARINE ENGINE BATTERY SYSTEM HOUSE BATTERY SYSTEM 24V VANNER Battery Equalizer 12V GND 12V Battery B 12V Battery A 12V 12 Volt Loads 24V 24V ALT _ 24V VANNER Battery Equalizer 12V GND 12V Battery B 12V Battery A 24V VANNER DC to AC Inv...

Page 335: ...taining batteries or flammable materials Safety goggles should always be worn when working near batteries Mounting Location The Equalizer may be mounted in any orientation however the recommended orientation for optimum heat dissipation is vertical It is recommended that the wiring terminals be down to prevent the possibility of a falling metal object shorting the terminals Do not mount in zero cl...

Page 336: ...attery Disconnect Switch 24V VANNER Battery Equalizer 12V GND 12V Battery B 12V Battery A 12V 12 Volt Loads Radio 24 Volt Loads 24V 24V ALT _ HIGH CURRENT DIODE BATTERY DISCONNECT SWITCH F2 F1 The system must be wired as shown to prevent Reverse Polarity Damage to polarity sensitive12 volt loads and Family 1 and Family 2 Equalizers while the ground side disconnect switch is open The equalizer s GN...

Page 337: ...930309 51 9 26 0 10 4 8 7 6 5 5 2 2 6 1 191930333 65 4 32 7 13 1 10 9 8 2 6 5 3 3 1 0 191930333 82 9 41 4 16 6 13 8 10 4 8 3 4 1 2 0 191930346 105 5 52 7 21 1 17 6 13 2 10 5 5 3 Fuse F1 20 amp 30 amp 80 amp 80 amp 100 amp 125 amp 250 amp Fuse F2 10 amp 15 amp 35 amp 40 amp 50 amp 80 amp 150 amp Crimp the ring terminals using Molex tool 192840002 14ga 192840001 10 12ga 192840035 2 8ga phone 813 521...

Page 338: ...connect that same 12 volt lamp between the 12 and GND terminals of the Equalizer The lamp should light and stay lit If the lamp does not light the light then goes out or the light dims the Equalizer requires repair 4 Further verification may be made by measuring the voltages on the Equalizer terminals Be certain that the lamp used earlier is connected between the 12 and GND terminals 5 Measure the...

Page 339: ...ditions may occur during bus maintenance it is recommended that the service personnel verify the circuit breaker is IN before releasing the bus for service and the tour bus operator do the same in his walk around Q What are some known conditions that could cause Battery Equalizer problems A1 Corrosive liquids or water forced into the Battery Equalizer s case from high pressure spray cleaning could...

Page 340: ...hts 3 Measure the input voltage between the 24 and GND posts of the equalizer This voltage should be between 25 5 volts and 29 0 volts If it isn t then check the alternator and 24 volt voltage regulator circuits 4 Zero the DC Clamp on ammeter as needed 5 Put the jaws of the clamp on ammeter around all wires connected to the equalizer 12 volt terminal stud 6 Observe the DC amperage out of the equal...

Page 341: ...ge therefore the DC connection sequence is not an issue Family 3 4 and 5 Equalizers will not function properly unless all three battery connections are made Battery A and Battery B voltages both must be above 8 volts for the unit to turn ON Any combination of Family 1 Family 3 Family 4 and Family 5 models may be operated in parallel Please note that the 24V 12V and GND stud position and orientatio...

Page 342: ...er out of balance If Battery A voltage falls below approximately 8 volts the equalizer will shut itself OFF To correct the overload condition the 12 volt load must be reduced or the equalizer capacity must be increased Trouble Shooting an Engine No Start Situation Situation A coach has dead batteries and won t start while jump starting The coach is equipped with a 24 volt starting and charging sys...

Page 343: ... There are no other warranties that extend beyond those described on the face of this warranty Some states do not allow limitation on how long an implied warranty lasts so the above limitations may not apply to you Vanner does not undertake responsibility to any purchaser of its product for any undertaking representation or warranty made by any dealers or distributors selling its products beyond t...

Page 344: ...R S MANUAL BATTERY EQUALIZER OWNER S MANUAL 16 Vanner Incorporated 4282 Reynolds Drive Hilliard Ohio 43026 1 800 AC POWER 1 800 227 6937 Tel 614 771 2718 Fax 614 771 4904 www vanner com e mail pwrsales vanner com Part Number D98761 July 15 2002 Printed in U S A ...

Page 345: ...FAULT CODE MANUAL Created on 00 04 25 15 30 1 FAULT CODE MANUAL B7L B7TL B12 ...

Page 346: ...al suppliers Due to problems with retrieving updated documents new signal specifications etc we cannot guarantee that the information is 100 correct Therefore we are very grateful to retrieve any notification about occurance of incorrect information We will however update the manual as soon as we get new information and distribute revised versions to all parties concerned ...

Page 347: ...s number with the VIC 8 8 Comparing HW SW id with the VIC 8 9 Fault codes ABS MID 136 10 10 Fault codes BIC MID 140 234 13 11 Fault codes CECM MID 164 14 12 Fault codes CIM MID 164 15 13 Fault codes EECU MID 128 16 14 Fault codes TECU Voith 863 3 retarders and transmission MID 130 19 15 Fault codes ZF HP 502 retarder and transmission MID 130 20 16 Fault codes Voith 115v retarder MID 222 22 17 Faul...

Page 348: ...of the instrument cluster there is a small display that can show various information about the bus From this display it is possible to read the fault codes that may have been set in one or more of the different control units 3 The windscreen wiper handle Using the the windscreen wiper handle at the right of the steeringwheel makes it possible to display the error at the lower left corner of the BI...

Page 349: ...rner of the instrument can display an icon of some sort depending on the bus status If this is the case then press Esc on the windscreen wiper handle to go to the main menu If the language of the display is not English we recommend that you change the language settings of the display This is done by entering the set up mode in the display menu Simply use the up down button on the windscreen wiper ...

Page 350: ...en wiper handle to move to that line Press the Return button again and the fault code set in the transmission ECU will now be displayed on the screen The fault codes can be displayed in both numeric and text mode Since the text mode is default you have to change it to numeric manually This is done by pressing the Return button when the display shows the fault code in text mode A menu with three ch...

Page 351: ...text mode The information about the PID number or SID PPID or PSID together with the explanation of the FMI number associated with the fault might help you to draw a conclusion of what may have caused the error The image below shows the FMI table which tells what type of fault the FMI number represents In this case the information MID 130 PID 191 FMI 2 means that the output shaft speed has retriev...

Page 352: ...urn buton on the windscreen wiper handle The fleet id and the chassis number should occur on the display 8 Comparing HW SW id with the VIC Just as with the chassis number the VIC can be used to verify HW SW id for each ECU in the bus To read the HW SW id from a control unit you first select System diagnostic from the main menu of the display and press the Return button on the windscreen wiper hand...

Page 353: ...04 25 15 30 9 The image below shows the HW SW id for the CECM the display cannot display both SW id and HW id at the same time therefore you have to use the up down buttons on the windscreen wiper handle to show SW id instead of HW id ...

Page 354: ...sor wheel sp RF 136 SID 2 10 Speed drop out Sensor wheel sp RF 136 SID 2 11 Abnormal speed Sensor wheel sp RF 136 SID 2 12 Frequency too high Sensor wheel sp RF 136 SID 3 1 Air gap Sensor wheel sp L1R 136 SID 3 2 Incorrect tyre Sensor wheel sp L1R 136 SID 3 3 Shorted to UBATT Sensor wheel sp L1R 136 SID 3 4 Shorted to ground Sensor wheel sp L1R 136 SID 3 5 Open circuit Sensor wheel sp L1R 136 SID ...

Page 355: ...6 SID 7 6 Shorted to ground Modulator valve LF 136 SID 8 1 Open circuit in and outlet Modulator valve RF 136 SID 8 3 Shorted to UBATT Modulator valve RF 136 SID 8 5 Open circuit Modulator valve RF 136 SID 8 6 Shorted to ground Modulator valve RF 136 SID 9 1 Open circuit in and outlet Modulator valve L1R 136 SID 9 3 Shorted to UBATT Modulator valve L1R 136 SID 9 5 Open circuit Modulator valve L1R 1...

Page 356: ...valve R 136 SID 19 6 Diff lock shorted to ground ATC valve R 136 SID 23 5 Warning lamp ABS Warning light bulb 136 SID 231 5 SAE J1939 Control link SAE J1939 data link 136 SID 231 6 SAE J1939 Control link SAE J1939 data link 136 SID 231 9 SAE J1939 Control link SAE J1939 data link 136 SID 231 12 SAE J1939 Control link SAE J1939 data link 136 SID 248 2 CAN plausibility 136 SID 248 5 CAN open circuit...

Page 357: ...rake pressure 1 234 PID 118 9 Brake pressure 2 Brake pressure 2 234 PID 120 9 ZF Allison oiltemp Hyd retard oil temp 234 PID 158 0 Yellow lamp Control unit battery potential Battery potential 234 PID 175 9 Engine oil temp Engine oil temp 234 PID 177 9 Voith oil temp Transm oil temp 234 PPID 91 9 Brake pressure circuit 3 Brake pressure 3 234 SID 250 2 SAE J1708 data link SAE J1708 data link 234 SID...

Page 358: ...0 4 Chassis data link 164 PSID 23 3 D data link 164 PSID 23 4 D data link 164 PSID 31 3 Output CECM 164 PSID 31 4 Output CECM 164 PSID 31 5 Output CECM 164 PSID 32 5 Panel switch 164 PSID 33 3 Warning lamp output 164 PSID 34 3 Engine run signal 164 PSID 34 4 Engine run signal 164 PSID 35 3 Ignition output 164 PSID 35 4 Ignition output 164 PSID 35 5 Ignition output 164 PSID 36 3 Steer wheel adjust ...

Page 359: ...PID SID FMI Seriousness Component function Display text 164 PSID 31 3 Short circuit to battery 164 PSID 31 4 Short circuit to ground 164 PSID 3 4 Alternator not charging 164 PSID 4 4 Alternator not charging 164 PSID 45 4 Alternator not charging 164 PSID 46 4 Alternator not charging ...

Page 360: ...ure sensor Boost pressure 128 PID 102 4 Yellow lamp Boost pressure sensor Boost pressure 128 PID 105 3 Yellow lamp Boost air temperature sensor Intake manif temp 128 PID 105 4 Yellow lamp Boost air temperature sensor Intake manif temp 128 PID 107 0 Yellow lamp Drop in pressure air filter Air filt press drop 128 PID 107 3 Yellow lamp Drop in pressure air filter Air filt press drop 128 PID 107 4 Yel...

Page 361: ...r Injector Cylinder SID 128 SID 1 6 11 Yellow lamp Injector Injector Cylinder SID 128 SID 17 3 Fuel shut off valve Fuel Valve 128 SID 17 4 Fuel shut off valve Fuel Valve 128 SID 17 5 Fuel shut off valve Fuel Valve 128 SID 20 2 Yellow lamp Actuator injection angle Timing actuator 128 SID 20 3 Red lamp Actuator injection angle Timing actuator 128 SID 20 4 Red lamp Actuator injection angle Timing act...

Page 362: ...trol link SAE J1939 data link 128 SID 231 11 Yellow lamp SAE J1939 Control link SAE J1939 data link 128 SID 231 12 Yellow lamp SAE J1939 Control link SAE J1939 data link 128 SID 232 3 Yellow lamp 5 V supply to sensor 5 V supply 128 SID 232 4 Yellow lamp 5 V supply to sensor 5 V supply 128 SID 240 2 Red lamp Programme memory Flash Program memory 128 SID 240 12 Programme memory Flash Program memory ...

Page 363: ...erature sensor Transm oil temp 130 PID 190 11 Engine speed Engine speed 130 PID 191 11 Output speed Output shaft speed 130 PID 234 14 Frequency output Software no 130 SID 1 12 Control solenoid valve turbine brake Solenoid valve 1 130 SID 4 12 Control solenoid valve 4 speed clutch Solenoid valve 4 130 SID 6 12 Solenoid valve converter brake Solenoid valve 6 130 SID 7 12 Control solenoid valve pump ...

Page 364: ...0 SID 3 3 Solenoid valve D shorted high Solenoid valve 3 130 SID 3 4 Solenoid valve D shorted ground Solenoid valve 3 130 SID 3 5 Solenoid valve D circuit break Solenoid valve 3 130 SID 4 3 Solenoid valve E shorted high Solenoid valve 4 130 SID 4 4 Solenoid valve E shorted ground Solenoid valve 4 130 SID 4 5 Solenoid valve E circuit break Solenoid valve 4 130 SID 5 3 Solenoid valve F shorted high ...

Page 365: ...t shorted high 222 SID 11 4 Retarder current shorted ground 222 SID 11 5 Retarder current circuit break 222 SID 12 3 Retarder accumulator shorted high 222 SID 12 4 Retarder accumulator shorted ground 222 SID 12 5 Retarder accumulator circuit break 223 PID 163 2 Shifter encoding error Gear attained 130 222 223 SID 231 2 CAN error SAE J1939 data link 130 222 223 SID 250 2 J1708 busoff SAE J1708 data...

Page 366: ...r air press 222 PPID 31 3 Retarder air press Retarder air press 222 PPID 31 5 Retarder air press Retarder air press 222 PPID 34 0 ECU 12V Output ECU 12V Output 222 PPID 34 1 ECU 12V Output ECU 12V Output 222 PPID 54 0 ECU 5V output ECU 5V output 222 PPID 54 1 ECU 5V output ECU 5V output 222 PPID 55 0 ECU temperature ECU temperature 222 SID 2 3 Retard modul Valve Retard modul valve 222 SID 2 4 Reta...

Page 367: ...lamp Repeated movement of the lever between position 1 and position 0 will display the next fault code in line if the same fault code is shown two times in a row there are no more fault codes set in the retarder Code Description 1 Stop light relay short to ground 2 LS1 short to battery 3 HS 1 short to ground 4 HS 2 short to ground 5 Terminal 15 undervoltage 6 Terminal 15 overvoltage 7 Pilot valve ...

Page 368: ...cription 35 Internal fault concerning ROM CRC check EEPROM data record 36 2 2 way valve fault 37 Non plausibility of brake pedal operation 38 Pressure sensor fault 41 Time out 500ms press signal VECU 42 Time out 500ms ABS signal J1939 43 J 1939 link bus off ...

Page 369: ...and retarder feeding sensor Output supply 1 144 PPID 73 3 Yellow lamp Extra throttle and wet tank feeding sensor Output supply 2 144 PPID 73 4 Yellow lamp Extra throttle and wet tank feeding sensor Output supply 2 144 PPID 75 3 Yellow lamp Range inhibitor Range inhibitor 144 PPID 75 4 Yellow lamp Range inhibitor Range inhibitor 144 PPID 76 3 Yellow lamp Brake light status relay Brakelight output 1...

Page 370: ......

Page 371: ...ring gear which has similar level of damage as these See the next page for the method to measure the depth of the damage Depth of wear damage on ring gear Service Bulletin A1 M1N 1729EN Flywheel Ring Gear Wear Damage Sample of Maximum Ring Gear Wear Damaged ...

Page 372: ... Measurement method Dimension between the mounting surface and the end surface of ring gear Dimension between the mounting surface and the damage depth portion of ring gear Less than 0 5mm ...

Page 373: ...TH RETARDER 12 7 CLEANING AND INSPECTION OF THE ALLISON AUTOMATIC TRANSMISSION 12 7 1 BREATHER 13 8 ALLISON TRANSMISSION INSTALLATION 13 9 TROUBLESHOOTING 14 9 1 ALLISON AUTOMATIC TRANSMISSION 14 9 1 1 4th Generation Transmission Control Module 14 9 1 2 Diagnostic Troubleshooting Codes DTC Allison 4th Generation Controls 14 9 1 3 Diagnostic Codes Allison 4th Generation Controls 15 9 1 4 Diagnostic...

Page 374: ...7 TRANSMISSION PA1553 2 FIGURE 9 ENGINE CRANKING POSITION 11 FIGURE 10 MODINE OIL COOLER 12 FIGURE 11 COOLER WITH RETARDER 12 FIGURE 12 AIR PRESSURE REGULATOR TYPICAL 14 FIGURE 13 TRANSMISSION CONTROL MODULE 14 ...

Page 375: ... it computes shift points and clutch pressures to meet immediate needs Using closed loop adaptive logic the electronic control looks at a number of parameters during the shift and makes minute adjustments to match the shift to desired profile stored in its memory It then looks at these adjustments and resets the parameters which allow the transmission to quickly compensate for variations in load t...

Page 376: ...and clogged passages Check the oil level using the procedures in Cold Check and Hot Check Record any abnormal level on your Maintenance Records Always check the oil level reading at least twice when the engine is running Consistency is important in maintaining the accuracy of the reading If inconsistent readings persist check the transmission breather to ensure it is clean and free of debris FIGUR...

Page 377: ...when selecting the Gauge Mode refer to the Operator s Manual for added information 2 Park the vehicle on a level surface and shift to Neutral N Apply the parking brake and allow the engine to idle 500 800 rpm 3 Remove the dipstick from the tube and wipe it clean Insert the dipstick into the fill tube pushing down until it stops 4 Remove the dipstick and observe the fluid level The safe operating l...

Page 378: ...roper fluid level be maintained at all times because the transmission fluid cools lubricates and transmits hydraulic power If the fluid level is too low the converter and clutches do not receive an adequate supply of fluid If fluid level is too high the fluid can aerate causing the transmission to shift erratically or overheat 3 6 KEEPING OIL CLEAN Oil must be handled in clean containers fillers e...

Page 379: ...ot available the TCM will restrict full operation until the sump temperature is increased 3 8 OIL CONTAMINATION At each oil change examine the drained oil for evidence of dirt or water A nominal amount of condensation will emulsify during operation of the transmission However if there is evidence of water check the cooler heat exchanger for other signs of leakage This however may also indicate lea...

Page 380: ... TM TES 295 Approved Fluid And Gold Series Filters MTH equipped with retarder MTH without retarder Filters Filters Main Main Fluid Initial Break in 5 000 miles 8 000 km Internal Lube Auxiliary Fluid Initial Break in 5 000 miles 8 000 km Internal Lube Auxiliary 50 000 Miles 80 000 km 24 Months 50 000 Miles 80 000 km 24 Months Overhaul 50 000 Miles 80 000 km 24 Months 150 000 Miles 240 000 km 48 Mon...

Page 381: ...ge Former Gold Series filter kits are completely cancelled and serviced with current High Capacity filter kits However if you are using stocked Gold Series filter kits with TES 295 approved fluid TranSynd use TABLE 3 for oil and filter change intervals The procedure for changing the transmission oil and oil filters is as follows Drain 1 The transmission should be at an operating temperature of 160...

Page 382: ... US qts 23 liters 28 US qts 26 5 liters if equipped with retarder and check the oil level using the Fluid Level Check Using Pushbutton Shift Selector procedure in this section 4 INSTALLATION OF ALLISON TRANSMISSION BRACKETS FIGURE 7 ALLISON TRANSMISSION BRACKETS 07133 5 ALLISON TRANSMISSION REMOVAL The following procedure deals with the removal of the Allison transmission without removing the powe...

Page 383: ...l may drain from oil lines when they are disconnected 9 Disconnect all sensors on L H side of the transmission 10 Disconnect main wiring harness 11 Disconnect the air supply line steel braided hose from retarder control valve if applicable 12 Remove any locking tie clamp and bracket that may interfere with the removal of transmission 13 Support transmission using a suitable transmission jack 14 Re...

Page 384: ... and allow engine to cool Close both heater line shutoff valves refer to Section 05 Cooling 1 To drain the cooling system proceed as per Section 05 Cooling paragraph 5 Draining If the cooling system is contaminated flush system as per Section 05 Cooling paragraph 7 Flushing 2 Disconnect and remove the engine air intake duct mounted between the air cleaner housing and the turbocharger inlet CAUTION...

Page 385: ...Molycote G or equivalent 5 Raise transmission and position the flywheel pilot boss into the flexible plate adapter Align the guide bolt previously installed in the flywheel with the flexible plate hole facing the access opening in the flywheel housing DANGER Severe damages and or personal injury can occur if transmission is not adequately supported 6 Seat the transmission against the engine flywhe...

Page 386: ...ssion Control Module The Allison automatic transmission has a new Transmission Control Module TCM which involves specific diagnostic incident codes The TCM is located in the coach rear junction box FIGURE 13 TRANSMISSION CONTROL MODULE 07140 TCM Replacement The TCM is a non serviceable electronic device When it fails it must be replaced using the following procedure o Open the coach engine compart...

Page 387: ...ushbutton shift selector d 1 P 0 7 SELECT 2 2 MONITOR d1 code list position The position which a code occupies in the list Positions are displayed as d1 through d5 code list position 1 through code list position 5 P0722 DTC The diagnostic troubleshooting code number referring to the general condition or area of fault detected by the TCM 9 1 4 Diagnostic Code Display And Clearing Procedure Allison ...

Page 388: ... approximately 10 minutes has passed The system will automatically return to the normal operating mode o Turn off power to the TCM shut off the engine using the ignition key NOTE If clearing a code while locked in a D Drive or R Reverse position fail to range the transmission will still be in D Drive or R Reverse when the clearing procedure is completed N Neutral must be manually selected 9 1 5 Di...

Page 389: ...D1 High Yes DNS SOL OFF hydraulic default P0702 Transmission Control System Electrical TransID Yes Use TID A calibration P0703 Brake Switch Circuit Malfunction No No Neutral to Drive shifts for refuse packer TCM inhibits retarder operation if a TPS code is also active P0708 Transmission Range Sensor Circuit High Input Yes Ignore defective strip selector inputs P070C Transmission Fluid Level Sensor...

Page 390: ...fault P0966 Pressure Control Solenoid 2 PCS2 Control Circuit Low Yes DNS SOL OFF hydraulic default P0967 Pressure Control Solenoid 2 PCS2 Control Circuit High Yes DNS SOL OFF hydraulic default P0968 Pressure Control Solenoid 3 PCS3 Control Circuit Open Yes DNS SOL OFF hydraulic default P0970 Pressure Control Solenoid 3 PCS3 Control Circuit Low Yes DNS SOL OFF hydraulic default P0971 Pressure Contr...

Page 391: ...emperature Sensor Circuit High Input No Use default retarder temp values P2761 TCC PCS Control Circuit Open Yes Inhibit TCC operation P2763 TCC PCS Control Circuit High Yes Inhibit TCC operation P2764 TCC PCS Control Circuit Low Yes 7 speed Allow 2 through 6 N R Inhibit TCC operation P278A Kickdown Input Failed ON No Inhibit kickdown operation P2793 Gear Shift Direction Circuit Yes Ignores PWM inp...

Page 392: ... Lockup clutch with torsional damper Integral standard Gearing Type Patented constant mesh helical planetary Ratio First 3 51 1 Second 1 91 1 Third 1 43 1 Fourth 1 00 1 Fifth 0 74 1 Sixth 0 64 1 Reverse 4 80 1 Ratio coverage 6 speed 5 48 1 Gear ratios do not include torque converter multiplication Oil System Oil type TRANSYND DEXRON III VI Capacity excluding external circuits Initial fill 47 US qt...

Page 393: ...CRIPTION 2 2 REMOVAL DISASSEMBLY REASSEMBLY AND INSTALLATION 2 3 CLEANING INSPECTION AND LUBRICATION 3 3 1 CLEANING AND INSPECTION 3 3 2 LUBRICATION 3 4 EXPLANATION OF COMMON DAMAGES 3 5 TROUBLESHOOTING 3 6 SPECIFICATIONS 4 ILLUSTRATIONS FIGURE 1 PROPELLER SHAFT ASSEMBLY 2 ...

Page 394: ...edle bearings Furthermore a slip joint on the propeller shaft compensates for variations in distance between the transmission and the differential or between the output retarder optional on the automatic transmission and differential The rise and fall of the drive axle bring about these variations as the vehicle passes over uneven surfaces The slip joint also eases removal of the transmission or t...

Page 395: ...t temperatures or NLGI No 1 suitable for extremely low temperatures Refer to Spicer Universal Joints and Driveshafts Service Manual under heading Inspection and Lubrication See lubrication procedures for U joints and lubrication for slip splines NOTE Do not assume that bearing cavities have been filled with new grease unless it has expelled around all seals 4 EXPLANATION OF COMMON DAMAGES 1 Cracks...

Page 396: ...t tube yoke Prevost number 580043 U joint kit slip yoke Supplier number 5 510X U joint kit slip yoke Prevost number 580062 Cap and bolt kit bolt torque 115 135 lbf ft 156 183 N m Supplier number 6 5 70 18X Cap and bolt kit bolt torque 115 135 lbf ft 156 183 N m Prevost number 580063 Bolts kit bolt torque 38 48 lbf ft 52 65 N m Supplier number 6 73 209 Bolts kit bolt torque 38 48 lbf ft 52 65 N m P...

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Page 409: ... 12 AXLE SHAFT SEALING METHOD 7 2 TAG AXLE 7 2 1 RETRACTING TAG AXLE 7 2 2 RETRACTING TAG AXLE FOR REPAIR PURPOSES 8 2 3 GREASE LUBRICATED WHEEL BEARINGS 8 2 4 REMOVAL AND INSTALLATION 8 2 4 1 Removing Tag Axle Only 8 2 4 2 Removing Tag Axle Along With Suspension Components 8 2 5 TAG AXLE ALIGNMENT 9 3 SPECIFICATIONS 10 ILLUSTRATIONS FIGURE 1 DRIVE AXLE 2 FIGURE 2 DIFFERENTIAL ASSEMBLY 2 FIGURE 3 ...

Page 410: ...er FIGURE 3 DRIVER CONTROLLED DIFFERENTIAL LOCK 11028 1 3 DRIVE AXLE LUBRICATION Additional lubrication information is covered in the Meritor Technical Bulletin TP 9539 Approved Rear Drive Axle Lubricants annexed to this section During initial stage of normal operation tiny metal particles originating from moving parts can be found on mating surfaces These particles are carried by the lubricant th...

Page 411: ...ke sure the axle is cold or at room temperature 3 Clean the area around the fill plug Remove the fill plug from the differential axle housing bowl Fig 4 4 The oil level must be even with the bottom of the hole of the fill plug a If oil flows from the hole when the plug is loosened the oil level is high Drain the oil to the correct level b If the oil level is below the bottom of the hole of the fil...

Page 412: ...ension 6 Remove cable ties securing the ABS cables if vehicle is so equipped to service brake chamber hoses Disconnect the ABS cable plugs from the drive axle wheel hubs NOTE When removing drive axle if unfastening cable ties is necessary for ease of operation remember to replace them afterwards 7 Disconnect the brake chamber hoses NOTE Position the hoses so they will not be damaged when removing ...

Page 413: ...rements for replacement If the axle has been removed for repairs or servicing and if all the parts are reinstalled exactly in the same place the axle alignment is not necessary However if the suspension supports have been replaced or altered proceed with the following instructions to verify or adjust the drive axle alignment NOTE When drive axle alignment is modified tag axle alignment must be re ...

Page 414: ...le the sensor from the right side of the front wheel is mounted on the right side of the tag axle For corresponding wheel mount sensor reference numbers refer to figure 7 o Adjust tag axle according to specifications chart below in reference with drive axle TAG AXLE ALL VEHICLES Alignment value Minimum value Nominal value Maximum value Parallelism deg 0 02 0 0 02 Total Toe deg 0 18 Toe in 0 0 18 T...

Page 415: ...ne sealant and its packing 3 Assemble components immediately to permit the silicone sealant to compress evenly between parts a Place a new gasket then install the axle shaft into the wheel hub and differential carrier The gasket and flange of the axle shaft must fit flat against the wheel hub b Install the tapered dowels at each stud and into the flange of the axle shaft Use a punch or drift and h...

Page 416: ...he manufacturing process The bearings are greased for life and there is no need or facility for re lubrication Front and tag axle wheel hub bearings need to be checked every 30 000 miles 48 000 km NOTE For more information on front and tag axle wheel hubs refer to DANA SPICER Maintenance Manual Model NDS and Maintenance Manual NDS Axles annexed at the end of this Section 2 4 REMOVAL AND INSTALLATI...

Page 417: ...h or without the output retarder move tag assembly very carefully Pay special attention to the U shaped section as the transmission end components may be easily damaged through a false maneuver 14 Reverse removal procedure to reinstall tag axle NOTE Refer to Section 16 Suspension for proper torque tightening of suspension components NOTE Refer to section 13 Wheels Hubs And Tires for correct wheel ...

Page 418: ...rive axle ratio World Transmission 4 88 1 Standard 4 56 1 Optional NOTE The drive axle alignment consists in aligning the axle with reference to the frame The axle must be perpendicular to the frame Tag Axle Make Prévost Rear track 83 6 inches 2 124 mm Axle type Dana Spicer Europe TS8U Hub Unit NOTE The tag axle alignment consists in aligning the tag axle parallel to the drive axle ...

Page 419: ...SPICER SPECIALITY AXLE DIVISION place product photo here SERVICE MANUAL GENERAL INFORMATION NDS Axle range ...

Page 420: ...ality Axle Division products are subject to continual development and we reserve the right to modify procedures and to make changes in specifications at any time without prior notice and without incurring obligation The recommendations of the vehicle manufacturer should be considered as the primary source of service information regarding this SPICER SPICER SPICER SPICER SPICER product This manual ...

Page 421: ...E OR MAINTENANCE PROCEDURE WARNING FAILURE TO FOLLOW INDICATED PROCEDURES CREATES A HIGH RISK OF PERSONAL INJURY TO THE SERVICE TECHNICIAN NOTE FAILURE TO FOLLOW INDICATED PROCEDURES MAY CAUSE COMPONENT DAMAGE OR MALFUNCTION FOR EASE OF ASSEMBLY DISASSEMBLY HELPFUL REMOVAL INSTALLATION PROCEDURES TO AID IN THE SERVICE OF YOUR NDS AXLE EVERY EFFORT HAS BEEN MADE TO ENSURE THE ACCURACY OF THE INFORM...

Page 422: ...ENT PERSONAL INJURY ALWAYS WEAR APPROPRIATE PERSONAL PROTECTION EQUIPMENT P P E WHEN PERFORMING ANY MAINTENANCE WORK SOLVENT CLEANERS IF SOLVENT BASED CLEANERS ARE TO BE USED THE MANUFACTURERS INSTRUCTIONS SHOULD BE CAREFULLY FOLLOWED AS WELL AS TAKING THE FOLLOWING BASIC PRECAUTIONS 1 WEAR EYE PROTECTION 2 WEAR PROTECTIVE CLOTHING 3 WORK IN A WELL VENTILATED AREA 4 DO NOT USE PETROLIUM GASOLINE B...

Page 423: ...ional nature of Spicer Speciality Axle Division products certain terms and wordsrequire clarification hence the following list ENGLISH U S A SWIVEL KNUCKLE COTTER PIN DRAW KEY AXLE BED I BEAM STEERING LEVER TIE ROD ARM HUB NUT SPINDLE NUT SWIVEL STOP SCREW STOP BOLT TOP BOTTOM CAP KING PIN CAP BUSHES BUSHINGS LUBRICATOR ZIRC ...

Page 424: ...ilable through either your vehicle manufacturer or through Spicer Speciality Axle Division spares department The use of non Spicer service parts may cause premature component failure and void the warranty The items included in the spare parts section of this manual are currently available as service spare parts at the time of printing The part numbers and illustrations are provided specifically as...

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Page 426: ...ICATION POLICY Capability ratings features and specifications vary depending upon the model type of service Applications approvals must be obtained from Spicer Speciality axle division We reserve the right to change or modify our product specifications configurations or dimensions at any time without notice ...

Page 427: ...SPICER SPECIALITY AXLE DIVISION place product photo here Maintenance Manual NDS axles Lubrication and Maintenance NDS Axle range Issue D ...

Page 428: ...ileage interval altered Updated spec Mar 2000 13 B Tie rod torques added New tie rod Mar 2000 14 B Tie rod torques added New tie rod Mar 2000 15 B Air cylinder torques added New spec Mar 2000 18 B Air cylinder torques added New spec Mar 2000 4 B Lockstop setting info added Clarification see SB1258 Sep 2000 3 B Greasing period altered Standardisation Jan 2001 4 C End float checking period added Sta...

Page 429: ... used in on off highway refuse or other severe service applications 1 1 2 Grease points as shown in fig no 1 Greasing points Fig No 1 Recommended lubrication LITHIUM BASE ROLLER BEARING GREASE NLGI NUMBER 2 1 2 Recommended Greases Use greases to grade F in lubrication manual Grease top and bottom lubricators until grease can be seen escaping from swivel axle bed interfaces Grease top and bottom lu...

Page 430: ...THIN THE UNIT IS DAMAGED DISPLACED AND A NEW UNIT MUST BE FITTED 2 2 To check front wheel Toe In a To preserve correct steering and avoid excessive tyre wear tracking or alignment of front wheels should be checked periodically as follows Set front wheels in straight ahead position and at points level with wheel centre measure distance over hubs wheel rims both in front and behind axle centre For c...

Page 431: ...nce then need for bush bearing attention and possible renewal is in evidence b Checking vertical slackness This is measured by a dial indicator anchored to axle beam and having its pointer placed vertical against swivel top Place a jack against underside of swivel and whilst applying a lifting force observe any movement on indicator dial If vertical movement is evident and it exceeds 0 040 1 02mm ...

Page 432: ...ion sheet metal tool eg spatula with cut out fig no 5 to push up the sealing boot without damaging it until ball pin surface is visible Degrease the ball pin surface If there is corrosion of the ball pin or the sealing boot has deteriorated through ageing or is damaged replace the ball joint in question or the complete tie rod or drag link as appropriate If there is corrosion of the steering lever...

Page 433: ...l assembly is stable and that no further relaxation is occuring see graphic on following page for correct tightening sequence of wheel nuts 3 1 Care of wheels Check for CRACKS in wheels especially around the fixing holes and in studs nuts and washers If in doubt RENEW DO NOT simply re tighten very loose wheel fixings or wheels which are continualy becoming loose Find out why they are loose and whe...

Page 434: ... Technical Publications Spicer Speciality Axle Division WHEELNUT TIGHTENING TORQUE SEQUENCE 6 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 8 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE 10 STUD FIXING 1 2 5 4 6 3 1 2 5 4 8 6 3 7 1 7 3 9 6 2 8 4 10 5 ...

Page 435: ...g if fitted Every 30000 miles 48000 km or whenever brake drums are removed for axle maintenance purposes they should be checked for crazing Brake drums with crazing in excess of that shown in fig 6 below and which are of Spicer Speciality axle division manufacture should not be re introduced into service Figs 7 8 show examples of unacceptable crazing fig 6 fig 7 fig 8 B ...

Page 436: ...nspect for the following Heat checking Cracks Grooves scoring Blue marks Banding Polished discs Heat checking can be light or heavy If light heat checking type cracks fine and light are found as shown in Fig 10 the disc can continue to be used If heavy heat checking type cracks deep and wide are found the disc must be replaced Cracks can be of 2 types Radial or Through If any radial cracks are fou...

Page 437: ...disc has been exposed to very high temperatures If Blue marks banding are found the reason for the high temperatures must be investigated and corrected Refer to the Brake manufacturer for details if left uncorrected the formation of heavy heat checking cracks will occur Polished discs indicate the use of improper lining material or that the disc has been re machined to too fine a surface finish Th...

Page 438: ...Page No 12 NDS2 issue A Spicer SpecialityAxle Division Technical Publications Spicer Speciality Axle Division ...

Page 439: ... 41 56 Bottom lever bolts M20 x 2 5 grade 12 9 520 575 lbs ft 705 780NM NDS 80 Bottom lever bolts M24 x 3 grade 10 9 751 830 lbs ft 1018 1125 NM NDS 80 27 Ball pin nut F4845T assembly 155 170 lbs ft 210 230 NM All axles Ball pin nut F4109T assembly 184 206 lbs ft 249 279 NM All axles Ball pin nut F4779S assembly 100 170 lbs ft 135 230 NM All axles Ball pin nut F4897S assembly 190 220 lbs ft 257 29...

Page 440: ...bolts M24 x 3 grade 10 9 751 830 lbs ft 1018 1125 NM NDS 80 25 Ball pin nut F4845T assembly 155 170 lbs ft 210 230 NM All axles Ball pin nut F4109T assembly 184 206 lbs ft 249 279 NM All axles Ball pin nut F4779S assembly 100 170 lbs ft 135 230 NM All axles Ball pin nut F4897S assembly 190 220 lbs ft 257 298 NM All axles 28 Socket pinch bolt F4845T assembly 33 37 lbs ft 45 50 NM All axles Socket p...

Page 441: ...bs ft 644 712NM 6 Brake Caliper Mounting Bolt M14 x 1 5 174 192 lbs ft 236 260NM Brake Caliper Mounting Bolt M16 x 1 5 266 294 lbs ft 360 399NM Brake Caliper Mounting Bolt M18 x 1 5 372 412 lbs ft 504 559NM Brake Caliper Mounting Bolt M20 x 1 5 520 574 lbs ft 705 778NM 4 Brake air cylinder retaining nuts M16 X 1 5 133 155 lbs ft 180 210NM 10 Hub flange retaining bolt M14 x 1 5 174 192 lbs ft 236 2...

Page 442: ... 1 Wheel nut M18 x 1 5 235 260 lbs ft 318 352NM Wheel nut M20 x 1 5 285 315 lbs ft 386 427NM Wheel nut M22 x 1 5 475 525 lbs ft 644 712NM 8 Hub flange retaining bolt M14 x 1 5 174 192 lbs ft 236 260NM 9 Brake drum retaining screw 26 32 lbs ft 35 43NM SWIVEL HUB END TIGHTENING TORQUES Fig No 20 7 1 2 3 4 5 6 20 21 9 8 10 11 19 18 17 16 15 14 13 12 ...

Page 443: ...T NO DESCRIPTION TIGHTENING TORQUE 1 Wheel nut M18 x 1 5 235 260 lbs ft 318 352NM Wheel nut M20 x 1 5 285 315 lbs ft 386 427NM Wheel nut M22 x 1 5 475 525 lbs ft 644 712NM 20 Hub flange retaining bolt M14 x 1 5 174 192 lbs ft 236 260NM 21 Brake drum retaining screw 26 32 lbs ft 35 43NM Fig No 21 1 2 3 4 5 7 8 9 6 ...

Page 444: ...2 x 1 5 475 525 lbs ft 644 712NM 5 Brake air cylinder retaining nuts M16 X 1 5 133 155 lbs ft 180 210NM 6 Brake Caliper Mounting Bolt M14 x 1 5 174 192 lbs ft 236 260NM Brake Caliper Mounting Bolt M16 x 1 5 266 294 lbs ft 360 399NM Brake Caliper Mounting Bolt M18 x 1 5 372 412 lbs ft 504 559NM Brake Caliper Mounting Bolt M20 x 1 5 520 574 lbs ft 705 778NM 10 Hub flange retaining bolt M14 x 1 5 174...

Page 445: ...ART NO DESCRIPTION TIGHTENING TORQUE 1 Wheel nut M18 x 1 5 235 260 lbs ft 318 352NM Wheel nut M20 x 1 5 285 315 lbs ft 386 427NM Wheel nut M22 x 1 5 475 525 lbs ft 644 712NM 7 Hub flange retaining bolt M14 x 1 5 174 192 lbs ft 236 260NM 8 Brake drum retaining screw 26 32 lbs ft 35 43NM 1 2 3 4 5 6 7 8 Fig No 23 ...

Page 446: ...ce Applications approvals must be obtained from Spicer Speciality Axle Division We reserve the right to change or modify our product specifications configurations or dimensions at any time without notice SPICER SPECIALITY AXLE DIVISION Abbey Road Kirkstall Leeds LS5 3NF England Tel 113 2584611 Fax 113 2586097 ...

Page 447: ...SPICER SPECIALITY AXLE DIVISION Maintenance manual Model NDS Hub and brake assembly With Knorr Bremse Disc brake Fitted to offset barrel swivel ...

Page 448: ...ions Spicer Speciality Axle Division Page No Issue Description Alteration Reason Date All A New Manual Mar 2000 11 B Page added all subsequent pages re numbered Brake disc checking added Oct 2000 7 C Optimol Paste Added To prevent fretting ECN 8695 Aug 2002 MANUAL ISSUE SHEET ...

Page 449: ...it plugs to connections to prevent dirt ingress 2 Loosen but do not remove brake caliper retaining bolts 3 Using suitable lifting equipment support the brake caliper 4 Remove brake caliper retaining bolts and remove brake caliper from axle WARNING BRAKE CALIPER IS HEAVY ENSURE WEIGHT IS FULLY SUPPORTED BEFORE REMOVING RETAINING BOLTS TAKE CARE TO AVOID CALIPER SWINGING AND TRAPPING FINGERS NOTE BR...

Page 450: ...flange bolts with 2 studs loosely fitted NOTE REPLACEMENT STUDS SHOULD PROTRUDE BEYOND FRONT FACE OF HUB FLANGE TO AID REMOVAL 8 Gently tap hub flange outwards using a hide faced hammer 9 Support weight of hub flange and remove hub flange retaining bolts 10 Remove hub flange and place on a suitable workbench WARNING COMPONENT IS HEAVY ENSURE WEIGHT IS FULLY SUPPORTED BEFORE REMOVING RETAINING BOLT...

Page 451: ...to remove WARNING COMPONENT IS HEAVY ENSURE WEIGHT IS FULLY SUPPORTED BEFORE REMOVING 15 Place brake disc on a suitable work bench and inspect for cracks and defects Replace if necessary See Lubrication and maintenance section for details of typical defects and acceptability Check brake disc thickness is within manufacturers specifications Refer to table below for Acceptable dimensions WARNING DO ...

Page 452: ...nd remove 21 Place on a suitable workbench and inspect for wear damage taking care not to damage the ABS exciter ring in the process NOTE THE UNITISED BEARINGS USED ON THE NDS RANGE OF AXLES ARE NON SERVICABLE ITEMS BEARINGS ARE PRE ADJUSTED LUBRICATED AND HAVE SEALS FITTED AS PART OF THE MANUFACTURING PROCESS THE BEARINGS ARE GREASED FOR LIFE AND THERE IS NO NEED OR FACILITY FOR RE LUBRICATION 22...

Page 453: ...ontained in swivel axle bed reassembly section before attempting to reassemble hub end 2 Fit Unitised hub bearing guide sleeve onto swivel stub see chart at front of swivel section 3 Lightly smear the axle stub bearing journal with a thin layer of anti fretting assembly paste white i e Optimol Paste White T Castrol or equivalent 4 Offer new unitised bearing onto swivel stub ...

Page 454: ... Technical Publications Spicer Speciality Axle Division OVERHAUL PROCEDURES HUB END REASSEMBLY CONTINUED 5 Place unitised hub bearing thrust washer onto axle stub 6 Fit hub nut 7 Tighten to specified torque NOTE ROTATE UNITISED HUB BEARING WHILST TIGHTENING ...

Page 455: ...fully position brake disc onto unitised hub bearing 10 Tap securely home using a hide faced hammer to avoid damaging the brake disc itself 11 Remove the modified hub flange bolt at this point 12 Carefully offer hub flange up to brake disc unitised hub bearing assembly and hold in position by inserting 1 off hub flange bolt and tightening hand tight 13 Insert remainder of hub flange bolts 14 Tighte...

Page 456: ...icer Speciality Axle Division 1 2 5 8 4 6 7 3 1 2 5 10 4 8 6 9 3 7 1 7 13 3 9 11 6 2 8 14 4 10 12 5 HUB FLANGE BOLT TIGHTENING TORQUE SEQUENCE FOR 8 BOLT FIXING HUB FLANGE BOLT TIGHTENING TORQUE SEQUENCE FOR 10 BOLT FIXING HUB FLANGE BOLT TIGHTENING TORQUE SEQUENCE FOR 14 BOLT FIXING ...

Page 457: ...sition stylus of dial test indicator onto brake disc as shown 18 Rotate the hub through 360 and note any movement of the dial test indicator NOTE MAXIMUM AXIAL RUNOUT IS 0 1mm 19 Should axial runout exceed 0 1mm the brake disc is out of specification 20 Remove and check out of specification disc to ensure no damage has occured to the mounting faces or that no dirt is present 21 Remove any dirt fou...

Page 458: ...BUSH SHOULD BE FITTED WHENEVER A NEW SENSOR IS FITTED IF FITTING A NEW SENSOR AND BUSH INTO AN ABS READY AXLE SENSOR AND BUSH SHOULD BE SUPPLIED FROM THE SAME MANUFACTURER 24 Push sensor through bush until it comes into contact with polewheel on hub assembly 25 Rotate hub bearing assembly through at least one revolution THIS SERVES TO SET THE CORRECT GAP BETWEEN SENSOR AND POLEWHEEL Refit ABS sens...

Page 459: ...g may not be steady due to the possibility of pole wheel run out and the inconsistent speed of the wheel d The maximum reading Vmax must not be more than 80 greater than the minimum reading Vmin ie If the following is true then it is likely that there is excessive pole wheel runout The pole wheel installation will therefore need to be inspected and remounted or replaced e The minimum reading must ...

Page 460: ...aliper is selected 29 Insert brake caliper retaining bolts and tighten hand tight 30 Tighten brake caliper bolts to secure assembly 31 Remove caliper lifting equipment WARNING BRAKE CALIPER IS HEAVY ENSURE WEIGHT IS FULLY SUPPORTED BY RETAINING BOLTS BEFORE REMOVING LIFTING EQUIPMENT 32 Tighten brake caliper bolts to correct torque 33 If the brake caliper air chamber has been removed Refit to cali...

Page 461: ...sure distance over hubs wheel rims both in front and behind axle centre c Front measurement B should be 0 0 to 0 04 0 0 to 1mm LESS than rear measurement A d Any adjustment on type A socket and tie rod assemblies can be effected by slackening clamp bolts in ball sockets and rotating track rod tube For type B socket and tie rod assemblies slacken the clamped end of the assembly and use the adjuster...

Page 462: ...interfaces of wheelnuts wheel rim hub then re fit road wheels securing with wheel nuts and tighten in correct sequence as shown on following page to specified torque NOTE INTERFACES MUST BE FREE FROM DIRT INCLUDING BRAKE LINER MATERIAL DEBRIS RUST AND PAINT FAILURE TO KEEP INTERFACES CLEAN CAN AND WILL CAUSE WHEEL RIM TO DISTORT UPON TIGHTENING OF WHEEL NUTS FOR FURTHER DETAILS SEE BS AU50 part 2 ...

Page 463: ...hnical Publications Spicer Speciality Axle Division WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 6 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 8 STUD FIXING WHEELNUT TIGHTENING TORQUE SEQUENCE FOR 10 STUD FIXING 1 2 5 4 6 3 1 2 5 4 8 6 3 7 1 7 3 9 6 2 8 4 10 5 ...

Page 464: ...Page No 18 Manual No NDS8 Spicer Speciality Axle Division Technical Publications Spicer Speciality Axle Division TP1193 ...

Page 465: ...ON OF NDS HUB END WITH SEPARATE BRAKE BRACKET PART NUMBER DESCRIPTION 1 Wheel nut Not Supplied By Spicer Speciality Axles 2 Hub flange 3 Wheel stud 4 Brake Caliper 5 Air chamber 6 Brake Caliper Mounting Washer 7 Brake Caliper Mounting Bolt 8 Unitised Hub Bearing 9 Brake Disc 10 Hub Flange Retaining Bolt 1 2 3 4 5 6 7 8 10 9 ...

Page 466: ...ICATION POLICY Capability ratings features and specifications vary depending upon the model type of service Applications approvals must be obtained from Spicer Speciality axle division We reserve the right to change or modify our product specifications configurations or dimensions at any time without notice ...

Page 467: ...s in housing 61163 71163 drive axles come standard with six magnets in housing and 3 use of approved extended drain interval lubricants per Table B Drive axles excluded are RC 26 633 634 and RC 26 27 720 Table A Oil Change Intervals and Specifications for All Rear Drive Axles Vocation or Vehicle Operation Linehaul Intercity Coach City Delivery School Bus Fire Truck Motorhome Construction Transit B...

Page 468: ... United States Distributors Name of Lubricant Viscosity Manufacturer Allied Mag Synthetic EP 75W 90 80W 140 Allied Oil and Supply Incorporated Altra Syntec GT 7 75W 90 80W 140 Allegheny Petroleum Products Amalie Synthetic Gear Lubricant 75W 90 80W 140 Amalie Refining Company Amoco Ultimate Multipurpose Gear Lube 75W 90 80W 140 Amoco Oil Company Archer Synthetic 75W 90 80W 140 McCollister Co Brad P...

Page 469: ...bricant 12345841 75W 90 80W 140 General Motors Service Parts Syncon HP Synthetic Gear Oil 75W 90 80W 140 Conoco Lubricants SYN EP Gear Lubricant 75W 90 80W 140 Black Bear Company Incorporated Synergy Syn Gear Lube EP 75W 90 80W 140 Northland Products Company Syn Gear 75W 90 80W 140 Castrol Heavy Duty Lubricants Inc Syngear EP 75W 90 80W 140 American AGIP Synolec 75W 90 80W 140 Lubrication Engineer...

Page 470: ...0 Aceites Y Parafinas Industriales Syn Star GL 75W 90 80W 140 Productos Texaco S A de C V Transintex Plus EP 75W 90 80W 140 Raloy Lubricantes S A de C V Name of Lubricant Viscosity Manufacturer Synstar GL 75W 90 80W 140 Caltex Oil Pty Limited Syntrax E 75W 90 80W 140 Castrol Australia PTY Limited TransGear S 80W 140 BP Oil Company Tutela Truck FE Axle 80W 140 Fiat Lubrificanti Name of Lubricant Vi...

Page 471: ...quipped with Traction Equalizer Replace the factory installed lubricant with an approved lubricant and one of the additives specified in the following table After the initial change interval Change the lubricant and the additive at or before 50 000 miles 80 000 km Specifications For all GL 5 oils petroleum oil or synthetic add one of the following modifiers specified in the following table Quantit...

Page 472: ...at the time the publication was approved for printing and is subject to change without notice or liability Meritor Heavy Vehicle Systems LLC reserves the right to revise the information presented or to discontinue the production of parts described at any time Copyright 2005 TP 9539 ArvinMeritor Inc Revised 09 05 All Rights Reserved Printed in USA 16579 24240 ...

Page 473: ...ER 6 7 1 AIR FILTER DRYER PURGE TANK 7 8 AIR LINES 7 8 1 COPPER PIPING 7 8 2 FLEXIBLE HOSES 7 8 3 NYLON TUBING 7 8 4 AIR LINE OPERATING TEST 7 8 5 AIR LINE LEAKAGE TEST 7 8 6 MAINTENANCE 8 9 PRESSURE REGULATING VALVES 8 9 1 MAINTENANCE 8 9 2 PRESSURE SETTING PROCEDURE 8 10 AIR COMPRESSOR BA 921 9 10 1 COMPRESSOR REMOVAL AND INSTALLATION 9 11 EMERGENCY PARKING BRAKE CONTROL VALVE PP 1 9 12 FLIP FLO...

Page 474: ...iper Guidance and Seal Condition 16 25 1 8 Checking the Tappet Boots 17 25 1 9 Pad Installation 17 25 1 10 Adjusting the Running Clearance 17 25 1 11 Brake Tools 18 25 1 12 Checking Brake Pads 18 25 1 13 Torque specifications 18 26 SAFE SERVICE PROCEDURES 18 27 AIR BRAKE TROUBLESHOOTING 19 28 BRAKE AIR CHAMBER 23 28 1 MAINTENANCE 23 28 2 EMERGENCY PARKING BRAKE MANUAL RELEASE 24 28 3 BRAKE CHAMBER...

Page 475: ...NCE 14 FIGURE 24 ADJUSTER PINION 15 FIGURE 25 BOX WRENCH ON ADJUSTER PINION 15 FIGURE 26 CALIPER AXIAL MOVEMENT 15 FIGURE 27 BRAKE PAD CHECK 15 FIGURE 28 PAD REMOVAL 16 FIGURE 29 PAD WEAR 16 FIGURE 30 ROTOR AND PAD WEAR LIMITS 16 FIGURE 31 CALIPER GUIDANCE 17 FIGURE 32 RUBBER BOOTS 17 FIGURE 33 PAD INSTALLATION 17 FIGURE 34 RUNNING CLEARANCE 18 FIGURE 35 BRAKE PAD CHECK 18 FIGURE 36 TORQUE SPECIFI...

Page 476: ...y a pneumatic relay valve R 12 will start with the rear axles and will be followed by the front axle thus providing uniform braking on a slippery road The vehicle is also equipped with an Anti Lock Braking System ABS which is detailed later in this section The drive and tag axles are provided with spring loaded emergency parking brakes which are applied automatically whenever the control valve sup...

Page 477: ...partment R H side door It is used to dissipate heat and to reduce noise produced by the air compressor cycling on and off FIGURE 3 FRONT SERVICE COMPARTMENT 12218 4 AIR SYSTEM EMERGENCY FILL VALVES All vehicles come equipped with two emergency fill valves that enable system pressurization by an external source such as an air compressor The rear valve is located in the engine compartment and is acc...

Page 478: ... The air pressure gauges located on the dashboard see Owner s Manual are connected to the DC 4 double check valve located on the pneumatic accessory panel in the front service compartment The latter is connected to the air lines running from the primary and secondary air tanks as shown on the pneumatic system diagram provided in the technical publications box The accessory air gauge is connected t...

Page 479: ...ttings and dirt Blow out piping with compressed air Any such particles will destroy sealing seats in air control units Also new piping must be the same size as the old one 8 2 FLEXIBLE HOSES A flexible hose is used normally where it is impractical to use copper or nylon tubing due to constant flexing during operation such as brake chamber hoses Hose connections should be tested for leakage at leas...

Page 480: ...e doors and is used to limit the air pressure in belt tensioners to 50 2 psi 345 15 kPa for WE and W0 MTH and to 45 2 psi 310 15 kPa for W5 MTH Fig 7 The optional regulator is located above the rear junction box in the engine compartment accessible through the engine R H side door It is used for transmission retarder and should be adjusted to 80 3 psi 550 20 kPa Air Pressure psi Air Pressure kPa B...

Page 481: ...connected to the air compressor Lubricating oil returns to the engine crankcase through the air compressor drive assembly Maintenance and repair information on the Bendix BA 921 air compressor is supplied in the applicable booklet annexed to this section under reference number SD 01 676 FIGURE 8 AIR COMPRESSOR LOCATION 03061 10 1 COMPRESSOR REMOVAL AND INSTALLATION 1 Exhaust compressed air from ai...

Page 482: ...the following procedure 1 Replace the linkage loosen threaded rod lock nuts and screw or unscrew the threaded adjustment rod in order to obtain a 45 o brake pedal inclination Fig 11 2 Tighten threaded rod lock nuts 13 1 1 Maintenance Maintenance and repair information on the E 10P dual brake application valve is supplied in the applicable booklet annexed to this section under reference number SD 0...

Page 483: ...information on these valves is supplied in the applicable booklet annexed to this section under reference number SD 03 1064 FIGURE 14 R 12 12074 FIGURE 15 R 14 12207 17 QUICK RELEASE VALVES QR 1 The quick release valve is located on the front axle service brakes air line and permit rapid exhaust of air pressure from brakes thus decreasing the brake release time Maintenance and repair information o...

Page 484: ...ure indicators is supplied in the applicable booklet annexed to this section under reference number SD 06 1600 The air system includes two low pressure switches Fig 19 both located on the pneumatic accessory panel in the front service compartment One serves for the parking brake signal its pressure setting is 66 6 psi 455 40 kPa The remaining pressure switch monitors the parking brake telltale pan...

Page 485: ...e axle is in the normal driving loaded position The spring type emergency brakes are mounted on the drive and tag axles and will apply automatically if primary system pressure falls below 40 psi 276 kPa Furthermore brake application or release which is speed up by a pneumatic relay valve R 12 will start with the rear axles and be followed by the front axle thus providing uniform braking on a slipp...

Page 486: ...t all pneumatic components in the braking system are functioning properly NOTE A residual pressure of 2 3 PSI in the system is sufficient to prevent the brakes from releasing Also the stop light switch can operate with as little as 1 PSI therefore an illuminated brake light does not mean brakes are dragging 2 Pad to rotor clearance inspection Remove clip and washer 26 45 Fig 22 push down retainer ...

Page 487: ...le lining clearance or lining thickness as specified for drum brakes The roadside inspector should use the following instructions to determine that the air disc brakes are within proper adjustment and have sufficient pad wear thickness The Knorr Bendix air disc brake is designed to move freely with minimal force in the axial direction on the two sliding pins as identified in figure 26 The movement...

Page 488: ...ree months or more often depending on the type of operation Sliding Test Refer to Fig 31 a Using hand pressure only the caliper 1 must slide freely with its guide pin arrange ments 4 7 across a distance of 1 3 16 inch 30 mm when the pads are removed The sleeve 5 is sealed using the boot 9 and the cap 10 b The rubber components 9 and 10 should show no damage The positioning must be checked If neces...

Page 489: ...appets are fully retracted and clean pad seat area Slide caliper to full outboard position and install outside pad Slide caliper to full inboard position and install inside pad WARNING It is recommended to change all pads on an axle at the same time FIGURE 33 PAD INSTALLATION 12111 25 1 10 Adjusting the Running Clearance a Insert a feeler gauge 0 028 inch 0 7 mm thickness between tappet and pad ba...

Page 490: ...rake pads all four pads on an axle have to be changed at the same time There is no inner or outer pad since all pads are the same Worn pads should be replaced in the same position FIGURE 35 BRAKE PAD CHECK 12117 25 1 13 Torque specifications For proper caliper maintenance refer to the following figures FIGURE 36 TORQUE SPECIFICATION 12145 FIGURE 37 TORQUE SPECIFICATION 11030 26 SAFE SERVICE PROCED...

Page 491: ...ash your hands before eating drinking or smoking Do not wear your work clothes home Vacuum your work clothes after use and then launder them separately without shaking to prevent fiber dust from getting into the air Material safety data sheets on this product as required by OSHA are available from Rockwell and Knorr Bremse 27 AIR BRAKE TROUBLESHOOTING The following tests and check lists have been ...

Page 492: ...Section 12 BRAKE AND AIR SYSTEM PA1553 20 FIGURE 38 AIR OPERATED BRAKING SYSTEM W0 WE ...

Page 493: ...Section 12 BRAKE AND AIR SYSTEM PA1553 21 FIGURE 39 AIR OPERATED BRAKING SYSTEM W5 ...

Page 494: ... restricted clean or replace element or faulty line o Check compressor head or discharge line for carbonization or restriction Clean or replace as necessary o If discharge valves leak pull head and correct or replace cylinder head o If drive is slipping replace gear o If inlet valves are stuck open or leaking severely replace unloader kit inlet valves and or seats as necessary o If drain cock is f...

Page 495: ... For more information on this policy refer to Bendix Prévost product notification annexed at the end of Section 12 of Maintenance Manual 28 BRAKE AIR CHAMBER Since this vehicle is equipped with Knorr Bremse SN7000 disc brakes on all axles it also uses Knorr Bremse brake chambers The tag and drive axle chambers consist of two separate air chambers each having its own diaphragm and push rod They are...

Page 496: ...g brake turn the nut counterclockwise Rein stall access plugs on the spring chambers and release stud tools in their storage places Tag Axle 1 Block the wheels to prevent the vehicle from moving 2 Turn the release bolt counterclockwise to cage the power spring approx 2 5 inches 6 cm Repeat on the opposite side 3 To manually reset the emergency parking brake turn the bolt clockwise 28 3 BRAKE CHAMB...

Page 497: ...cedure for assembly Tap clamp ring to ensure proper seating Check for proper operation before placing vehicle in service 29 ANTI LOCK BRAKING SYSTEM ABS This device has been designed to ensure stability and permit steering control of vehicle during hard braking and to minimize its stopping distance whatever the road conditions are On slippery roads and generally in emergency situations over brakin...

Page 498: ...ng It then establishes a reference speed average speed from each wheel data and compares the speed of each wheel with this reference speed to determine which wheel is accelerating or decelerating As soon as wheel deceleration or wheel slip threshold values are exceeded the electronic control unit signals a solenoid control valve to limit the excessive brake pressure produced by the driver in the a...

Page 499: ... toothed wheels have been assembled to the axle connect a suitable AC voltmeter across the output terminals With the hubs rotating at 30 rpm the output voltages should read from 50 to 1999 mV to be acceptable 29 2 4 Sensor Installation The following procedure deals with sensor installation on the axle wheel hubs Read procedure carefully before reinstalling a sensor as its installation must comply ...

Page 500: ...Section 12 BRAKE AND AIR SYSTEM PA1553 28 FIGURE 46 ABS 4S 4M CONFIGURATION ...

Page 501: ...FITTING 12054 NTA Type Plastic Tubing Hand tighten nut Fig 49 From that point tighten using a wrench the number of turns indicated in the following chart Tubing diameter inches Number of additional turns required following hand tightening 1 4 3 3 8 to 1 2 4 5 8 to 3 4 3 FIGURE 49 HOSE FITTING 12055 AB Type Copper Piping Hand tighten nut Fig 50 From that point tighten with a wrench the number of tu...

Page 502: ...siccant cartridge Prévost number 3097369 Flip Flop Control Valve Make Bendix Westinghouse Model TW 1 Type On Off Prévost number 640136 Emergency Parking Brake Control Valve Make Bendix Westinghouse Model PP 1 Automatic release pressure 40 psi 275 kPa nominal Prévost number 641128 Dual Brake Application Valve Make Bendix Westinghouse Model E 10P Prévost number 641856 Stoplight Switches Make Bendix ...

Page 503: ...ndicators Make Bendix Westinghouse Model LP 3 Contact close 66 psi 455 kPa Prévost number 640975 Air Pressure Regulator Make Norgren Adjustable output range 0 80 85 psi 0 552 586 kPa Recommended pressure setting 75 psi 517 kPa Prévost number 641472 Air Filter Element Make Norgren Type With manual drain Prévost number 641338 Front Wheel Brake Chambers Make Knorr Bremse Type 24 Prévost number R H 64...

Page 504: ...n Tag Brakes Make Knorr Bremse Type 16 as emergency Prévost number 641431 Brake Lining All Axles Make Knorr Bremse Prévost number 611049 Prévost number 641226 ABS ANTILOCK BRAKING SYSTEM ABS MODULATOR VALVE Make Rockwell Wabco Voltage 24 V Prévost number 641097 Sensor Front Wheel Prévost number 641288 Sensor Drive Axle In Wheel End Prévost number 641095 ...

Page 505: ...service conditions showed significant performance reductions Insufficient pad strength caused cracking across the friction material Shear testing of the friction material adhesion resulted in the friction material completely separating from the backing plate in many instances Pad wear was accelerated Early rotor cracking symptoms were observed much earlier that for typical genuine parts Based on ou...

Page 506: ...lth NIOSH should be worn at all times during brake servicing Workers must wash before eating or drinking should not use tobacco products in any form shower after working and not wear work clothes home Work clothes should be vacuumed using a high efficiency particulate filter HEPA vacuum and laundered separately without shaking OSHARegulations regarding testing disposal of waste and methods of reduci...

Page 507: ... air system When compressor cut out is reached dry air is allowed to flow back to regenerate the desiccant bed The SIX 6 different applications available for the DRYest are illustrated on the next page 5 space for cartridge change Heater 12V 24V Turbo Protection Valve Port 4 Control 1 4 18 NPTF Port 22 Regeneration Reservoir 1 4 18 NPTF Port 1 21 Inlet Outlet 1 2 14 NPTF Safety Valve Governor Valv...

Page 508: ...Regeneration Valve Port 22 plugged Dryer Inlet Port 1 Turbo Protection Valve Compressor Reservoir Port Unloader Port Governor Supply Tank Primary Secondary Dryer Output Port 21 Port 22 Dryer Inlet Port 1 Turbo Protection Valve Purge Tank Can be mounted Horizonally or Vertically No Check Valve Check Valve Unloader Port 4 Compressor Supply Tank Primary Secondary Purge Tank Can be mounted Horizonally...

Page 509: ...ted by the vehicle or component manufacturer 11 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition General The vehicle installation guidelines presented in the Application Schematic apply to all DRYest Air Dryer installations Determine your system configuration and plumb accordingly Vehicles with the Holset Type E or Q...

Page 510: ...air dryer purges with an audible exhaust of air If system 2 E or 2 F is used the purge will be followed by a steady pulsating flow of air indicating that the system is unloaded and is venting to atmosphere 3 Actuate the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pressure and is followed by a purge 4 It is recommended that the vehi...

Page 511: ...ed 25 output compressor Safety valve 1 Desiccant cartridge is plugged 1 Excessive oil passage from compressor is open Check for worn compressor Replace desiccant cartridge 2 Ice block in dryer 2 Check heater function 3 Excessive system pressure 3 Repair or replace governor Short life of 1 Air at inlet of dryer exceeds 170 F 1 Extend length of compressor discharge dryer or line see Installing the D...

Page 512: ...8 12 V Heater 47110020 9 24 V Heater 47110021 10 Integrated Turbo Protection Valve 47189189 Not Shown Service Parts Brake Systems Division North American Sales Service Organization 10707 N W Airworld Drive Kansas City MO 64153 1215 Phone 816 891 2470 Fax 816 880 9766 Brake Systems Division Haldex Limited 525 Southgate Drive Unit 1 Guelph Ontario Canada N1G 3W6 Phone 519 826 7723 Fax 519 826 9497 B...

Page 513: ...GE PORT 2 CRANKCASE WATER PORT CRANKCASE COVER CYLINDER HEAD VALVE PLATE ASSEMBLY OILPORT APPLICATION SPECIFIC AIR INLET PORT WATER PORT GOVERNOR CONNECTION conducting air and engine coolant into and out of the cylinder head The discharge valves are part of the valve plate assembly The cylinder head with the valve plate comprise a complete cylinder head assembly The cast iron crankcase and cylinde...

Page 514: ...fills the cylinder bore above the piston See figures 4 7 AIR COMPRESSION LOADED When the piston reaches approximately bottom dead cen ter BDC the inlet reed valve closes Air above the piston is trapped by the closed inlet reed valve and is compressed as the piston begins to move toward top dead center TDC When air in the cylinder bore reaches a pressure greater than that of the system pressure the...

Page 515: ... enters the head and passes through inter nal passages in the cylinder head and valve plate assembly and is returned to the engine Proper cooling is important in maintaining discharge air temperatures below the maximum recommended 400 degrees Fahrenheit Figure 8 illustrates the various approved coolant flow connections See the tabu lated technical data in the back of this manual for specific requi...

Page 516: ...Refer to the tabulated technical data in the back of this manual for oil pressure minimum values COMPRESSOR DRIVE Check for noisy compressor operation which could indi cate excessive drive component wear Adjust and or replace as necessary Check all compressor mounting bolts and retighten evenly if necessary Check for leakage and proper unloader mechanism operation Repair or replace parts as necess...

Page 517: ... available from an authorized Bendix parts outlets Unloader In order to test the inlet and discharge valves and the un loader piston it is necessary to have shop air pressure and an assortment of fittings A soap solution is also required Build Up tests 1 With the engine running lower air system pressure to 90 psi and raise engine RPM to 1800 Measure and record the time required to raise system pre...

Page 518: ...sented in this manual 1 Block the wheels of the vehicle and drain the air pres sure from all the reservoirs in the system 2 Drain the engine cooling system and the cylinder head of the compressor Identify and disconnect all air water and oil lines leading to the compressor 3 Remove as much road dirt and grease from the exte rior of the compressor as possible 4 Remove the discharge and inlet fittin...

Page 519: ... 1 Head Gasket 2 1 Unloader Cover 7 1 O Ring 12 Intentionally Left Blank 3 1 Unloader Cap Gasket 8 1 Unloader Piston 13 1 Inlet Reed Valve Gasket 4 1 Unloader Balance Piston 9 1 O Ring 14 1 O Ring 5 1 Spring 10 1 Safety Valve 15 1 Bottom Cover Gasket CRANKCASE COVER CRANKCASE CYLINDER BLOCK CYLINDER HEAD 1 2 7 8 END COVER 4 6 9 10 3 5 CRANKCASE SCREW 15 END COVER SCREW 13 11 14 ...

Page 520: ...ke certain the unloader vent passage under the un loader cover 2 in the head is open and free of debris INSPECTION OF PARTS CYLINDER HEAD VALVE PLATE 1 Carefully inspect the cylinder head gasket surfaces for deep gouges and nicks If detected the compressor must be replaced 2 Carefully inspect the valve plate assembly gasket sur faces for deep gouges and nicks Pay particular attention to the metal ...

Page 521: ...of the balance piston 4 making certain the stamped logo is visible 10 Press and hold the unloader cover 2 in place on the cylinder head and install both unloader cover cap screws 1 Torque the cover cap screws 1 to 62 to 71 inch pounds INSTALLING THE COMPRESSOR 1 If the compressor was removed for replacement install the drive components Torque the crankshaft nut to 250 foot pounds 2 Install any sup...

Page 522: ...nloaded 1800 RPM 1 3 HP Maximum inlet air temperature 250 F Maximum discharge air temperature 400 F Minimum oil pressure required at engine idling speed 15 PSI Minimum oil pressure required at maximum governed engine speed 15 PSI Minimum oil supply line size 3 16 I D Minimum unloader line size 3 16 I D Minimum Governor Cutout Pressure 90 PSI TORQUE SPECIFICATIONS Assembly Torques in inch pounds in...

Page 523: ... intake should not be connected to any part of the exhaust gas recirculation E G R system on the engine D Insufficient compressor D For water cooled portions of the compressor cooling compressor runs 1 Check for proper coolant line sizes Minimum hot recommended size is 3 8 I D tubing 2 Checkthecoolantflowthroughthecompressor Minimum allowable flow is 2 5 gallons per minute at engine governed speed...

Page 524: ...defects exist 2 Noisy compressor A Loose drive gear or A Inspect the fit of the drive gear on the compres operation components sor crankshaft The gear or coupling must be completely seated and the crankshaft nut must be tight If the compressor crankshaft surface is damaged it is an indication of loose drive components If damage to the compressor crankshaft is detected replace the compressor When i...

Page 525: ...aulty sections of the discharge vehicle manufacturer Do line not downsize the original equipment compressor D Slipping drive components D Check for faulty drive gears and couplings and replace as necessary Check the condition of drive belts and replace or tighten whichever is appropriate E Excessive air system E Test for excessive system leakage and repair as leakage necessary Use the following as...

Page 526: ...r Replace or repair the compressor as necessary C Loose crankcase end C Check the cap screw torques and tighten as cover or bottom cover necessary Replace gaskets or o ring D Loose oil supply or return D Check the torque of external oil line fittings and line fittings tighten as necessary E Porous compressor casting E Replace the compressor if porosity is found F Mounting flange or end F Replace a...

Page 527: ...en as necessary improper antifreeze Check coolant flow through compressor to as strength sure the proper antifreeze mixture reaches the compressor C Faulty compressor C If casting porosity is detected replace the com porous castings pressor 8 Compressor head A Restricted discharge line A Clear restriction or replace line gasket failure B Loose head bolts B Tighten evenly to a torque of 265 292 inc...

Page 528: ...16 BW2158 Honeywell Commercial Vehicle Systems Company 4 2001 Printed in USA ...

Page 529: ...agm and piston The LP 3 is available with either one terminal or two The single terminal unit utilizes a metallic gasket between body and case to ground the lower contract strip The two terminal unit utilizes a phenolic insulating gasket to isolate both terminals from the vehicle frame The electrical contacts provided in both the LP 2 and LP 3 indicators remain closed by spring force until the air...

Page 530: ...tions at the Low Pressure Indicator 5 Disconnect the air line and mounting bolts or unscrew the Indicator from the fitting and remove INSTALLING 1 Install in a convenient location for servicing 2 Connect to a reservoir pressure line at a high point in the system for adequate drainage 3 If installing an LP 2G Indicator use a supply line of 1 4 O D minimum 4 Connect the Indicator terminals in series...

Page 531: ...t the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always ...

Page 532: ......

Page 533: ...endently from the trailer The PP 5 is unique in having an auxiliary piston in the lower cover which upon receiving a pneumatic signal of 18 psi or more will cause the valve to move from the applied to the exhaust position from a 100 psi application The RD 3 differs slightly in that it normally remains in the exhaust position and requires a constant manual force to hold it in the applied position T...

Page 534: ...present in the delivery volume and leakage at the exhaust port should not exceed a 1 bubble in five seconds Note If any of the above push pull valves do not function as described or if leakage is excessive it is recommended they be returned to our nearest authorized distributor for a factory rebuilt or new valve IMPORTANT PLEASE READ When working on or around a vehicle the following general precau...

Page 535: ...rain the air pressure from all reservoirs before beginning any work on the vehicle 4 Following the vehicle manufacturer s recom mended procedures deactivate the electrical system in a manner that removes all electrical power from the vehicle 5 When working in the engine compartment the en gine should be shut off Where circumstances require that the engine be in operation extreme caution should be ...

Page 536: ...precautions pertaining to use of those tools 9 Use only genuine Bendix replacement parts com ponents and kits Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 10 Components with stripped threads or damaged parts should be replaced rather than repaired Re pairs requiring ...

Page 537: ...ir controlled devices They may be lever or button operated direct or remote control The TW 1 Figure 1 is normally panel mounted with a steel zinc or nylon manually operated lever Some are equipped with a steel lever with connectors for Bowden cable control All TW 1 s have 1 8 NPT ports The TW 3 Figure 2 is lever operated either direct or remote and differs from the TW 1 in having 1 4 NPT ports and...

Page 538: ...es No leakage permitted If the TW valve does not function as described or if leakage occurs it is recommended that it be replaced with a new unit or repaired with genuine Bendix parts REMOVING Secure the vehicle with other means than brakes and drain the reservoirs Disconnect all air lines and remove the valve INSTALLING Place valve handle through appropriate hole in panel place dial if used over ...

Page 539: ...used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove ...

Page 540: ......

Page 541: ... DESCRIPTION Double Check Valves are used in an air brake system to direct a flow of air into a common line from either of two sources whichever is at the higher pressure They may be used for directing air flow for specific functions or to select the higher pressure of either of two sources of air as a sup ply source AlliedSignal manufactures two types of Bendix Double Check Valves shuttle and dis...

Page 542: ...laced with genuine Bendix parts The follow ing instructions should prove helpful DISASSEMBLY 1 Remove end cap s from valve 2 Remove grommets if applicable 3 Remove shuttle and or shuttle guide disc and or disc guide depending upon type of valve CLEANING AND INSPECTION 1 Clean all metal parts in a cleaning solvent 2 Inspect all metal parts for signs of cracks wear or dete rioration Replace all part...

Page 543: ... leaking heated or electrically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly unde...

Page 544: ...4 main local global operation trouble m e n u search search shooting BW1846 AlliedSignal Truck Brake Systems Co 1 1999 Printed in U S A ...

Page 545: ...valves can also be used to delay filling of auxiliary reservoirs to insure a quick build up of brake system pressure The PR 2 and PR 4 pressure protection valves have one 1 4 N P T F supply port and one 1 4 N P T F delivery port which are identified Both valves are provided with two 9 32 mounting holes through the body The closing pressure of the PR 2 is externaIly adjustable while the PR 4 has a ...

Page 546: ... the pressure indicated on the valve s label or in the vehicle handbook The gauge on the delivery side of the valve should continue to show loss of pressure while the gauge on the supply side should stop at the same pressure as the setting of the valve 4 PR 3 only Build pressure up again and shut off engine Slowly exhaust air from the supply side of the PR 3 The gauge on the delivery side of the v...

Page 547: ...king heated or electrically charged components 6 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understa...

Page 548: ......

Page 549: ...d to it from the foot brake valve or other source The R 12 and R 14 Relay Valves are designed for either reservoir or frame mounting A universal mounting bracket is furnished that permits easy interchange with other Bendix relay valves Both valves are available in the two body styles illustrated in Figure 1 The R 14 differs from the R 12 in that it incorporates a quick release and anti compounding...

Page 550: ...e change holding the brake application at that level EXHAUST OR RELEASE When air pressure is released from the service port and air pressure in the cavity above the relay piston is ex hausted air pressure beneath the piston lifts the relay piston and the exhaust seat moves away from the exhaust valve opening the exhaust passage With the exhaust passage open the air pressure in the brake chambers i...

Page 551: ...oins the body to check for seal ring leakage no leakage is permitted 5 If the R 14 is used to control the spring brakes place the park control in the released position and coat the balance port with a soap solution to check the dia phragm and its seat Leakage equivalent to a 1 inch bubble in 3 seconds is permitted Note If the anti compound feature is in use the line attached to the balance port mu...

Page 552: ... R1 BOBTAIL PROPORTIONING VALVE FRONT AXLE SERVICE RESERVOIR REAR AXLE SERVICE RESERVOIR SPRING BRAKES GAUGE SR 5 TRAILER SPRING BRAKE VALVE SUPPLY LINE SERVICE LINE E 7 E 12 OR E 15 R 14 RELAY VALVE R 12 RELAY VALVE SPRING BRAKES COMPRESSOR MV 3 TRAILER RELEASE TRAILER PARK SYSTEM PARK LP 3 TRAILER CONTROL VALVE PP 1 PP 1 LQ 5 FIGURE 3 TYPICAL PIPING SCHEMATIC SR 1 SPRING BRAKE VALVE FRONT SERVIC...

Page 553: ...he body 9 Install the exhaust cover assembly in the body taking care not to damage the o ring 10 While depressing the exhaust cover install the retain ing ring Make certain the retainer is completely seated in its groove in the body 11 Install the R 14 service port cap nut o ring on the cap nut Install the diaphragm in the R 14 cover making certain it is positioned between the guide ribs in the co...

Page 554: ...nd kits Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 10 Components with stripped threads or damaged parts should be replaced rather than repaired Re pairs requiring machining or welding should not be at tempted unless specifically approved and stated by the vehicle o...

Page 555: ......

Page 556: ...8 main local global operation trouble m e n u search search shooting BW1431 AlliedSignalTruckBrakeSystemsCo 1 1999 PrintedinU S A ...

Page 557: ... pressure forces the edges of the diaphragm down and air flows out the delivery port When air pressure being delivered beneath the diaphragm equalsthepressurebeingdeliveredbythebrakevalve above the diaphragm the outer edge of the diaphragm will seal against the body seat The exhaust port is still sealed by the center portion of the diaphragm when the brake valve application is released the air pre...

Page 558: ...nly and securely Torque to 30 60 inch pounds 3 Perform tests as outlined in Operating and Leakage Tests section IMPORTANT PLEASE READ When working on or around a vehicle the following general precautions should be observed 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels 2 Stop the engine when working around the vehicle 3 If the vehicle is equipped with ai...

Page 559: ...therefore provides the driver with a less sensitive feel when making a brake application The E 10P Dual Brake Valve is generally used on busses where smooth brake applications contribute to passenger comfort The circuits in the E 8P E 10P Dual Brake Valves are identified as follows The No 1 or primary circuit is that portion of the valve between the spring seat which contacts the plunger and the r...

Page 560: ...STCOVER ATTACHINGSCREWS BODY ATTACHING SCREWS 13 12 FIGURE 3 TYPICAL PIPING SCHEMATIC TP 5TRACTOR MV 3 BRAKE SLACK COMPRESSOR SUPPLY RESERVOIR 1 SERVICE 2 SERVICE DOUBLE CHECK SPRING SLACK TRAILER CONTROL AIR DRYER GOVERNOR E 8P OR E 10P DUAL BRAKE BP R1 BOBTAIL PROPORTIONING QUICK RELEASE 9 FIGURE 4 E 8P SECTIONAL VIEW UPPER BODY SUP 2 DEL 1 DEL 2 14 ...

Page 561: ...ve such as broken air lines and broken or missing parts Every 3 months or 25 000 miles or 900 operating hours Clean any accumulated dirt gravel or foreign material away from the heel of the treadle plunger boot and mounting plate OPERATION Refer to Figure 3 APPLYING NORMAL OPERATION NO 1 OR PRIMARY CIRCUIT PORTION When the brake treadle is depressed the plunger exerts force on the spring seat 26 g...

Page 562: ... with genuine Bendix parts available at authorized Ben dix parts outlets Refer to figures 4 5 and 6 for item numbers referenced in parenthesis REMOVAL 1 Chock the vehicle wheels or park the vehicle by mechanical means Block and hold vehicle by means other than air brakes Drain all air system reservoirs 2 Identify and disconnect all supply and delivery lines at the brake valve 3 Remove the brake va...

Page 563: ...R BODY EXHAUST COVER ATTACHING SCREWS QTY 4 BODY ATTACHING SCREWS QTY 4 12 UPPER BODY 14 16 28 9 17 24 32 11 10 13 14 9 30 LOWER BODY BODY ATTACHING SCREWS QTY 4 12 EXHAUST COVER ATTACHING SCREWS QTY 4 21 31 33 UPPER BODY 20 8 2 5 34 6 19 16 18 1 7 4 FIGURE 5 E 8P BRAKE VALVE EXPLODED VIEW FIGURE 6 E 10P BRAKE VALVE EXPLODED VIEW ...

Page 564: ...lobal operation trouble m e n u search search shooting FIGURE 5 E 8P BRAKE VALVE EXPLODED VIEW FIGURE 6 E 10P BRAKE VALVE EXPLODED VIEW FIGURE 5 E 8P BRAKE VALVE EXPLODED VIEW FIGURE 6 E 10P BRAKE VALVE EXPLODED VIEW ...

Page 565: ...rotate clockwise until the top surface of the spring seat is even with the top surface of the piston Set aside 6 Place relay piston spring 21 in concave portion of relay piston 20 and install relay piston through primary inlet exhaust assembly 33 into under side of upper body 7 For E 10P only Install o ring 4 on adapter 1 and install adapter on upper body Install o ring 34 on pri mary piston 2 8 P...

Page 566: ...jury resulting from contact with moving rotating leaking heated or electrically charged com ponents 6 Never connect or disconnect a hose or line con taining pressure it may whip Never remove a component or plug unless you are certain all sys tem pressure has been depleted 7 Never exceed recommended pressures and always wear safety glasses 8 Do not attempt to install remove disassemble or assemble ...

Page 567: ...9 main local global operation trouble m e n u search search shooting BW2066 AlliedSignal Truck Brake Systems Co 7 1999 Printed in USA ...

Page 568: ......

Page 569: ...ry failure occur in the service brake system 3 Prevents compounding of service and spring forces The valve has one park control one service control one supply one balance four delivery NPTF ports and an exhaust port protected by an exhaust diaphragm The valve incorporates two mounting studs for mounting the valve to the frame rail or cross member where applicable MOUNTING STUDS 2 EXHAUST 42 CONTRO...

Page 570: ... UPPER BODY VALVE RETAINER SPRING LOWER BODY SPRING CHECK VALVE GUIDE O RING O RING DOUBLE CHECK VALVE O RING CHECK VALVE COVER DIAPHRAGM WASHER RETAINING RING VALVE SEAT DIAPHRAGM 10 TORX HEAD SCREW RETAINING RING O RING O RING EXHAUST PORT FIGURE 2 SECTIONAL VIEW OF SR 7 USED IN RELAY VALVE APPLICATIONS IN LINE SINGLE CHECK VALVE SPRING BALL CHECK VALVE O RING O RING O RING O RING LOWER VALVE GU...

Page 571: ...3 FIGURE 3 SYSTEM SCHEMATIC WITH PP DC PARK CONTROL FIGURE 4 SYSTEM SCHEMATIC WITH PP 1 PARK CONTROLAND DC 4 DOUBLE CHECK VALVE DC 4 ...

Page 572: ...FIGURE 6 Once the SR 7 valve delivery pressure reaches 107 psi nominal the inlet and exhaust are closed valve lap position This maintains the spring brake hold off pressure at 107 psi nominal BALANCE PORT SECONDARY RESERVOIR CONSTANT PRESSURE FIGURE 5 CHARGING LESS THAN 107 PSI à CONTROL LINE PRESSURE DELIVERY TO SPRING BRAKES INLET EXHAUST VALVE OPEN à à à à à à à à à à CONTROL PORT FIGURE 6 CHAR...

Page 573: ... dash valve button out exhausts spring brake air pressure through the SR 7 exhaust port FIGURE 8 PARKING INLET VALVE SEATED SECONDARY RESERVOIR CONSTANT PRESSURE CONTROL LINE PRESSURE AIR EXHAUSTS FROM SPRING BRAKES CONTROL PORT MAIN AND CONTROL PISTONS MOVE UP à à à à à à BALANCE PORT à à à à SECONDARY RESERVOIR CONSTANT PRESSURE CONTROL LINE PRESSURE BALANCE PORT PRIMARY CIRCUIT PRESSURE CONTROL...

Page 574: ...IT PRESSURE CONTROL PORT SECONDARY CIRCUIT PRESSURE SECONDARY RESERVOIR NO PRESSURE CONTROL LINE PRESSURE DELIVERY TO SPRING BRAKES CONTROL PORT LOSS OF SECONDARY CIRCUIT PRESSURE à à à à à à à à à à à à à MAIN PISTON MOVES UP à à à à à à à à à à à à BALANCE PORT PRIMARY CIRCUIT PRESSURE SERVICE APPLICATION WITH LOSS OF AIR IN SECONDARY CIRCUIT FIGURE 10 With the parking brakes released dash valve...

Page 575: ...Correct spring brake actuator hold off pressure is 107 psi nominally 3 Place parking control valve in park position gauge reading should drop to zero promptly A lag more than 3 seconds in drop of pressure would indicate faulty operation 4 With the parking control valve in the park position gradually apply foot brake valve and note a pressure reading increase on the gauge installed in the SR 7 deli...

Page 576: ...ad and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 9 Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc should be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 10 Components w...

Page 577: ... FRONT AND TAG AXLE STUDS 5 7 HUB MOUNTED WHEELS 6 7 1 CARE OF WHEELS 6 8 FRONT AND TAG AXLE WHEEL HUBS 6 8 1 HUB BEARING INSPECTION 6 9 DRIVE AXLE WHEEL HUBS 7 9 1 BEARING ADJUSTMENT 7 9 2 DISASSEMBLY AND REPAIR 7 10 CHANGING A FLAT TIRE 8 11 TIRE MAINTENANCE 8 11 1 INFLATION PRESSURE 8 11 2 TIRE MATCHING 9 11 3 WHEEL BALANCING 10 11 4 TIRE ROTATION 10 12 SPECIFICATIONS 11 ILLUSTRATIONS FIGURE 1 ...

Page 578: ...ns Check all parts for damage and make sure that wheel nuts are tightened to the proper torque In the case of a new vehicle or after a wheel installation stud nuts should be tightened every 100 miles 160 km for the first 500 miles 800 km to allow setting in of clamping surfaces Wheel studs and nuts must be kept free from grease and oil No lubricant whatsoever should be used Cleanliness of the whee...

Page 579: ... 500 lbf ft 610 680 Nm for aluminum wheel CAUTION Insufficient mounting torque can result in damage to parts Excessive mounting torque can cause studs to break and the wheel to crack in stud hole area 3 DUAL WHEELS 3 1 OUTER WHEEL REMOVAL Same as described in Single Wheel Removal procedure described previously 3 2 INNER WHEEL 1 Remove outer wheel 2 Unscrew inner cap nuts 3 Remove inner wheel 3 3 I...

Page 580: ...l The following measures should be taken to maintain original appearance of the aluminum wheels 1 Remove any tar from wheel surface with a good quality tar remover 2 Spray Alcoa Cleaner Prévost 683529 evenly on cool outer surface of wheel Let work 15 20 minutes keep wet by spraying more Cleaner if necessary 3 Rinse thoroughly with clean water and let air dry Heavy oxidation may require a repeat ap...

Page 581: ...h side of the broken one must also be replaced since they could have been subjected to excessive strain and may be fatigued When installing wheel studs to hubs check nuts retaining the wheel stud to wheel hub and replace if they are deformed damaged or severely corroded Install nut and washer where applicable to new stud Torque to 450 500 Ft lbs 610 680 Nm NOTE For stud mounted wheels turn nuts co...

Page 582: ...in doubt renew Do not simply retighten very loose wheel fixings or wheels that are continually becoming loose Find out why they are loose and whether any damage has been caused Use trained personnel and keep records of all attention to wheels and fixings including which parts were renewed and when 8 FRONT AND TAG AXLE WHEEL HUBS The unitized hub bearings used on the NDS range of axles are non serv...

Page 583: ...y Replace the lock ring and adjust nut dowel pin in one of the holes The ring may be turned over if necessary to allow more accurate bearing adjustment 4 Tighten lock nut and check bearing adjustment Replace the axle shaft using a new gasket 9 2 DISASSEMBLY AND REPAIR 1 Jack vehicle as per Bearing Adjustment and remove axle shaft as indicated in Meritor Maintenance Manual No 5 entitled Single Redu...

Page 584: ...azards of under inflation always maintain tires at their recommended inflation pressure Improper inflation decreases tire life An under inflated tire builds up heat that can cause sudden tire destruction resulting in improper vehicle handling and possible loss of vehicle control At least once a week before driving when tires are cold check inflation pressure on all the tires including the spare ti...

Page 585: ...re wear and adversely affect road holding of the vehicle which may lead to loss of vehicle control FIGURE 7 TIRE LIFE INFLATION PRESSURE 13010 WARNING Recommended tire inflation pressures and maximum allowable loads apply to speeds up to 65 mph 105 km hr Do not drive vehicle at a higher speed than 65 mph 105 km h or above the posted speed limit WARNING All tires on the same axle should always be i...

Page 586: ...g Wheel Straightness Check WARNING When balancing wheel and tire assemblies it is strongly recommended to closely follow instructions covering the operation of wheel balancer CAUTION A maximum of 16 oz 450 g of balancing weight is recommended If more weight is necessary check and correct the cause 11 4 TIRE ROTATION Radial tires should be rotated only when necessary If the tires are wearing evenly...

Page 587: ...ertification plate according to the tire selection WARNING Special tire selection may lower maximum allowable speed limit even below posted speed limit For maximum safety check with tire manufacturer CAUTION Bus shell vehicles should be weighed fully loaded and tires pressurized according to tire manufacturer s recommendations WARNING Recommended tire inflation pressures and maximum allowable load...

Page 588: ......

Page 589: ...ite 207 Mississauga Ontario Canada L5R 3L1 800 668 1150 Alcoa Inc Wheel Products International 1600 Harvard Ave Cleveland Ohio 44105 800 242 9898 www alcoawheels com 08 02 New Dura Bright wheels shed dirt brake dust and grease Wash them off no scrubbing no special chemical solutions and watch them shine ...

Page 590: ...a Wheel Service Center at 800 242 9898 option 2 or 888 279 3055 Limited Warranty FOR HEAVY DUTY TRUCKS TRUCK TRAILERS AND BUSES Dura Bright wheels denoted by Alcoa part numbers ending with a 4 and 7 with bead seat diameters measured in 0 5 inch increments Do not exceed maximum wheel load Customer must compare OEM vehicle load raiting to maximum wheel load rating Refer to tire manufacturer s recomm...

Page 591: ...mum of one inch from the periphery of any hand hole 3 Location of stamped identification on inside of wheel should be as close to the factory identification stamping as possible Note Use of an impression stamp on Dura Bright wheels can affect the appearance and performance of the Dura Bright surface treatment local to the stamp Owner in service identification Irregular wear on the sruface of the r...

Page 592: ...mum of one inch from the periphery of any hand hole 3 Location of stamped identification on inside of wheel should be as close to the factory identification stamping as possible Note Use of an impression stamp on Dura Bright wheels can affect the appearance and performance of the Dura Bright surface treatment local to the stamp Owner in service identification Irregular wear on the sruface of the r...

Page 593: ...a Wheel Service Center at 800 242 9898 option 2 or 888 279 3055 Limited Warranty FOR HEAVY DUTY TRUCKS TRUCK TRAILERS AND BUSES Dura Bright wheels denoted by Alcoa part numbers ending with a 4 and 7 with bead seat diameters measured in 0 5 inch increments Do not exceed maximum wheel load Customer must compare OEM vehicle load raiting to maximum wheel load rating Refer to tire manufacturer s recomm...

Page 594: ......

Page 595: ...ly wash away brightens the wheel Now your wheels can look their best with less effort than with any previous steel or aluminum wheel That lets you save money and time and still hit the road with clean bright good looking wheels on your trucks and trailers Along with faster easier cleaning and maintenance you get all the advantages you ve come to expect from Alcoa aluminum wheels including less wei...

Page 596: ...ailable are listed below Other wheel part numbers may be available upon request Contact your Alcoa sales representative for availability Do not exceed maximum wheel load Customer must compare OEM vehicle load rating to maximum wheel load rating Do not overinflate Refer to tire manufacturer s recommendation for proper tire pressure Before mounting the tire perform a wheel fitment check to ensure pr...

Page 597: ......

Page 598: ...r alkaline Dura Bright Surface Treated Wheels are warranted against a Filiform corrosion worm or hair like lines generally milky in appearance underneath surface protective treatment and emanating from damage to the surface treatment such as nicks scratches or damage from mounting hardware or wheel weights b Blistering due to loss of adhesion of the surface treatment c Lift off of the surface trea...

Page 599: ...t thread engagement stud located wheels ball seat mounting 29 4 9 Tightening stud located ball seat cap nuts 29 4 10 Single dualed and wide base wheels hub piloted mounting two piece flange nuts 31 4 11 Tightening hub piloted mounting two piece flange nuts 32 4 12 Incorrect assemblies 34 5 Proper Torque Wheel Identification Valves and Surface Maintenance 35 5 1 Avoid abuse 35 5 2 Keep wheel nuts t...

Page 600: ...lt hole diameter 3 22 5x7 50 15 DC 7200 53 6 28 5 32 120 TR545D 873100 3 4 016000 1 1 8 017000 2225 3 4 Stud 5995 L R 1 1 8 Stud 5996 L R 5988 L R 7896 L R 5996 L R 150 Front 076015 Rear 077015 DB 4 22 5x8 25 15 DC 7200 53 6 66 5 68 120 TR545D 883110 3 4 016000 1 1 8 017000 2225 3 4 Stud 5995 L R 1 1 8 Stud 5996 L R 5988 L R 7896 L R 5996 L R 150 Front 076015 Rear 077015 5 22 5x9 00 15 DC 9000 60 ...

Page 601: ... 011000 39874 39874 181 Front 076018 or 076085 Rear 077018 or 077085 DB DF 27 22 5x12 25 15 DC 11 000 71 5 8 4 68 120 TR545E 823660A 011000 39874 39874 181 Front 076018 or 076085 Rear 077018 or 077085 10 hole hub piloted mounting 285 75mm bolt circle 220 1mm hub bore 26 75mm bolt hole diameter use two piece flange nuts continued from previous page DB DF 28 22 5x12 25 15 DC 11 000 71 5 8 4 68 130 T...

Page 602: ...se 1 Capacity ratings as dual or single in highway service bias ply or radial Load ratings in lbs for items 39 through 50 rounded to nearest multiple of 5 2 Some wheels may bear part numbers not shown in this manual Before servicing these wheels contact your Alcoa wheel representative for proper load inflation and part compatibility information 3 Outset positive inset negative The distance from th...

Page 603: ...heel when the outer wheel is removed During tire changes thoroughly examine the entire wheel Pay particular attention to the rim contour and the surfaces of the rim On tube type wheels carefully inspect the gutter area normally concealed by the side rings Be sure that the best wheels are on the front of the vehicle Hidden damage Do not exceed maximum wheel load Customer must compare OEM vehicle lo...

Page 604: ...ed A wheel that has been exposed to excessive heat may appear to be in good condition if it has been cleaned Even if a wheel does not appear to be obviously burned check the valve hole and labels for evidence of charring melting blistering or burning A wheel may discolor from excessive heat It can appear a dull grayish color and will not polish to a bright finish as a typical wheel would Any wheel...

Page 605: ...re the circumference of the bead seat on the open side see illustration below with a ball tape Ball tapes used for measuring wheel circumference can be purchased from the Tire and Rim Association Inc 175 Montrose West Avenue Copley Ohio 44321 If the circumference of the bead seat does not match the required dimension as indicated by the ball tape remove the wheel from service Be sure to clearly ma...

Page 606: ...ear can also be caused by improperly seated tires Inspect the tire for proper seating on the wheel The tire beads may not be seated properly If so remove the wheel from the vehicle deflate and break the bead seats see 3 5 page 22 for recommendations and instructions for demounting tubeless tires and 6 5 page 43 for recommendations and instructions for demounting tube type tires Adequately lubricat...

Page 607: ...racks emanating from stud hole to stud hole Causes are undersized diameter of wheel support surface see specifications below support surface not flat incorrect attachment parts see 4 12 page 34 and insufficient torque see 4 9 page 29 and 5 2 page 35 Remove wheel from service Support surface should be flat to the diameter recommended on the chart on the following page Inspect the hub drum contact a...

Page 608: ...Some of these are salt chloride compounds used for snow removal and highly alkaline materials If the air used to fill tubeless tires or the tire itself is not dry the areas of the wheel under the tire can corrode severely Bead seat and valve stem corrosion often are caused by entrapped moisture which contains corrosive elements Mild corrosion should be removed thoroughly by wire brush and the rim ...

Page 609: ...can lead to damaged ball seats on stud located wheels and can damage the disc surface of hub piloted wheels Remove damaged wheels from service Damaged hub piloted bolt hole Elongation from true round dashed circle indicated by arrows Damaged ball seat contact area Pounding of nut on ball seat contact area identified by arrows Disc area 2 8 Inspect both sides of disc area for hand hole cracks If cr...

Page 610: ...the gutter Such projections must be removed Remove the wheel from service if damaged Cracking in bottom of gutter flange Occasionally circumferential cracks may appear in the bottom of the gutter area This area should be thoroughly cleaned and carefully inspected after a tire is removed from the wheel Also check the side underneath gutter flange for circumferential cracks Gutter flange cracks can ...

Page 611: ...able Rim Gauge Alcoa P N 000700 Daylight in this area indicates acceptable rim No daylight in this area indicates excessive wear Remove from service immediately Irregular wear on the surface of the rim flange is caused by abrasion from the tire chafer and sidewall Rim flange wear happens most often in applications with heavy or shifting loads If you are experiencing excessive rim flange wear in yo...

Page 612: ...g sharp enough to cut the rubber on the sharpness indicator gauge the edge can be removed per the edge removal procedures below If the rubber is not cut then the wheel can be returned to service without further work for rim flange wear Photo 2 A rubber sharpness gauge constructed from a section of tire side wall or a suitable piece of rubber attached to a block of wood Photo 3 Run the sharpness in...

Page 613: ...ethod of removing the edge Operators should use all care to keep a uniform edge when using these tools photo 5 Air or Electric Grinder Another quick and effective method of removing the sharp edge caused by rim flange wear Be careful as grinding pads may gum up from the aluminum that is removed photo 6 Care must be used to avoid gouging the wheel Edge Removal Procedures Photo 4 Removing sharp edge...

Page 614: ...gh metal to smooth the edge Take care to make sure the edge removal is as uniform as possible Avoid gouging the wheel 16 2 Rim flange wear continued CAUTION Removing sharp edges with hand or power tools produces metal filings and sparks Many power tools have edges that are sharp or may become hot during use Some power tools produce excessive noise when used Metal filings can be sharp and when proj...

Page 615: ...ice Manual or OSHA safety wall charts and procedures 17 2 Rim flange wear continued WARNING Welding or brazing the rim flange or any area of an Alcoa aluminum wheel will weaken the wheel Weakened or damaged wheels can lead to an explosive separation of tires and wheels or wheel failure on the vehicle Explosive separations of tires and wheels or wheel failure on the vehicle could cause injuries or ...

Page 616: ...l for damage Do not use a damaged or severely corroded wheel See Section 2 page 5 4 Clean the wheel face with mild detergent and the tire bead seat areas with a wire brush Be sure the wheel is dry before applying tire lubricant 5 Inspect the tire for damage Be sure the inside of the tire is dry before it is mounted 6 Use of a non water based lubricant is recommended as a rim surface protectant and...

Page 617: ...parate violently This violent separation can cause serious injury or death Always contain the tire wheel assembly in an inflation cage during inflation WARNING WARNING Recommendations for mounting tubeless tires continued Position wheel on machine Lubricate wheel entire air chamber surface and tire bead using approved lubricant Tire beads should be mounted over the rim flange closest to the wheel ...

Page 618: ... Fulfillment Markinetics Inc P O Box 809 Marietta OH 45750 WARNING Use of a volatile or flammable material such as ether or gasoline as an aid to seating the tire beads on the wheel can lead to an uncontrolled pressure build up in the tire and may result in an explosion Explosive separation of the tire and wheel can occur while seating beads in this manner while adding air to the tire or later on ...

Page 619: ...00 Tire Size Tire Size for both radial Approved for both radial Approved and bias tires Rim Widths and bias tires Rim Widths Recommendations for demounting tubeless tires 3 4 WARNING An aluminum wheel can be structurally weakened by uncontrolled excessive heat Tire wheel assemblies using wheels that have been exposed to excessive heat may experience a sudden and unpredictable tire wheel separation...

Page 620: ...tween bead and flange a short distance from the spanned area Pry bead free of rim repeating process until entire bead is free from wheel Insert straight end of tire tool between beads and both rim flanges hooking stop on the tool over second flange Position inserted tool at 90 angle to tire assembly at top of wheel and lubricate bead areas on both sided of tool Lean tire assembly toward tool and r...

Page 621: ...lace the studs on each side of the broken stud If two or more studs are broken replace all the studs for that wheel position Check with the stud manufacturer for regular maintenance and stud replacement practices All wheel fastener hardware should be grade 8 or metric conversion 10 9 Follow the hardware manufacturer s recommendations when replacing studs 6 Do not introduce any foreign objects such...

Page 622: ...ead flange nut Mounts dualed wheels with 32mm bolt holes to wheel centering hubs Right hand threads used on both sides of vehicle P N 4307 32 M22x1 5 RH threads 2 piece 33mm hex head flange nut Mounts single wheels to wheel centering hubs with 32mm bolt holes Right hand threads used on both sides of vehicle P N 4306 32 M22x1 5 RH threads 1 1 8 cap nut Mounts standard single wheels and wide base wh...

Page 623: ...ounting surface Mounting surface End of stud End of stud 4 Stud located ball seats are spherical 4 4 The nut seat for the stud located ball seat mounting system is a precision machined spherical surface Cap nuts must be properly manufactured to assure correct seating Never use one or two piece flange nuts on a wheel designed with ball seats see 4 12 page 34 Ball seat cap nuts may be obtained from ...

Page 624: ...ce treated wheels to protect the wheel contact surfaces from marring DiscMate wheel spacers are placed between the contact surfaces of the Dura Bright wheel and the brake drum as shown below Correct single mounting with 1 1 8 inch stud located ball seat mount Correct single mounting with 3 4 inch stud located ball seat mount Dualed wheels stud located ball seat mounting 4 6 Rear wheels are most fr...

Page 625: ...placed between the contact surfaces of the Dura Bright wheel and the brake drum and between the dual aluminum wheels as shown below On occasion Alcoa aluminum truck wheels are operated dualed with a steel inner wheel In the event a steel inner wheel is used extreme care must be exercised to properly seat it to the hub or drum prior to mounting the outer aluminum wheel Selection of an inner cap nut...

Page 626: ... can run loose cause stud breakage and disengage from the vehicle which can cause serious injury or death Loose running wheels can lead to stud breakage Use only cap nut 7896R or L or its equivalent when mounting steel inner duals WARNING Inadequate wheel support surface can lead to stud hole to stud hole fracture resulting in separation of the outer disc and rim from the vehicle Separation of the...

Page 627: ... seat cap nuts 4 9 The number of turns to disengage a 1 1 8 inch nut should be at least five full turns At least seven full turns should be required to disengage a 3 4 inch nut WARNING Lubricants should not be applied to the cap nut seat or to the cap nut to wheel contact surface Oiled seats can lead to over torquing which can stretch studs causing failure of studs Failed studs can cause the wheel...

Page 628: ...wheel hub or drum Do not use aerosol cans for lubrication of stud threads On vehicles equipped to accept wheels manufactured for use with the stud located ball seat mounting system wheel studs on the right side of the vehicle have right hand threads and those on the left have left hand threads The R and L on the studs and nuts indicate right and left hand threads respectively see 4 2 page 24 After...

Page 629: ...to either the right or left side of the vehicle The same flange nut is used to mount dualed or single wheels Proper stud standout for single wheels is 2 inch 50 8mm minimum dualed wheels require 2 81 inch 71 4mm minimum and single wide base wheels require 2 32 inch 59mm Some states have laws which dictate full thread engagement or thread engagement past the nut body Make sure you know the laws for...

Page 630: ...Torquing of flange nuts should be done in recommended sequences WARNING Undertorqued flange nuts allow wheels to run loose and fatigue studs or lose nuts Overtorquing can stretch studs causing them to fail Both under and overtorquing can lead to wheel disengagement causing injury or death Check all parts including wheels studs and flange nuts Check mounting faces of wheels hubs and drums Check for...

Page 631: ...tighten all two piece flange nuts then tighten to the recommended torque following the proper sequence shown below for your type wheel After 50 100 miles of operation torque should be rechecked Check torque frequently from then on If nuts require frequent tightening studs break frequently or wheel bolt holes are pounding out hardware and mounting practices should be reviewed Do NOT lubricate the f...

Page 632: ... proper hardware assemblies The following are examples of incorrect wheel assemblies Incorrect use of ball seat cap nut Do not use ball seat cap nuts with hub piloted wheels Incorrect use of two piece flange nut Do not use two piece flange nuts with ball seat wheels Incorrect use of one piece flange nut positioned on Alcoa ball seat wheel Do not use one piece flange nut on ball seat wheels Little ...

Page 633: ...ure they are in good condition If nuts require frequent tightening or studs break frequently hardware and mounting practices should be reviewed For proper nut torque refer to the chart below Mount Nut Torque Level Ft Lb Torque Level Ft Lb Type Thread Lubricated Dry Hub piloted using 11 16 16 300 400 two piece flange nut M20 x 1 5 280 330 M22 x 1 5 450 500 Stud piloted double cap 3 4 16 350 400 450...

Page 634: ...for straightening to repair damage from striking curbs or other causes The special alloy used in these wheels is heat treated and uncontrolled heating will weaken the wheel Do not rework weld heat or braze Alcoa aluminum wheels for any reason This does not include normal wheel maintenance as described and approved by Alcoa Lead balance weights clip on 5 3 Lead balance weights for Alcoa wheels are ...

Page 635: ...es abrasive brushes steel wool scouring pads or strong chemicals such as acids or lye based products Never spray cold water on extremely hot wheels Always allow time to cool before cleaning 2 When tires are removed the entire rim must be cleaned and inspected see section 2 page 5 With a brush remove any foreign products from the tire side of the rim portion of the wheel that supports the tire Do n...

Page 636: ... such as Alcoa DiscMates is highly recommended The use of the Alcoa Hub Cover System on Alcoa Dura Bright wheels will also assist in limiting such damage and help maintain the appearance of your Alcoa Dura Bright wheels Identification 5 9 Alcoa wheel identification Since 1977 all Alcoa aluminum disc wheels have been identified with a stamp that shows the wheel load rating maximum inflation pressur...

Page 637: ...Chart The following is the Alcoa Aluminum Wheel inter changeability information from the OSHA Multipiece Rim Matching Chart For a complete matching chart write to U S Department of Labor Occupational Health and Safety Administration Publications Department Room N4101 Washington DC 20210 Read across the chart to find interchangeable components for specific size and type of Alcoa wheel The informati...

Page 638: ...ck ring which is not clearly identifiable WARNING Use of a Firestone 5 side and lock ring assembly with a wheel machined for Firestone DT or Goodyear LW split side ring and vice versa can lead to explosive separation of wheel and tire An explosive separation of miss matched wheel components can lead to injury or death Alcoa Aluminum Disc Wheels are available to accept 1 Firestone 5 side and lock r...

Page 639: ...ing groove If a split side ring is required start the leading edge and walk the side ring onto the wheel Seat the second end of the split side ring or lock ring with a rubber plastic or leather facet mallet as shown Check carefully to see that the split side ring or side ring and lock ring assembly is in the proper position If not completely remove the components and start over Inflate to 10 psi C...

Page 640: ...en subjected to uncontrolled excessive heat such as a tire fire wheel bearing failure or braking system drag seize or a high pressure tire wheel separation 1 Before removing wheel from vehicle remove the valve core from the valve stem to ensure complete deflation of tire 2 Do not gouge or nick the wheel Place aluminum wheels on a clean wooden floor or rubber mat 3 Always use a rubber leather faced...

Page 641: ...are if gouging the rim is to be avoided A stop welded to the tool is recommended Insert the tapered end of the tire tool into the notch on the locking ring Pry up carefully to avoid bending the ring and gouging the wheel Using the same procedures as outlined in Step 1 loosen the bead on the opposite side of the wheel Do not drive tools into rim area Lift wheel from tire Once the tool is inserted p...

Page 642: ...ster which contains at least the same instructions safety precautions and other information contained in the charts that is applicable to the types of wheels being serviced Installing a rim wheel means the transfer and attachment of an assembled rim wheel onto a vehicle axle hub Removing means the opposite of installing Mounting a tire means the assembly or putting together of the wheel and tire c...

Page 643: ...nuals and the contents of this standard iii Where an employer knows or has reason to believe that any of his employees is unable to read and understand the charts or rim manual the employer shall assure that the employee is instructed concerning the contents of the charts and rim manual in a manner which the employee is able to understand 2 The employer shall assure that each employee demonstrates...

Page 644: ...in line valve with a pressure gauge or a presettable regulator and iii A sufficient length of hose between the clip on chuck and the in line valve if one is used to allow the employee to stand outside the trajectory 5 Current charts or rim manuals containing instructions for the type of wheels being serviced shall be available in the service area 6 The employer shall furnish and assure that only t...

Page 645: ...ess the employer can demonstrate that performance of the servicing makes the employee s presence in the trajectory necessary 11 No heat shall be applied to a multi piece wheel or wheel component f Safe operating procedure single piece rim wheels The employer shall establish a safe operating procedure for servicing single piece rim wheels and shall assure that employees are instructed in and follow...

Page 646: ...uce accidents among employees who service large vehicle rim wheels Reprints of the charts are available through the Occupational Safety and Health Administration OSHA Area and Regional Offices The address and telephone number of the nearest OSHA office can be obtained by looking in the local telephone directory under U S Government U S Department of Labor Occupational Safety and Health Administrat...

Page 647: ... which supports the rim DISC WHEEL A one piece forged or two piece welded assembly of a disc and a rim DROP CENTER The well or center portion of the wheel rim FLAT BASE WHEEL A multi piece wheel with a removable side ring FOOT POUNDS The measure of the amount of torque applied to a cap nut or other part May be measured with a torque wrench GUTTER FLANGE A groove which supports the removable portio...

Page 648: ...iation for pounds per square inch REVERSIBLE Term applied to a disc wheel which can be reversed on the hub without changing the position of the tire centerline RIM CENTERLINE A line to the radial axis of the wheel running through the mid point between the rim flanges RIM FLANGE That portion of the rim which extends above the rim surface which retains the tire bead RIM That portion of the wheel whi...

Page 649: ... is equal to or greater than the tire manufacturer s recommendation there will be sufficient minimum dual spacing Wheel inset and outset is given for each Alcoa wheel on pages 2 and 3 Both inset and outset wheels are measured from the mounting surface of the wheel to the center line of the rim Maintaining proper tire inflation and load ratings are essential to maintaining proper minimum dual spaci...

Page 650: ...52 9 Inch Fraction Decimal and Millimeter Equivalents Chart Up to 1 inch 9 1 9 Conversion Tables ...

Page 651: ...limeters to Inches Millimeters x 0 03937 Inches PSI to kPa PSI x 6 8948 kPa kPa to PSI kPa x 0 145 PSI Pounds to Kilograms Pounds x 0 4536 kg Kilograms to Pounds kg x 2 2050 Pounds Foot pounds to Kilogram Meters Ft lbs x 0 13826 kgm Kilogram Meters to Foot pounds kgm x 7 23 Ft lbs ...

Page 652: ... Wheel and Forged Products 1600 Harvard Avenue Cleveland Ohio 44105 800 242 9898 www alcoawheels com Copyright 2004 Alcoa Wheel and Forged Products All Rights Reserved Form E37 13584 Printed in USA 03 05 30M ...

Page 653: ...ESCRIPTION 5 6 2 REMOVAL AND INSTALLATION 5 6 3 MAINTENANCE 6 7 STEERING WHEEL 6 7 1 REMOVAL 6 7 2 INSTALLATION 6 8 STEERING COLUMN 6 8 1 REMOVAL 6 9 TURNING ANGLE ADJUSTMENT 6 10 STEERING LINKAGE ADJUSTMENT 7 11 PITMAN ARM 7 11 1 REMOVAL 7 11 2 INSTALLATION 8 11 3 ADJUSTMENT 8 12 MAINTENANCE 8 12 1 POWER STEERING RESERVOIR AND FILTER 9 12 1 1 Oil Level Check Procedure 9 12 1 2 Filter Replacement ...

Page 654: ...PARTMENT 4 FIGURE 4 STEERING COLUMN 6 FIGURE 5 STEERING STOP SCREW 6 FIGURE 6 DRAG LINK TO BELL CRANK CONNECTION 7 FIGURE 7 PITMAN ARM ADJUSTMENT 7 FIGURE 8 FIXING NUT PUNCH MARK 8 FIGURE 9 DRAG LINK INSTALLATION 8 FIGURE 10 HYDRAULIC FLUID RESERVOIR LOCATION 9 FIGURE 11 POWER STEERING FLUID RESERVOIR 10 FIGURE 12 DRAG LINK COMPONENTS 10 ...

Page 655: ...transfers the turning motion of the steering wheel to the steering arms Hydraulic components are added to transmit increase and regulate steering control forces These elements are 1 A hydraulic power cylinder 2 A vane type hydraulic pump and 3 Hydraulic reservoir and hoses The hydraulic power cylinder provides an added source of assistance and being connected to the R H wheel makes it such that th...

Page 656: ...torsion bar which is pinned with the valve slide and the worm keeps the control valve in the neutral position as long as no opposing force is applied to the steering wheel The steering housing contains a pressure relief valve which limits the discharge pressure of the oil pump to the maximum value required A replenishing valve can also be used through which oil is sucked from the return if steerin...

Page 657: ...G Perform troubleshooting of the steering gear as outlined in the ZF SERVOCOM Repair Manual the ZF SERVOCOM Operating Servicing Maintenance and Inspection Instructions and the TRW Power Steering Pump Service Manual NOTE For vehicles equipped with ZF SERVOCOMTRONIC unit refer to the supplement to the repair manual ZF SERVOCOM 6 POWER STEERING HYDRAULIC PUMP 6 1 DESCRIPTION The power steering pump i...

Page 658: ...e accessible from the front driver s area To access these joints proceed as follows 1 From the front driver s compartment area remove the three plastic fasteners on steering column lower cover Remove the lower cover Fig 4 2 Unscrew the four retaining screws on steering column middle cover 3 Unscrew the four retaining screws fixing steering column upper cover to middle cover Remove the steering col...

Page 659: ...ly detected while rotating the steering wheel in both directions Replace defective parts CAUTION Front wheel alignment should be checked and adjusted if necessary any time a component of the steering system is repaired disassembled or adjusted Refer to section 16 Suspension under heading 7 Front End Alignment 11 PITMAN ARM 11 1 REMOVAL 1 Remove cotter pin nut and washers from drag link ball stud a...

Page 660: ...ng a protractor check the angle of the pitman arm refer to Fig 7 for details 3 The pitman arm should be adjusted with reference marks aligned or to an angle of 90 in relation with the vertical axis towards front of vehicle If not unscrew and remove fixing nut Remove the pitman arm according to the procedure outlined under previous heading Pitman arm removal Adjust to the proper angle 4 When adjust...

Page 661: ... Every precaution should be taken to prevent entry of dirt grit lint or other foreign matter into lubricant containers Replace fittings that have become broken or damaged Lubrication intervals as well as the recommended lubricants for the steering components are given in the Lubrication And Servicing Schedule in Section 24 of this manual The intervals given in the schedule are recommended for norm...

Page 662: ...turn the steering wheel when the vehicle is stationary and especially when service brakes are applied wheel locking will oppose the effect of steering geometry which tends to make the front wheels rotate in opposite directions Persisting in turning or maintaining the steering wheel with an extra effort could make the hydraulic system work at the relief pressure and consequently cause the hydraulic...

Page 663: ...75 psi 150 Bar Gear ratio center 22 2 1 Gear ratio extremities 26 2 1 Minimum pump flow for 1 5 hwt sec 4 22 gpm 16 lpm Power Steering Gear Make ZF SERVOCOM Model 8098 Supplier number 8098 988 570 Prevost number 661045 F E W 16 600 lbs 7 545 kg Pressure rating 2 175 psi 150 Bar Gear ratio center 22 2 1 Gear ratio extremities 26 2 1 Minimum pump flow for 1 5 hwt sec 4 22 gpm 16 lpm Power Steering P...

Page 664: ...fler Oil capacity 4 US qts 3 7 liters Supplier number 91410A Prevost number 660982 Make Nelson Muffler Element filter Supplier number 83804 E Element filter Prevost number 660987 Power Steering Hydraulic Cylinder Make Hyco Supplier number 007 0300 0 Prévost number 661076 ...

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Page 823: ...TEERING ARMS 11 2 9 1 Removal 11 2 9 2 Installation 11 2 10 LUBRICATION FITTINGS 11 3 BALL JOINTS 13 3 1 LOWER AND UPPER A ARM BALL JOINT 13 3 1 1 Inspection 13 3 1 2 Stripping Down 13 3 1 3 Assembly 14 3 2 LOWER A ARM CENTRAL BALL JOINT 14 3 2 1 Inspection 14 3 2 2 Stripping Down 14 3 2 3 Assembly 14 3 3 UPPER A ARM CENTRAL BALL JOINT 15 3 3 1 Visual Inspection 15 3 3 2 Play Measurement 15 4 FRON...

Page 824: ... 4 Bushing installation 27 8 3 5 Installation 28 9 SUSPENSION HEIGHT ADJUSTMENT 28 10 HEIGHT CONTROL VALVE 29 10 1 LOADING POSITION 30 10 2 NEUTRAL POSITION 30 10 3 UNLOADING POSITION 30 10 4 MAINTENANCE 30 10 5 REMOVAL AND INSTALLATION 30 11 LEVEL LOW LEVELING SYSTEM 30 11 1 PRINCIPLES OF OPERATION 31 11 2 MAINTENANCE 31 12 AIR SYSTEM 31 12 1 AIR TANK MAINTENANCE 32 12 1 1 Wet Air Tank 32 12 1 2 ...

Page 825: ...RAL BALL JOINT 15 FIGURE 21 STEERING LINKAGE MEASURE 16 FIGURE 22 FRONT END ALIGNMENT DIAGRAM 18 FIGURE 23 AIR SPRINGS 19 FIGURE 24 AIR SPRING AND SHOCK ABSORBER 20 FIGURE 25 SHOCK ABSORBER 21 FIGURE 26 SWAY BAR FRONT SUSPENSION 22 FIGURE 27 SWAY BAR REAR SUSPENSION 22 FIGURE 28 REAR SUSPENSION COMPONENTS 23 FIGURE 29 DETAILS OF REAR SUSPENSION 23 FIGURE 30 TAG AXLE SUSPENSION 23 FIGURE 31 AIR SPR...

Page 826: ...l The bell crank and idler arm are connected by a relay rod A drag link connected to the bell crank and the pitman arm which is mounted to the steering gear transfers the turning motion of the steering wheel to the steering arms The hydraulic power cylinder provides an added source of assistance and being connected to the R H wheel makes it such that the total steering forces are produced with min...

Page 827: ...t in this section To check steering maximum turning angle proceed with the following method 1 Check if front tires rub against the frame or if the steering gear has been serviced CAUTION If clamps are not correctly installed they can interfere with other parts 2 For a full left and right turn check clamps position and for interfering parts Refer to figures 2 to 7 for location and positioning of cl...

Page 828: ...SPENSION PA1553 6 FIGURE 3 CLAMP POSITIONING 16169 FIGURE 4 CLAMP POSITIONING 16178 FIGURE 5 CLAMP POSITIONING 16172 FIGURE 6 CLAMP POSITIONING 16179 FIGURE 7 CLAMP POSITIONING 16170 FIGURE 8 CLAMP POSITIONING 16171 ...

Page 829: ...T 14057 2 3 PITMAN ARM REMOVAL 1 Remove cotter pin nut and washer from drag link ball stud at pitman arm 2 Disconnect drag link from pitman arm using jaw style pullers pressure screw type WARNING Always wear approved eye protection when operating pullers CAUTION Do not drive pitman arm on or off pitman shaft as this can damage the steering gear CAUTION Heating of components to aid in disassembly i...

Page 830: ... change position of pitman arm 4 Install stud with nut and torque to 150 200 lbf ft 203 271 Nm Align nut with cotter pin slot tighten and install a new cotter pin 5 Torque mounting clamp bolt nut to 40 60 lbf ft 55 80 Nm then test the adjustment Front wheels should turn from right to left extremities without noticeable binding at drag link ends 2 6 BELL CRANK AND IDLER ARM Bell crank and idler arm...

Page 831: ...cording to figure 11 Grease must be able to exit the bell crank or idler arm mechanism For grease retainer installation use tool Prévost 110683 3 Install bell crank or idler arm onto its mounting spindle while holding the bell crank or idler arm slide on the bearing assembly thrust washer and secure using nut Fig 12 NOTE Apply grease on bearing before installation 4 Unscrew nut until bell crank or...

Page 832: ...absorb shocks Strike the studs with a brass hammer to loosen end assemblies 3 Remove stud nuts then remove studs 4 Position new relay rod studs into bell crank and idler arm then tap stud ends with a brass hammer to seat tapered surfaces 5 Install stud nuts Tighten nuts to 150 200 lbf ft 203 271 Nm torque Align cotter pin slot tighten and install a new cotter pin 2 8 TIE RODS Tie rod ends are conn...

Page 833: ...on 1 Install steering arm onto steering knuckle 2 Torque steering arm to steering knuckle fixing bolts Torque short bolt M20 X 65 to 520 575 lbf ft 705 780 Nm Torque long bolt M24 X 100 to 751 830 lbf ft 1018 1125 Nm 3 Position tie rod ball stud in steering arm and tap with a brass hammer to seat ball stud in steering arm Install nut on stud Torque nut to 150 200 lbf ft dry 203 271 Nm Tighten nut ...

Page 834: ... and the other on the crank bell every 6 250 miles 10 000 km with good quality lithium base grease NLGI No 2 Shell Retinax LX or equivalent Apply grease gun pressure to the fitting until lubricant appears at the top seal 6 Upper A Arm Central Ball Joint Lubricate at fitting until you see some grease on the relief valve nearby every 6 250 miles 10 000 km with good quality lithium base grease NLGI N...

Page 835: ... load on the joint in all of the degrees of freedom in an axial radial etc sense with a suitable lever tool After the load is taken off the joint has to spring back into its starting position Free play is not acceptable Separation of rubber from ball pin or external joint shell is in accordance with normal wear characteristics When the following characteristics are noted the joint is to be changed...

Page 836: ...all joint by lifting the front of the vehicle Apply a load on the joint in all of the degrees of freedom in an axial radial etc sense with a suitable lever tool After the load is taken off the joint has to spring back into its starting position Free play is not acceptable Separation of rubber from ball pin or external joint bushing shell is in accordance with normal wear characteristics When the f...

Page 837: ...e difference between the two dimensions is greater than 0 060 1 5mm then the ball joint should be replaced FIGURE 20 UPPER A ARM CENTRAL BALL JOINT 16116 4 FRONT END ALIGNMENT Proper front end alignment must be maintained to insure ease of steering and provide satisfactory tire life When making front end alignment inspections the vehicle must be level and empty with the full weight of the vehicle ...

Page 838: ... at the bottom B Fig 22 Front Axle Caster The inclination of the king pin from vertical in the fore and aft direction C Fig 22 4 2 FRONT END INSPECTION Before checking front end alignment make the following inspection 1 Check that the vehicle is at normal ride height see paragraph 9 Suspension Height Adjustment 2 Check the tires for proper inflation 3 Check wheel installation and run out 4 Check w...

Page 839: ... height from the floor Incorrect toe in results in excessive tire wear and steering instability with a tendency to wander 4 4 1 Toe In Check 1 Check the camber adjustment and adjust if necessary 2 Hoist the front of the vehicle and spin the wheels marking the centerline of the tire treads 3 Place the wheels in the straight ahead position and lower the vehicle to rest on the floor 4 Roll the vehicl...

Page 840: ... 16133 ALIGNMENT SPECS See Figure 22 Minimal Nominal Maximal Load Non converted Converted Non converted Converted Non converted Converted A WHEEL CAMBER 0 2 0 150 0 35 0 0 0 55 0 200 B KING PIN INCLINATION 8 not adjustable C CASTER 2 55 2 8 3 05 D E TOE IN 0 08 0 10 0 12 ...

Page 841: ...akage is detected replace bellows WARNING To prevent personal injury do not apply more than 10 psi 69 kPa air pressure to the unmounted air spring 5 2 REMOVAL NOTE Front air springs can be removed without removing the entire suspension assembly 1 Safely support vehicle at the recommended body jacking points and jack up body understructure 2 To gain access to a given air spring the corresponding wh...

Page 842: ...ary air system at normal operating pressure 95 125 psi 655 860 kPa coat the air line connections and air spring mounting areas with a water and soap solution Bubbles will indicate an air leak and none is permissible Repair or replace defective parts 7 Remove the hydraulic floor jack from under neath shock absorber bracket 6 SHOCK ABSORBERS The two front shock absorbers are double acting and telesc...

Page 843: ...n in figure 24 with the mounting stud protruding through the hole in the mounting bracket and the shock absorber eyes over the mounting pins Install the outer washer 6 Place a rubber joint and washer on the shock absorber mounting stud Place the lower shock absorber mounting stud nut and torque to 60 75 lbf ft 81 102 Nm 7 Place the upper mounting pin stud nut and torque to 70 85 lbf ft 95 116 Nm 7...

Page 844: ...Section 16 SUSPENSION PA1553 22 FIGURE 26 SWAY BAR FRONT SUSPENSION 16138D FIGURE 27 SWAY BAR REAR SUSPENSION 16014 ...

Page 845: ...23 8 REAR SUSPENSION For a description of all these systems refer to the appropriate heading in this section FIGURE 28 REAR SUSPENSION COMPONENTS 16140 FIGURE 29 DETAILS OF REAR SUSPENSION 16106 FIGURE 30 TAG AXLE SUSPENSION 16107 ...

Page 846: ... Removal NOTE Suspension air springs drive and tag axles can be removed without removing the entire axle assembly 1 Safely support vehicle at the recommended body jacking points To gain access to a given air spring the corresponding wheel can be removed as follows a Jack vehicle until the tire clears the ground and place safety supports under neath body CAUTION Only the recommended jacking points ...

Page 847: ...pins at the proper torque of 500 550 lbf ft 680 750 Nm when shock absorber replacement occurs If a shock absorber becomes inoperative complete unit must be replaced CAUTION When a shock absorber is found defective always replace with a new set on affected axle except if there has been a recent re placement of one unit The following method will help in determining if both shock absorb ers on the sa...

Page 848: ...and lower 3 Place the inner washers with washer convex side facing the shock absorber rubber bushing on each shock absorber pin Fig 33 4 Install the shock absorber eyes over the mounting pins then the outer washers with washer convex side facing the shock absorber rubber bushing on each shock extremity NOTE If shock absorber pins are removed they must be reinstalled using loctite see Parts Specifi...

Page 849: ... REMOVAL 16011 2 Place a flat steel disc slightly smaller than the outside diameter of the bushing Fig 35 3 Using an arbor press or a suitable driving tool press or drive the old bushing out of the rod and discard the bushing CAUTION Make sure to prevent the steel disc from contacting the radius rod end 8 3 4 Bushing installation 1 Lightly spray the inner and outer surfaces of radius rod bushing w...

Page 850: ...from the accessory air tank to the air springs is controlled by three height control valves The two rear valves are mounted to the subframe one on each inner side of rear wheelhousing and connected to the rear axles through an arm and link connection The front valve is mounted to the subframe at center of front sway bar and connected to the front air tank support Fig 38 The front height control va...

Page 851: ...ort on subframe to top of the lower air spring support on axle refer to figure 39 for more details If adjustment is required begin with the drive axle 2 Loosen the clamp on the height control valve rubber coupling and bring it up or down Fig 40 NOTE Allow suspension to stabilize before taking reading When the desired height is obtained tighten clamp Rear air springs clearance 1 With the vehicle at...

Page 852: ...lve After installation check for leakage using a soap and water solution 11 LEVEL LOW LEVELING SYSTEM Bus shells are equipped with LEVEL LOW leveling system The purpose of the LEVEL LOW is to adjust suspension in three separate points front rear right and rear left air springs in order to level vehicle body Three height control valves automatically control air pressure in the three separate points...

Page 853: ...VE posi tion the air is entrapped between air springs and five way three position air control valves to ensure the adjusted level will be kept WARNING Never move vehicle with selector knob in any other position than the DRIVE position 11 2 MAINTENANCE Since the kneeling action is issued from both the air system and electrical system refer to Section 12 Brake and Air System and Section 06 Electrica...

Page 854: ...a bottom drain valve Fig 42 It is recommended to purge the primary air tank by its bottom drain valve every 12 500 miles 20 000 km or once a year whichever comes first FIGURE 43 REAR VALVE LOCATION 12202 12 1 3 Secondary Air Tank This tank is located in front wheelhousing between air springs The tank is installed vertically and is provided with a bottom drain valve Fig 42 It is recommended to purg...

Page 855: ...ear valve is located in engine compartment and accessible from engine R H side door Fig 43 CAUTION No other point should be used to supply air system The maximum allowable air pressure is 125 psi 860 kPa The front valve is located in the front service compartment close to accessory air filter Fig 44 These two air valves are fitted with the same valve stems as standard tires and can be filled by an...

Page 856: ...2 Torque Rod Mounting Bracket Stud 4 90 110 122 150 Torque Rod Mounting Bracket Nut 4 140 155 190 210 Idler Arm and Bell Crank Mounting Spindle Nut 8 90 105 122 142 Jacking Point Bracket Nut 8 70 80 95 110 Sway Bar Bushing Collar Nuts 8 80 100 110 135 Sway Bar Link Upper and Lower Nuts Front Suspension 2 165 200 225 270 Sway Bar Link Upper Nuts Rear Suspension 2 100 120 135 160 Sway Bar Link Lower...

Page 857: ...l 1100 Type Mae West Nominal diameter 11 5 304 mm Supplier number 1R12 319 Prévost number 630259 Drive axle air springs Make Goodyear Tire and Rubber Model 1100 Type Double Flare Nominal diameter 11 5 292 mm Supplier number 1R11 088 Prévost number 630105 Front axle shock absorbers Make Arvin Color Black Piston Diam 1 5 8 inch Collapsed length 14 16 inches Extended length 22 44 inches Supplier numb...

Page 858: ... number 680039 Sway bar bushing Front Suspension Make Prévost Prévost number 630020 Sway bar bushing Drive Axle Make Prévost Prévost number 130953 Sway bar link Make Tennaco Automotive Supplier number 934400 Prévost number 630230 Shock absorber bushings Make Monroe Supplier number 45380 Prévost number 630062 Air regulator Make Norgren Recommended pressure sett 90 psi 621 kPa Supplier number R74G 4...

Page 859: ...uring regular maintenance schedules however at least linehaul applications every 100 000 miles vocational applications every 50 000 miles The visual inspection should include the shock itself leakage any irregularities shock bushings tires tire cupping The most common failures and their possible causes are compiled in this document By understanding the cause you may be able to correct the problem ...

Page 860: ...days of operation CAUSE Oil vapor is necessary to lubricate the rod seal At high operating temperatures this results in oil mist and precipitation EFFECT none ACTION none 2 Misting Appearance might be deceptive A certain degree of vapor is normal and actually necessary for lubrication of the rod seal The inspection must not be conducted after drive in wet weather or a vehicle wash Shock needs to b...

Page 861: ...nly visible around the bottom it likely stems from an outside source CAUSE worn damaged or overheated seal EFFECT loss of oil loss of damping function loss of ride control and safety ACTION replace leaking shock 3 Leaker OBSERVATION A shock is considered a leaker if the reservoir tube smaller diameter is largely covered with oil finger gets wet when touching shock see Misting SACHS Automotive of A...

Page 862: ...rubber bushing is visibly deformed or damaged eye or loop is eccentrically deformed sleeve is not centered within bushing CAUSE extensive use of rebound stop incorrect ride height shock may be too short for application extremely high conical angles not suitable for this design EFFECT noise increased wear of shock and suspension ACTION verify ride height verify that shock is suitable for this appli...

Page 863: ...er scratches reservoir tube OBSERVATION Paint scratched off reservoir tube CAUSE suspension is misaligned shock is under unintended lateral or longitudinal preload EFFECT noise corrosion of reservoir tube subsequently wear of rod seal leakage and loss of function ACTION check suspension while vehicle is at design height replace shock only if significant amount of paint is already scratched off or ...

Page 864: ... measure temperature of shock absorbers 4 Both shocks should be warmer than the original reference point similar in temperature 5 A cool or significantly colder shock absorber likely is a failure and needs to be replaced 6 After removal from the vehicle the following may hint to the cause of failure Manually stroke shock several times in vertical position no or delayed resistance would indicate a ...

Page 865: ...6 1 1 Front Bumper 20 6 1 2 Front Crest 20 6 1 3 Headlights 21 6 1 4 Rear View Mirrors 21 6 1 5 Windshield Wipers 22 6 1 6 Windshield 22 6 1 7 Front face Body Panel 24 6 1 8 Entrance Door 24 6 1 9 Front Electrical Service Compartment Door 25 6 1 10 Upper Lateral Window 25 6 1 11 Front Cap 26 6 2 ZONE 2 26 6 2 1 Upper Side Panel 26 6 2 2 Fixed Windows 26 6 2 3 Electric Awning Windows 27 6 2 4 Elect...

Page 866: ...ld Wipers 49 7 1 6 Windshield 49 7 1 7 Front face Body Panel 50 7 1 8 Entrance Door 51 7 1 9 Front Electrical Service Compartment Door 51 7 1 10 Upper Lateral Window 52 7 1 11 Front Cap 52 7 2 ZONE 2 52 7 2 1 Upper Side Panel 53 7 2 2 Fixed Windows 53 7 2 3 Electric Awning Windows 54 7 2 4 Electric Sliding Windows 54 7 3 ZONE 3 54 7 3 1 Rear Cap 54 7 3 2 Engine Compartment Doors 54 7 3 3 Rear Bump...

Page 867: ...rtment Door 75 8 5 3 Evaporator Compartment Door 75 8 5 4 Fuel Filler Door 76 8 6 ZONE 6 76 8 6 1 Front Fender 76 8 7 ZONE 7 77 8 7 1 Smooth Side Panel 77 8 7 2 Side Crest 78 8 8 ZONE 8 78 8 8 1 Slide Out Exterior Finishing Panels Windows 78 8 9 BODY PANEL AND WINDOW SPACING FOR WE MTH FITTED WITH SLIDE OUT 79 9 VEHICLE JACKING POINTS 80 9 1 HYDRAULIC JACK 81 10 TOWING THE VEHICLE 81 10 1 LIFTING ...

Page 868: ... R H SIDE REAR SERVICE COMPARTMENT DOOR 37 FIGURE 35 ZONE 5 37 FIGURE 36 BAGGAGE COMPARTMENT DOOR 38 FIGURE 37 BAGGAGE DOOR CATCH STRIKER 39 FIGURE 38 CONDENSER DOOR 39 FIGURE 39 EVAPORATOR DOOR 39 FIGURE 40 FUEL FILLER DOOR 40 FIGURE 41 ZONE 6 40 FIGURE 42 ZONE 7 41 FIGURE 43 ZONE 8 42 FIGURE 44 ZONE 9 43 FIGURE 45 BODY PANEL WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE OUT 44 FIGURE 46 BODY P...

Page 869: ...RE 81 ZONE 4 72 FIGURE 82 ENGINE COMPARTMENT R H SIDE DOOR 72 FIGURE 83 RADIATOR DOOR 73 FIGURE 84 ZONE 5 73 FIGURE 85 BAGGAGE COMPARTMENT DOOR 74 FIGURE 86 BAGGAGE DOOR CATCH STRIKER 75 FIGURE 87 CONDENSER DOOR 75 FIGURE 88 EVAPORATOR DOOR 75 FIGURE 89 FUEL FILLER DOOR 76 FIGURE 90 ZONE 6 76 FIGURE 91 ZONE 7 77 FIGURE 92 ZONE 8 78 FIGURE 93 BODY PANEL WINDOW SPACING FOR WE MTH FITTED WITH SLIDE O...

Page 870: ...3 Hinged rear fender 4 Baggage compartment 5 Fuel filler door 6 Condenser compartment or Baggage compartment 7 Entrance door 8 Entrance door power window 9 Engine compartment rear doors 10 Rear view mirror 11 Reclining bumper 12 Front electrical service compartment 13 Driver s power window 14 Evaporator compartment or Baggage compartment 15 Radiator door ...

Page 871: ...oor 6 Condenser compartment or Baggage compartment 7 Entrance door 8 Engine compartment rear doors 9 Rear view mirror 10 Reclining bumper 11 Front electrical service compartment 12 Front Slide Out Optional 13 Evaporator compartment or Baggage compartment and access to Slide out elec trical panel 14 Rear Slide Out Optional 15 Radiator door 16 Hinged rear fender 17 Entrance door power window 18 Driv...

Page 872: ...t 4 Condenser compartment or Baggage compartment 5 Fuel filler door 6 Entrance door 7 Engine compartment rear doors 8 Rear view mirror 9 Reclining bumper 10 Front electrical service compartment 11 Evaporator compartment or Baggage compartment 12 Radiator door 13 Hinged rear fender 14 Entrance door power window 15 Driver s power window 16 Front Slide Out Optional ...

Page 873: ...ng corrosion and must be considered as part of the regular service intervals The entire underside of the vehicle is sprayed with a heavy application of asphalt base undercoating The operating environment the vehicle is subjected to will largely influence the amount of dirt and corrosion that will accumulate over a given period Corrosion is one of the most costly factors of part failure and shorten...

Page 874: ...SUALLY INSPECT WHEELHOUSING COATING MAKE SURE DISCHARGE TUBES ARE FREE FROM OBSTRUCTIONS APPLY UNDERCOATING LOCALLY AS NECESSARY APPLY UNDERCOATING LOCALLY AS NECESSARY REMOVE ANY OBSTRUCTION OR REPLACE DEFECTIVE TUBE SUSPENSION AND UNDERSTRUCTURE 12 100 000 60 000 VERIFY THE CONDITION OF ALL SUSPENSION AND UNDERSTRUCTURE FASTENERS AND CLAMPS TIGHTEN OR REPLACE DEFECTIVE OR MISSING FASTENERS FLOOR...

Page 875: ...21 Avoid rubber parts 2 0 Dry all water sprayed parts Surface temperature and dew point must be respected before applying rust inhibitor Air pressure system may be used refer to annex 1 for surface temperature and dew point 3 0 Front wheelhousing a Mask all rubber joints Braking system must also be protected refer to arrows Commercial aluminum foil may be used for masking 3 1 Front wheelhousing Fr...

Page 876: ...ousing Entire braking system 4 0 Rear wheelhousing a Mask all rubber joints Braking system must also be protected refer to arrows Commercial aluminum foil may be used for masking Entire braking system 4 1 Rear wheelhousing Entire braking system ...

Page 877: ...umping system are required to apply the rust inhibitor If the application is done inside a paint room select high speed ventilation Minimum required thickness is 10 mils wet or 5 mils dry 7 0 Remove all masking material 30 minutes after application ANNEX 1 1 Check and confirm that dew point and surface temperature are in accordance with to the following criteria Surface temperature 10 C Surface te...

Page 878: ... 7 10 11 13 15 7 3 1 4 6 9 10 12 14 14 6 1 2 5 7 10 11 13 15 14 6 1 2 6 8 10 12 14 16 13 5 0 4 6 9 11 14 15 17 12 4 1 4 7 10 12 14 16 18 11 4 1 5 9 11 13 15 17 19 10 3 2 6 9 12 14 16 18 20 10 2 3 7 10 13 15 17 19 21 9 1 4 8 11 14 16 18 20 22 9 0 5 9 12 15 17 19 21 23 8 0 5 10 13 16 18 20 22 24 7 1 6 11 14 16 19 21 23 25 6 2 7 11 15 17 20 22 24 26 6 2 8 12 16 19 21 23 25 27 5 3 9 13 16 20 22 24 26 ...

Page 879: ... V at the broken or cracked portion Sides of V should have a shallow pitch for maximum bonding area NOTE Roughening the surface improves adhesion of resin If part is warped from original shape use clamping equipment to straighten the surface Preheat area to be repaired with one or two heat lamps placed 18 to 24 inches 450 610 mm from repair CAUTION Temperature should not exceed 140 o F 60 o C duri...

Page 880: ...all dirt grease and paint from area to ensure good bonding surface Feather the cleaned area all around Fig 4 FIGURE 4 FIBERGLASS REPAIR 18089 Cut a piece of fiberglass mat slightly larger than area being repaired Impregnate mat with general purpose polyester resin catalyzed normally Use a clean paint brush to apply the polyester resin Apply impregnated mat over hole and press onto surface with bru...

Page 881: ...cold Park vehicle in the shade whenever possible o Do not park under trees which drop sap or near factories with heavy smoke fallout Tree sap and industrial fallout may mar or spot a freshly painted surface o Trees are also likely to attract birds Bird droppings are highly acidic and will damage a freshly painted surface Bird droppings tree sap and industrial fallout should be washed off as soon a...

Page 882: ...lations 3 Maintain adequate ventilation at all times 4 Dispose of any leftover paint mix properly 5 Wear rubber gloves rubber apron and face shield during all phases of paint and chemical handling 5 3 2 Surface Preparation And Paint Application Aluminum and or Stainless Steel Fiberglass Comments Surface Preparation Sand using P 150 grit sandpaper It is recommended to sandblast rivets and panel edg...

Page 883: ... repair installation and replacement for various doors panels and windows pertaining to W5 MTH The paragraph divides the vehicle into zones to facilitate the search each zone is then sub divided into components Refer to the appropriate zone then component for complete procedure FIGURE 9 W5 MTH ZONING FIGURE 10 W5 MTH FITTED WITH SLIDE OUT ...

Page 884: ...To install bumper reverse the removal procedure WARNING Front bumper is heavy Use proper lifting equipment to support the bumper during the removal and installation operations to avoid personal injury FIGURE 12 FRONT BUMPER REMOVAL WARNING The compartment behind the bumper is not designed for storage Never store loose objects in this compartment since they can interfere with the steering linkage m...

Page 885: ...void continuous heating Use the appropriate switch on the dashboard to activate the defroster system on both mirrors simultaneously The mirrors can easily be adjusted by using the remote controls located on the L H side control panel The mirrors have easy to replace glass in case of breakage Remote control motors can also be replaced FIGURE 14 REAR VIEW MIRROR RAMCO 18398A Adjustment At the base o...

Page 886: ...rror head behind the mirror glass Turn pointer knob to the left for mirror head adjustments and to the right for convex mirror adjustment then push down on either of the button s 4 sides to adjust the selected mirror viewing angle Disassembly At end of mirror arm loosen the setscrews to relieve tension on the ball stud Remove the ball stud Remove the ball stud from the arm and gently pull the harn...

Page 887: ...e a loop Spray soapy water onto rope and rubber extrusion Fig 15 o Slide windshield into rubber seal groove starting with the bottom curved side edge Using a plastic spatula move the rubber seal lip aside to gradually insert the wind shield into the groove o Spray soapy water on a regular basis to ease this operation o Using the same type of plastic spatula repeat the same operation from inside of...

Page 888: ...e self adhesive tape Remove the Sika bead and self adhesive tape residue with the scraper o Pry loose the front face body panel using the lever o While somebody cuts the Sika bead and double face self adhesive tape another person pulls the body panel using the C clamp to exert tension o Using the window scraper remove any Sika bead or self adhesive tape residue left on fiber glass surface Front Fa...

Page 889: ...icone to remove any dust or residue For assembly gluing or finishing joints of front electrical service compartment door refer to procedure PR280021 included at the end of this section For gluing of driver s window refer to procedure PR290013 included at the end of this section For gluing of front electrical service compartment door horizontal finishing molding refer to procedure PR00213 included ...

Page 890: ...was drilled Razor sharp window scraper Braided windshield wire and a pair of handles Gloves goggles or face shield Fixed Window Removal 1st Method NOTE This method is used only in the case of a regular fixed side window For the fixed upper portion of awning or sliding windows you must use method number 2 o Apply a sticky plastic film onto all of window outside surface for safety reason o Using a d...

Page 891: ... of this section For the installation of awning or sliding window refer to procedure PR00038 included at the end of this section For gluing of lateral fixed window refer to various procedures PR00037 for gluing vertical and bottom rubber seals PR00043 for the installation of lateral fixed window and PR00044 for making the Simson joint around fixed windows All these procedures are included at the e...

Page 892: ... Proximity sensor magnet Fixing frame FIGURE 19 ELECTRIC AWNING WINDOW EXPLODED VIEW FRAME 18586 Roller Swivelling arm Releasing bar Guide Guide Motor support Horizontal latch handle Window pane Relay Proximity sensor Actuators Latch guide 1 2 3 3 4 5 6 Window ajar sensor 7 Releasing bar roller FIGURE 20 ELECTRIC AWNING WINDOW EXPLODED VIEW SASH 18583 ...

Page 893: ...CONVERTER CHECKLIST Check the electrical circuit proximity sensor A The latching system will not operate without power Is there electrical power to the latching circuit The horizontal latch handle on the sill sash will be seen to move if there is power on this circuit or it can be checked with an electrical tester If there is no power to this circuit when the window is closed and either rocker swi...

Page 894: ... belt line trim seal Check for missing parts or misaligned parts A The frame and sash are misaligned Is there any interference between the sash and frame Is there clearance between the sash and the rocker switch covers B Releasing bar guides are missing Check that the releasing bar guides are installed There should be 4 installed on H win dows and 3 installed on XL2 windows 6 2 4 Electric Sliding ...

Page 895: ...to disengage the bottom of the sash from the window frame Figure 23 FIGURE 23 DISENGAGING THE BOTTOM OF THE SASH Installation 1 Align the leading edge of the slot on the lower cam follower block with the sash stop Use the power toggle switch to obtain the correct alignment Figure 24 ...

Page 896: ...f the slot of the cam follower block Do the same at the rear of the sash 4 Pull down on the release latches and rotate the sash inwards until it is parallel with the window frame 5 Release the latches to engage the latch pins with the upper cam follower blocks 6 Confirm that both latches are in the closed latched position The upper edge of the latch opening must be aligned with upper edge of the s...

Page 897: ...n assembly 6 3 ZONE 3 FIGURE 27 ZONE 3 6 3 1 Rear Cap The fiberglass rear cap does not need any maintenance except painting as needed It is held in place with adhesive If ever it has to be replaced make an appointment at a Prévost service center near you For minor damages refer to Paragraph 4 Common Fiberglass Repair Procedure and Paragraph 5 Common Painting Procedure 6 3 2 Engine Compartment Door...

Page 898: ...pe tool Razor sharp window scraper A pair of locking pliers Isopropyl alcohol o Remove damaged engine compartment door from vehicle o Install the damaged door onto an appropriate support o Wearing gloves goggles and ear plugs pry loose body panel using a Zip gun or lever starting from the edge opposite the curved side o Use the Zip gun to detach completely the stainless steel body panel from door ...

Page 899: ...is section 6 4 2 Engine Compartment R H Side Door Engine compartment R H side door may be adjusted for proper fit by untightening hinge bolts 1 Loosen the bolts 1 Fig 31 holding the hinge to the vehicle structure to shift the door IN or OUT and UP or DOWN 2 Loosening the bolts 2 Fig 31 allows the door to be shifted LEFT or RIGHT and UP or DOWN 3 Adjust the door position depending on the gap needed...

Page 900: ... gap needed between exterior finishing panels 4 Tighten the bolts 5 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation To adjust the latch mechanism 3 Fig 32 and the striker pin 1 Open the door to access the striker pin 2 Slightly loosen the striker pin 3 Using a hammer adjust the striker pin to center it in the door l...

Page 901: ...Loosen the screws fixing the hinge to hinge attachment or hinge to door assembly Loosening the screws allows the compartment door assembly to be shifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjust compartment door assembly position at the hinge 4 Tighten the screws 5 Respect the required gap between exterior finishing panels 6 Check that the door swings freely and closes properly It may be...

Page 902: ...a wooden block between one of the panto graph arms and the upper frame 2 Remove cap screw lock washer and flat washer retaining lower arm to door 3 Remove spring pins and lock washers fastening the pantograph arms to the door WARNING Support the door properly to prevent it from falling 4 Spread the pantograph arms away from the door and remove door 5 Inspect all pivot points and bushings for wear ...

Page 903: ...shifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjust condenser door assembly position at the hinge 4 Tighten the screws 5 Respect the required gap between exterior finishing panels 6 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation FIGURE 38 CONDENSER DOOR For the installation of condenser compartment door bod...

Page 904: ...cording to distance required between exterior finish ing panels o Tighten the nuts o Check that the door swings freely and closes properly FIGURE 40 FUEL FILLER DOOR 03046 6 6 ZONE 6 FIGURE 41 ZONE 6 6 6 1 Front Fender Front fender may be removed using the following procedure Remove the nuts on the inside of the fender Remove the fender from the vehicle To reinstall reverse the procedure For the i...

Page 905: ...panel Insert a flat screwdriver between the side panel and the vehicle chassis in the top left and right corners Use the c clamp to peel the side panel from the back structural panel as far as the middle and at the same time gradually cut Sika bead with a sharp knife Do the same for the other corner Ideally the hoist or chain block must be fastened to the floor while pulling from a 45o angle so as...

Page 906: ...Fitted With Slide Out Removal Refer to paragraph 6 7 1 for procedure CAUTION Because most junction panels are only riveted and not spot welded be careful when removing a side panel not to damage adjacent panels For the slide out junction panel preparation before the installation of a ridged side panel refer to procedure PR00031 included at the end of this section For gluing of ridged side panels o...

Page 907: ...nce Manual Section 26 Paragraph 16 for the procedure on slide out exterior finishing panels windows 6 9 ZONE 9 FIGURE 44 ZONE 9 6 9 1 Slide Out Exterior Finishing Panels Windows Refer to Maintenance Manual Section 26 Paragraph 16 for the procedure on slide out exterior finishing panels windows ...

Page 908: ...Section 18 BODY PA1553 44 6 10 BODY PANEL AND WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE OUT FIGURE 45 BODY PANEL WINDOW SPACING FOR W5 MTH NOT FITTED WITH SLIDE OUT ...

Page 909: ...Section 18 BODY PA1553 45 6 11 BODY PANEL AND WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE OUT FIGURE 46 BODY PANEL WINDOW SPACING FOR W5 MTH FITTED WITH SLIDE OUT ...

Page 910: ...ard to give access to the bumper compartment Pull the release handle located inside front service compartment to unlock Tilt down the entire bumper assembly to access the compartment Push the bumper back up firmly in place to lock in position Two people are required to remove and install the front bumper Safely support the bumper and remove the two bolts on each bumper side to ...

Page 911: ...ce they can interfere with the steering linkage mechanism Use care when opening or closing the reclining bumper compartment to prevent personal injury FIGURE 50 FRONT BUMPER RELEASE HANDLE 18613 For gluing of front bumper panel refer to procedure PR00198 included at the end of this section 7 1 2 Front Crest o Use a Chix cloth and anti silicone to clean the surface where the crest will be applied C...

Page 912: ...en the socket setscrews NOTE Position the ball cup halves so the joint between them lies on the centerline of the arm Ensure that the setscrews are not on the joint between the cup halves Replacement of Mirror Glass Remove the broken glass Position new glass in mirror head and press to lock the Velcro in place Heated Remote Controlled Rear View Mirrors Heated remote controlled external rear view m...

Page 913: ... pressing to lock the Velcro in place 7 1 5 Windshield Wipers Refer to Paragraph 23 7 Windshield Wipers and Washers included in Section 23 Accessories of the Maintenance Manual for complete information on windshield wipers 7 1 6 Windshield For the removal or installation of windshield you will need A rope A plastic spatula to lift the rubber seal lip A metal rod or screwdriver to clean the seal gr...

Page 914: ...ndshield o At the top of windshield clean surface between fiberglass and rubber extrusion using Sika 205 Fig 53 o Apply Sika 221 black between fiberglass and rubber extrusion o Spray filler and rubber seal groove generously with soapy water o Using the special filler insertion tool insert the filler into the rubber seal groove o Gradually insert filler into the rubber seal groove ensuring to leave...

Page 915: ...also remove horizontal finishing molding located underneath the window This molding is glued and will have to be replaced because it will be damaged at removal o Remove interior finishing panel to access rub rail fixing bolts then remove rub rail o Using the Zip Gun cut Sika bead located inch 7 8 mm from each body panel edge and around cornering light o Separate body panel from door o Remove from ...

Page 916: ...dow from the outside NOTE Wear ear plugs during this operation o Then move outside of vehicle and cut Sika bead to free window while somebody else hold the window from the inside o Carefully remove window from frame ask for help if needed o Using a razor sharp window scraper remove from window frame Sika bead and double face self adhesive tape residue o First of all check Sika 205 cleaner expirati...

Page 917: ...of vehicle to gradually cut the Sika bead on the window perimeter o When you reach top corner detach wire from the outside handle secure it to a fish wire or rod and thread it underneath the aluminum molding behind the rivets o Detach wire from fish wire and continue cutting using the handle o Cut Sika bead until you come back to starting point then you can remove the window by carefully pushing i...

Page 918: ...e Compartment Doors Engine Compartment Doors Adjustment Engine compartment doors may be adjusted for proper fit by untightening hinge bolts 1 Loosen the bolts 1 2 Fig 57 holding the hinge to the vehicle structure to shift the door UP or DOWN 2 Loosening the bolts 3 Fig 57 allows the door to be shifted LEFT or RIGHT and IN or OUT 3 Adjust the doors position depending on the gap needed between exter...

Page 919: ...ainted surface o Use a second person equipped with a pair of locking pliers to pull the body panel as you cut the Sika bead WARNING Be very careful when pulling the body panel somebody could get hurt if the body panel suddenly detach from the door surface without notice o Using the window scraper remove any Sika bead or self adhesive tape residue left on the fiber glass surface For gluing of engin...

Page 920: ...g on the gap needed between exterior finishing panels 4 Tighten the bolts FIGURE 59 ENGINE COMPARTMENT R H SIDE DOOR18635 5 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation To adjust the latch mechanism 3 Fig 59 and the striker pin 1 Open the door to access the striker pin 2 Slightly loosen the striker pin 3 Using a ...

Page 921: ...s on the vehicle are of identical design The doors are pantograph vertical lift type and are fully sealed Each door has a flush mounted latch handle To open lift latch handle then pull door outward and up The door is held open by 2 gas charged cylinders To close leave latch handle in the open position pull downward on door and push down on latch to secure door The door lower arm is spring loaded t...

Page 922: ...izontal member of the pantograph to the pivot pin 3 Slide pantograph assembly to the right and remove assembly from the vehicle 4 To install perform the removal instructions in reverse Door Installation 1 Use a wooden block to support the pantograph arms horizontally 2 Support the door and insert each panto graph arm into the pivot pins on the side of the door 3 Install washer and spring pin to fa...

Page 923: ...NSER DOOR For the installation of condenser compartment door body panel refer to procedure PR00131 included at the end of this section 7 5 3 Evaporator Compartment Door 1 Open the evaporator door 2 Loosen the screws fixing the hinge to hinge attachment or hinge to door assembly Loosening the screws allows the evaporator door assembly to be shifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjus...

Page 924: ...ront Fender Front fender may be removed using the following procedure Remove the nuts on the inside of the fender Remove the fender from the vehicle To reinstall reverse the procedure For the installation of front fender body panel refer to procedure PR470024 included at the end of this section ...

Page 925: ...lat screwdriver between the side panel and the vehicle chassis in the top left and right corners Use the c clamp to peel the side panel from the back structural panel as far as the middle and at the same time gradually cut Sika bead with a sharp knife Do the same for the other corner Ideally the hoist or chain block must be fastened to the floor while pulling from a 45o angle so as not to damage t...

Page 926: ...the side panels upper portion refer to procedure PR00030 included at the end of this section For gluing of horizontal finishing molding refer to procedure PR00208 included at the end of this section 7 7 2 Side Crest o Clean vehicle surface using anti silicone where the side crest and stickers will be applied o Using hands apply and compress side crest o Apply required stickers 8 WE MTH EXTERIOR FI...

Page 927: ...ifting equipment to support the bumper during the removal and installation operations to avoid personal injury FIGURE 72 FRONT BUMPER REMOVAL WARNING The compartment behind the bumper is not designed for storage Never store loose objects in this compartment since they can interfere with the steering linkage mechanism Use care when opening or closing the reclining bumper compartment to prevent pers...

Page 928: ... ball stem from the arm Remove the four screws fastening the mirror arm base to the coach Assembly Mount the mirror arm base to the coach Insert the ball stem into the mirror arm and tighten the socket setscrews NOTE Position the ball cup halves so the joint between them lies on the centerline of the arm Ensure that the setscrews are not on the joint between the cup halves Replacement of Mirror Gl...

Page 929: ... The mirror glass assembly is mounted to the control mechanism or to mirror base with Velcro strips Remove the mirror glass by gently pulling the lens to release the Velcro Disconnect the heater grid at the two connectors Connect the connectors of the new mirror s grid to the harness Install the lens by positioning the lens in the mirror frame and pressing to lock the Velcro in place 8 1 5 Windshi...

Page 930: ...e wind shield into the groove Use also soapy water on the inside of vehicle to insert the windshield into the rubber seal groove o Insert the top curved corner then finish with the top of windshield o At the top of windshield clean surface between fiberglass and rubber extrusion using Sika 205 Fig 75 o Apply Sika 221 black between fiberglass and rubber extrusion o Spray filler and rubber seal groo...

Page 931: ...you will need Pneumatic Zip gun type tool Razor sharp window scraper o Before removing body panel you can to ease repair uninstall entrance door from vehicle If applicable remove reflector keyless system keyboard and cornering light o You must also remove horizontal finishing molding located underneath the window This molding is glued and will have to be replaced because it will be damaged at remo...

Page 932: ...r s window only open front service compartment door o Mark the position of the driver s window for future reference o From inside of vehicle cut Sika bead around window perimeter using a Zip gun while another person hold the win dow from the outside NOTE Wear ear plugs during this operation o Then move outside of vehicle and cut Sika bead to free window while somebody else hold the window from the...

Page 933: ...ference to the vehicle o This procedure requires accuracy and it is possible not to succeed on the first at tempt From the inside of vehicle a sec ond person ensures the rod passes through o Remove the rod thread the wire into the small hole Reinsert the rod and the wire into the hole far enough so that the person inside the vehicle can pull the rod using a pair of pliers o Attach the wire ends to...

Page 934: ...on of lateral fixed window and PR00044 for making the Simson joint around fixed windows All these procedures are included at the end of this section 8 2 3 Electric Awning Windows For window or components replacement refer to paragraph 6 2 3 8 2 4 Electric Sliding Windows For sash removal or replacement refer to paragraph 6 2 4 8 3 ZONE 3 FIGURE 78 ZONE 3 8 3 1 Rear Cap The fiberglass rear cap does...

Page 935: ...port o Wearing gloves goggles and ear plugs pry loose body panel using a Zip gun or lever starting from the edge opposite the curved side o Use the Zip gun to detach completely the stainless steel body panel from door frame CAUTION Do not damage painted surface o Use a second person equipped with a pair of locking pliers to pull the body panel as you cut the Sika bead WARNING Be very careful when ...

Page 936: ...t R H side door may be adjusted for proper fit by untightening hinge bolts 1 Loosen the bolts 1 Fig 82 holding the hinge to the vehicle structure to shift the door IN or OUT and UP or DOWN 2 Loosening the bolts 2 Fig 82 allows the door to be shifted LEFT or RIGHT and UP or DOWN 3 Adjust the door position depending on the gap needed between exterior finishing panels 4 Tighten the bolts 5 Check that...

Page 937: ...ws the door to be shifted LEFT or RIGHT and UP or DOWN 3 Adjust the door position depending on the gap needed between exterior finishing panels 4 Tighten the bolts 5 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation To adjust the latch mechanism 3 Fig 83 and the striker pin 1 Open the door to access the striker pin FI...

Page 938: ...a wooden block between one of the panto graph arms and the upper frame 2 Remove cap screw lock washer and flat washer retaining lower arm to door 3 Remove spring pins and lock washers fastening the pantograph arms to the door WARNING Support the door properly to prevent it from falling 4 Spread the pantograph arms away from the door and remove door 5 Inspect all pivot points and bushings for wear ...

Page 939: ...shifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjust condenser door assembly position at the hinge 4 Tighten the screws 5 Respect the required gap between exterior finishing panels 6 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation FIGURE 87 CONDENSER DOOR For the installation of condenser compartment door bod...

Page 940: ...cording to distance required between exterior finish ing panels o Tighten the nuts o Check that the door swings freely and closes properly FIGURE 89 FUEL FILLER DOOR 03046 8 6 ZONE 6 FIGURE 90 ZONE 6 8 6 1 Front Fender Front fender may be removed using the following procedure Remove the nuts on the inside of the fender Remove the fender from the vehicle To reinstall reverse the procedure For the i...

Page 941: ...ary fix side panel Warning Panel weights over 200 pounds E Insert a flat screwdriver between the side panel and the vehicle chassis in the top left and right corners Make sure to separate side panel from structure Be careful not to damage the adjacent surfaces F Use the c clamp to separate the side panel from the back structural panel and at the same time gradually cut Sika bead with a sharp knife...

Page 942: ...ED TIG WELDING SPOTS PR00216 SMOOTH SIDE PANEL GLUING SLIDE OUT VERTICAL MOLDING PR00217 SMOOTH SIDE PANEL CUTTING HORIZONTAL FINISHING MOLDING AT SLIDE OUT LEVEL PR00220 8 7 2 Side Crest o Clean vehicle surface using anti silicone where the side crest and stickers will be applied o Using hands apply and compress side crest o Apply required stickers 8 8 ZONE 8 FIGURE 92 ZONE 8 8 8 1 Slide Out Exte...

Page 943: ...Section 18 BODY PA1553 79 8 9 BODY PANEL AND WINDOW SPACING FOR WE MTH FITTED WITH SLIDE OUT FIGURE 93 BODY PANEL WINDOW SPACING FOR WE MTH FITTED WITH SLIDE OUT ...

Page 944: ... figures 94 to 99 WARNING Extra lift capacity may be required if luggage or any other type of load e g conversion equipment are onboard the vehicle CAUTION The suspension of the vehicle must be in the normal ride position before jacking The Level Low system on a motorcoach must be in the DRIVE position prior to turning the ignition key OFF Twelve jacking points are located on the vehicle three are...

Page 945: ...d secure vehicle with tie downs Check that overall height will clear obstacles on the route to follow and obtain required permits The vehicle can also be towed by lifting the front axle or by towing from the front with all wheels on the ground These two methods are described below under their respective headings Whatever the method used the vehicle should be towed by truck operators authorized and...

Page 946: ...ift the vehicle from under the front axle and adequately secure the underside to the tow vehicle lifting attachment with chains 5 Observe safety precautions when towing 10 2 TOWING WITHOUT LIFTING WARNING When towing vehicle without lifting use only a tow truck with a solid link tow bar and related equipment All other means of towing are unauthorized Tow only from the front of the vehicle 1 Remove...

Page 947: ...MEMORANDUM SEALANT GLUING PRODUCT PROCEDURE NO PR000001 REVISION 14 2006 06 09 GLUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 10 DISCARD AS PER P908 WEAR GLOVES WEAR SAFETY GLASSES ...

Page 948: ...or 50 drying time and job time are increased Keep in mind that it is forbidden to use products parts to prepare and or glue surfaces if temperature is below 15 C Using Sika Products and Solvent in Nalgene Bottles Primer 206G P Insert a ball in Nalgene bottle This will enable mixing of product Use thinner to clean bottle Allow drying Never put Sika product back in bottle with thinner inside Never u...

Page 949: ...ng operation again Before applying any other product If surface seems dusty greasy or with finger marks start cleaning operation again Section B Sika 205 1 Apply For a smooth surface aluminum stainless steel fiberglass gelcoat side etc 2 minutes Minimum time For a porous surface fiberglass non gelcoat side etc 10 minutes 2 Allow to evaporate Mandatory After 2 hours Reactivate surface with Sika 205...

Page 950: ...ow to evaporate Do not use pads supplied in the box Minimum time 5 minutes Mandatory After 2 hours Remove dust using Chix cloth repeat application If surface seems dusty dust using dry Chix cloth repeat application Before applying any other product If surface seems greasy or with finger marks start operation again Plastic spatula CHIX cloth CHIX cloth CHIX cloth CHIX cloth ...

Page 951: ...inutes After 2 hours Remove dust using damp CHIX cloth pure water Mandatory 206 G P After 8 days Reactivate with Aktivator as per section C Minimum time 10 minutes After 2 hours Remove dust using damp CHIX cloth pure water After 8 days Reactivate with Aktivator as per section C Mandatory 210 T After 1 year Throw away the part Minimum time 20 minutes Mandatory 215 After 2 hours Remove dust using da...

Page 952: ...roduct Mandatory After 2 hours Start cleaning operation again Before applying any other product If surface seems dusty greasy or with finger marks start cleaning operation again Section F Sika Remover 208 This product is specially designed to remove fresh sealant and Sika adhesive from a surface This product has the advantage of not contaminating the sealant BLUE cloth ...

Page 953: ...Use belt sander Ridged surface Sand bottom of creases by hand Change paper or belt on a regular basis as per procedure In the case of Stainless steel eliminate reflection mirror image Important aspects to follow Maximum delay between sanding and surface preparation otherwise start operation again Stainless 7 days Aluminum and 3cr12 4hrs Fiberglass No delay ...

Page 954: ...se a knife Zip Gun or braided windshield wire Cleaning If required remove dirt dust sand calcium grease using Anti silicone Good adherence of glue to surface If glue or primer become unstuck Remove former glue Remove excess of glue using a scraper It is acceptable and recommended to keep a small layer of glue on the surface instead of breaking the surface of adherence with the blade If primed surf...

Page 955: ... minutes max 90 min 4 hrs minimum Sika 254 booster pump 25 minutes max See specific PR 2 5 hrs minimum Sika Ultrafast II 10 minutes max See specific PR 6 hrs minimum Sika 255 15 minutes max See specific PR 24 hrs minimum Sika STP or PC booster pump 15 minutes max See specific PR 2 hrs minimum Sika 221 30 45 minutes max See specific PR 24 hrs minimum Smoothing down Water or soapy water Authorized s...

Page 956: ...tube This product is good for 9 months Coding example 601251 First number indicates year 6 2006 Next 2 numbers indicate month 01 January Next 2 numbers indicate day 25 25th Add 9 months to the manufacturing date to get the expiration date example Manuf January 25th 2006 9 months expires October 25th 2006 Section 3d Liquid Butyl 680096 Expiration Date Manufacturing date is indicated on the tube Thi...

Page 957: ...LICATION PROCEDURE NO PR000001A REVISION 00 2006 06 09 GLUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 4 Section 1 Triangular Beads Application Section 2 Irrelevant Section 3 Finishing Joint around glass aesthetic appearance ...

Page 958: ...ISION 00 Page 2 of 4 Section 1 Triangular Beads Application Rules Nozzle must be as perpendicular to the surface as possible Nozzle must be positioned to follow the direction of movement towards the rear not side Bead Appearance ...

Page 959: ...h down the joint using a plastic spatula D As needed remove the small lines left by the plastic spatula by smoothing down the joint with a finger and water or soapy water E Carefully remove masking tape F As needed finish smoothing down the joint with a finger and water 3 00 G Clean if necessary using Sika 208 Mandatory Result A Must be smooth No bubbles No dirt or lumps No start or boundary lines...

Page 960: ...001A REVISION 00 Page 4 of 4 Joint must be parallel visually straight and without notch C D Cavity in the sealant joint due to the plastic spatula and or sealant shrinking Accepted Notch Repeating notches Stepped sealant ...

Page 961: ...Preparation Important Before cleaning make sure there is no paint gravel guard or urethane residue If necessary remove using sander Structure Sanding A Clean using anti silicone in the direction of the arrows See PR000001 Section A Make sure that grooves are very clean 1 00 B Sand using belt sander grit coarse belt See PR000001 Section G ...

Page 962: ...PROCEDURE NO PR00027 REVISION 00 Page 2 of 3 Structure Cleaning 1 05 Clean using anti silicone Use white clothes 684009 for vertical backers ...

Page 963: ...in the center of vertical backers Make sure that grit blasting is uniform on the whole surface B Apply Sika 206 G P Use white clothes 684009 for vertical backers See PR000001 Section D 1 10 C Remove protective tape 1 15 Apply foam tape 1 8 x 1 4 in the center of side panel horizontal supports and at each end if needed ...

Page 964: ......

Page 965: ...l tubing underneath C Install engine air intake panel in position 2 Vertically Adjust side panel with reference to 1 side panel ridges max 1mm Make sure to meet standard 3mm 1 with reference to structural tubing Horizontally Adjust gap 3 4 5mm with reference to 1 side panel Drill through structure using side panel pre drilled holes 2 R H side and 3 L H side D Side panel positions 3 and 4 Verticall...

Page 966: ...ng a scraper or damp cloth 2 00 Make sure that structure is sealed at the back of engine air intake panel location Add some Sikaflex 221 if required 2 05 Check side panel for defects S S Side panel Preparation 2 10 Reactivate surface as per PR000001 section D 2 15 Apply foam tape 1 16 x 1 4 at each side panel end Make sure foam tape reaches bottom of creases Install foam tape 1mm 1 0 from side pan...

Page 967: ... If accessible seal the back of vertical backers as indicated in picture Use Sika 221 grey Awnings Reinforcement Plates 3 05 Apply Sika 252 or 255 onto the awnings reinforcement plates A B C D Height of bead 3 8 1 8 0 Perform before installing side panels 3 4 6 3 10 Apply Sika 221 booster Seal vertical backer upper and lower portions using Sika 221 grey ...

Page 968: ...and rivet install engine air intake panel in position 2 and rivet Check gap between 2 panels Install side panels 3 4 5 6 and rivet making sure to check the gap 3 4 5mm between side panels Check adjustment with vertical backers Horizontal alignment max 1 mm Curing time 4 hours minimum ...

Page 969: ... some kind of supports for temporary side panel holding Measure height of 4th ridge from top of structural tubing on backer located between side panels 4 and 5 should be 320 5 mm Take the measurement for the other junction panels Connect dashes 4 and 5 with a chalk line Note Make sure to overrun dash 5 by 6 inches towards the rear side panel width will hide the dash 1 00 B MEASURE ...

Page 970: ...t structure Note Make sure that junction panel does not overrun the bottom of Slide out by more than 3mm A Measure distance between rear tubing and slide out 5439 mm This measurement should be 3 mm longer than structure side panel overrun by 3 mm If measurement is different readjust gaps between side panels Note Temporary secure junction panel using a rivet 504108 and drill bit 30 and or clamp 1 0...

Page 971: ...h reference to side panel 5 horizontal alignment of 1 mm max Vertically Rear line up with side panel 5 ridges 1mm Check that 4th ridge is lined up with dash 3 If difference is too big readjust side panel 5 horizontally Side Panel 8 Draw a line 28 mm from the top of vertical molding E Vertically Front line up with side panel 7 ridges 1mm Rear line up with marking of 28mm Horizontally gap of 3 mm 1 ...

Page 972: ...el located between side panels 2 and 3 Rear line up with side panel 4 ridges 1mm H Side Panel 2 Horizontally Lined up with reference to slide out window pane 1 mm gap of 3 mm 1 5 0 with reference to side panel 3 horizontal alignment of 1 mm max Vertically Rear line up with side panel 3 ridges 1mm Check that front of side panel is lined up with dash 1 If difference is too big readjust side panel 3 ...

Page 973: ...r junction panel between side panels 2 and 3 K Metal Strip 10 Vertically Gap of 8mm with reference to side panel 3 Horizontally Gap of 3 5 5 mm with reference to side panel 4 L Metal Strip 9 Vertically Gap of 8mm with reference to side panel 2 Horizontally Gap of 3 5 5 mm with reference to side panel 4 Gap of 3mm 1 5 0 with reference to metal strip 10 M Visually check ridges alignment Readjust sid...

Page 974: ...nction panels C Install junction panel between side panels 5 and 7 3 00 D Remove side panel 7and metal strips 9 and 10 and junction panels A Reactivate side panels junction panels and structure See PR000001 section D Important Do not apply Sika Aktivator onto seals side panels and junction panels visible portion 3 05 B Make sure that structure behind engine air intake panel is sealed Add Sikaflex ...

Page 975: ... be located D Apply Sika 221 onto all junction panels perimeter Make sure to fill creases Rivet junction panels onto structure Hand press junction panels to flatten Sika bead E Apply Sika 221 black to seal junction panels Smooth down the ends with a spatula to give a gentle slope Junction Panel 1 9 Junction Panel 10 4 ...

Page 976: ...PROCEDURE NO PR00029 REVISION 00 Page 8 of 9 Junction Panel 4 5 Junction Panel 5 7 Junction Panel 7 8 Junction Panel 2 3 ...

Page 977: ...ly Sika 221 Booster onto side panels B Curing time 4 hours C Seal corners between metal strips and structure using Sika 221 black 4 00 D Seal side panel ridges using Sika 221 vehicle not slide out If side panel is too far from structure apply a bead of Sika over the total length ...

Page 978: ......

Page 979: ... side panels will stain the S S Sealing joint height onto vertical tubing 6mm maximum C Clean using anti silicone See PR000001 Section A D Apply Sika 205 Use a plastic spatula and a Chix cloth to get to the bottom of structural tubing See PR000001 Section B 1 00 E Apply Sika 252 black and smooth down the joint Seal the front of the first side panel and the back of the last A Apply Sika 205 See PR0...

Page 980: ......

Page 981: ...Page 1 of 1 Junction Panel Preparation A Clean using anti silicone both junction panel sides See PR000001 Section A B Normally in the center of the junction panel there is a masking tape Apply one if this is not the case C Apply Sika 206 G P onto both junction panel sides See PR000001 Section D 1 00 D Remove masking tape ...

Page 982: ......

Page 983: ...UCTURE PREPARATION Effective 9082 REVISION 01 DATE 06 10 11 Spec 15 0 LVA077 Page 1 of 2 A Clean structure using anti silicone See PR000001 Section A B Sand structure using Scotchbrite See PR000001 Section G 1 00 ...

Page 984: ... 01 Page 2 of 2 C Clean structure and window frames using anti silicone See PR000001 Section A D Apply Sika 206G P onto structure and window frames See PR000001 Section D EDGES EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE EDGE ...

Page 985: ...e panel will be glued Affix foam tape in the center of vertical and horizontal members 1 05 Not fitted with slide out Affix a double face self adhesive tape 3 16 x1 4 at the bottom of the structure where the side panel will be glued W5 Fitted with front and rear slide out Affix a neoprene foam tape 3 16x1 2 1 10 Glue a piece of window rubber seal at the top in the curvature ...

Page 986: ...PROCEDURE NO PR00036 REVISION 01 Page 2 of 2 WE OR W5 Fitted with front slide out Glue a neoprene foam tape 3 16x1 2 1 15 Glue a piece of window rubber seal at the top in the curvature ...

Page 987: ... of each rubber seal Draw a 13mm about long line in the center of the post B Glue the vertical rubber seals in the center of the post where fixed windows will be installed MTH Remove strips from rubber seal 1 00 C Compress rubber seal using roller A Glue the bottom rubber seal where fixed windows will be installed 1 05 B Compress rubber seal using roller STRIP ...

Page 988: ......

Page 989: ...LVA081 Spec 15 0 Page 1 of 5 Section 1 Awning Window Installation 1 00 Glue 2 stops onto the horizontal structure tubing or underneath the window A Check that D O T AS 3 is present and readable Glue 4 stops 790602 onto window frame 1 03 B Section A A VIEWED FROM INSIDE VIEW A A INSIDE OF VEHICLE ...

Page 990: ...See PR000001 Section A 1 05 B Apply Sika Aktivator See PR000001 Section C 1 07 Add a bead of Sika 252 on each side 1 10 Apply Sika 252 onto structure and onto 2 welding joints in the lower bottom corners Triangular bead 12mm X 10mm 1 15 Install and center window into the opening compressing it lightly FILL THE CORNER ...

Page 991: ... smooth down the excess of Sika Important Do not remove the white blocks They will be removed when the batteries will be connected B If required clean up surfaces using Sika 208 1 25 C Manually close window 1 30 Smooth down the excess from inside the vehicle Add a bead of Sika 252 or 255 in the window upper corners as required Smooth down the joint of Sika 252 or 255 starting about 25mm lower than...

Page 992: ...ly Sika 252 onto structure and onto 2 welding joints in the lower bottom corners Triangular bead 12mm X 10mm A Check that D O T AS 3 is present and readable 2 10 B Install and center window into the opening compressing it lightly Note The opening portion of the sliding window must be facing the rear of vehicle The arrow decal on window should be pointing towards the front of vehicle in the directi...

Page 993: ...rson should push the window from outside the vehicle while another one tightens the frame from inside A From inside the vehicle add a bead of Sika 252 or 255 in the window upper corners as required 2 20 B From inside the vehicle fill the space between the bead of Sika and the vertical rubber in the window front upper corners Use Sika 252 or 255 ...

Page 994: ......

Page 995: ... B Apply 206 G P primer See PR000001 Section D 1 05 Apply Sika 221 black Booster onto structure Triangular bead at the top Use the applicator 25mm x 15mm Triangular bead in the radius 20mm x 10mm Triangular bead at the bottom and onto the vertical members 15mm x 10mm Apply also onto the 2 samples as per PR000001A section 2 1 10 Apply an additional bead of glue at each tubing ends where the panel w...

Page 996: ... the glue is cured verify with a finger that it is Tack Free Distance between panel and windows 8 2mm WE only Adjust gaps between slide out box frame windows and fiberglass panel as per the following standard 9 2mm W5 small rear side panel Adjust gaps A W5 center side panel Adjust gaps 1 15 B Install two retaining blocks onto panel about 600mm from ends Fiberglass even with side panels 1mm ...

Page 997: ...heck panel alignment flatness with adjacent panel or windows 2mm max at the front and 3mm max at the rear Use go nogo 31133 Do not use a metal ruler onto glass to prevent scratching Important Vehicle must not move until 90 minutes after compressing last panel or window 1 25 Smooth down using a brush excess of glue inside the vehicle all around the panel If required add Sika 252 or 255 Note do not ...

Page 998: ......

Page 999: ...1 Section E 1 00 C Apply Sika Aktivator See PR000001 Section C Windows Installation A Apply Sika 255 or Ultrafast onto fixed window perimeter Triangular bead 20mm X 10mm B Install fixed window into the opening Center window and line up sides before pressing fixed window against structure Important Never raise a window once it has been pressed against the structure because the joint would be too da...

Page 1000: ...mpression time 8 hours minimum 30 minutes with Ultrafast F Install suction cup puller onto fixed window in order to compress the bead Compression time 8 hours minimum 30 minutes with Ultrafast Important Make sure that window flatness with reference to the adjacent windows remains acceptable G Smooth down using a brush excess of glue inside the vehicle all around the window Remove excess using a sp...

Page 1001: ...p between the 2 Awning windows is 2mm Note These dimensions are references given by engineering If the assembly is out of tolerance the aesthetic aspect will have to be evaluated Interior Tolerance Thermos Window Only If the thermos window is too close to the post less than 6mm fill the gap between the thermos window and the post with Sika 252 fill the whole window perimeter to ensure watertightne...

Page 1002: ......

Page 1003: ...lue inside the vehicle all around the window B Single Glass Add a bead of Sika 252 or 255 if necessary to get a joint of 10 12 mm Note Do not use Simson glue C Thermos Glass Add Simson glue black 70 03 Remove the excess using a spatula Smooth down the joint with finger Note Wait 60 minutes between gluing of window and Simson glue application 1 00 Fixed Window Fixed Half Window ...

Page 1004: ...PROCEDURE NO PR00044 REVISION 00 Page 2 of 2 Slide out ...

Page 1005: ...tion A 1 00 B Apply Sika Aktivator See PR000001 Section C Half Window Preparation Bonding surface must be clean If it is greasy clean using anti silicone as per PR000001 Section A and or use a scraper to remove glue residue A Check that D O T AS 3 is present and readable B Clean using glass cleaner See PR000001 Section A 1 05 C Apply Sika Aktivator See PR000001 Section C 1 10 Install some shims on...

Page 1006: ... the structure because the joint would be too damaged D Check window alignment flatness with adjacent panel or windows 2mm max at the front and 3mm max at the rear Use go nogo 31133 Do not use a metal ruler onto glass to prevent scratching E Compress bottom of window using two Quick Grip Compress top of window Note If necessary use hands to compress window to reach required flatness 1 15 F Install...

Page 1007: ...ltrafast Important Make sure that half window flatness with reference to the adjacent windows remains acceptable I Smooth down using a brush excess of glue inside the vehicle all around the window Remove excess using a spatula 1 20 Add some Sika 252 at the top of half window Smooth down the joint CLEAN WELL SINGLE GLASS THERMOS SMOOTH DOWN USING A BRUSH REMOVE EXCESS USING A SPATULA ...

Page 1008: ......

Page 1009: ...tivator See PR000001 Section C edge Structure Preparation A Affix neoprene foam tape 3 16x1 2 1 05 B Affix another piece in the corner onto the rubber seal Window Gluing A Apply Sika 255 or Ultrafast Triangular bead 20mm X 10mm 1 10 B Install some type of conforming jig Align window exterior flatness with adjacent windows tolerance of 2mm maximum WE Make sure that gap is 9 2 with slide out W5 Make...

Page 1010: ......

Page 1011: ...ucture Preparation S S A Clean using anti silicone See PR000001 Section A B Sand using belt sander See PR000001 Section G Sand using grit coarse belt Change paper on a regular basis C Clean using anti silicone See PR000001 Section A 1 00 D Apply Sika 205 See PR000001 Section B WE L H AND R H SIDE WE FITTED WITH SLIDE OUT ...

Page 1012: ......

Page 1013: ...de Panel Preparation S S A Clean using anti silicone See PR000001 Section A B Sand using belt sander See PR000001 Section G Sand using grit coarse belt Change paper on a regular basis C Clean using anti silicone See PR000001 Section A 1 00 D Apply Sika 205 See PR000001 Section B WE WE FITTED WITH SLIDE OUT FRONT OF SIDE PANEL FRONT OF SIDE PANEL 300 mm WIDE 300 mm WIDE ...

Page 1014: ...r indications SECTION A A A Clean using anti silicone See PR000001 section A 2 05 B Apply and compress foam tape 1 8 x1 2 onto mid reinforcement A Use supports to hold up side panel weight Adjust height to ensure proper panel positioning 2 10 B Use upper supports to hold up side panel upper portion ...

Page 1015: ...ection B B Section C C A Apply Sika 252 onto structure Watertight Joint 2 25 B WE Slide Out L H side only Apply a bead near the rectangular section Bead height in the area of the rectangular section 6 mm higher than rectangular section Section D D C Position side panel onto structure 1 Adjust lower supports so that side panel is 30 2mm above tubing bottom RECTANGULAR SECTION ...

Page 1016: ... TIG spots WE A Install pulling equipment at the other end of side panel B Make a final adjustment in height C WE Slide out Adjust pressure in the box frame cylinder to 6600 PSI 100 0 D Pull side panel so that panel moves 3 16 WE 2800 50 psi E Ensure proper side panel positioning 2 35 F Remove upper supports WE 2 45 A Sand front of side panel 2 inches wide for TIG arc welding ...

Page 1017: ...e from WE slide out reinforcement bar E Remove protective film from double face self adhesive tape F Compress top and bottom section of side panel A Cut excess of side panel Make sure that cut is parallel with tubing WE Slide out Cut even with tubing 2 50 B Grind side panel end to line up with door tubing ...

Page 1018: ......

Page 1019: ...174 Page 1 of 2 Engine Air Intake Panel Gluing 1 00 Make sure that sealing of structure has been performed properly Engine Air Intake Panel Preparation S S 1 05 Entertainer 1 10 Install foam tape 1 8 X onto structure as shown in picture 1 15 Install foam tape 1 16 X onto air intake panel pleat ...

Page 1020: ...nuous Triangular bead 10mm x 8mm Panel Installation A Install 2 supports onto structure and lay down panel SECTION A A View B B Adjust supports so that panel is 2 1mm lower than tubing C Position panel flush without projecting beyond rear structural tubing see view B 3 30 D Use a brush to compress Sika bead REAR CAP AIR INTAKE PANEL ...

Page 1021: ...aches as far as the corner See PR000001 section B 1 00 B Apply Sika 252 black at the junction of both tubing leave 43 mm minimum without Sika to ensure gluing of window rubber On top of smooth side panel Smooth down the joint Rear Front A Perform finishing joints using Sika 221 grey at each side panel end 1 05 B Smooth down the joint SMOOTH DOWN THIS AREA USING A PLASTIC SPATULA 43 mm MINIMUM WITH...

Page 1022: ......

Page 1023: ...ilicone See PR000001 Section A 1 05 D Apply Sika 206 G P See PR000001 Section D S S Body Panel Preparation E Coat Body Panel Preparation black A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 10 D Apply Sika 206 G P See PR000001 Section D OR Clean using anti silicone See PR000001 Section A A Appl...

Page 1024: ......

Page 1025: ... Drilling Back Panel 1 00 Install back panel onto frame and drill Back Panel A Clean frame using anti silicone See PR000001 Section A B Apply Sika 205 onto body panel and frame perimeter See PR000001 Section B C Install insulation behind rub rail 1 05 D Apply some black butyl tape onto the frame and remove protective tape liner ...

Page 1026: ...7 E Apply Sika 205 aound the opening in the frame See PR000001 Section B F Apply Sika 221 gey onto the perimeter Bead diameter about 4mm G Lay down back panel and rivet 1 10 Install latch Caution Install the tip of the latch towards the top MTH ...

Page 1027: ...0 Page 3 of 7 Damper A Apply foam tape 1 16x1 2 underneath damper box B Install and rivet 1 15 C Install filter A C Junction Box 1 20 Install A C junction box Install 3 tie mount and rivet Marker Light Grommets 1 25 Install grommets ...

Page 1028: ... layer in the frame C Remove body panels 1 40 D Remove metal burrs using a disc sander Lower Body Panel Preparation A Remove blue plastic film and inspect body panel Reinstall transparent plastic film 1 45 B Apply Sika 205 See PR000001 Section B Upper S S Body Panel Preparation A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti sil...

Page 1029: ...001 Section A S S Frame Preparation A Apply masking tape onto hinge B Clean using anti silicone See PR000001 Section A C Sand using Scotchbrite See PR000001 Section G D Clean using anti silicone See PR000001 Section A E Apply Sika 206 G P See PR000001 Section D 1 60 F Apply Sika 205 onto frame See PR000001 Section B edge ...

Page 1030: ...d the opening B Install grid 1 65 C Apply Sika 221 grey again aroud the grid Body Panel Installation A Apply some butyl tape onto the frame and remove protective tape liner B Apply Sika 221 grey onto lower body panel and frame Bead diameter about 4mm 1 70 C Install lower body panel and rivet ...

Page 1031: ... rests perfectly against the frame Remove protective tape from hinge Hold down body panel using masking tape Curing time 4 hours minimum F If upper body panel is ridged Seal lower body panel rivets using silver sealant Finishing Joint A Clean using anti silicone See PR000001 Section A B Apply Sika 205 See PR000001 Section B C Apply Sika 221 Bead diameter 6mm 1 75 D Smooth down the joint ...

Page 1032: ......

Page 1033: ...ng 1 00 Position back panel Apply masking tape to hold it in place 1 05 Drill using a 11 drill bit 1 10 Remove masking tape and back panel Section 2 Frame Squareness and Flatness Verification Verify that frame is square and flat using a long ruler Important Frame edges must be flat tolerance of 2mm maximum If this is not the case straighten the frame out 2 00 OR RULER RULER ...

Page 1034: ...a 205 at the top of the handle handle exterior side B Apply Sika 221 Bead diameter Ø3 16 3 05 C Smooth down the joint with your finger A Apply Sika 205 at the bottom of the handle handle exterior side Voir PR000001 Section B B Apply Sika 221 Bead diameter Ø3 16 3 10 C Smooth down the joint with your finger 3 20 A Apply Sika 205 Into the 4 interior corners of the frame Into the 2 lower corners on t...

Page 1035: ... 205 from the interior of the frame hinge side See PR000001 Section B B Apply Sika 221 Bead diameter Ø3 16 3 25 C Smooth down the joint with your finger Section 4 Locking System Installation If required tap 3 motor support holes using a M4 X 0 7 screw tap 4 00 Install locking system fixing plates and electric motor if applicable 4 05 Check locking system operation ...

Page 1036: ...ic motor cable into the insulation cavity 5 10 Reinstall back panel and rivet Section 6 Upper Panel Installation Important Make sure that all bonding surfaces are clean and free of dust residue or dry glue If required clean using a scraper or damp cloth SS Frame Preparation A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicon...

Page 1037: ...n using anti silicone See PR000001 Section A 6 05 D Apply Sika 206 G P See PR000001 Section D E Coat Body Panel Preparation 6 10 Clean using anti silicone Repeat this step if panel seems greasy See PR000001 Section A A Apply Sika 221 grey into the 4 corners on top of the frame Caution Apply only onto half of 2 lower corners 6 15 B Smooth down the joints using a plastic spatula ...

Page 1038: ...d 8mm wide X 9mm high Important There should be no more than 18 minutes between the beginning of the glue application and the panel installation onto the frame 6 20 B Apply Sika 221 around the handle 6 25 Position the body panel onto the door frame Compress and hold Curing time 4 hours ...

Page 1039: ...y Sika 221 onto the rivet heads 6 35 D Clean the excess of sealant and rivet heads using Sika 208 6 40 Install and adjust handle 6 45 Install the lock Important Make sure that the lock gasket rests perfectly against the body panel Section 7 Lower Body Panel Installation A Position lower body panel onto door structure B Fix body panel using c clamps C Drill structure using a 11 drill bit 7 00 D Cou...

Page 1040: ...ree and also at the top so that the portion inserted underneath the upper panel is free 7 05 D Inspect the body panel to make sure that it is free of bumps or defects Frame A Apply Sika 205 onto frame back of panel See PR000001 Section B Panel 7 10 B Apply Sika 221 onto frame in front of the holes Bead diameter Ø3 16 7 15 Insert lower body panel underneath upper body panel Note To insert body pane...

Page 1041: ...to help removal using a blowtorch 8 10 Lift body panel edge using a pair of pliers Pull the panel while cutting the Sika bead Important Remove rivet shanks fell inside the door 8 15 Prepare surface See PR000001 Section 2 8 20 Install the new panel as per section 6 LOWER BODY PANEL REMOVAL 8 25 Remove rivets 8 30 Cut beads of Sika 221 on the body panel L H and R H sides using an Olfa knife or a pne...

Page 1042: ...PROCEDURE NO PR00177 REVISION 00 Page 10 of 10 Appendix 1 Replacement Repair Remove part See PR000001 Section 2 A1 00 Preparation and gluing See PR000001 Section 2 and or do procedure again ...

Page 1043: ...001 Section G C Clean using anti silicone See PR000001 Section A 1 00 D Apply Sika 205 See PR000001 Section B S S Panel Preparation A Clean using anti silicone See PR000001 Section A B Use Scotchbrite to sand panel See PR000001 Section G C Clean using anti silicone See PR000001 Section A D Apply Sika 205 See PR000001 Section B A Clean using anti silicone See PR000001 Section A 1 05 B Apply Sika 21...

Page 1044: ... face self adhesive tape 1 16 x 1 4 onto perimeter of frame 1 15 B Apply Sika 252 A Remove protective film from double face self adhesive tape and lay down panel onto frame 1 20 B Press panel against frame to compress the glue and double face self adhesive tape ...

Page 1045: ...Rear Cap and Engine Air Intake Snap on Finishing Molding Installation Snap On Finishing Molding Pre positioning A Position snap on finishing molding and put a pencil mark underneath the snap on finishing molding where indicated onto engine air intake panel and 1st side panel 1 00 B Draw a chalk line between the 2 marks SNAP ON FINISHING MOLDING ...

Page 1046: ...52 Apply Sika 320 mm long from the edge of engine air intake panel 1 05 E Smooth down the joint using a plastic spatula If necessary remove masking tape Section View 1 10 Clean using anti silicone the area on the rear cap where the snap on finishing molding will be installed and also underneath the snap on finishing molding See PR000001 Section A 1 15 Apply double face self adhesive tape 1 16 X an...

Page 1047: ... corner molding onto snap on finishing molding Level corner molding and draw a line above it to establish the rear snap on finishing molding proper positioning Important Make sure corner molding follows the rear cap round C Remove corner molding 1 25 D Line up snap on finishing molding with the pencil lines Level finishing molding Drill using a 11 drill bit and rivet S S Snap On Finishing Molding ...

Page 1048: ...a 252 A Glue corner molding onto snap on finishing molding 2 10 B Compress molding with a nylon block Section 3 Rear Finishing Molding Gluing 3 00 Measure distance between 2 corner moldings and cut the excess of rear finishing molding SS Molding Preparation A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Se...

Page 1049: ...asking tape See PR000001 Section A B Sand using orbital sander See PR000001 section G Be careful not to scratch side panels apparent area not hidden by finishing molding C Clean using anti silicone side panels gutters and cavities See PR000001 Section A 4 00 D Apply Sika 205 See PR000001 Section B Be careful not to stain side panels apparent area not hidden by finishing molding 5 10 Seal engine ai...

Page 1050: ... 221 or 252 B Smooth down the joint with a plastic spatula Important There must be no more than 15 minutes between the start of cavity filling and the installation of molding 5 15 C W5 Fitted With Slide out If required cut the Slide out rubber seal with a knife just above the joint of sealant Push the lip inside ...

Page 1051: ...osition front upper and lower finishing moldings onto vehicle B Draw a line onto moldings in line with the end of the last side panel Cut the excess of molding and file down the end 6 05 C 1 Remove blue plastic paper and inspect moldings 6 10 W5 Fitted With Slide out Line up molding ends with windows and side panels S S Finishing Moldings Preparation A Clean using anti silicone See PR000001 Sectio...

Page 1052: ...out Upper Finishing Molding in front of slide out Apply foam tape 1 4 x1 4 at the bottom There must be 3 100mm 25 long clearings 7 05 Apply Sika 252 Do not apply Sika in front of the previous clearings Upper Finishing Molding Installation A Install finishing moldings B Compress finishing molding using a nylon block 7 10 C W5 Fitted With Slide out Seal Slide out finishing molding ends using Sika 22...

Page 1053: ...on A Apply foam tape 1 4 x1 4 8 00 B Make 3 100mm 25 long clearings in the bottom foam tape 8 05 Apply Sika 252 Do not apply Sika in front of the previous clearings Lower Finishing Molding Installation A Install finishing moldings 8 10 B Compress lower finishing molding using a nylon block ...

Page 1054: ......

Page 1055: ...000001 Section G C Clean using anti silicone See PR000001 section A 1 00 D Apply Sika 205 See PR000001 Section B W5 W0 Molding Preparation SS A Clean using anti silicone See PR000001 section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 section A D Apply Sika 205 See PR000001 Section B E Apply some foam tape 1 4 x1 4 WE Molding Preparation 1 05 F Clean ...

Page 1056: ...ue the molding underneath the chalk line making sure it is lined up with the horizontal side molding maximum 1mm B WE Position and glue the molding making sure it is lined up with the horizontal side molding maximum 1mm C Compress the molding 1 15 D If necessary remove the excess using Sika 208 Line up moldings ...

Page 1057: ...aration Primer E Sand using Scotchbrite PR000001 Section G 1 00 F Clean using anti silicone PR000001 Section A W5 W0 Corner Molding Preparation SS A Clean using anti silicone PR000001 Section A B Sand using Scotchbrite PR000001 Section G C Clean using anti silicone PR000001 Section A D Apply Sika 205 PR000001 Section B WE Corner Molding Preparation Triax E Remove sticker from corner F Sand using S...

Page 1058: ...WE X3 Apply Sika 252 A Apply corner molding so that it is level and lined up maximum 1mm with engine compartment R H side door molding or radiator door molding 1 15 B Apply some masking tape onto the corner molding in order to hold it in place during curing LEVEL LINED UP ...

Page 1059: ...0001 Section A B Use Scotchbrite to sand frame See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 05 D Apply Sika 205 See PR000001 Section B Front Face Preparation beige primer A Use Scotchbrite to sand frame See PR000001 Section G 1 10 B Clean using anti silicone See PR000001 Section A MTH 1 15 MTH Affix some neoprene foam tape 1 16 x 1 4 onto front face Make sure that th...

Page 1060: ...2 MTH Onto front face Triangular bead 8mm MTH A Affix moldings Note Affix moldings so that the joint falls on the center of the vertical molding B Compress moldings using hands 1 25 C Use masking tape to hold moldings in place during curing process Vertical Molding ...

Page 1061: ...See PR000001 Section A B Use Scotchbrite to sand molding See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 00 D Apply Sika 205 See PR000001 Section B Entrance Door or Front Electrical Service Compartment Door Preparation Entertainer SMC A Use Scotchbrite to sand frame See PR000001 Section G B Clean using anti silicone See PR000001 Section A 1 05 C Apply Sika 206 G P See P...

Page 1062: ...1 2 onto the door 1 20 Apply Sika 252 onto the door Triangular bead 8mm MTH Molding Installation 1 25 Line up with front and side moldings Even within 1mm 1 35 MTH If necessary adjust entrance door handle so that it is parallel with finishing molding Use a hammer and plastic bloc to make the adjustment ...

Page 1063: ... required straighten horizontal moldings using a grinder Molding Preparation SS A Clean using anti silicone See PR000001 Section A B Sand using a Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 05 D Apply Sika 205 See PR000001 Section B WE Side Panel Preparation primer Important If there is no primer on top of the TIG welding spots perform PR00216 A Sand usi...

Page 1064: ...B Sand using a Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A D Apply Sika 205 See PR000001 Section B Front Fender Preparation E coat 1 15 E Clean using anti silicone See PR000001 Section A WE Apply foam tape 1 32 x 1 4 onto molding In the top of the molding apply foam tape 1 4x1 4 1 20 ...

Page 1065: ...ing Installation A Position top of the molding even with 1mm maximum top of horizontal finishing molding B Drill molding using a 30 drill bit and rivet 1 30 C Seal rivet heads using Sika 221 1 35 Seal top of molding using Sika 252 1 40 If required clean excess usingSika 208 ...

Page 1066: ......

Page 1067: ...quired cut the excess Molding Preparation aluminum A Sand using a Scotchbrite See PR000001 Section G B Clean using anti silicone See PR000001 Section A 1 05 C Apply Sika 205 See PR000001 Section B 1 10 Apply double face self adhesive tape 1 8 x 1 4 Side Panel Preparation primer Important If there is no primer on top of welding spots perform PR00216 A Sand using a Scotchbrite See PR000001 Section G...

Page 1068: ...SION 00 Page 2 of 2 1 20 Apply Sika 252 onto molding A Glue molding 6mm from side panel Important Make sure that molding hides Sika 221 bead 1 25 B Compress molding with hands MOLDING EDGE OF SIDE PANEL ENGINE AIR INTAKE PANEL ...

Page 1069: ...luing vertical moldings A Apply masking tape on each side of the welding spots B Clean using anti silicone See PR000001 Section A C Sand side panel using a Scotchbrite See PR000001 Section G D Clean using anti silicone See PR000001 Section A E Apply Sika 205 See PR000001 Section B F Apply Sika 252 onto side panel along the welding spots G Compress joint using a plastic spatula 1 00 G Remove maskin...

Page 1070: ......

Page 1071: ...anti silicone See PR000001 Section A B Sand using a Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A Molding Preparation stainless D Clean using anti silicone See PR000001 Section A E Sand using a Scotchbrite See PR000001 Section G F Clean using anti silicone See PR000001 Section A G Apply Sika 205 See PR000001 Section B 1 00 H Apply double face self adhesive t...

Page 1072: ...y Sika 252 black J Apply moldings Distance of 9mm 2 with reference to slide out panel and line up at the top with fiberglass or lateral fixed window behind driver K If applicable clean up the excess with Sika 208 Adjust evenness of moldings if required ...

Page 1073: ... OUT LEVEL MTH 9090 Effective REVISION 00 DATE 06 10 20 L00015 Page 1 of 1 Cutting Upper Horizontal Finishing Molding A Wait 24 hours before cutting horizontal molding at Slide Out level 1 00 B Using a circular saw cut molding even with the box frame and structure CUT HERE ...

Page 1074: ......

Page 1075: ...liter 683446 Anti silicone 682989 Silver sealant 680462 Tack cloth Blue Loctite Sika 221 grey CHIX cloth 682384 Glass cleaner 683926 Blue cloth 682383 Sika 205 1 liter 683097 Sika 252 black Sika Remover 208 685101 Sika Aktivator 683661 Sika 255 black Soapy water Simson glue grey 684517 Pure water Masking tape Loctite glue 430 680042 Equipments Glue Applicator Safety rules See PR000001 ...

Page 1076: ...r window motor 1 05 Install electric motor onto door frame Section 2 Door Assembly Power Window Frame Preparation E Coat 2 00 Clean bonding area using anti silicone See PR000001 Section A Window Preparation A Clean using glass cleaner See PR000001 Section E 2 05 B Apply Sika Aktivator See PR000001 Section C Edges ...

Page 1077: ...mes in contact with window pane A Apply Sika 255 onto frame B Affix the frame onto window pane 2 15 C Secure assembly using clamps Door Frame Preparation SS A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 2 20 D Apply Sika 206 G P See PR000001 Section D ...

Page 1078: ...ng anti silicone See PR000001 Section A 2 25 D Apply Sika 206 G P See PR000001 Section D Fiberglass Preparation beige primer A Sand using Scotchbrite See PR000001 Section G 2 30 B Clean using anti silicone See PR000001 Section A 2 35 Affix double face self adhesive tape 1 8 x onto door frame Note Leave a gap at the bottom about 50mm for water dripping On top ...

Page 1079: ... 255 onto door frame Note Leave a gap at the bottom about 50mm for water dripping 2 45 Apply Sika 255 onto window pane 2 50 Lay down and center window pane onto door frame Window pane must extend 1mm at the frame top Note Do not compress window pane at this moment ...

Page 1080: ...e so that it is even with panel Tolerance is 4 2mm between window pane and fiberglass panel 2 60 B Compress window pane using hands Compress window pane upper corners using clamps Section 3 Gluing of SS Body panels Fiberglass Preparation LPLT A Sand using Scotchbrite See PR000001 Section G B Clean using a tack cloth C Clean using anti silicone See PR000001 Section A 3 00 D Apply Sika 206 G P See P...

Page 1081: ... anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 3 05 D Apply Sika 205 See PR000001 Section B 3 10 Affix double face self adhesive tape 1 16 x 3mm from panel edge 3 15 A Apply Sika 252 onto body panels ...

Page 1082: ...5 Compress panels using evenly distributed clamps Curing time 8 hours minimum Section 4 Installation of mechanisms Power Window Installation A Insert two seals in the power window frame B Apply some loctite glue at the intersection of the 2 seals and also sparingly in order to fix the seals to the window frame Exterior Window Wiper Installation 1 Use Scotchbrite to sand molding See PR000001 Sectio...

Page 1083: ...iper Installation 1 Position window wiper Note If rubber is too long cut the excess F 2 Drill three Ø5 32 holes into the molding and secure using screws 4 05 Fix cable harness A Adjust power window travel When it is lowered it must be at the same height than the interior wiper molding Note Once adjusted raise the window 4 10 B Cut excess of strap Exterior Window Wper Interior Window Wper Adjust he...

Page 1084: ...Do the finishing joints See Section 5 steps 5 15 5 20 4 20 Install Keyless pad 4 25 Install locking plates Lock Installation A If necessary put together the lock 4 30 B Install lock Note Make sure that lock is even with door once fixed Calfeutrant 285198 ...

Page 1085: ...rommet into the frame A Cut pneumatic tubing Note The green tubing is shorter than the red one 4 40 B Identify both tubing at each end A green one and a red one Upper Lock Installation A Feed both pneumatic tubing through the grommet and connect to cylinder Green tubing Red tubing 4 45 B Insert the cylinder into a water container to perform an air leak test Not There should be no bubble New piece ...

Page 1086: ...sure that door handle is parallel with fiberglass panel Door Handle Mechanism Installation adjustment A Install door handle mechanism B Adjust mechanical parts and micro switches Finish installing rods Important Door handle must be at mid course when door unlatches Adjust by changing rod angles 4 55 C Lubricate grease mechanical parts 4 60 Finish installing electric cables 4 65 Apply some urethane...

Page 1087: ...1 Section A C Apply double face self adhesive tape 1 8 x 1 4 onto deflector D Apply some grey Simson glue onto deflector E Position glue deflector 4 70 F Using soapy water smooth down the joint with your finger 4 72 Perform finishing joints See Section 5 steps 5 00 5 05 5 07 5 10 4 75 Make sure that glue is not blocking up drip holes If this is the case remove the glue 4 77 Install all other mecha...

Page 1088: ...0001 Section A B Peel back from the membrane with the exception of the area where the mechanism is located prevent mechanism from bonding to the membrane C Glue the membrane so that it bonds 100 with the frame 4 80 D Heat the membrane using a heat gun and compress using a plastic spatula to remove pleats Leave the protective film at this location ...

Page 1089: ...or Drill 9 7 64 dia holes and fasten plate using screws Installation of Window Interior Finishing Molding A Position plastic molding onto the door frame to check for proper fit Note If it does not fit properly grind the radius B Clean the area where the double face self adhesive tape will be applied using anti silicone See PR000001 Section A C Affix some double face self adhesive tape 1 16 x 3 8 N...

Page 1090: ...r Section 5 Finishing Joints A Apply Sika 221 to fill in the pleats and light perimeter B Using soapy water smooth down the joints with your finger 5 00 C If necessary clean up the excess using Sika 208 A Apply masking tape 1mm from window pane and fiberglass panel edges B Apply Sika 255 into the cavity between the fiberglass and window panel C Smooth down the joint with a plastic spatula then car...

Page 1091: ...indow wiper end S S portion 5 07 D Smooth down the joint with your finger then remove masking tape A Apply Sika 221 at the top of the door and on the window pane sides B Using soapy water smooth down the joint with your finger 5 10 C If necessary clean up the excess using Sika 208 A Apply Sika 221 around Keyless pad 5 15 B Using soapy water smooth down the joint with your finger 5 20 Apply Sika 22...

Page 1092: ...PROCEDURE NO PR280020 REVISION 14 Page 18 of 18 Section 6 Replacement Repair Remove part See PR000001 Section 2 6 00 Preparation and gluing See PR000001 Section 2 and or do procedure again ...

Page 1093: ...NLY Page 1 of 12 Material Scotchbrite grey 680226 Sika 206 G P 1 liter 683446 Anti silicone 682989 Silver sealant 680462 CHIX cloth 682384 Simson 70 03 grey Blue cloth 682383 Glass cleaner Sika Remover 208 685101 Sika 205 1liter 683097 Sika 252 black Sika 255 black Glue 680066 Equipments Glue Applicator Ruler Safety rules See PR000001 ...

Page 1094: ... A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 10 D Apply Sika 206 G P See PR000001 Section D MTH Fiberglass Panel Preparation SMC A Sand using Scotchbrite See PR000001 Section G B Clean using anti silicone See PR000001 Section A 1 15 C Apply Sika 206 G P See PR000001 Section D MTH 90 ...

Page 1095: ... self adhesive tape 1 32 x 1 4 onto the whole window frame perimeter Section View 1 25 Fix window frame onto door frame Important Make sure that top of window frame is lined up with top of door frame 1 30 Apply Sika 255 onto door frame Note Apply an additional bead of Sika 255 in the center of a MTH 89 door MTH Door frame Window Frame 12 mm All around Add bead for MTH 89 door ...

Page 1096: ...using hands Use a ruler 1 40 Perform steps in section 3 A Door Exterior Install appropriate number of c clamps and wooden blocks all around B Door Interior Install appropriate number of c clamps and wooden blocks all around 1 45 Compression time 120 minutes minimum Door Frame 3 mm All around Fiberglass Panel ...

Page 1097: ...50 Important Make sure window pane slides perfectly within its frame 1 55 If necessary clean up the excess all around door frame using Sika 208 Clean using anti silicone see PR000001 section A and apply Simson 70 03 grey from the inside between bottom tubing and fiberglass panel Apply also onto spot welding 1 60 Rule r ...

Page 1098: ...r corners from the inside 1 65 C Apply glue 680066 into Norryl molding and affix window wiper Important Anti friction side must be on window pane side 1 70 Install door locking mechanism components Note 1 Do not forget to replace latch spring Note 2 Check lock operation using key Note 3 Grease mechanism components 1 75 Install hinge supports 1 80 When compression time is over remove clamps Anti fr...

Page 1099: ...intersection of the 2 seals and also sparingly in order to fix the seals to the window frame C Clean window using glass cleaner D Insert pane into window frame E Fix electric motor and all components connected to the window F Fix electric components and test window operation 1 85 G Adjust power window travel 6 3mm above wiper Cut the excess Adjust here ...

Page 1100: ...ued using anti silicone See PR000001 Section A B Peel back from the membrane with the exception of the area where the mechanism is located prevent mechanism from bonding to the membrane C Glue the membrane so that it bonds 100 with the frame 2 10 D Heat the membrane using a heat gun and compress using a plastic spatula to remove pleats Leave the protective film at this location ...

Page 1101: ...A B Affix double face self adhesive tape 1 16 x 1 2 inside Norryl C Position Norryl onto door and temporary fix using Quick grip 2 20 D Drill 5 30 holes and screw in molding Latch Cover Installation A Clean the area where the foam tape will be applied using anti silicone See PR000001 Section A B Affix some foam tape 3 16 x 1 2 inside the cover 2 25 C Position the cover onto the door Drill 1 30 hol...

Page 1102: ... See PR000001 Section A 3 00 C Apply Sika 206 G P See PR000001 Section D MTH Body Panels Preparation S S A Cut and remove from the appropriate areas on the 2 panels the blue protective film B Clean using anti silicone See PR000001 Section A MTH C Sand using Scotchbrite See PR000001 Section G D Clean using anti silicone See PR000001 Section A 3 05 E Apply Sika 205 See PR000001 Section B ...

Page 1103: ...PROCEDURE NO PR280021 REVISION 18 Page 11 of 12 Affix double face self adhesive tape 1 16 x 1 2 3 10 MTH Apply Sika 252 onto panels 3 15 A MTH AFFIX NEAR THE EDGE ...

Page 1104: ...d rivet F Seal rivets using silver sealant MTH Finishing Joint A Apply Simson 70 03 Fill in the space between body panels and fiberglass panel at the indicated location 3 20 B Using soapy water smooth down the joints with your finger MTH Appendix 1 Replacement Repair Remove part See PR000001 Section 2 A1 00 Preparation and gluing See PR000001 Section 2 and or do procedure again ...

Page 1105: ... PR280022 REVISION 10 2006 06 04 GLUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 5 Material Anti silicone 682989 Chiffon CHIX 682384 Sika 215 1 liter 683916 Chiffon Bleu 682383 Sika 205 1liter 683097 Simson 70 03 black Sika 252 black Equipments Compression roller 1 Safety Rules See PR000001 ...

Page 1106: ...nce Door or Front Service Door Final Adjustment Door Adjustment with reference to front face Line up each door groove with front face groove within 3mm max Aligning door pleats with front fender pleats 3 00 Line door pleats with front fender pleats within 2mm max ...

Page 1107: ...l A Apply Simson 70 03 black at the seal 4 corners each side of the tape B Glue seal 4 corners Upper corners Press corners against door frame Lower corners Glue onto bottom of door frame may vary depending on seal length C Glue the rest of the seal Important Seal must be positioned correctly the first time otherwise it will not bond as well the second time D Compress seal using roller Compress sea...

Page 1108: ...ners Press corners against door frame Lower corners Glue 10mm lower than bottom of door frame may vary depending on seal length C Glue the rest of the seal Important Seal must be positioned correctly the first time otherwise it will not bond as well the second time D Compress seal using roller Compress seal 3 times 4 10 E If necessary clean up the excess PR000001 section 3 ...

Page 1109: ...rieur Interior Hinge Cover Preparation ABS A Clean using anti silicone See PR000001 Section A 6 00 B Apply Sika 215 See PR000001 Section D Hinge Preparation E Coat 6 05 Clean using anti silicone See PR000001 Section A 6 10 Apply Sika 252 black 2 triangular joints 6 15 Position and glue ...

Page 1110: ......

Page 1111: ...DURE QUALIFIED PERSONNEL ONLY Page 1 of 5 Material Anti silicone 682989 Scotchbrite grey 680226 CHIX cloth 682384 Blue cloth 682383 Sika 205 1liter 683097 Sika 252 black Simson 70 03 grey Equipments Glue Applicator Compression Roller Protective grease 680111 Conforming jig Pencil Safety Rules See PR000001 ...

Page 1112: ...ape before gluing Verify especially the corners by lifting the blue paper Remove blue paper from the adhesion side Stainless Steel Panel A Clean using anti silicone See PR000001 section A B Sand using scotchbrite See PR000001 section G C Clean using anti silicone See PR000001 section A 1 05 D Clean using Sika 205 See PR000001 section B ...

Page 1113: ...See PR000001 section A OR Primed door beige primer A Sand using Scotchbrite See PR000001 section G 1 10 B Clean using anti silicone See PR000001 section A Install double face self adhesive tape onto body panel CAUTION Make sure that drip hole is in the bottom 1 15 Cut double face self adhesive tape leaving the back sticking out ...

Page 1114: ...ody panel 1 25 Lay down stainless steel body panel onto fiberglass door Note Be careful upon installing the upper or lower small body panel Make sure that drip hole is in the bottom 1 30 Check body panel proper positioning 1 35 Peel back from double face self adhesive tape ...

Page 1115: ...PROCEDURE NO PR280032 REVISION 4 Page 5 of 5 Appendix 1 Replacement A1 00 Remove body panel A1 05 See PR000001 section 2 A1 10 For gluing procedure refer to section 1 ...

Page 1116: ......

Page 1117: ... grey 680226 Sika 206 G P 1 liter 683446 Anti silicone 682989 CHIX cloth 682384 Blue cloth 682383 Glass cleaner 683926 Sika 221 black booster Sika Remover 208 685101 Sika 205 1liter 683097 Sika Aktivator 683661 Sika 255 black Pure water v Masking tape Equipments Glue Applicator Suction Cup Puller Cartridge oven Plastic spatula Safety Rules See PR000001 ...

Page 1118: ...apply some masking tape Structure Preparation A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 05 D Apply primer 206 G P See PR000001 Section D Section 2 Window Installation 2 00 Affix double face self adhesive tape onto edge of structure ...

Page 1119: ... Window Pane Preparation A Clean using glass cleaner interior surface and edges See PR000001 Section E 1 DOT AS2 inscription must be present at the bottom left corner of the window B Apply Sika Aktivator onto interior surface and edges See PR000001 Section C 2 10 C Make sure DOT AS 2 is present and readable 2 15 Apply Sika 221 black booster onto structure EDGE EDGE EDGE ...

Page 1120: ... puller Line up window exterior flatness with adjacent surfaces If necessary use quick grip at bottom of window Conforming time 90 minutes minimum A Remove excess of glue on the window exterior B Remove masking tape 2 30 C If required clean up surfaces with Sika 208 2 35 If necessary excess of glue inside the vehicle with Sika 208 2 40 Drill small 9 64 hole into the tubing for water dripping ...

Page 1121: ...See PR000001A section 3 for details of finishing joint A Apply Sika 205 into cavity See PR000001 Section B 3 00 B Fill cavity with Sika 255 Appendix 1 Replacement Repair Remove part See PR000001 Section 2 A1 00 Preparation and gluing See PR000001 Section 2 and or do procedure again ...

Page 1122: ......

Page 1123: ...EL ONLY Page 1 of 6 Material Sika 206 G P 1 liter 683446 Anti silicone 682989 CHIX cloth 682384 Blue cloth 682383 Glass cleaner 683926 Sika Remover 208 685101 Sika 205 1liter 683097 Sika 252 black Soapy water Sika Aktivator 683661 Sika 255 black Pure water Masking tape Equipments Glue Applicator Spatula Safety Rules See PR000001 ...

Page 1124: ...6G P primer as per PR000001 section D Fiberglass Preparation Gel Coat side Faire le côté intérieur extérieur de la lunette A Clean using anti silicone See PR000001 Section A B Apply masling tape onto front face 1 05 C Apply Sika 206 G P See PR000001 Section D Window Preparation A Make sure DOT AS 3 is present and readable B Clean using glass cleaner bonding area and edges See PR000001 Section E 1 ...

Page 1125: ...e 3 of 6 Apply masking tape onto window pane Interior Exterior 1 15 A Glue 4 stops 790392 onto fiberglass 1 20 B Affix a double face self adhesive tape 1 8 x 1 8 onto fiberglass structure perimeter STOPS Glue all stops half of their length ...

Page 1126: ...th front of driver s window If necessary adjust window height by adding shims R H side Once centered apply some masking tape at the bottom of the window and mark for future reference will help for centering when gluing window R H side 1 30 B Peel back from double face self adhesive tape 1 35 Apply Sika 255 onto fiberglass Note Make sure to fill the 2 small cavities between fiberglass and structure...

Page 1127: ...ated area must be flush within 2mm A Install suction cup puller in the window center from inside of vehicle Note Make sure window rests against structure frame without deforming window pane 1 45 B Conforming time 60 minutes minimum 1 50 See PR290013 for driver s window finishing joint Finishing Joint For more details on finishing joint see PR000001A section3 1 55 Apply Sika 255 FLATNESS AREA ...

Page 1128: ...side of vehicle make two joints 1 60 B Smooth down the joints and remove masking tape 1 65 Reinstall markers light Appendix 1 Replacement Repair Remove part See PR000001 Section 2 A1 00 Preparation and gluing See PR000001 Section 2 and or do procedure again INTERIOR VIEW ...

Page 1129: ...of 8 Material Alcohol 680536 Scotchbrite grey 680226 Anti silicone 682989 CHIX cloth 682384 Sika 221 grey Blue cloth 682383 Sika 221 black booster Sika Remover 208 685101 Sika 205 1 liter 683097 Sika 252 black Soapy water Masking tape Equipments Glue applicator Compression roller Pencil Ruler Safety Rules See PR000001 ...

Page 1130: ...ture surface A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 05 D Apply Sika 205 See PR000001 Section B A Clean using anti silicone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 10 D Apply Sika 205 See PR000001 Section...

Page 1131: ...2 black onto structure 1 20 B Smooth down the joint with a finger or spatula to prevent bumps Section 2 Smooth Body Panel Gluing 2 00 Apply a foam tape onto body panel and peel back A Apply Sika 221 booster onto panels 2 05 B Apply Sika 221 booster onto structure ...

Page 1132: ...ure curvature B Front Body Panel Install body panel in the best possible position Allow the panel to float on the glue Make the final adjustment and then press body panel using hands 1 Lean the body panel against the other to get a 0 mm gap 2 Follow as much as possible the structure curvature 2 10 C Using a roller compress body panel along Sika joints Make sure body panels and foam tape rest perfe...

Page 1133: ...ace between body panel and structure C Smooth down the joints with a finger and soapy water 2 35 D Remove masking tape If required clean up surfaces with Sika 208 Section 3 Gluing of Ridged Body Panels 3 00 Apply double face self adhesive tape onto body panel and remove protective tape A Apply Sika 221 booster onto body panel 3 05 B Apply Sika 252 onto structure ...

Page 1134: ...1mm B Front Body Panel Install body panel in the best possible position Allow the panel to float on the glue Make the final adjustment and then press body panel using hands 1 Lean the body panel against the other to get a 0 mm gap 2 Line up body panel ridges with entrance door or front service compartment door 1mm 3 10 C Using a roller compress body panel along Sika joints Make sure body panels an...

Page 1135: ...Joint A Apply masking tape onto body panel edge and structure B Apply Sika 221 grey in order to fill the space between body panel and structure C Smooth down the joints with a finger and soapy water 3 35 D Remove masking tape If required clean up surfaces with Sika 208 3 40 Apply Sika 252 black to fill ridges ...

Page 1136: ... 4 Front Fender With Reference To Body Panel 4 00 Front fender with reference to body panel Appendix 1 Repair A1 00 See PR000001 Section 2 Out of alignment between body panel ridge and front fender ridge 2mm 2mm maximum between body panel and front fender ...

Page 1137: ... PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 5 Material Anti silicone 682989 Scotchbrite grey 680226 Sika 206 G P 1 liter 683446 CHIX cloth 682384 Sika 221 booster Blue cloth 682383 Sika Remover 208 685101 Sika 252 black Equipments Glue applicator Safety Rules See PR000001 ...

Page 1138: ...Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A D Apply Sika 206 G P See PR000001 Section D 1 00 Section 2 E Coat black Body Panel Preparation Clean using anti silicone See PR000001 Section A 2 00 Apply double face self adhesive tape 1 16 x 1 2 onto edges and remove protective tape 2 05 ...

Page 1139: ...cone See PR000001 Section A B Sand using Scotchbrite See PR000001 Section G C Clean using anti silicone See PR000001 Section A D Apply Sika 206 G P See PR000001 Section D 3 00 Apply double face self adhesive tape 1 16 x 1 2 6mm from panel edges and remove protective tape do not apply into the grooves 3 05 ...

Page 1140: ...e PR000001 Section A 4 00 C Apply Sika 206 G P See PR000001 Section D 4 10 Apply double face self adhesive tape 1 16 x 1 2 SECTION 5 GLUING Important Make sure that all bonding surfaces are clean and free of dust residue or dry glue If required clean using a scraper or damp cloth Lamp Casing Gluing SI APPLICABLE A Apply Sika 252 5 00 B Install casing If necessary remove excess using Sika 208 ...

Page 1141: ...D BODY PANEL GLUING 5 15 Apply Sika 221 booster 5 20 Install body panels Compress for 4 hours minimum RIDGED BODY PANELS 5 25 Apply Sika 252 to fill the ridges Appendix 1 Repair A1 00 See PR000001 Section 2 A Prepare structure B Prepare body panel A1 05 C Perform required steps described in the procedure ...

Page 1142: ......

Page 1143: ...GLUING PROCEDURE QUALIFIED PERSONNEL ONLY Page 1 of 4 Material Scotchbrite grey 680226 Anti silicone 682989 CHIX Cloth 682384 Blue Cloth 682383 Sika 205 1litre 683097 Sika Remover 208 685101 Sika 252 black Double face tape Equipment Glue applicator Pencil Eraser Safety rules See PR000001 ...

Page 1144: ...e See PR000001 Section G C Clean using anti silicone See PR000001 Section A 1 05 D Apply Sika 205 See PR000001 Section B Fiberglass Preparation A Sand using Scotchbrite See PR000001 Section G B Clean using anti silicone See PR000001 Section A 1 10 C Apply Sika 205 See PR000001 Section B Panel Positioning 1 15 A Position the panel so that its outline follows the contour of the headlamp ...

Page 1145: ... Installation A B C A Apply double face tape 1 32 x on top of center piece B Apply double face tape 1 8 x underneath center piece C Apply Sika 252 1 20 D Center and position center piece with reference to the lines performed at step 1 15b and affix center piece Note Position center piece before compressing double face tape L H R H Panel Installation 1 25 A Apply double face tape 1 16 X 1 4 about 1...

Page 1146: ...ard eraser Note Position side panel before compressing double face tape D If applicable remove excess of Sika and clean surfaces using Sika 208 Section view A Position entrance door and service door frame vertical molding 1 30 B Drill using a 30 drill bit rivet Section 2 Replacement Repair Panel removal See la PR000001 Section 2 2 00 Preparation and installation See PR000001 Section 2 and or do pr...

Page 1147: ...CYCLE 13 8 2 REFRIGERANT 14 8 2 1 Procurement 14 8 2 2 Precautions in Handling Refrigerant 14 8 2 3 Treatment in Case of Injury 14 8 2 4 Precautions in Handling Refrigerant Lines 15 8 3 PUMPING DOWN 17 8 4 ADDING REFRIGERANT VAPOR STATE 18 8 5 EVACUATING SYSTEM 18 8 5 1 Double Sweep Evacuation Procedure 18 8 6 CHARGING SYSTEM 20 8 7 REFRIGERANT SYSTEM CLEAN OUT AFTER COMPRESSOR FAILURE 20 8 7 1 De...

Page 1148: ...2 9 10 TROUBLESHOOTING 33 9 10 1 Expansion Valve 33 9 10 2 A C 34 9 11 TEMPERATURES PRESSURES 36 9 12 LEAK TESTING 37 10 SMALL HVAC SYSTEM AIR CONDITIONING COMPONENTS 37 10 1 COMPRESSOR 37 10 2 MAGNETIC CLUTCH 37 10 3 MAINTENANCE PRECAUTIONS 38 10 3 1 Work Area 38 10 3 2 Refrigerant Handling 38 10 3 3 PAG Oil Handling 38 10 3 4 Refrigerant Recovery 38 10 3 5 Compressor Handling 39 10 4 COMPRESSOR ...

Page 1149: ...RATOR COIL CLEANING 9 FIGURE 12 CONDENSER COIL CLEANING 9 FIGURE 13 ACCESS TO DRIVER S HVAC UNIT AIR FILTERS 10 FIGURE 14 DRIVER S HVAC UNIT AIR FILTERS 10 FIGURE 15 CABIN HVAC UNIT AIR FILTERS 10 FIGURE 16 REFRIGERANT CIRCUIT CENTRAL SYSTEM 16 FIGURE 17 DOUBLE SWEEP EVACUATION SET UP 19 FIGURE 18 AIR PRESSURE REGULATOR 21 FIGURE 19 BELT TENSIONER 22 FIGURE 20 COMPRESSOR ALIGNMENT 22 FIGURE 21 COM...

Page 1150: ...EATING SYSTEM COMPONENTS 45 FIGURE 51 CEILING OF THE SPARE WHEEL COMPARTMENT 46 FIGURE 52 DRIVER S HVAC UNIT 46 FIGURE 53 HEATER LINE SHUTOFF VALVES 46 FIGURE 54 HEATER LINE SHUTOFF VALVES 46 FIGURE 55 CABIN HVAC UNIT DRAIN COCK 47 FIGURE 56 DRIVER S HOT WATER PNEUMATIC VALVE ASSEMBLY 47 FIGURE 57 PNEUMATIC WATER VALVE 48 FIGURE 58 CENTRAL HOT WATER PNEUMATIC VALVE ASSEMBLY 49 FIGURE 59 PNEUMATIC ...

Page 1151: ...ir enters the vehicle on the L H side through the recirculation damper located inside the evaporator compartment door Fig 2 The damper can be fully opened for normal operation or closed for extreme weather or highly polluted areas Refer to the Owner s Manual for more details The recirculation REC button is located on the HVAC control module Press down the button to partially close the fresh air da...

Page 1152: ...to prevent battery discharge HVAC system will not operate if vehicle charging system is not working properly 5 1 DRIVER S UNIT OPERATION The temperature control in the driver s area is provided directly by the L H portion of the HVAC control module mounted on the R H dashboard panel Fig 5 FIGURE 5 CENTRAL HVAC SYSTEM CONTROL MODULE The driver s HVAC unit piping is paralleled with the cabin HVAC un...

Page 1153: ...5 95 1806 40 104 1465 45 113 1195 50 122 980 55 131 808 60 140 670 65 149 559 70 158 468 75 167 394 80 176 333 85 185 283 90 194 241 95 203 207 100 212 178 105 221 153 110 230 133 115 239 115 120 248 100 125 257 88 130 266 77 135 275 68 140 284 60 145 293 53 150 302 47 5 2 CABIN UNIT OPERATION The HVAC control module located on the R H dashboard panel Fig 5 enables the selection of the temperature...

Page 1154: ...compartment R9 24V Condenser fan R H R10 24V Condenser fan L H R12 24V Evaporator fan R20 Water pump R26 Pre heating Diodes evaporator compartment D9 Pre heating D10 Pre heating D16 Baggage compartment 3 D17 Baggage compartment 5 D19 Baggage compartment 2 D20 Baggage compartment 1 DXX Not used 6 HVAC UNIT MAINTENANCE No special maintenance is required on the cabin and driver s HVAC units with the ...

Page 1155: ...ENSER COIL CLEANING 22243A CAUTION Direct the pressure straight through the coil to prevent bending of fins and do not use extremely high pressure Do not use hot water steam or caustic soap 6 2 DRIVER S HVAC UNIT CABIN HVAC UNIT AIR FILTERS The driver s HVAC unit is located behind the dashboard s R H side lateral plastic panel To gain access to the A C filters unscrew the R H lateral console s gri...

Page 1156: ...essure water jet to avoid damaging filter CAUTION Be sure not to reverse filter upon installation 7 HVAC SYSTEM PARTICULARITIES TESTING AND TROUBLESHOOTING Before undertaking any troubleshooting on the HVAC system study the appropriate wiring diagrams to get a complete understanding of the HVAC components circuitry read and understand section 06 ELECTRICAL of this manual under Troubleshooting And ...

Page 1157: ...TICULARITIES Conditions for engaging the 2 nd speed on the evaporator motor cooling demand The 2nd speed engages if the cabin area air temperature is 1 degree above the set point and it revert to speed 1 if the temperature gets equal or below the set point Conditions for hot water recirculating pump activation heating demand The pump turns to OFF if the outside temperature is above 50 F 10 C when ...

Page 1158: ...rcuit breaker CB2 3 Check replace fuse F5 HVAC condenser fans not functioning in speed 1 Circuit breaker CB5 was manually tripped and not reset Seized bearing Faulty brushes Bad wiring Check reset circuit breaker CB9 HVAC condenser fans not functioning in speed 1 Module A54 is not powered or is faulty 1 Check the SYSTEM DIAGNOSTIC menu of the message center display MCD Select FAULT DIAGNOSTIC and ...

Page 1159: ...ig 16 and 40 For vehicles equipped with a small A C system refer to paragraph 10 SMALL HVAC SYSTEM AIR CONDITIONING COMPONENTS further in this section 8 1 A C CYCLE Refrigeration may be defined as the transfer of heat from a place where it is not wanted to a place where it is unobjectionable Components required for a closed circuit refrigeration system are shown in Figures 16 and 41 The air condit...

Page 1160: ...to liquid refrigerant WARNING One of the most important precautions when handling refrigerant consists in protecting the eyes Any liquid refrigerant which may accidentally escape is approximately 40o F 40o C If refrigerant comes in contact with the eyes serious injury could result Always wear goggles to protect the eyes when opening refrigerant connections All refrigerant cylinders are shipped wit...

Page 1161: ...cm from the exhaust manifold 3 Use only sealed lines from parts stock 4 When disconnecting any fitting in the refrigeration system the system must first be discharged of all refrigerant However proceed very cautiously regardless of gauge readings If there happens to be liquid refrigerant in the line disconnect fittings very slowly keeping face and hands away so that no injury can occur If pressure...

Page 1162: ...Section 22 HEATING AND AIR CONDITIONING PA1553 16 FIGURE 16 REFRIGERANT CIRCUIT CENTRAL SYSTEM 22247 ...

Page 1163: ...ents NOTE Before attempting any repair between compressor and receiver tank use a recovery unit to remove refrigerant from the system NOTE On vehicles equipped with a small A C system only refer to Small HVAC System Air Conditioning Components paragraph 10 9 OIL RETURN OPERATION and 10 3 4 Refrigerant Recovery further in this section WARNING To prevent any injury when air conditioning system must ...

Page 1164: ...kseat the compressor valves by turning out all the way 8 Shut down the vacuum pump 9 Remove the hoses 10 Reinstall the caps at the suction valve take off points 8 5 1 Double Sweep Evacuation Procedure 1 Remove any remaining refrigerant from the system using a refrigerant recovery machine 2 Connect the evacuation manifold vacuum pump hoses and micron gauge to the unit 3 With the unit service valves...

Page 1165: ...Section 22 HEATING AND AIR CONDITIONING PA1553 19 FIGURE 17 DOUBLE SWEEP EVACUATION SET UP ...

Page 1166: ...The system is now ready for operation CAUTION The evacuation of the system must be made by authorized and qualified personnel only Refer to local laws for R 134a recuperation 8 7 REFRIGERANT SYSTEM CLEAN OUT AFTER COMPRESSOR FAILURE Although the vast majority of reciprocating refrigerant compressors manufactured today are extremely reliable a small percentage do fail These failures usually result ...

Page 1167: ...e filter dryer Also check the liquid line dryer for signs of restriction If the pressure drop across the filter dryer exceeds 12 to 14 psig 82 75 to 96 5 kPa with a 40 F 5 C evaporator coil temperature stop the unit and change the liquid line and suction line filter dryer After 4 or 5 hours of operation stop the unit and replace the filter dryer 8 After 8 hours of operation stop the unit and remov...

Page 1168: ...lley positioning the other end close to the compressor clutch pulley Figs 20 21 2 Check the distance between each extremity of straight edge 1 Fig 21 and the first drive belt If they are different loosen the compressor support bolts and with a hammer knock support to slide it in order to obtain the same distance then tighten bolts 9 1 4 Horizontal Compressor Alignment 1 Rest an extremity of the st...

Page 1169: ...erly positioned gasket at assembly Warped cylinder head Severe liquid refrigerant floodback Blown Valve Plate Gaskets Symptom Loss of unit capacity at medium and low temperatures Very hot cylinder head surface Higher than normal suction pressure Cause Improperly torqued cylinder head bolts Severe liquid refrigerant floodback Oil slugging caused by an overcharge of oil or flood starts Discharge val...

Page 1170: ...tor plate 7 From under the vehicle remove the eight bolts retaining the evaporator fan motor support Remove the complete unit from the evaporator compartment Fig 23 24 CAUTION Never support evaporator motor by its output shafts while moving it 8 On a work bench unscrew the fan square head set screws the Phillips head screws retaining cages to support and slide out the assemblies from the evaporato...

Page 1171: ...nerally done on the machine itself in accordance with various processes and conformably to the importance and the type of machines a Grinding with abrasive cloth 60 grit sandpaper applied to the commutator must be done by hand With the new brushes installed in brush holders and pressing against the abrasive cloth rotate the armature by hand until satisfactory seating of each brush is achieved Refe...

Page 1172: ... check the evaporator motor amperage in 1st speed and in 2nd speed Make sure that the evaporator compartment door is closed and that the reading is 30 A 3 in 1st speed Confirm that the reading is 64 A 4 MAX 68 A in 2nd speed 9 3 6 Brush Holder Adjustment NOTE The brush holders are mounted on a support that can rotate Rotating that rocker ring will move all the brush holders at the same time 1 Remo...

Page 1173: ... when pressure drops to 130 psi the motors will run at low speed and if the pressure continues to drop to 90 psi a pressure switch stops the motors so that fans do not operate needlessly When pressure rises to 120 psi the pressure switch reactivates the motors If the pressure rises to 170 psi the motors will switch to high speed For details about electrical wiring refer to A C and Heat system in t...

Page 1174: ...and discard the complete unit and replace with a new unit of the same type according to this procedure 1 Isolate the refrigerant in the receiver tank by following the Pumping Down procedure explained in this section 2 Change the filter dryer as a unit 3 Add a small quantity of refrigerant R 134a to the low side of the system Check for leaks Return the system to normal operation CAUTION Do not use ...

Page 1175: ...OID VALVE 22181 9 7 1 Manual Bypass This type of solenoid valve is equipped with a manual operating stem The 3 16 square stem located on the bonnet is exposed when the seal cap is removed To manually open valve turn stem turn counterclockwise To manually close valve turn stem clockwise until tight against seat Manual stem must be in closed position for automatic electric operation 9 7 2 Coil Repla...

Page 1176: ... power assembly surpasses the combined pressures of the evaporator pressure and the superheat spring causing the valve pin to move in the opening direction Conversely as the temperature of the refrigerant gas leaving the evaporator decreases the pressure in the remote bulb and power assembly also decreases and the combined evaporator and spring pressures cause the valve pin to move in the closing ...

Page 1177: ... fast idle with temperature control set at 82o F 27 7o C Then set temperature to minimum to keep the compressor on 6 cylinders FIGURE 35 SUPERHEAT ADJUSTMENT INSTALLATION22046 2 Install pressure gauge at the evaporator suction header You may install the pressure gauge at compressor suction but then add 3 psi to reading 3 Install a remote reading thermometer to the evaporator outlet line near the e...

Page 1178: ...se conditions will give a high superheat Maintenance 1 Pump down the system as previously indicated in this section 2 Disconnect the external equalizer line from the under side of the power head and unclamp the remote control bulb from the evaporator coil outlet line 3 Remove the two cap screws holding the power assembly to the valve body flange Lift off the power assembly and remove the cage asse...

Page 1179: ...lace valve Air filter screens clogged Clean or replace air filter screens Clogged lines Clean repair or replace lines LOW SUCTION PRESSURE LOW SUPERHEAT Uneven or inadequate evaporator loading due to poor air distribution or liquid flow Balance evaporator load distribution by providing correct air or liquid distribution HIGH SUCTION PRESSURE HIGH SUPERHEAT Compressor discharge valve leaking Replac...

Page 1180: ...k condition of air filter and motors Insufficient air flow Dirty or iced evaporator Dirty air filter Blowers inactive Clogged ducts No flow of refrigerant through expansion valve Filter dryer is clogged Remote bulb has lost charge or expansion valve is defective Expansion valve hisses Bubbles in moisture and liquid indicator Gas in liquid line Add refrigerant Loss of capacity Clogged filter Obstru...

Page 1181: ...9 psi 171 9 psi 199 8 psi the pressure in the condenser is inferior to the pressure corresponding to the exterior temperature in this case the condenser pressure may be too low Check for refrigerant leaks and add refrigerant if necessary If the pressure corresponding to the condenser temperature is superior to the pressure corresponding to the exterior temperature then the air cooled condenser pre...

Page 1182: ... 2 50 45 6 18 5 127 6 40 40 0 14 7 101 4 30 34 4 9 8 67 6 20 29 3 8 26 2 10 23 1 8 12 4 0 18 6 3 43 4 10 12 11 6 80 20 7 18 0 124 1 30 1 25 6 176 5 40 4 34 5 237 9 50 10 44 9 309 6 60 16 56 9 392 3 70 21 1 70 7 487 5 80 27 86 4 595 7 90 32 2 104 2 718 5 100 38 124 3 857 0 110 43 3 146 8 1012 2 120 49 171 9 1185 3 130 54 4 199 8 1377 6 140 60 230 5 1589 3 150 65 6 264 4 1823 0 160 71 301 5 2078 8 1...

Page 1183: ...that the top of the cone is approximately level or within one half inch above the plate 2 Probe end of suction test tube around all joints valves etc When a leak has been found at a soldered joint this section of the system must be pumped down Do not solder as pressure will force hot solder out If the system is empty it is more economical to put in just enough R 134a to produce about 15 psi 103 kP...

Page 1184: ...ver throw or strike refrigerant cylinder and never handle roughly 10 3 3 PAG Oil Handling Whenever a part replacement has to be done on the system additional task about PAG oil will have to be performed The compressor has little reserve and is lubricated by the oil refrigerant mixture To perform correctly the compressor needs the mixture to be from 3 to 6 of Poly Alkaline Glycol PAG oil When a com...

Page 1185: ...ility 10 4 COMPRESSOR REMOVAL 10 4 1 When the compressor is operational Perform the OIL RETURN OPERATION Refer to paragraph 10 9 10 4 2 When the compressor is inoperable Perform the Refrigerant Recovery operation Refer to paragraph 10 3 4 FIGURE 39 COMPRESSOR REMOVAL OR INSTALLATION 22285 Slacken bolts A Refer to figure 39 Remove bolts B C Refer to figure 39 Remove the compressor 10 5 INSTALLATION...

Page 1186: ...Section 22 HEATING AND AIR CONDITIONING PA1553 40 FIGURE 42 REFRIGERANT CIRCUIT SMALL SYSTEM 22336 ...

Page 1187: ... on the label 180 ml FIGURE 46 ADDING NEW COMPRESSOR OIL 10 6 1 Evacuating System Before Adding Refrigerant Small System When a system has been opened for repairs change the filter dryer and evacuate the system XL2 MTH equipped with a small system must use high pressure service port located on the other side of check valve and low pressure port located alongside rear truss Figs 42 and 43 It would ...

Page 1188: ...thod 2 Replace the filter dryer 3 Supply with new oil as specified in paragraph 10 6 COMPRESSOR OIL CHANGE 10 9 OIL RETURN OPERATION There is a close affinity between oil and refrigerant During normal operation part of the oil recirculates with the refrigerant in the system Therefore when checking the amount of oil in the system or replacing any system component the compressor must be run in advan...

Page 1189: ...sor will enter the cylinders causing liquid compression which will damage the compressor s suction and delivery valves 10 12 TIGHTENING TORQUES FIGURE 49 TIGHTENING TORQUES PART THREAD SIZE TIGHTENING TORQUE 1 Bolt Armature M6 x 1 0 12 14 Nm 8 7 10 1 Lbf Ft 2 Field Coil Screw M5 x 0 8 4 6 Nm 2 9 4 3 Lbf Ft 3 Body Bolt M8 x 1 25 20 24 Nm 14 5 17 3 Lbf Ft 4 Oil Drain Plug M8 x 1 25 13 15 Nm 9 4 10 8...

Page 1190: ...oisture level For positive protection the drying of the system should be continued until the color of the element turns to deep blue The liquid refrigerant is readily visible through the center opening of the moisture element where the presence of bubbles indicates a shortage of refrigerant or restriction in line 11 HEATING SYSTEM As seen earlier in this section the vehicle interior is pressurized...

Page 1191: ...Section 22 HEATING AND AIR CONDITIONING PA1553 45 FIGURE 50 CENTRAL HEATING SYSTEM COMPONENTS 22338 ...

Page 1192: ...re located in engine compartment One is on the L H side of compartment in front of the radiator and the other valve is located under the radiator fan gearbox Fig 54 FIGURE 54 HEATER LINE SHUT OFF VALVES 05067 c The main heater core drain cock is located in the evaporator compartment To access open the baggage compartment forward of the evaporator compartment An access door held shut by three retai...

Page 1193: ...ant has been added it is necessary to bleed air from heating system Locate the manual vent illustrated in Figure 52 and open momentarily until no air escapes from the line 11 1 4 Soldering Before soldering any part of the system make sure the area is well ventilated Use stay clean flux sparingly and apply solder 95 5 round wire 1 8 inch 3 1 mm After completing repairs test for leaks When using hea...

Page 1194: ... Reassembly a Assemble the actuator casing tube nipple spindle and closure member b Tighten the nipple in place in the body cavity as per figure 54 Fasten pilot solenoid vale to the pneumatic water valve Reconnect air supply pressure and electrical current to the pilot solenoid valve c Check for proper operation o Pilot Solenoid Valve a No maintenance is needed unless a malfunction occurs b A pilo...

Page 1195: ...ylinder spring pushes up against the cylinder thereby allowing the hot water to enter the main heater core The central heater water valve requires a minimum amount of maintenance The valve should be free of dirt sediment that might interfere with its operation No other maintenance is needed unless a malfunction occurs FIGURE 58 CENTRAL HOT WATER PNEUMATIC VALVE ASSEMBLY 22240 o Pneumatic Water Val...

Page 1196: ...t main actuator and cylinder springs are free to travel 2 Check that there is no restriction to the air escaping from the actuator casing 3 Make sure that pilot solenoid valve operates properly 11 1 7 Water Recirculating Pump This vehicle is provided with a water recirculating pump which is located in the evaporator compartment Fig 60 The water recirculating pump consists of a centrifugal pump and...

Page 1197: ... usable brush is left less than 0 300 inch 8 mm b Chipped edges Chips can be caused by improper handling or installation Badly chipped brushes should be replaced regardless of their length c Annealed brush spring This can be detected by noting the resiliency of the spring Annealing is caused by failing to tighten the brush caps properly thus not providing a good low resistance contact between the ...

Page 1198: ...FIGURE 61 WATER RECIRCULATING PUMP CENTRAL HVAC SYSTEM 22091 ITEM DESCRIPTION QTY 1 Housing 1 2 O Ring 1 3 Washer SS 2 4 Rotor Assembly 1 5 Shaft SS 1 6 Screw Cap Hex Soc Head 8 32 X 3 8 8 7 Adaptor 1 8 Drive Magnet 1 9 Motor Assembly 24V 1 10 Brush 2 ...

Page 1199: ...iner to recover coolant and disconnect silicone hose from hot water pneumatic valve d From inside of vehicle remove the two finishing panels in front of unit Remove the three screws fixing the unit front panel Open the manual vent located inside the HVAC unit on the driver s side Fig 52 to ensure an efficient draining 11 2 2 Filling Heating System a Ensure that the drain hose is reconnected and th...

Page 1200: ...Section 22 HEATING AND AIR CONDITIONING PA1553 54 FIGURE 62 CEILING OF THE SPARE WHEEL COMPARTMENT FIGURE 63 HEATER LINE SHUTOFF VALVES W5 ...

Page 1201: ...Section 22 HEATING AND AIR CONDITIONING PA1553 55 FIGURE 64 HEATER LINE SHUTOFF VALVES WE W0 ...

Page 1202: ...Section 22 HEATING AND AIR CONDITIONING PA1553 56 FIGURE 65 SMALL HEATING SYSTEM COMPONENTS 22337 ...

Page 1203: ...r Prevost number 563008 Brush Prevost number 562951 Condenser fan motors Make US MOTOR Type TF 12 Voltage 28 5 V DC Current draw 20 amps Horsepower 0 57 Revolution 1950 rpm Insulation Class F Motor 20 000 hours Brush life 10 000 hours Qty 2 Prevost number 562579 Brush Prevost number 561914 Evaporator air filters Central system Make Permatron Corp Type Polypropylene Prevost number 871383 Driver s H...

Page 1204: ...g Compressor Central system Make Carrier Transicold Capacity 41 CFM Model 05G 134A No of cylinders 6 Bore 2 50 8 mm Operating speed 400 to 2200 rpm 1750 rpm Nominal Minimum speed for lubrification 400 rpm Nominal horsepower 15 Oil pressure at 1750 rpm 15 to 30 psi 103 207 kPa Oil capacity 1 13 U S gal 4 3 liters Weight 142 lbs 64 5 kg Approved oils Castrol SW 68 POE Prevost number option R 134a 95...

Page 1205: ...a 2 B grooves Voltage 24 V DC Coil resistance at 68 o F 20 o C 5 15 5 69 ohms Prevost number 950204 Compressor V belts Make Dayco Model matching set of 2 BX97 Prevost number with Delco 270 300 Amp Alternator 506664 Compressor V belt Make Dayco Model BX100 Prevost number with two BOSH Alternators 506681 Condenser coil Central system Make Carrier Transicold Aluminum Prevost number 870654 Copper Prev...

Page 1206: ...noid valve Make Parker Type Normally closed with manual bypass Voltage 24 V DC Amperage draw 0 67 amps Watts 16 Prevost number without coil 95 0054 Coil Prevost number 950055 Repair kit Prevost number 950056 Driver s hot water pneumatic valve Make Burkert Type Normally open Voltage 24 V DC Prevost number 871252 Seal kit Water Side 871311 Seal kit Actuator Side 871312 Seal kit Pilot Solenoid Valve ...

Page 1207: ...er Side 871389 Seal kit Actuator Side 871388 Seal kit Pilot Solenoid Valve 871390 Water recirculating pump Make M P pumps Voltage 24 V DC Prevost number 871342 Driver s expansion valve Prevost number 950221 Expansion valve Central system Make Alco Model TCLE 5 1 2 Prevost number 950320 ...

Page 1208: ......

Page 1209: ...Compressor 62 11052 Rev A WORKSHOP MANUAL for MODEL 05G TWIN PORT COMPRESSOR R ...

Page 1210: ...WORKSHOP MANUAL COMPRESSOR MODEL 05G TWIN PORT ...

Page 1211: ...work on the equipment alone MAINTENANCE PRECAUTIONS Be sure power is turned off before working on motors controllers solenoid valves and electrical control switches Tag circuit breaker and power supply to prevent accidental energizing of circuit Do not bypass any electrical safety devices e g bridging an overload or using any sort of jumper wires Problems with the system should be diagnosed and an...

Page 1212: ...y other means relieve pressure in replacement compressor before removing plugs WARNING Do not unscrew capscrews all the way before breaking seal Entrapped pressure could result in injury CAUTION The high capacity oil pump must be set to rotate in the same direction as the crankshaft Refer to Section 3 5 CAUTION Ensure that thrust washer does not fall off dowel pins while installing oil pump CAUTIO...

Page 1213: ... 1 5 2 Pressure Operated Unloaders 1 5 COMPRESSOR REPLACEMENT 2 1 2 1 COMPRESSOR REMOVAL 2 1 2 2 COMPRESSOR REPLACEMENT 2 1 2 2 1 Installing Compressor Unloaders 2 1 2 2 2 INSTALLING COMPRESSOR 2 2 COMPRESSOR MAINTENANCE 3 1 3 1 SHAFT SEAL RESERVOIR 3 1 3 2 INTRODUCTION 3 1 3 3 INSPECTION AND PREPARATION FOR REASSEMBLY 3 1 3 4 CYLINDER HEAD AND VALVE PLATE 3 1 3 4 1 Disassembly 3 1 3 4 2 Reassembl...

Page 1214: ... 2 2 Oil Level in Sight Glass 2 2 Figure 3 1 Shaft Seal Reservoir 3 1 Figure 3 2 Cylinder Head Valve Plate 3 2 Figure 3 3 Installing Suction Valves 3 2 Figure 3 4 Checking Suction Valve 3 2 Figure 3 5 Oil Pump and Bearing Head Assembly 3 3 Figure 3 6 Oil Pump 3 3 Figure 3 7 Shaft Seal 3 3 Figure 3 8 Shaft Seal Removal 3 4 Figure 3 9 TOP Orientation 3 4 Figure 3 10 Bottom Plate Removal 3 5 Figure 3...

Page 1215: ...om of the crankcase for maintenance WARNING Do not operate compressor unless suction and discharge service valves are open Capacity of the Model 05G Twin Port compressor is determined by piston displacement and clearance suction and discharge valve size compressor speed suction and discharge pressure type of refrigerant and unloader valves 1 3 COMPRESSOR REFERENCE DATA Table 1 1 Compressor Referen...

Page 1216: ...vice Valve 2 High Pressure Connection 3 Low Pressure Connection 4 Suction Service Valve 5 Guage Connection 6 Oil Fill Plug 7 Oil Level Sight Glass 8 Bottom Plate 9 Oil Drain Plug 10 Oil Pump See Figure 1 3 11 Unloader 12 Shaft Seal Reservoir 12 12 5 5 5 5 COMPRESSOR WITHOUT MOUNTING FLANGE Figure 1 1 Model 05G Compressor ...

Page 1217: ...filter screen and pick up tube to the oil pump located in the bearing head assembly The crankshaft is drilled to enable the pump to supply oil to the main bearings connecting rod bearings and the shaft seal Figure 1 3 Oil Pump The oil flows to the pump end main bearings connecting rod bearings and seal end main bearings where the oil path is divided into two directions The largest quantity flows t...

Page 1218: ...ion in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the d...

Page 1219: ...se Discharge gas bleeds into the valve chamber the pressure closes the piston bypass valve 5 and the cylinder bank loads up Discharge gas pressure forces the discharge piston check valve 6 open permitting gas to enter the discharge manifold During unloaded operation Figure 1 9 when suction pressure drops below the valve control point the poppet valve 4 will open Discharge gas bleeds from behind th...

Page 1220: ...mpressor is to be returned for overhaul or repair install the pads on the compressor for sealing purposes during shipment Service replacement compressors are furnished with cylinder head bypass piston plugs installed on the unloader flanges in lieu of the unloader valves The unloaders if used must be removed from the defective compressor and transferred to the replacement compressor prior to insta...

Page 1221: ...ll new locknuts on compressor mounting bolts and new gaskets on suction and discharge service valves b Check oil level in sight glass See Figure 2 2 If necessary add or remove oil c Leak test evacuate and dehydrate the compressor d Fully backseat suction and discharge service valves e Run the compressor and check for leaks and noncondensibles in the refrigerant system f Check refrigerant level g R...

Page 1222: ...ondition Replace any defective or excessively worn parts c Inspect suction and discharge valve seats on valve plate d If unloaders are installed inspect operation of unloader e After cleaning ensure all moving parts are coated with compressor oil before reassembly f Use only new gaskets during reassembly Ensure all gaskets includes cylinder head valve plate and un loader or bypass plug gaskets are...

Page 1223: ...ves e Place the valve plate and new valve plate gasket on cylinder deck ensuring that the valve plate is properly positioned on the four dowel pins f Using a small screwdriver operate the suction valves to ensure that the valve tips are not being held by the valve plate gasket See Figure 3 4 g Install capscrews cylinder head and new cylinder head gasket with flat side to valve plate ensuring that ...

Page 1224: ...p end thrust washer on the two dowel pins located on the bearing head See Figure 3 5 CAUTION Ensure that thrust washer does not fall off dowel pins while installing oil pump b Install the bearing head assembly with a new gasket on the compressor crankshaft Carefully push oil pump on by hand ensuring that the thrust washer re mains on the dowel pins the tang on the end of the drive engages the slot...

Page 1225: ... Insure that the back side of the lipseal seats on the shoulder machined in the cover clutch mounting hub g Using clean refrigerant oil lubricate the new O ring and install it into the outside groove of the new stator being careful not to touch the sealing surfaces of the stator with your fingers NOTE Do not touch the sealing surfaces with your fingers If the sealing surfaces become contaminated c...

Page 1226: ...Push piston rod assemblies out of the way and remove crankshaft and seal end thrust washer b Remove and check operation of oil return check valves See Figure 3 11 The check valves are free floating devices and can easily be checked visually c Remove and check oil pressure relief valve See Figure 3 11 The oil pressure relief valve is a spring loaded device which can be checked by using a small piec...

Page 1227: ...o installing new piston rings it is necessary to break the hard glazed surface of the cylinder in order to reduce the wearing in period of the new rings Break the glaze by honing lightly in an up and down rotating motion Clean thoroughly after breaking glaze Some 05G compressors for refrigeration use only may have contoured pistons See Figure 3 15 When installing contoured pistons into compressor ...

Page 1228: ...eet metal b Install connecting rod caps on connecting rods using new capscrews special and flat washers Reuse of the old capscrews is not recommended Ensure that the caps are installed on the locating pins Torque capscrews to torque value shown in Table 3 1 Ensure freedom of movement of crankshaft after capscrews are torqued on each rod cap c Check operation and reinstall check valves and relief v...

Page 1229: ... 20 10 to 13 1 4 to 1 8 Connecting Rod Counter Weight 5 5 to 7 0 8 to 1 0 Crankshaft Setscrew 1 4 28 8 to 18 1 1 to 2 5 Unloader Valve 1 4 28 12 to 16 1 7 to 2 2 Discharge Valve Backer 5 16 18 16 to 20 2 2 to 2 8 Cover Oil Pump 5 16 18 20 to 30 2 8 to 4 1 Discharge Service Valve 8 to 15 1 1 to 2 1 Oil Reservoir Bottom Plate Crankcase 3 8 16 30 to 50 4 1 to 6 9 End Flange Crankcase 3 8 16 30 to 50 ...

Page 1230: ... Rod Diameter 1 3768 34 9707 1 3760 34 9504 0020 0 051 Piston Pin Bearing 0 6883 17 4752 0 6878 17 4701 001 0 0254 CRANKSHAFT Crankpin Diameter 1 3740 34 8996 1 3735 34 8869 0025 0 0635 Throw Height 37 CFM 0 9698 24 6329 0 9678 24 5821 Throw Height 41 CFM 1 072 27 2288 1 070 27 1780 THRUST WASHER Thickness Pump End 0 145 3 6830 0 144 3 658 0250 0 6350 Seal End 0 157 3 987 0 155 3 937 0250 0 6350 C...

Page 1231: ...tem 1 3 O Oil 1 1 Oil Level 2 2 Oil Adding 3 7 Oli Pump Maintenance 3 2 P Pistons Rods and Rings 3 5 R Reference Data 1 1 Running Gear Removal 3 4 S Service Valves 1 3 Shaft Seal Maintenance 3 3 Shaft Seal Reservoir 1 3 Suction Strainer 3 7 T Torque Values 3 8 U Unloader Replacemant 2 1 Unloader Electric Operated 1 4 Unloader Pressure Operated 1 5 W Wear Limits 3 9 ...

Page 1232: ...ransicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 357 7223 Fax 1 706 355 5435 Central America and Mexico Ejercito Nacional No 418 Piso 9 Torre Yumal Col Chapultepec Morales 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX Carrier Transport Air Conditioning 50 Grumbacher Road York PA 17402 USA Tel 1 800 673 2431 F...

Page 1233: ...Compressor 62 11053 Rev B SERVICE PARTS LIST for MODEL 05G TWIN PORT COMPRESSOR 1 2 3 4 5 6 R ...

Page 1234: ...FT ROD AND PISTON GROUP 5 6 SHAFT END GROUP 6 7 SHAFT SEAL RESERVOIR AND SHAFT END FLANGES 7 8 UNLOADERS 8 9 VALVE PLATE ASSEMBLY 10 10 UNLOADER VALVE PLATE ASSEMBLY 11 11 CYLINDER HEAD SIDE 12 12 CYLINDER HEAD CENTER 12 13 GASKET SET 13 14 CLUTCH ASSEMBLY HOUSING MOUNTED WARNER GRAY IN COLOR 14 15 CLUTCH ASSEMBLY HOUSING MOUNTED LINNIG GOLD IN COLOR 16 16 CLUTCH ASSEMBLY SHAFT MOUNTED 18 17 UNLOA...

Page 1235: ...s No Oil Trailer 18 00091 106 6GCG008WB03131 18 00059 130RM Standard Bottom Cover 37 CFM Contoured Pistons Star Flange 1 Electric Unloader No Oil Truck Supra 9XX 18 00091 108 6GDG00DUA0313A 18 00059 128RM Ultra Bottom Cover 37 CFM Contoured Pistons Ultra Flange With Threaded Clutch Hub 2 Electric Unloaders No Oil Trailer With Standby 18 00091 150 6GCF00ATA03031 18 00059 169 Standard Bottom Cover 3...

Page 1236: ...sembly or kit COMPRESSOR OIL CHART Part Number Oil Type Viscosity Refrigerants Application Packaging 07 00275 00 Mineral 150 R 12 R 22 R 500 R 502 Large Bus 1 Gallon x 6 07 00377 00 Mineral 300 R 12 R 22 R 500 Large Bus 1 Gallon x 6 07 00430 00 Alkyl Benzene A B 68 R 22 Large Bus 1 Gallon x 6 07 00274 00 Alkyl Benzene A B 150 R 12 R 22 R 500 R 502 Trailer 1 Gallon x 6 07 00317 00PK6 Polyolester PO...

Page 1237: ...r 1 10 17 13020 00 Capscrew 1 2 13 x 2 1 2 Inches Long SAE Grade 8 4 11 17 40007 00 Gasket Capscrew 1 2 Inch 4 12 17 10812 00 Cap Service Valve Plastic 1 12 17 10806 10 Cap Service Valve Brass 1 9 17 44141 00 Gasket 4 Bolt Service Valve Metal 1 13 17 13022 00 Packing Service Valve Stem package of 10 1 14 06DA403 844 Valve Access 1 4 Flare Schrader for R 12 R 22 R 404A 1 15 DD19CA061 Cap 1 4 Flare ...

Page 1238: ...pressors 1 2 17 44117 00 Capscrew Hex Head 3 8 16 x 2 1 4 Inches Long SAE Grade 8 22 3 17 44037 00 Plug O Ring 7 16 20 Includes 1 4 42 00243 07 O Ring 1 5 17 40020 00 Oil Filter Screen Assembly 1 6 17 40021 00 Tube Oil Suction 1 7 17 44011 00 Oil Relief Valve 1 8 17 40042 00 Oil Return Check Valve Assembly 2 9 17 44129 00 Gasket Bottom Plate Metal 1 ...

Page 1239: ...tyle Compressors 1 2 17 44117 00 Capscrew Hex Head 3 8 16 x 2 1 4 Inches Long SAE Grade 8 22 3 17 44037 00 Plug O Ring 7 16 20 Includes 1 4 42 00243 07 O Ring 1 5 17 40020 00 Oil Filter Screen Assembly 1 6 17 40021 00 Tube Oil Suction 1 7 17 44011 00 Oil Relief Valve 1 8 17 40042 00 Oil Return Check Valve Assembly 2 9 17 44129 00 Gasket Bottom Plate Metal 1 ...

Page 1240: ...hes Long SAE Grade 5 8 2 17 44137 00 Oil Pump and Bearing Head Includes 1 3 17 44037 00 Plug O Ring 7 16 20 Includes 2 4 42 00243 07 O Ring 2 5 17 44139 00 O Ring Pump Cover Plate 1 6 17 40204 00 Pin Roll 1 8 x 1 2 Inch 2 7 17 55009 01 Thrustwasher Pump End 1 8 17 40078 05 Gasket Bearing Head Fiber 1 8 17 44022 00 Gasket Bearing Head Metal 1 ...

Page 1241: ...andard 12 5 17 55025 00 Ring Compression 020 Inch Oversize 12 6 17 40324 00 Key Crankshaft 1 4 x 1 4 x 1 1 2 Inches Long For Shaft Mounted or No Clutch 1 6 68G2 9072 Key Crankshaft For Housing Mounted Clutch 1 7 17 44036 00 Pin Spiral 1 8 x 1 2 Inch Long 2 8 17 44008 00 Thrustwasher Seal End 1 9 17 44074 00 Crankshaft Assembly 05G37 CFM 05G Twin Port Includes 1 9 17 44075 00 Crankshaft Assembly 05...

Page 1242: ...44773 00 O Ring Stator 1 7 17 44766 00 Hub Assembly Housing Mounted Clutch Threaded No Groove Trailer Includes 1 7 17 44767 00 Hub Assembly Housing Mounted Clutch Threaded W Grease Groove Bus Includes 1 8 17 44765 00 Seal Lip Shaft Seal 1 4 17 44004 06 Gasket Seal Cover Metal 1 9 17 40308 00 Capscrew 3 8 16 X 1 1 4 Inch Long Grade 5 6 34 01304 00 Nut Hub Without Grease Fitting Port Trailer Only 10...

Page 1243: ...ad 3 8 16 X 0 75 Inch Long Grade 8 1 5 17 44119 00 Gasket End Flange Ultra Style or Full Ring Flange Used With Items 6 and 7 1 6 17 44025 00 End Flange Ultra Style Trailer 1 7 17 44002 00 End Flange Full Ring Star Flange 1 8 17 44127 00 End Flange Half Moon Bus 1 9 17 44118 00 Gasket Half Moon End Flange Used Only With Item 8 1 10 17 44014 00 Gasket Flange Spacer Used Only With Items 8 and 9 2 11 ...

Page 1244: ...8 62 11053 8 UNLOADERS 11 9 10 8 7 6 4 5 3 2 1 COILS 29 12 12 13 14 6 6 7 8 8 15 16 17 18 19 20 21 22 4 5 3 23 24 25 26 27 28 OR Pressure Valve Electric Valve Valve Plug ...

Page 1245: ...ve 115 VAC With 42 inch Wire Leads Includes 17 10829 00 Coil Valve 230 VAC With 42 inch Wire Leads Includes 13 17 40408 02 Cap Snap 1 14 22 50078 02SV Connector 2 Wire 22 02804 00 Coil Only Mates W 22 50078 01SV 1 15 17 40417 00 Valve Assembly Electric Includes A R 3 NSS Body Assembly Valve 1 4 17 40409 00 Piston Unloader Includes 1 5 17 55010 00 Ring Piston 1 6 17 40104 07 Gasket Unloader Valve 1...

Page 1246: ... Assembly Center or Side Bank With No Unloader Includes 1 2 17 44113 00 Capscrew HexHead 1 4 28 x 3 8 Inch Long 4 3 17 10715 00 Lockwasher 1 4 Inch 4 4 17 44750 00 Backer Discharge Valve 2 5 17 44749 00 Valve Discharge 2 6 NSS Valve Plate 1 7 17 44748 00 Valve Suction 2 8 17 40057 00 Dowel Pin Suction Valve 4 9 17 44751 00 Spring Suction Valve 2 10 17 44746 00 Gasket Valve Plate Center or Side Ban...

Page 1247: ...8 x 3 8 Inch Long 4 3 17 10715 00 Lockwasher 1 4 Inch 4 4 17 44750 00 Backer Discharge Valve 2 5 17 44749 00 Valve Discharge 2 6 NSS Valve Plate 1 7 17 44748 00 Valve Suction 2 8 17 40057 00 Dowel Pin Suction Valve 4 9 17 44751 00 Spring Suction Valve 2 10 17 55012 00 Check Valve Unloader Includes 1 11 17 40104 08 Piston Check Valve 1 12 17 40104 09 Spring Check Valve 1 13 NSS Screw Round Phillips...

Page 1248: ...40013 00 Gasket Capscrew 5 16 Inch 2 3 17 01042 04 Valve Service 7 8 Inch ODF 1 8 Inch FPT Gauge Port Includes 1 3 14 00206 01 Valve Service 7 8 Inch ODF M15 Gauge Port For R 134a Includes 1 4 17 10812 00 Cap Service Valve Plastic 1 5 17 10811 05 Gasket Service Valve Fiber 1 5 17 44138 00 Gasket Service Valve Metal 1 4 17 10806 10 Cap Service Valve Brass 1 6 17 44752 00 Cylinder Head Center Bank O...

Page 1249: ...04 06 Gasket Shaft Seal 1 3 17 44746 00 Gasket Valve Plate 3 4 17 44118 00 Gasket End Flange 1 5 17 44119 00 Gasket End Flange 1 6 17 44129 00 Gasket Bottom Plate 1 7 17 44747 00 Gasket Cylinder Head Center or Side Banks 3 8 17 44022 00 Gasket Pump End Bearing Head 1 9 17 40104 07 Gasket Unloader Body 2 10 17 44021 00 Gasket Sight Glass 2 11 17 44138 00 Gasket Service Valve 2 Bolt 2 ...

Page 1250: ...ainer 1 8 68 G 2 9072 Key Crankshaft Special 1 9 17 10308 00 Capscrew Hex Head 3 8 16 x 1 1 4 Inches Long SAE Grade 8 1 10 50 01122 01 Clutch Assembly 24 VDC 2 C Grooves 9 Inch Diameter Includes 1 11 50 01122 50 Coil 24 VDC 1 12 50 01122 85 Rotor Armature 2 C Grooves 9 Inch Diameter Includes 1 13 34 01186 00 Ring Snap 1 14 04 00130 00 Bearing Rotor 1 10 50 01122 04 Clutch Assembly 12 VDC 2 C Groov...

Page 1251: ... Rotor Armature 4 Grooves 2 A 2 B 10 35 Inch Diameter Includes 1 13 34 01186 00 Ring Snap 1 14 04 00130 00 Bearing Rotor 1 10 50 01122 12 Clutch Assembly 24 VDC 2 5V Grooves 8 7 Inch Diameter Includes 1 11 50 01122 50 Coil 24 VDC 1 12 50 01122 91 Rotor Armature 2 5V Grooves 8 7 Inch Diameter Includes 1 13 34 01186 00 Ring Snap 1 14 04 00130 00 Bearing Rotor 1 10 50 01122 14 Clutch Assembly 24 VDC ...

Page 1252: ... Ring Felt and Retainer 1 7 68 G 2 9072 Key Crankshaft Special 1 8 17 10308 00 Capscrew Hex Head 3 8 16 x 1 1 4 Inches Long SAE Grade 8 1 9 50 00226 09 Clutch Assembly 24 VDC 4 Grooves 2A 2B 10 35 Inch Dia Includes 1 10 50 00226 50 Coil 24 VDC 1 11 50 00226 501 Rotor Armature 4 Grooves 2A 2B 10 35 Inch Diameter Includes 1 12 50 50040 05 Ring Snap 1 13 50 50040 04 Bearing 1 9 50 00226 09 Clutch Ass...

Page 1253: ...ring 1 9 50 01130 20 Clutch Assembly 12 VDC 2 B Grooves 10 35 Inch Diameter Includes 1 10 50 00226 41 Coil 12 VDC 1 11 50 50040 03 Rotor Armature 2 B Grooves 10 35 Inch Diameter Includes 1 12 50 50040 05 Ring Snap 1 13 50 50040 04 Bearing 1 9 50 01130 21 Clutch Assembly 24 VDC 2 B Grooves 10 35 Inch Diameter Includes 1 10 50 00226 50 Coil 24 VDC 1 11 50 50040 03 Rotor Armature 2 B Grooves 10 35 In...

Page 1254: ... 8 4 3 2 1 14 Item Part Number Description Qty 1 34 00613 07 Capscrew Hex Head 3 8 UNF x 7 8 Inch Long SAE Grade 8 1 2 AU 11AR 241 Washer Lock Spring 3 8 Inch 1 3 34 00616 00 Washer 13 32 ID x 1 1 2 OD x 3 16 Inch Thick 1 4 17 40037 05 Capscrew Hex Head 3 8 16 x 1 Inch Long 2 ...

Page 1255: ...ameter 6 50 50011 00 Coil 24 VDC 1 6 50 50014 00 Coil 12 VDC 1 7 50 50015 00 Ring Retaining External 1 8 50 50016 00 Ring Retaining Internal 1 9 50 50017 00 Bearing 1 10 17 10308 00 Capscrew Hex Head 3 8 16 x 1 1 4 Inches Long SAE Grade 8 2 11 68 G 2 8522 1 Spacer 1 3 8 OD x 1 2 Inch Thick CRES 2 12 17 40324 00 Key Crankshaft 1 4 x 1 4 x 1 1 2 Inches Long 1 13 50 01115 00 Plate Adapter Used with 5...

Page 1256: ... Valve 2 2 68PD 2 102 3 Solenoid Coil 24 VDC 2 3 12 00334 02 Switch Pressure UPS2 R 134a 1 4 12 00334 03 Switch Pressure UPS1 R 134a 1 5 40 00249 01 Fitting Tee Male Branch 1 4 FPT x 1 4 FPT x 1 4 MPT 1 6 40 00243 01 Fitting Tee Street 1 4 MPT x 1 4 x 1 4 FPT 1 7 06DA403 844 Valve Access 1 4 Flare Schrader 3 8 40 00528 02 Connector 1 4 FPT x 7 16 20 Straight Thread With O Ring Includes 1 9 42 0024...

Page 1257: ...il 36 VDC 2 3 12 00334 02 Switch Pressure UPS2 R 134a 1 4 12 00334 03 Switch Pressure UPS1 R 134a 1 5 40 00249 01 Fitting Tee Male Branch 1 4 FPT x 1 4 FPT x 1 4 MPT 1 6 40 00243 01 Fitting Tee Street 1 4 MPT x 1 4 x 1 4 FPT 1 7 06DA403 844 Valve Access 1 4 Flare Schrader 3 8 40 00528 02 Connector 1 4 FPT x 7 16 20 Straight Thread With O Ring Includes 1 9 42 00243 07 O Ring 1 10 DD19CA061 Cap 1 4 ...

Page 1258: ...7 00 5 17 40324 00 5 18 17 40408 02 9 17 40409 00 9 17 40417 00 9 20 21 17 40417 02 21 17 40418 00 9 17 44002 00 7 17 44004 06 6 13 17 44005 00 1 17 44008 00 5 17 44011 00 2 3 17 44012 00 12 17 44013 00 12 17 44014 00 7 17 44015 00 1 17 44017 00 12 17 44022 00 4 13 17 44025 00 7 17 44026 00 2 17 44035 00 3 17 44036 00 5 17 44037 00 1 2 3 4 17 44041 01 14 16 17 44042 00 14 16 17 44045 01 5 PART NO ...

Page 1259: ...6 50 00226 09 16 50 00226 18 16 50 00226 19 17 50 00226 41 16 17 50 00226 50 16 17 50 00226 501 16 50 00226 65 17 50 00226 66 17 50 01108 00 18 50 01110 00 18 50 01110 01 18 50 01114 00 18 50 01115 00 18 50 01116 00 18 50 01117 00 18 50 01122 01 14 50 01122 02 14 50 01122 04 14 50 01122 07 15 50 01122 09 15 50 01122 12 15 50 01122 14 15 50 01122 41 14 50 01122 50 14 15 50 01122 65 15 50 01122 66 1...

Page 1260: ...ransicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 357 7223 Fax 1 706 355 5435 Central America and Mexico Ejercito Nacional No 418 Piso 9 Torre Yumal Col Chapultepec Morales 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX Carrier Transport Air Conditioning 50 Grumbacher Road York PA 17402 USA Tel 1 800 673 2431 F...

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Page 1273: ...G IF SYSTEM IS NON FUNCTIONING 4 5 3 THERMAL CUTOUT VALVE QUICK TEST 5 5 AIR HORN VALVE 5 5 1 AIR HORN VALVE MAINTENANCE 5 6 HEADLIGHTS CLEANING SYSTEM 5 6 1 GENERAL DESCRIPTION 5 6 2 WASHER FLUID REFILLING 6 6 3 WASHER NOZZLES ADJUSTMENT 6 7 WINDSHIELD WIPERS AND WASHERS 6 7 1 GENERAL DESCRIPTION 6 7 2 WIPER ARM 7 7 2 1 Wiper Arms Positioning 7 7 3 WINDSHIELD WIPER MOTOR 8 7 3 1 Windshield Wiper ...

Page 1274: ...5 FIGURE 6 TUBING AND FITTINGS 6 FIGURE 7 WASHER NOZZLES ADJUSTMENT 6 FIGURE 8 WINDSHIELD WIPER INSTALLATION 7 FIGURE 9 MULTIFUNCTION LEVER 7 FIGURE 10 WINSHIELD WASHER RESERVOIR 7 FIGURE 11 WINDSHIELD WIPER MOTOR SIDE 8 FIGURE 12 WINDSHIELD WIPER DRIVER SIDE 8 FIGURE 13 DRIVING MECHANISM DRIVER SIDE 8 FIGURE 14 DRIVING MECHANISM MOTOR SIDE 8 FIGURE 15 WIPER ARMS POSITIONING 9 ...

Page 1275: ...nner on hubodometer face or on plastic hubcaps Do not weld on hubodometer 2 3 REMOVAL To remove the unit remove the two lock nuts and washers securing it to the wheel hub and pull the unit off the studs 2 4 INSTALLATION Place the hubodometer unit over the wheel hub studs Replace the lock washers and nuts Torque stud nuts to 110 165 Lbf ft 150 225 Nm 3 BACK UP CAMERA AND MONITOR An optional back up...

Page 1276: ...s of ignition as this fuel is extremely flammable Avoid breathing vapors and contacting fuel with skin Never smoke during test FIGURE 3 COLD STARTING AID 23048 1 Check cylinder for hand tightness and fuel supply Fig 3 Empty cylinder weight is approximately 17 oz 480 g full cylinder weight is approximately 35 oz 990 g If cylinder is empty replace it Before replacing cylinder install new valve gaske...

Page 1277: ...Disconnect tube at thermal cutout valve as in step 2 and repeat step 3 No fuel should be discharged 5 AIR HORN VALVE The air horn valve is located in the front service compartment and the air horn valve button is on the steering wheel center 5 1 AIR HORN VALVE MAINTENANCE When needed the air horn valve can be serviced or replaced using the following procedure 1 Unplug the cable connector 2 Disconn...

Page 1278: ...00377 with the reference line shown on the front view detail As seen on the side view position the end of the adjustment tool to a distance of high beam and 1 low beam from the top of the headlight for proper aiming FIGURE 6 TUBING AND FITTINGS 23381 CAUTION Because they are made of plastic firmly tighten nozzle and bulkhead fittings by hand only FIGURE 7 WASHER NOZZLES ADJUSTMENT 23382 7 WINDSHIE...

Page 1279: ... front service compartment fig 10 This unit pumps the washer liquid to the spray nozzles where it is dispersed across the windshield 7 2 WIPER ARM Check operation of the wipers for proper blade sweep and angle CAUTION Do not attempt to manually move the wiper arms to make wiper blade sweep adjustments as damage to the wiper linkage or motor may occur If it is necessary to adjust the sweep of blade...

Page 1280: ...R MOTOR 7 3 1 Windshield Wiper Motor Replacement The windshield wiper motor is located at lower front of the vehicle behind the defroster panel Refer to figure 8 for motor location WARNING Park vehicle safely apply parking brake stop engine and set battery master switch to the OFF position prior to working on the vehicle 1 Remove the Phillips head screws retaining the defroster panels and remove p...

Page 1281: ...tions A Add proper fluid B Store coach or parts in heated area then purge system with low temperature solution C Remove with compressed air if severely clogged replace items D Replace section E Realign tubing and or refit Trim end to ensure proper fit or re place INADEQUATE SPRAYING A Tubing failure A Replace tubing SLOW OPERATION A Improper solution B Jet stream improperly directed C Check if val...

Page 1282: ...ODOMETER Canada model km Make Stemco Prevost number 650117 AIR HORN Make Allied Signal Inc Prevost number 640093 AIR HORN VALVE Make Allied Signal Inc Prevost number 640128 WINDSHIELD WIPER MOTOR Make BOSCH Prevost number 800328 WIPER BLADE Make BOSCH Prevost number 800329 WIPER ARM Make BOSCH Prevost number 800331 ...

Page 1283: ...CHEDULE 2 2 1 ENGINE OIL CHANGE INTERVALS 3 2 1 1 Engine Oil Reserve Tank 3 2 2 COLD WEATHER OPERATION 3 2 3 FLEXIBLE HOSE MAINTENANCE 3 2 3 1 Pre Starting Inspection 3 2 3 2 Leaks 4 2 4 WALK AROUND INSPECTION 6 2 5 LUBRICANT AND COOLANT SPECIFICATIONS 7 2 6 PART NUMBER SPECIFICATIONS 8 ILLUSTRATIONS FIGURE 1 ENGINE OIL RESERVE TANK 3 FIGURE 2 LUBRICATION AND SERVICING POINTS ON INDEPENDENT FRONT ...

Page 1284: ...lters in an environmentally safe manner according to federal and or local recommendations 1 1 FIRST SERVICE ON NEW VEHICLE Perform the following maintenance procedures after the first 3 000 miles 4 800 km of operation unless otherwise specified Once initial maintenance is performed refer to recommended intervals in the lubrication schedule Repeat a component s initial maintenance procedure when it...

Page 1285: ...ing valve Comparison of oil levels in sight gauge before and after adding oil to crankcase shows approximately how much oil has been added Filling of this tank can be made by opening the rear engine doors The tank is mounted on R H side of engine compartment over the A C compressor FIGURE 1 ENGINE OIL RESERVE TANK 01172 2 2 COLD WEATHER OPERATION The proper selection of the engine oil grade will e...

Page 1286: ...the gas or fluid within it the time in service its installation the ambient temperatures amount of flexing and the vibration it is subjected to With this in mind it is recommended that all hoses be thoroughly inspected at least every 500 operating hours or after 15 000 miles 24 000 km Look for surface damage or indications of damaged twisted worn crimped brittle cracked or leaking lines Hoses havi...

Page 1287: ...Section 24 LUBRICATION PA1553 5 FIGURE 2 LUBRICATION AND SERVICING POINTS ON INDEPENDENT FRONT SUSPENSION VEHICLES 24036 ...

Page 1288: ...r tanks ENGINE COMPARTMENT ITEM DESCRIPTION 24 Check engine crankcase oil level Add if necessary 19 Check Allison transmission oil level can be checked from push button shift selector Add if necessary 29 Check power steering reservoir fluid level Add if necessary 21 Check coolant surge tank fluid level Add if necessary 28 Drain accumulated water in primary fuel filter water separator if equipped V...

Page 1289: ...uivalent 35 Differential Oil Multigrade gear oil meeting MIL L 2105 D 85W 140 If temperature drops below 10 F 12 C 80W90 should be used Below 15 F 26 C 75W90 should be used In extreme conditions or for better performance full synthetic gear oil can be used 20 Fan Gearbox Oil Synthetic oil ISO VG viscosity grade 460 Natural oil Mobil SHC 630 19 Allison Automatic Transmission Oil Dexron III or Castr...

Page 1290: ...ry Fuel Filter 510128 28 Secondary Racor Fuel Filter 531390 18 Engine Coolant Precharge Unit 550629 18 Engine Coolant Filter Conditioner 550630 10 A C And Heating Driver s Air Filter 871147 871144 10 A C And Heating Cabin s Air Filter 871051 16 Allison Automatic Transmission Oil Filter Kit 572050 11 Coolant Strainer 871029 3 Accessories Air Filter 641340 36 Air Dryer Cartridge 641244 Alternator dr...

Page 1291: ... 4 17 12 Filter 510458 Engine crankcase breather clean breather steel mesh 23 12 03 FUEL Change primary secondary fuel filters fill with clean fuel before installation 28 12 Primary 510137 prim w sep 531390 secondary 510128 05 COOLING Radiator fan drive gearbox check oil level add if necessary 20 6 Mobil SHC 630 180217 Radiator fan drive gearbox change oil 20 12 Mobil SHC 630 180217 Coolant filter...

Page 1292: ...ers if filled with TranSynd TM TES 295 Synthetic Fluid only 16 12 Filters 572050 Transmission oil cooler replace unit if vehicle is equipped with transmission retarder 43 24 Castrol Syntrans grade SAE 75W 85 09 PROPELLER SHAFT Grease one fitting on each universal joint and slip joint 34 6 Multipurpose grease 11 REAR AXLE Differential check oil level add if necessary 35 6 Multigrade gear oil Differ...

Page 1293: ...kle 9 6 Multi purpose grease Power steering reservoir replace oil and filter cartridges 29 12 Cartridge 660987 16 SUSPENSION Upper A Arm Ball Joint grease fitting 6 Molykote longterm 2 78 grease preferably or lithium NLGI no2 or no1 Hub unit and Swivel assembly 12 See Dana Maintenance Manuals 22 HEATING AIR CONDITIONING A C compressor check oil level add if necessary 25 6 Polyolester oil A C recei...

Page 1294: ......

Page 1295: ...ENT 8 5 PINION 9 5 1 PINION AND KEYLESS BUSHING POSITIONING 9 5 2 FRONT SLIDE OUT SHAFT PINION REPLACEMENT 9 5 3 REAR SLIDE OUT SHAFT PINION REPLACEMENT 10 5 4 KEYLESS BUSHING 10 5 4 1 Installation 10 6 ELECTRIC MOTOR 13 6 1 MAINTENANCE 13 6 2 REPLACEMENT 13 7 SPEED REDUCTION GEARBOX 13 7 1 MAINTENANCE 13 7 2 GEARBOX REPLACEMENT 13 8 JAW COUPLING 14 8 1 MAINTENANCE 14 8 2 REPLACEMENT ADJUSTMENT 14...

Page 1296: ...4 15 5 SLIDE OUT LIMIT SENSORS 25 15 5 1 Maintenance and adjustment 25 16 SLIDE OUT EXTERIOR FINISHING PANELS WINDOWS 26 16 1 FACE PANEL REMOVAL 26 16 2 FACE PANEL INSTALLATION 26 16 3 SIDE PANELS REMOVAL 26 16 4 SIDE PANELS INSTALLATION 27 16 5 TOP AND BOTTOM PANEL REMOVAL 28 16 6 TOP AND BOTTOM PANEL INSTALLATION 28 16 7 WINDOWS REMOVAL 29 16 8 FIXED WINDOWS INSTALLATION 29 16 9 AWNING WINDOW IN...

Page 1297: ... 18 DRIVE MOTOR GEARBOX ASSEMBLY MOUNTING BOLTS 13 FIGURE 19 CLAMPING HUB POSITION ON GEARBOX SHAFT 14 FIGURE 20 JAW COUPLING 14 FIGURE 21 SLIDE OUT LEVEL ADJUSTEMENT 15 FIGURE 22 SLIDE OUT LEVELING 16 FIGURE 23 TILT ADJUSTMENT 16 FIGURE 24 RAIL POSITIONING 17 FIGURE 25 ACETAL PLASTIC BLOCKS 17 FIGURE 26 REMOVE THE UPPER ACETAL PLASTIC BLOCKS WITH A PICKING TOOL 17 FIGURE 27 LOWER ACETAL PLASTIC B...

Page 1298: ...NG WINDOW RUBBER BUMPER INSTALLATION 31 FIGURE 62 SIDE BUMPERS 32 FIGURE 63 MASKING TAPE APPLICATION 32 FIGURE 64 SIKA 255 APPLICATION 32 FIGURE 65 AWNING WINDOW SIKA AKTIVATOR 32 FIGURE 66 AWNING WINDOW SIKA 255 APPLICATION 32 FIGURE 67 CORRECT TIGHTENING SEQUENCE 32 FIGURE 68 SMOOTH DOWN THE JOINT 33 FIGURE 69 AWNING WINDOW SEAL THE UPPER CORNERS 33 FIGURE 70 AWNING WINDOW SEAL THE CHINK 33 FIGU...

Page 1299: ...side structure keys figure 1 2 FIGURE 1 FRONT SLIDE OUT 1 1 1 Maintenance Check that the inner stopper screws are tight and that no damage or deformation has taken place for both the side and the upper stoppers 1 1 2 Adjustment 1 Adjust the side inner stoppers at 1 8 from the vehicle side structure keys and tighten the screws Make sure there is a minimum gap of 2mm 0 079 between the side inner sto...

Page 1300: ...lastic in limit stoppers add or remove shims as required between the stopper and the extrusion 4 Using the manual override procedure section 18 move the slide out up to its full in position 5 Using a straight edge check if the outer face of the slide out is flush with the vehicle body with the stoppers contacting their bearing surface Readjust the stoppers if necessary 6 Readjust the in limit sens...

Page 1301: ...h the engine running If the pin produces excessive knocking when it engages with releasing of the parking brake reduce air cylinder speed by adjusting the air flow regulator on the pneumatic control panel FIGURE 29 item 11 2 2 AIR CYLINDER REPLACEMENT 1 Assure the parking brake is applied 2 Disconnect the cylinder air tubing from the 2nd baggage compartment front slide out or under the bed structu...

Page 1302: ...red for recessed screw heads reduce plastic thickness Do not torque higher than specified 4 3 REAR SLIDE OUT RACK REPLACEMENT 1 Using the slide out handheld control or the manual override procedure section 18 if using the manual override procedure do not forget to deflate the inflatable seal completely extend the slide out about one foot 2 From outside unscrew and remove only the first two screws ...

Page 1303: ...de out shaft pinion replacement check the following conditions The locking collars located on the side of the pinion being replaced are disengaged The drive motor gearbox assembly is removed see section 7 2 FIGURE 13 MECHANICAL COMPONENTS TYPICAL 1 Loosen the keyless bushing see section 5 4 of the pinion to be replaced Slide the pinion and its bushing out of the shaft Check the keyless bushing con...

Page 1304: ...ghten the keyless bushing use a special open end wrench to retain the yellow part and another wrench to tighten the black part Figure 20 shows how to tighten the keyless bushing When tightening make sure the pinion does not move or rotate FIGURE 15 TORQUE WRENCH FORMULA CAUTION Make sure all keyless bushings are tightened to 125 lb ft before moving the slide out A lower torque value may cause the ...

Page 1305: ...Section 26 XLII SLIDE OUT PA1553 11 ...

Page 1306: ...Section 26 XLII SLIDE OUT PA1553 12 FIGURE 16 KEYLESS BUSHING INSTALLATION INSTRUCTION ...

Page 1307: ...rom the gearbox 4 Fasten the new motor to the gearbox using screws 5 Re connect the electric cable connector 7 SPEED REDUCTION GEARBOX The speed reduction gearbox used is a helical worm gear type This gearbox has a 2 stage 740 1 ratio and the output shafts are self locking Keys on output shafts are glued into keyseats 7 1 MAINTENANCE Inspect the gearbox to check if there is any leakage or backlash...

Page 1308: ...Leave a gap of 20mm 0 787inch between each clamping hubs as shown on FIGURE 20 Use the motor hexagonal socket output shaft to align the keyways 9 Tighten clamping screws to a torque of 18 lbf ft FIGURE 20 JAW COUPLING 9 FLANGE BEARING There are two different types of flange bearing on the slide out mechanism FIGURE 13 Their purpose is to maintain the shaft in position while permitting rotation The...

Page 1309: ...rews A B C D maintain the support plate seated on the leveling screws Also the retaining screws prevent the slide out from tipping inside the vehicle when it is retracted The slide out is slightly tilted When retracting the upper in limit stoppers touch first the vehicle structure followed by the lower in limit stoppers Tilt adjustment is done by changing the linear bearing support plate inclinati...

Page 1310: ... 7 Loosen slightly levelling screw 3 and then tighten it so it is perfectly in contact with the support plate Make sure screws 1 2 3 4 are in contact with the support plate 8 Loosen retaining screw A B 9 Using a crisscross pattern tighten progressively 3 rounds the retaining screw A B C D to a torque of 50 ft lb 10 Assure that the levelling screw 1 2 3 4 are firmly leaning on the support plate and...

Page 1311: ...at bar is inserted in the slide out lower body extrusion and can be removed through the end cap FIGURE 24 6 Adjust the flat bar position to align the weldnuts with the rail mounting holes 7 Temporarily tighten the bolts 8 Adjust the rail position with as per FIGURE 24 For each rail make sure the gap is the same both side of the rail 9 For final tightening of the bolts tighten on either end of the ...

Page 1312: ...solenoids One solenoid is used for inflating of the seal and the other for deflating of the seal When one of the solenoids is activated seal deflating valve for example the valve will keep its state even if the solenoid is deactivated The inflating valve solenoid is activated to re inflate the seal when the slide out reaches its inner or outer limit The inflatable seal pressure is set to 10 psi an...

Page 1313: ... the Prevost maintenance manual INFLATABLE SEAL CIRCUIT The efficiency of the seal could be affected by impurities such as white powder in the pneumatic control valve It is recommended to inspect the inflatable seal control components once a year to prevent malfunction In this case remove the seal valves and clean the interior valve components using a compressed air nozzle Do the same thing with t...

Page 1314: ...ealing device for both retracted and extended slide out position and a wiper seal as a secondary sealing device which is used to wipe water out and to ensure sealing during slide out movement INFLATABLE SEAL WIPER SEAL ADHESIVE TAPE EXTERIOR PANEL FIGURE 30 SEAL ASSEMBLY The seal deflation is done each time the slide out moves The deflating valve solenoid is activated before and during the slide o...

Page 1315: ... wiper seal and the exterior panels and glasses 14 3 3 Seal assembly installation NOTE This procedure is to install the inflatable seal assembly on the structure CAUTION Always apply product in the same direction to prevent dirt from being brought back CAUTION Check before using any cleaning or adhesive product on seal panel or glass to prevent alteration or damage NOTE Refer to the slide out part...

Page 1316: ... out are accessible from outside figure 7 4 Using a knife cut the sealant between the extrusion and the roof figure 7 Unscrew and remove the central exterior extrusion screws and the two end extrusion screws CAUTION Do not use the slide out handheld control to move the slide out 2 inside the vehicle because the limits are not recognized over the closed position The slide out will not stop and dama...

Page 1317: ...ess compartment The other interconnections are located on the pneumatic panel and the electrical panel in the front service compartment All the interconnections are shown on the electrical diagrams of your vehicle A blinking signal is added on the dashboard telltale panel figure 33 to indicate that an error condition or a missing operation condition is present on a slide out The slide out telltale...

Page 1318: ... black connector To disconnect the black connector slide downwards the red latch Turn the ignition key to the ON position This engages the automatic reprogramming The slide out telltale light will turn on and stay on until the reprogramming is complete Once completed the slide out telltale light will turn off or stay on not blinking if at least one slide out is extended Check the SYSTEM DIAGNOSTIC...

Page 1319: ...the in limit stoppers are perfectly adjusted see section 1 2 2 1 Retract the slide out to its full IN position with the in limit stoppers in contact with their bearing surface 2 Loosen the in limit sensor mounting bracket screws and move back the sensor completely toward the inside of the vehicle 3 Bring slowly the sensor toward the outside of the vehicle until the light emitting diode LED turns o...

Page 1320: ...ing supports and clean them before re using Check where adhesive sealant and double face adhesive tape are on the structure and the panel back side in order to be able to stick the new panel in the same way Check the tape width and use same width tape when installing new panels FIGURE 40 SLIDE OUT PANELS AND WINDOWS 16 2 FACE PANEL INSTALLATION For surface cleaning and preparation panel installati...

Page 1321: ...refer to the MTH side panel installation procedure described in section 18 BODY 1 Protect adjacent surfaces with appropriate material 2 Refer to figure 41 for 1 16x1 4 double face adhesive tape location on structure 3 Apply Sika 206 G P on the side panel as shown in figure 42 4 Apply Sika Tack Booster triangular bead 9mm width X 6mm high as shown in Figure 43 and glue panel in place as shown in FI...

Page 1322: ...icity never use a buffer or other sanding method to remove it 16 6 TOP AND BOTTOM PANEL INSTALLATION NOTE The top and bottom panels are made of aluminum sheets and need aluminum rivet For surface cleaning preparation panel installation and products needed refer to the MTH side panel installation procedure described in section 18 BODY 1 Protect adjacent surfaces with appropriate material 2 Refer to...

Page 1323: ...emical adhesives 16 7 WINDOWS REMOVAL 1 Remove the slide out 2 If needed remove the exterior extrusion as described in section 1 3 CAUTION Be careful not to damage the adjacent surfaces 3 With a knife or a wire cut the sealant and the adhesive between the windows and the structure Make sure not to damage the rubber seal between the windows 4 With a helper remove the window from the slide out 16 8 ...

Page 1324: ... SEAL INSTALLATION FIGURE 52 FACE FIXED WINDOWS 3 16 X 1 2 DOUBLE FACE ADHESIVE TAPE INSTALLATION FIGURE 53 SIDE FIXED WINDOW X DOUBLE FACE ADHESIVE TAPE INSTALLATION FIGURE 54 FACE FIXED WINDOW AND HALF WINDOW SIKA AKTIVATOR FIGURE 55 SIDE FIXED WINDOW SIKA AKTIVATOR FIGURE 56 FACE FIXED WINDOW INSTALLATION SIKA TACK BOOSTER ...

Page 1325: ...m high 7 Install the windows on the slide out structure see FIGURE 59 or FIGURE 60 8 Press the jigs on the windows and wait for the adhesive to dry 90 minutes minimum 9 After drying apply Sika 221 as a finishing joint Clean excess with Sika 208 10 Refer to section 16 11 for the finishing joint application procedure FIGURE 59 FACE FIXED WINDOW INSTALLATION FIGURE 60 SIDE FIXED WINDOW 16 9 AWNING WI...

Page 1326: ... APPLICATION 6 Apply Sika Aktivator as per FIGURE 65 7 Apply Sika 255 as per FIGURE 66 triangular bead 10mm width X 10mm high FIGURE 65 AWNING WINDOW SIKA AKTIVATOR FIGURE 66 AWNING WINDOW SIKA 255 APPLICATION 8 Install the awning window centered in the opening Press the window slightly The awning window must be kept closed 9 While a helper is pressing on the window from outside install the awning...

Page 1327: ...priate cleaner abrasives and primers Clean surfaces with anti silicone 2 Apply Sika Aktivator on sliding window as per FIGURE 71 3 Apply Sika Aktivator on the structure as per FIGURE 72 4 Apply Sika 252 as per FIGURE 73 triangular bead 20mm width X 10mm high 5 Install the sliding window centered in the opening Press the window slightly The window must be kept closed 6 While a helper is pressing on...

Page 1328: ...EQUENCE FIGURE 75 SLIDING WINDOW SEAL THE UPPER CORNERS FIGURE 76 SEAL 16 11 FINISHING JOINT The following procedure applies to section 16 11 1 up to 16 11 4 For surface cleaning and preparation tools cleaner adhesives and other product needed refer to the MTH side panel installation procedure described in section 18 BODY 1 Place masking tape to protect surfaces from smudge 2 Apply Sika 221 ...

Page 1329: ...nd the structural member FIGURE 77 Apply Sika 221 between the top of face window and the structural member FIGURE 78 16 11 2 Slide out side Apply Sika 221 between the top of side window and the structural member FIGURE 79 Apply Sika 221 between the bottom of side window and top of side panel FIGURE 80 Apply Sika 221 between side window and top of face fixed window FIGURE 81 ...

Page 1330: ... security pin cavity FIGURE 85 16 11 4 Top of Slide out Apply Sika 221 between edge of top panel and structural member FIGURE 86 17 WELDING PRECAUTION CAUTION Prior to arc welding on the vehicle refer to the Welding Precautions Procedure Prior To Welding in section 00 GENERAL of this manual to avoid serious damage to the vehicle components 18 SLIDE OUT MANUAL OVERRIDE PROCEDURES In case of power r...

Page 1331: ... a vacuum or pressure build up inside the vehicle FRONT SERVICE COMPARTMENT SLIDE OUT CONTROL PANEL INSIDE ENGINE R H SIDE ACCESS COMPARTMENT FIGURE 87 COMPARTMENTS LOCATION FIGURE 88 VEC CIRCUIT BREAKERS ON SLIDE OUT CONTROL PANEL SLIDE OUT BREAKER FIGURE 89 MAIN SLIDE OUT BREAKER IN ENGINE R H SIDE ACCESS COMPARTMENT PNEUMATIC COMPONENT PANEL PRESSURE TRANSDUCER SLIDE OUT VEC MASTER ID CECM FRON...

Page 1332: ...y turning the shut off valve handle counterclockwise Check the pressure gage on the inflatable seal regulator to see if the pressure is increasing to 10 psi FIGURE 93 0 psi SEAL DEFLATED 10 psi SEAL INFLATED 15 10 5 0 psi 20 25 30 15 10 5 0 psi 20 25 30 FIGURE 93 INFLATABLE SEAL PRESSURE GAGE NOTE The slide out control system inhibits transmission range selection to prevent the vehicle from moving...

Page 1333: ...the drive mechanism and cause damage to the reduction gearbox 7 Finally the inflatable seal can be re inflated by turning the shut off valve handle counterclockwise Check the pressure gage on the inflatable seal regulator to see if the pressure is increasing to 10 psi FIGURE 94 NOTE The slide out control system inhibits transmission range selection to prevent the vehicle from moving if the slide o...

Page 1334: ... 2 Check that the slide out is straight when completely extended and that it leans against all inner stoppers 3 Make sure the vehicle upper member is parallel with the front slide out structure If not readjust the roof reinforcing rod This may be affected by the loading on the roof 4 Make sure the front slide out lower member deflection is within 1 4 If not redistribute the slide out load 5 Check ...

Page 1335: ... system from the CECM Press the enter key If applicable the MCD shows the device ID the fault messages or fault codes recorded When more than one fault is recorded an arrow pointing down appears on the right of the display Use the down arrow to see all the fault messages Once the problem corrected the MCD still shows the fault as being active You have to leave the FAULT DIAGNOSTIC menu wait approx...

Page 1336: ...n of the vacuum generator B Faulty vacuum generator connection to the vacuum generator open seal deflating valve solenoid open circuit C I O B module output defective in limit sensor shorted to ground connection to the motor positive relay solenoid open circuit A Run the engine at fast idle a few minutes to increase air pressure in the accessory air tank and try again B Turn the relieving shut off...

Page 1337: ...out moves out slightly when vehicle is traveling A Lower in limit stoppers are not leaning against the structure at the moment when the in limit sensor detects the magnet A Adjust the sensor position in order to have contact of the stoppers against the structure at the time when the system stops the slide out retraction Slide out moves when vehicle is moving A Inflatable seal not inflated A Check ...

Page 1338: ...ce or adjust acetal plastic block proper position Top of slide out not flush with vehicle body A Broken or misadjusted leveling or retaining screw B Faulty upper in limit stopper A Check and replace screw B Replace upper in limit stopper Lower edge of slide out not parallel with vehicle body opening A Faulty leveling and retaining screw 8 screws each side A Inspect screw replace and adjust slide o...

Page 1339: ...function E Excessive load in the slide out F Slide out not centered in the structure opening A Always deflate the seal when manually retracting or extending the slide out B Check the pressure transducer condition replace if necessary C Readjust the roof reinforcing rod D Check the seal valve condition E Reduce load or distribute load evenly in order to respect the deflection criterion and slide ou...

Page 1340: ...connected Faulty pressure transducer Connection or wiring harness open Check replace vacuum transducer Check reconnect the connector SESo1 Fix wiring harness 5 SldO Vacuum Sensor Shorted High Pressure transducer is faulty Wiring harness shorted to 12v or 24v Check replace vacuum transducer Fix wiring harness 6 SldO Seal Deaf Vac Mechanical Fault Does not reach vacuum level 5 PSIG Slide out seal da...

Page 1341: ...ound Fix solenoid or wiring harness Open Circuit Solenoid is broken or open Bad connection on solenoid or bloc valve Wiring harness is cut Check fix solenoid or connection Check fix wiring harness 12 SldO Seal Inf Sol Current Above normal Solenoid or wiring harness shorted to 12v or 24v Fix solenoid or wiring harness Shorted High Solenoid or wiring harness shorted to 12v or 24v Fix solenoid or wir...

Page 1342: ...d High Switch or wiring harness shorted to 12v or 24v Fix switch or wiring harness 19 SldO Limit In Se Shorted High Sensor or wiring harness shorted to 12v or 24v Fix sensor or wiring harness 20 SldO Limit Out Se Shorted High Sensor or wiring harness shorted to 12v or 24v Fix sensor or wiring harness 21 SldO Secu Pin Sol Shorted High Solenoid or wiring harness shorted to 12v or 24v Fix solenoid or...